M2/4 30/40/50 CP/ - PS M4 30 CP - P M2 30 CP - P/ - PL/ - PXL Parts Manual

Alphabetical Contents PARTS INDEX CONTENTS
MANITOU NORTH AMERICA, INC.

6401 IMPERIAL DRIVE
Waco, TX 76712--6803
NOTE: Manitou Forklift Manuals are continually updated and subject to change
without prior notice. If your Forklift Model or parts are not found in this manual,
please contact your dealer or the Manitou North America Parts Department
for the latest information and parts availability.
M2/4 30/40/50 CP/--PS

M4 30 CP--P
M2 30 CP--P/--PL/--PXL
4 SPEED TRANSMISSION
PARTS MANUAL
S/N: M2300546, M240332, M2500264,
M4300288, M4400372, M4500252 and above
S/N: 164968 thru 181963
(except 170493 & 170514)
For Parts Orders contact your Manitou North America Dealer or call:
Manitou North America, Parts Dept. 800--425--3727 or (254) 799--0232
Parts Dept. Fax: (254) 867--6504 Website: www.manitou--na.com
CATALOG B398
R12--07
ALPHABETICAL CONTENTS
!"#!!!$

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!

’M’ SERIES LIFT TRUCK

MODEL NO. DESCRIPTION
M2=FRONT WHEEL DRIVE --D=DIESEL (NOT ALWAYS SHOWN)
M4=FOUR WHEEL DRIVE --G=GASOLINE
STANDARD CAB* (95”) when omitted
30=6,000lb. LIFT CAP. M2 30 C P --PS --D

40=8,000lb. LIFT CAP..
50=10,000lb. LIFT CAP.. --PS=POULTRY CAB* 95”
--P=POULTRY CAB 84”
--PL=POULTRY LOW CAB 81”
--PXL=POULTRY EXTRA LOW CAB 77”
C=CONVERTER (TORQUE) TRANS. --PSL=POULTRY SUPER LOW CAB 75”
H=HYDROSTATIC TRANSMISSION
P=PERKINS ENGINE
C=CATERPILLAR ENGINE
* The STANDARD or POULTRY CAB 95” has an enclosed steering column, only the upper column can be seen.
The POULTRY CAB 84”, 81”, 77” & 75” has an exposed steering column, the entire column is visible.
- 2-
LIFT TRUCK COMPONENT

IDENTIFICATION
MANUFACTURER’S
SERIAL NO. PLATE
(INSIDE THE CAB, BEHIND THE
DRIVER AND TO THE RIGHT)
TURNER POWERTRAIN SYSTEMS
TRANSMISSION ID PLATE
(LEFT HAND SIDE OF
TRANSMISSION, LOWER FRONT)
MAST MANUFACTURER’S
SERIAL NO. PLATE
HURTH AXLE
IDENTIFICATION PLATE
(FRONT CENTER UPPER
HALF OF AXLE)
ENGINE IDENTIFICATION
PLATE
(ENGINE BLOCK)
MANUFACTURER’S
SERIAL NO.
(ABOVE THE RIGHT REAR
TIRE, ON THE FRAME)
- 3-
GENERAL INFORMATION
The purpose of this catalog is to provide illustrations for identifying and ordering Lift Truck parts. The
illustrations provide a general description and may not show the exact shape or detail of the parts or com-
ponents represented.
The parts are identified by an Item number on the Illustration Page. Find the Item Number for the part
desired, then locate that Item Number under the ”Items” column on the parts page. The part number will
be located directly to the right of the Item Number. Also provided is a part description, dimensions
(where necessary), quantity of parts required and the Truck Model Identification.
Lift Truck Models designated as CP--P, CP--PL or CP--PXL are Poultry Trucks. Models designated as CP
are Standard or Commercial Trucks. 2WD refers to Two Wheel Drive Lift Trucks and 4WD refers to
Four Wheel Drive Lift Trucks.
Common hardware such as standard nuts, bolts and washers may not have part numbers, replace these
items with grade five zinc or stainless steel hardware.
When ordering parts or requesting technical information, the following numbers are required:
Truck Model No:
Truck Serial No:
Mast Model No:
Mast Serial No:
Engine No:
Transmission No:
Front Drive Axle No:
Attachment Model No:
Attachment Serial No:
For quick reference it is recommended these numbers be recorded as soon as possible.
-- 4 --
FILTER CHART
2
1 3 4
5 6 7 9
8
10
11
DESCRIPTION PART NO. CLEAN REPLACE

1 - Engine oil filter (Perkins & Cat) 133755 - - - - 150 hrs.
2 - Air filter cartridge (Nelson) 424974 150 hrs. 450 hrs.
3 - Transmission oil filter 561749 - - - - 450 hrs.
4 - Fuel filter w/ drain (Perkins) 561370 - - - - 450 hrs.
4 - Fuel filter (Caterpillar) 494171 - - - - 450 hrs.
4 - Water/Fuel filter, w/ glass (Perkins) (contact Perk.) - - - - if damaged
4 - Water/Fuel glass bowl (Perkins) 49206 - - - - if damaged
4 - Water/Fuel filter, w/o glass (Cat) 496223 - - - - if damaged
4 - Water/Fuel glass bowl (Caterpillar) (contact Cat) - - - - if damaged
5 - Hydraulic oil filter cartridge 422141 - - - - 450 hrs.
6 - Air filter safety cartridge (Nelson) 492503 450 hrs. 900 hrs.
7 - Hydraulic suction screen 424764 900 hrs. if damaged
8 - Air intake pre--cleaner* 493776 150 hrs. if damaged
9 - Turbo pre--cleaner II* 492009 150 hrs. if damaged
10 - Axle oil cooler filter (Poultry) 425481 900 hrs. if damaged
11 - Vaculator (Nelson) 426203 150 hrs. if damaged
*See Section 8 for additional information.
- 5-
CONTENTS
DESCRIPTION SECTION
TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tires, Rims & Assemblies
BRAKE & ACCELERATOR PEDAL ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . 2
Brake & Inching Pedals, Park Brake Lever & Accelerator Pedal
FRONT DRIVE AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Drive Axle Assembly, Brake Disc Assembly & Diff. Lock Assembly
STEERING SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Steering Axles & Supports, Steering Hydraulics & Steering Cylinders
TRANSMISSION & SHIFT LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Gear Box, Converter, Clutch, Control Valve, Shift Lever & Trans. Mounts
ENGINE, ALTERNATOR & STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine, Mounts, Alternator and Misc.
COOLING SYSTEMS: ENGINE/TRANSMISSION & DRIVE AXLE . . . . . . . . . . 7
Radiator, Engine/Transmission, Drive Axle Oil Coolers & Misc. Hrdwr.
FUEL SYSTEM, AIR INTAKE & EXHAUST SYSTEMS . . . . . . . . . . . . . . . . . . . . . 8
Tank, Pump, Filters & Misc. Hrdwr.
HYDRAULIC SYSTEMS (LESS STEERING SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . 9
Tank, Pump, Filters, Control Valves, Tilt/Side Shift Cylinders & Misc. Hrdwr.
ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Schematics, Harnesses, Lights, Instruments, Electrical Options, Etc.
FRAME, HOOD, CAB & COUNTER WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Frame, Fenders, Firewall, Cab, Seat, Weights & Mast Mounts
DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Location & Pictures
PARTS INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPENDIX
SECTION 1
TIRES & WHEELS
DESCRIPTION PAGE
TIRES AND WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--2
CATALOG B398 - 1- 1- R/07-- 2000

TIRES & WHEELS
WARNING!
WHEN REPLACING WHEELS: ALWAYS USE THE
SAME SIZE TIRE AND RIM AS PROVIDED BY THE
FACTORY! OTHERWISE THE DRIVETRAIN,
OVERALL HEIGHT, AND PERFORMANCE OF THE
LIFT TRUCK WILL BE ALTERED!
3 1
2
5
4a
4b 6
9
7
R/07-- 2000 - 1- 2- CATALOG B398

ITEM PART NUMBER DESCRIPTION QTY MODEL
1a 495970 RH Drive Wheel Assembly, 17.5-- 24 1 M2/4 30/40/50 CP/-- PS/-- P/-- PL
(Items 3a, 5a & 7a)
1b 495971 LH Drive Wheel Assembly, 17.5-- 24 1 M2/4 30/40/50 CP/-- PS/-- P/-- PL
(Items 3a, 5a & 7a)
1c 496070 Drive Wheel Assembly, 16.9-- 24 Turf 2 M2 30 CP/-- PS/-- P/-- PL
(Items 3b, 5a & 7a)
1d 425985R Drive Wheel Assembly, 15-- 19.5 1 M2 30/40 CP-- PXL
(Items 3c, 5b & 7c)
1e 425985L Drive Wheel Assembly, 15-- 19.5 1 M2 30/40 CP-- PXL
(Items 3c, 5b & 7c)
1f 176697 Drive Wheel Assembly, 16.9-- 24 2 M2 30 CP/-- PS/-- P/-- PL
(Items 3d, 5a & 7a)
1g 492167 Drive Wheel Assembly, 17.5L-- R24 2 M2 30 CP/-- PS/-- P/-- PL
(Items 3e, 5a & 7a)
1h 424734 Drive Wheel Assembly, 17.5-- 25 2 M2 30 CP/-- PS/-- P/-- PL
(Items 3f, 5c & 7a)
1j 493164 Drive Wheel Assembly, 19.L5-- 24 2 M2 30/40 CP/-- PS/-- P/-- PL
(Items 3g, 5d & 7a)
1k 496127 LH Drive Wheel Assembly, 17.5LR24 1 M2/4 30 CP/-- PS/-- P/-- PL
(Items 3h, 5a & 7a)
1m 496128 RH Drive Wheel Assembly, 17.5LR24 1 M2/4 30 CP/-- PS/-- P/-- PL
(Items 3h, 5a & 7a)
2a 495976 RH Steer Wheel Assembly, 12-- 16.5 1 M2 30/40/50 CP/-- PS/-- P/-- PL
(Items 4a, 6a & 7b)
2b 495977 LH Steer Wheel Assembly, 12-- 16.5 1 M2 30/40/50 CP/-- PS/-- P/-- PL
(Items 4a, 6a & 7b)
2c 495974 RH Steer Wheel Assembly, 12-- 16.5 1 M4 30/40/50 CP/-- PS/-- P
(Items 4a, 6b & 7b)
2d 495975 LH Steer Wheel Assembly, 12-- 16.5 1 M4 30/40/50 CP/-- PS/-- P
(Items 4a, 6b & 7b)
2e 424099 Steer Wheel Assembly, 12-- 16.5 2 M2 30/40/50 CP/-- PS/-- P/-- PL/-- PXL
(Items 4b, 6a & 7b)
3a 495973 Drive Tire, 17.5-- 24 R3 12PR 2

3b T0009 Drive Tire, 16.9-- 24 R3 8PR Turf 2
3c T0036 Drive Tire, 15-- 19.5 12PR 2
3d T0030 Drive Tire, 16.9-- 24 10PR 2
3e 491950 Drive Tire, 17.5L-- R24 IT510 2
3f 424207 Drive Tire, 17.5-- 25 Sure Grip 2
3g 492791 Drive Tire, 19.5L-- 24 R4 12PR 2
3h 496129 Drive Tire, 17.5LR24 XM27T 145B 2
4a 495980 Steer Tire, 12-- 16.5 12PR (standard) 2 2WD and 4WD
4b 424100 Steer Tire, 12-- 16.5 12PR (optional) 2 2WD only
5a 176617 Drive Wheel, 15-- 24 2

5b 425982 Drive Wheel, 15-- 19.5 2
5c 424511 Drive Wheel, 14-- 25 2
5d 492786 Drive Wheel, 16-- 24 2
CATALOG B398 - 1- 3- R/07-- 2000

6a B5497 Steer Wheel, 9-- 16.5 2 2WD only

6b 495978 Steer Wheel, 16.5-- 9.75 2 4WD only
7a B2257 Stem, Valve 2

7b B2258 Stem, Valve 2
7c 423417 Stem, Valve 2
8 109480 Nut, Drive Wheel Lug 8/10 Ea. Wheel

9a 421116 Nut, Steer Wheel Lug 8 Ea. Wheel 2WD
9b 475260 Nut, Steer Wheel Lug 8 Ea. Wheel 4WD
R/07-- 2000 - 1- 4- CATALOG B398

SECTION 2
BRAKE & ACCELERATOR PEDAL ASSEMBLIES
DESCRIPTION PAGE
BRAKE & INCHING PEDAL (95” MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--2
BRAKE & INCHING PEDAL (77”--84” MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--4
PARKING BRAKE LEVER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--6
ACCELERATOR PEDAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--8
BRAKE DISC ASSEMBLIES (See FRONT DRIVE AXLE, Section 3)
CATALOG B398 - 2- 1- R/07-- 2000

BRAKE & INCHING PEDAL (MODELS CP & CP--PS)
5
9
6 3 10
8
1
7 35
12
36
37
5
4 33 11
13
2
22
14
20
34
19
18 31
7 31
30
15 23 39
16 21
17 29
32
30
40
24 28
25 26
38
26
27
27
TO DRIVE AXLE
APPLY TEFLON TAPE
R/07-- 2000 - 2- 2- CATALOG B398

1 494580 Bracket Assembly, Brake Cylinder 1 95” Cab only

2 426098 Hose Assembly 1
3 R18147--4 Adapter 1
4 426097 Bracket Assembly 1
5 80305 Seal, Copper 2
6 185232 Tank, Brake Fluid 1
7 K34806SS Washer, Lock 4

8 K304648SS Bolt 2
9 K33799 Nut 4
10 K34807 Washer, Lock 4
11 K20388SS Bolt 4
12 R13453--12 Ring, Snap 1
13 B309 Washer, Brass 2

14 425879 Pin, Brake Pivot 1
15 81047 Clevis 1
16 3212 Nut 1
17* 78237 Rod, Master Cylinder 1
18 199624 Cylinder, Master 1
19** R18147--4 Adapter 1

20 80305 Seal, Copper 1
21 B3168 Adapter 1
22 K20386SS Bolt 2
23 K33797SS Nut 2
25 K11--6 Adapter, Tee 1

26 425201 Tube, Assembly 2
27 425180 Adapter 2
28 425830 Pedal, Brake 1
29 K74181 Key, Woodruff 1
30 494587 Spring 2
31 K300141 Screw, Set 2

32 425875 Spacer 1
33* 492631 Switch, Micro 1
34 K43401 Screw 2
35 K34079 Nut, Hex 2
37 K44712 Washer, Flat 2

38 495244 Pedal, Inching 1
39* K20472SS Bolt, Hex, Stainless 1
40 K55828 Nut, Hex 2
* Adjust Master Cylinder Pushrod (Item 17) to obtain 1/8” to 3/16” clearance, or 1/2” movement measured
at the foot pad. Adjust Bolt (Item 39) on Inching Pedal to allow 1/4” to 1/2” of free travel before actuating the
Brake Pedal. Adjust Switch (Item 33) to disengage the transmission within the free travel range of the Inching
Pedal.
** Remove O--Ring from hose side of Adapter.
CATALOG B398 - 2- 3- R/07-- 2000

BRAKE & INCHING PEDAL (MODELS CP--P/--PL/--PXL)
8 10
11 7
12 6
1
13
15 5
9 2
26 3
4
27
27 33
8 28
29 32
8
38 30
31 25
24 16
36
35 4 17
3 18
2
19
13 37
34 14
22
22
20
23
21
APPLY TEFLON TAPE 23
R/07-- 2000 - 2- 4- CATALOG B398

1 424895 Bracket, Mounting 1 All (except 95” Cab)

2 K33799 Nut, Hex 5
4 K20388SS Bolt 5
5 425244 Pin 1
7 K20348 Bolt, Hex 1

8 B312 Bushing 4
9 426070 Pedal 1
10 81047 Clevis 1
11 3212 Nut 1
12* 78237 Rod, Master Cylinder 1
13 494587 Spring 2
14 K33797SS Nut 2
15 K20386SS Bolt, Hex 2
16 185232 Brake Fluid Tank 1
17 80305 Washer, Seal 1
18 199624 Master Cylinder 1
19 B3168 Adapter 1
21 K11--6 Tee Union 1
22 425201 Tube Assembly 2
23 425180 Adapter, Metric / J.I.C. 2
24 426110 Plate, Cover 1
25 496091 Bracket 1
29 K33799 Nut, Hex 1
30* 492631 Switch, Micro 1
31 K54351 Screw 2
33 K44710 Nut, Hex 2
34 426072 Inching Pedal 1
35* 426100 Bolt 1
36 K33924 Nut, Jam 1
38 R7333 Snap Ring 1
* Adjust Master Cylinder Pushrod (Item 12) to obtain 1/8” to 3/16” clearance, or 1/2” movement measured at
the foot pad. Adjust Bolt (Item 35) on Inching Pedal (Item 34) to allow 1/4” to 1/2” free travel before actuating
the Brake Pedal (Item 9). Adjust the Micro Switch (Item 30) to disengage the transmission within the free
travel range of the Inching Pedal (Item 34).
CATALOG B398 - 2- 5- R/07-- 2000

PARKING BRAKE LEVER ASSEMBLY
5
6
1 A
7
8
9
10
11 12
VIEW A---A 2
A
2
14 13
18 19
20
15
16
17
16
15 REAR AXLE MOUNTING
BOLT, TYP. BOTH SIDES
(REF.)
R/07-- 2000 - 2- 6- CATALOG B398

1 491828 Brake Lever 1 All

2 491902 Cable, E--Brake 1
3 425398 Pin, Brake Lever 1
5 K72016 Pin, Cotter 2
6 425402 Switch, Brake Light 1

9 K33798 Nut, Hex 3
10 B5776 Clamp 1
11 B5777 Spacer 1
12 425401 Bracket, Switch Mounting 1
13 B5593 Grommet 1
14 425339 Clip, Spring 1
15 425207 Bracket, Spring 2
16 425451 Spring 2
17 424950 Weldment, Arm 1
18 K76184 Pin, Clevis 1
20 425340 Clip, Spring 1
CATALOG B398 - 2- 7- R/07-- 2000

ACCELERATOR PEDAL ASSEMBLY
13
12
11
7 14
6 10 4
8
1 3
9 2
5
3
17
3
5 3
15
16
4
APPLY ANTI--SEIZE LUBRICANT
1 424947 Cable, Accelerator 1 All

2 425217 Pedal, Accelerator 1
3 K34079 Nut 4
4 421481 Rod End 2

7 77957 Pedal Mount 2 required
9 K33795 Nut, Hex 2

10 425316 Spring Tab 1
11 -- -- -- -- Bolt, Hex (Cat Dealer) 1
12 -- -- -- -- Washer, Lock (Cat Dealer) 1
13 425340 Spring Clip 1

14 B1074 Spring 1
15 KN605531 Bolt, Hex 2
16 KN630173 Washer, Lock 2
17 495925 Bracket 1
R/07-- 2000 - 2- 8- CATALOG B398

SECTION 3
FRONT DRIVE AXLE
DESCRIPTION PAGE
FRONT AXLE & MOUNTING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--2
FRONT AXLE DRIVE SHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--3
FRONT AXLE LATERAL CASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--4
FRONT AXLE DIFFERENTIAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--6
FRONT AXLE CASING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--9
BRAKE DISC ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--10
DIFFERENTIAL LOCKING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--12
FRONT AXLE COOLING SYSTEM (See COOLING SYSTEMS, Section 7)
CATALOG B398 - 3- 1- R/07-- 2000

FRONT DRIVE AXLE & MOUNTING ASSEMBLY
1
2
FRAME
(REF)
2
4
5
197474 Drive Axle, Model 172/303 1 All
1 426648 Bolt 8
2 426650 Washer 14
3 424888 Plate 2
4 426649 Nut (Torque to 280 ft.lbs.) 8
5 K34691 Jam Nut 8
R/07-- 2000 - 3- 2- CATALOG B398

FRONT AXLE DRIVE SHAFT ASSEMBLY
9
1
8
5
7 4
6 3
APPLY LOCTITE 242

3
PACK WITH LUBRICATING GREASE
AFTER ASSEMBLY
1 77369 Drive Shaft 1 All

2 109756 Flange Yoke 1
3 424647 Cross Block 2
4 162809 Grease Fitting 3
5 109755 Seal 1
6 425330 Fastening Flange 2

7 109752 Screw 4
8 426604 Bolt, Hex 8
9 426605 Nut, Lock 8
CATALOG B398 - 3- 3- R/07-- 2000

FRONT AXLE LATERAL CASE ASSEMBLY
2 106080 Stud 16 All

3 42741 ”O” Ring 2
4 106578 Spacer 2
5 105938 Seal 2
6 160904 Bearing 4
7 473512 Wheel & Hub 2
8 109480 Lug Nut 16
9 109481 ”O” Ring 2
R/07-- 2000 - 3- 4- CATALOG B398

10a 106589 Shim, 0.006in (0.15mm) A/R All

10b 106590 Shim, 0.008in (0.20mm) A/R
10c 550564 Shim, 0.010in (0.25mm) A/R
10d 109483 Shim, 0.012in (0.30mm) A/R
10e 106591 Shim, 0.020in (0.50mm) A/R
11 109484 Circlip 2
12 133011 Seal 2
13 473513 Ring Gear Bracket 2
14 106568 Pin 8
15 109487 Locking Plate 2
16 109488 Ring Gear 2

17 49354 Circlip 2
18 473514 Plug 2
19 473515 Differential Spider Pinion Bracket 2
20 5374 Seal 2
21 106586 Plug 2
22 109490 Pin 6
23 129586 ”O” Ring 6
24 133197 Screw 8
25 109492 Differential Spider Pinion 6
26 473520 Bearing 12
27 109494 Washer 6
28 561873 Lateral Axle Case 2
29 550058 Pin 2
31 109497 Screw 8
32 474314 Nut 4
33 551798 Bolt 24
34 133276 Plug 2
35 474316 Stud 4
CATALOG B398 - 3- 5- R/07-- 2000

FRONT AXLE DIFFERENTIAL ASSEMBLY
22 25
23 24
13 24 25 27
14 26
15
16 23
22
21
18
40
19
25 28
26 24
17 25
27
29 41
26
14
13
45 39
30
38
37
36 44
35
42 34
43 33
15
31 32
4
8
9
20
10
1
11
2
12
3
4
5
6
7
R/07-- 2000 - 3- 6- CATALOG B398

1 109500 Flange 1 Axle Model 172/303

2 133026 ”O”Ring 1
3 107292 Nut 1
4 494842 Bearing 2
5 477817 Nut 1
6 107293 Seal 1
7 107294 Cover Plate 1
8a 133563 Spacer 1
8b 133564 Spacer 1
8c 105117 Spacer 1
8d 133566 Spacer 1
9a 133567 Wedge 1
9b 133568 Wedge 1
9c 133569 Wedge 1
9d 106542 Wedge 1
10a 106543 Wedge 1

10b 106544 Wedge 1
10c 106545 Wedge 1
11 65723F301071 ”O”Ring 1
12 63547 Bolt 12
13 106547 Screw 2
14 106548 Bracket 2
15a* 107196 Nut 2
15b** 563101 Nut 2
16 106550 Bearing 1
17a 473519 Conical Set 1 Axle Model 172/303
17b 492714 Conical Set 1 Axle Model 177
18 109949 Screw 16
19 109948 Casing 1
20 107296 Cover 1
21a* 473503 Flange 1

21b** 561563 Flange 1
22 106555 Washer 2
23 108553 Planetary 2
24 108554 Pinion, Differential 4
25 106558 Washer 4
CATALOG B398 - 3- 7- R/07-- 2000

26 491864 Pin 3 Axle Model 172/303

27 477278 Axle 2
28 473504 Brace, Diagonal 1
29 106561 Axle 1
30 25714 Nut 1
31a*** -- -- -- -- Sleeve 1
31b** 554964 Sleeve 1
32a* 133453 Pad 1
32b** 561564 Pad 1
33a* 473506 Lever 1
33b** 561565 Lever 1
34 42412 Bolt 1
35 133025 ”O”Ring 1
36 106565 Spacer 1
37 105988 Lever, Drive 1
38 106567 Spacer 1
39 31140 Screw 1
40 108556 Washer 16
41 105492 Screw 8
42a*** -- -- -- -- Bearing 1
42b** 106550 Bearing 1
43 473507 Spacer 1
44 109507 Spring 1
45 106535 Center Housing 1

46 109960 Kit, Selector 1
Items 15 (563101), 21 (561563), 31 (554964),
32 (561564), 33 (561565) & 42 (106550).
* Use the Part No. shown if Item 46 (Selector Kit) has not been installed (see Note below).
** Use the Part No. shown if Item 46 (Selector Kit) has been installed (see Note below).
*** The Selector Kit (Item 46) must be installed when replacing the original part (see Note below).
Note: The Selector Kit has been installed if Item 32 (Pad) has a shaft diameter of 0.393in. (9.98mm). The
original Pad has a shaft diameter of 0.470in. (11.94mm).
R/07-- 2000 - 3- 8- CATALOG B398

FRONT AXLE CASING ASSEMBLY
APPLY LOCTITE TEFLON 30534
1 551807 Central Casing 1 All

2 420431 Air Breather 1
3 474304 L.H. Housing 1
4 133296 Magnet Plug 3
5 106533 ”O” Ring 4

6 473518 ”O” Ring 2
8 561356 Cover 1
9 476251 Circlips 1
11 109499 R.H. Housing 1
12 106530 Plug 1
13 106537 Plug 1
14 107796 Plug 1
15 106010 Bleeder Screw 1
CATALOG B398 - 3- 9- R/07-- 2000

BRAKE DISC ASSEMBLIES
1 133199 Screw 2 All

2 106567 Spacer 2
3 105988 Change Lever 2
4 106019 Screw 8
5 106597 Flange 2
6 106598 Spacer 2
7 133025 ”O” Ring 2
10* 473508 Ring 8
11 551629 Axle 6
12 475796 Complete Disc Brake 10
13 477279 Intermediate Disc 10
14 561573 Spacer 2
15 107284 Lever, L.H. 1
R/07-- 2000 - 3 - 10 - CATALOG B398

16 106027 Plug 2 All

17 107285 Lever, R.H. 1
18* 476819 Snap Ring 8
19* 106609 Spring 16
20* 105305 Snap Ring 8
21* 106610 Ring 8

22* 655932074071 Ring 8
23* 473510 Piston 8
24 107286 Pusher 4
25 108056 Grub Bolt 2
26 900894100571 Nut 2
27 109498 Bracket 2
28 474149 Screw 4
29 107283 Spacer 2
30 493648 Kit, Brake Piston 8
* Included in Brake Piston Kit 493648 (Item 30).
CATALOG B398 - 3 - 11 - R/07-- 2000

DIFFERENTIAL LOCKING ASSEMBLY
4 5
6
3 7
6
2
8
9
10 3
11 1
12
13
14
16
15
17
18 APPLY ANTI--SEIZE LUBRICANT
1 425847 Shaft 1 CP & CP--PS Only

2 425229 Pedal Weldment 1 All
3 B5176 Ring, Retaining 1/2
4 K87907 Fitting, Grease 1
6 K33796 Nut, Hex 2
7 425228 Pivot 1
8 K20346 Bolt, hex 2
10 424913 Bracket Weldment 1
11 424920 Cable Assembly 1
12 B1074 Spring 1
13 423307 Clevis 1
14 423440 Pin, Clevis 1
15 K33796 Nut, Hex 1
16 424917 Bracket Weldment 1
18 KN601815 Bolt, Hex 2
R/07-- 2000 - 3 - 12 - CATALOG B398

SECTION 4
STEERING SYSTEMS
DESCRIPTION PAGE
STEERING AXLE ASSEMBLY, 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--2
STEERING AXLE & SUPPORT, 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--6
STEERING HYDRAULICS, 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--8
STEERING CYLINDER, 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--10
STEERING AXLE & SUPPORT, 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--11
STEERING AXLE ASSEMBLY, 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--12 thru 4--20
DRIVE SHAFT, 4WD STEERING AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--21
HYDRAULICS, 4WD STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--22
CATALOG B398 - 4- 1- R/07-- 2000

STEERING AXLE ASSEMBLY, 2WD
32
33
29
33
34 28
27
35
31
36 30 26
1
36 25
24
3
23
8 38
10 36
39
37
40
39
21
2 22
20
19 23
18 25
4
17
11
5J 26
12
(13,14,15,16) 29
9
5B 6
7
5C
5D
5E 8
5F 5K
5G
5H 5
5I 5A
APPLY LUBRICATING GREASE
R/07-- 2000 - 4- 2- CATALOG B398

493133 Steer Axle, Complete 1 M230 & M240

496102 Steer Axle, Complete 1 M250 only
1 425675 Axle Weldment 1 M230 & M240

1 426043 Axle Weldment 1 M250 only
2 422252 Steer Cylinder 2 All
3 423994 Spindle Arm Assembly (R.H.) 1
4 423995 Spindle Arm Assembly (L.H.) 1
5 421318 Hub Assembly 2
5A 421116 Nut, Lug 8 per Hub

5B 421538 Washer, Felt 1 per Hub
5C 421307 Seal, Grease 1 per Hub
5D 421305 Bearing, Inner 1 per Hub
5E 421303 Hub Casting 1 per Hub
5F 421306 Bearing, Outer 1 per Hub
5G 421309 Washer, Spindle 1 per Hub

5H 421310 Nut, Slotted 1 per Hub
5I 421304 Dust Cover 1 per Hub
5J 421315 Bolt, Lug 8 per Hub
5K 421311 Pin, Cotter 1 per Hub
6* 421458 Cylinder End 2

7 421536 Machined Washer 2
8 K72071 Cotter Pin 4
9** 421457 Tie Rod End (L.H.) 1
10** 421456 Tie Rod End (R.H.) 1
11 421377 Tie Rod 1
12 421459 Clamp Assembly 2
13 K20538 Bolt, Hex 2

14 -- -- -- -- Clamp (Included w/ Item 12) 2
16 K33845 Nut, Hex 2
17 K33946 Nut, Hex--Jam 2
18 K45754 Bolt, Hex 2
* Includes required hardware, except Item 8 (Cotter Pin) and Item 7 (Washer) which are purchased separately.
** Includes a Castle Nut, Grease Fitting & Cotter Pin.
CATALOG B398 - 4- 3- R/07-- 2000

THIS PAGE LEFT BLANK INTENTIONALLY
R/07-- 2000 - 4- 4- CATALOG B398

19 K33799 Nut, Hex 2 All

20 K20468 Bolt, Hex 2
21 421520 Bearing, Thrust 2
22 426131 Shim A/R
23 426041 Bushing 4
24 426042 Pin, King 2
25 K134 O--Ring 4
26 425674 Cover, King Pin 4
27 R13351--3 Washer, Lock 8
28 K302210 Bolt, Hex 8
29 K87901 Fitting, Grease 4
30 K71C5301 Pin, Cylinder 2

32 K20468 Bolt, Hex 1
33 B3698--9 Clamp, Hose 2
35 K33799 Nut, Hex 1
36 R19452--6 Fitting, Hose 3

CATALOG B398 - 4- 5- R/07-- 2000

STEERING AXLE & SUPPORT, 2WD
13
14
2*
7
3 ** 15
5
6
7 16
12
9
11 8
10
8
4 **
1 493133 Steer Axle, (includes hoses) 1 M230 & M240

1 496102 Steer Axle, (includes hoses) 1 M250 only
2a* 496096 Hanger, Axle 1 77” Cab

2b* 496095 Hanger, Axle 1 81” Cab
2c* 496094 Hanger, Axle 1 84” & 95” Cab
* Universal Radiator Brackets (see Section 7) must be utilized when installing this new style Axle Hanger.
R/07-- 2000 - 4- 6- CATALOG B398

3** 421181 Bushing, Front 1 All

4** 421128 Bushing, Rear 1
5 421180 Pin (Front) 1
6 421510 Bearing Cover (Front) 1
7 K302264 Screw, Socket Head 4
8 K87901 Grease Fitting 2

9 426247 Washer, Thrust 2
10 421237 Pin (Rear) 1
11 K58758 Bolt, Hex 1
12 B5091 Cover, Bearing 6
13 426688 Bolt, Hex 6

15 R32 Nut, Lock 6
16 424959 “D” Ring (Welding required) 2
** Included with Item 2.
CATALOG B398 - 4- 7- R/07-- 2000

STEERING HYDRAULICS, 2WD
14
13
15
5 FROM PUMP
4 16
6 17
3
2 7 21
1
19
20 18
8 12 TO
HYDRAULIC
11 22 TANK
37 24
29
TO
9 28 STEERING
36 25 AXLE
26
10 35 27 32
33
34
23
32
33 31
34
30
32
33
34 APPLY TEFLON TAPE
1a 426175 Valve, Steering 1 All

1b 492771 Seal Kit, Steering Valve 1
2a 426176 Steering Column (12 3/8” lg) 1 All except 95” Cab
2b 492122 Steering Column (18 1/2” lg) 1 95” Cab only
3 B1828 Wheel, Steering 1
4 B1829 Nut 1
5 B2007 Cover, Steering Wheel 1
R/07-- 2000 - 4- 8- CATALOG B398

6 K20348SS Bolt, Hex 4 All

8 R18147--4 Fitting 2
9 426178 Check Valve Fitting 1
10 R19452--8 Elbow Fitting 1
11 426460 Fitting 1
13 R18147--9 Fitting 2
15 426174 Flow Divider Valve 1
16 K33797 Nut 2
18 K45546 Bolt 2
19 R18147--4 Fitting 1
21 R18147--6 Fitting 1
22 R19831--2 Tee Fitting 1
24 425126 Fitting 1
25 424921 ”T” Connector 1

26 B109A90 Adaptor 1
27 KHI1616 Fitting 1
28 B116A10--2 Pipe 1
29a 422140 Filter & Assembly 1
29b 422141 Hydraulic filter 1

32 425069 Clamp 5
34 K20426 Bolt, Hex 5
35 425071 Plate, mounting 4
36 425065 Clamp 4 pair
37 K20464 Bolt, mounting 8
CATALOG B398 - 4- 9- R/07-- 2000

STEERING CYLINDER, 2WD
4*
12
3*
8
9
6*
10
1*
11
2
3*
4*
5*
NOTE: APPLY HYDRAULIC FLUID TO INTERNAL

COMPONENTS DURING ASSEMBLY.
422252 Cylinder Assembly 2 All

1* -- -- -- -- Wiper 1
2 422257 Cylinder Head 1
3* -- -- -- -- Back Up Ring 3
4* -- -- -- -- ”O”Ring 2
5* -- -- -- -- Back Up Ring 2
6* -- -- -- -- ”O”Ring 1
7 422251 Piston Assembly 1
8 492862 Cylinder Piston 1
9 K55700 Lock Nut 1

10 R4573--5 Lock Wire 1
11 422253 Barrel Assembly 1
12 422252K Seal Kit 1
(Includes dwg. 422252)
* Items included in Seal Kit 422252K (Item 12).
R/07-- 2000 - 4 - 10 - CATALOG B398

STEERING AXLE & SUPPORT, 4WD
1
3
4
5
11 6
10
9
7
8
APPLY LOCTITE 242
1* 496093 Steering Axle Hanger 1 84” & 95” Cab

2 426688 Bolt, Hex 6
3 K44746 Flat Washer 6
4 R32 Nut, Self--locking 6

5 424959 “D” Ring 2 welding required
6 495930 Steering Axle, 4WD Clark--Hurth 1
w/ Mountings & Bushings
9 495207 Drive Shaft, Steer Axle w/ U--Joints 1

10 426604 Bolt, Hex 8
11 426605 Nut, Lock 8
* Universal Radiator Brackets (see Section 7) must be utilized when installing this new style Axle Hanger.
CATALOG B398 - 4 - 11 - R/07-- 2000

4
2
3
1 495930 Steering Axle, 4WD, Complete 1 4WD

(Includes Items 2 thru 5)
2 477538 Bushing 2
3 495894 Axle Bracket 2
4 51534 Grease Fitting 2
5 477964 Coupling 4
R/07-- 2000 - 4 - 12 - CATALOG B398

6
4
1 5
2
7
1 420431 Vent Plug 1 4WD

2 106533 O--Ring 2
3 474303 Central Casing 1
4 106537 Locking Screw 4
5 474296 Plug 1
6 133044 Circlip 1
7 133296 Magnetic plug 1
8 106530 Locking Screw 1
CATALOG B398 - 4 - 13 - R/07-- 2000

2 4 5 6 7 3 9 10 11 12
26
9 8
14
15
26
1 4
13 10
23
16
17
21
25
24
23 19
18
22
20
1 133173 Bolt 8 4WD

2 562103 Cover 1
3 561362 Planetary Gear 2
4 491864 Pin 3
5 106559 Shaft 2
6 106558 Washer 4
7 561363 Planetary Gear 4
8 474302 Diagonal Brace 1
9 106555 Washer 2
10 495893 Pinion Gear Set 1
R/07-- 2000 - 4 - 14 - CATALOG B398

11 109948 Differential Housing 1 4WD

12 106550 Bearing 2
13 106561 Shaft 1
14 109949 Bolt 16
15 108556 Washer 16
16 133564 Spacer 1
17 447817 Nut 1
18 107292 Nut 1
19 133026 O--Ring 1
20 109500 Flange 1

22 107293 Seal 1
23 494842 Bearing 2
24a 550555 Shim (0.10mm, 0.004in) A/R

24b 550556 Shim (0.15mm, 0.006in) A/R
24c 550557 Shim (0.30mm, 0.012in) A/R
24d 551616 Shim (0.40mm, 0.016in) A/R
24e 552517 Shim (0.50mm, 0.020in) A/R
25a 552516 Shim (0.10mm, 0.004in) A/R

25b 551615 Shim (0.15mm, 0.006in) A/R
25c 474298 Shim (0.20mm, 0.008in) A/R
25d 474300 Shim (0.30mm, 0.012in) A/R
26a 133136 Shim (0.10mm, 0.004in) A/R

26b 552515 Shim (0.15mm, 0.006in) A/R
26c 133137 Shim (0.25mm, 0.010in) A/R
26d 133138 Shim (0.30mm, 0.012in) A/R
26e 478022 Shim (0.40mm, 0.016in) A/R
CATALOG B398 - 4 - 15 - R/07-- 2000

CONTENTS
42
5
PARTS INDEX
Alphabetical Contents
R/07-- 2000 - 4 - 16 - CATALOG B398

1 549233 Lateral Axle Case 2 4WD

2 58548 Nut 2
3 474306 Allen Bolt 2
4 552541 Pivot Pin 4
5 58546 Bolt 16
6 107738 Washer 16
7a 105660 Shim (0.10mm, 0.004in) A/R

7b 550584 Shim (0.15mm, 0.006in) A/R
7c 105662 Shim (0.50mm, 0.020in) A/R
8 105664 Seal 4
9 133029 Bushing 4
10 106583 Spacer 6
11 562126 Steering Case, L.H. 1
12 562127 Steering Case, R.H. 1
13 42741 O--Ring 2
14 105938 Seal 2
15 106578 Spacer 2
16 160904 Roller Bearing 4
17 106800 Wheel Stud 16
18 473512 Wheel Hub 2
19 109481 O--Ring 2
20 109480 Wheel Nut 16
21 106592 Snap Ring 2
22 474689 Ring Gear Bracket 2
23 106568 Pin 8
24 109487 Locking Plate 2
25 548661 Gear 2
26 106576 Gear Ring 2
27 106579 Circlips 2
28 473514 Washer 2
29 474158 Planet Wheel Bracket 2
30 5374 Seal 2
31 106586 Plug 2
32 474160 O--Ring 6
33 474159 Shaft 6
34 133197 Screw 4
35 133078 Bearing 12
36 106573 Planet Wheel 6
37 474161 Washer 6
38 109497 Bolt 8
39 455701 Washer 2
CATALOG B398 - 4 - 17 - R/07-- 2000

R/07-- 2000 - 4 - 18 - CATALOG B398

40a 550564 Shim (0.10mm, 0.004in) A/R 4WD

40b 106589 Shim (0.15mm, 0.006in) A/R
40c 106590 Shim (0.20mm, 0.008in) A/R
40d 109483 Shim (0.30mm, 0.012in) A/R
40e 106591 Shim (0.50mm, 0.020in) A/R
41 108247 Bearing 2
42 108381 Snap Ring 2
43 108380 Seal 2
44 108379 Dust Excluder 2
45 549234 Drive Shaft, Inner 2
46 108794 O--Ring 2
47 108383 Reduction Bushing Kit 2

48 108100 Seal 2
49 125016 Bearing 2
50 105424 Circlip 2
51 133044 Circlip 2
52 474312 Adjusting Screw 4
53 474313 Nut 4
54 474314 Nut 8
55 552521 Bolt 20
56 133276 Plug 2
57 478042 Stud 8
CATALOG B398 - 4 - 19 - R/07-- 2000

1 5
2
4
5
6
1
1 549235 Tie--Rod Link 2 4WD

2 474684 Steering Cylinder 1
3 108794 O--Ring 1
4 133191 Bolt 5
5 550659 Rubber Boot 1
6 561909 Seal Kit, Steering Cylinder 1
R/07-- 2000 - 4 - 20 - CATALOG B398

DRIVE SHAFT, 4WD STEERING AXLE
2
1
4
8
3
6
7
4
3
APPLY LOCTITE 242
1 495207 Drive Shaft Complete 1 4WD

2 109756 Yoke, Flange (8 bolt pattern) 1
3 424647 Joint, Universal 2
4 162809 Fitting, Grease 3
5 109755 Seal 1
6 425330 Fastening Flange 2
7 426264 Shaft End 1
8 109752 Screw 4
CATALOG B398 - 4 - 21 - R/07-- 2000

HYDRAULICS, 4WD STEERING
14
13
FROM PUMP
15
5 36
30
4 16
6 17
3
2 7 21
1
19
20 18
8 12
TO
11 22 HYDRAULIC
TANK
24
35
29
9 28 31
25 35
26
27
10
23
32
33
34
32
33
34 APPLY TEFLON TAPE
1a 492120 Valve, Steering 1 All

1b 492771 Seal Kit, Steering Valve 1
2 492122 Steering Column, 18 1/2” lg 1 95” Cab Only
2 426176 Steering Column 1 84” Cab Only
3 B1828 Wheel, Steering 1 All
4 B1829 Nut 1
5 B2007 Cover, Steering Wheel 1
R/07-- 2000 - 4 - 22 - CATALOG B398

6 K20348SS Bolt, Hex 4 All

8 R18147--4 Fitting 2
9 426178 Check Valve Fitting 1
10 R19452--8 Elbow Fitting 1
11 426460 Fitting 1
13 R18147--9 Fitting 2
15 426174 Flow Divider Valve 1
16 K33797 Nut 2
18 K45546 Bolt 2
19 R18147--4 Fitting 1
21 R18147--6 Fitting 1
24 425126 Fitting 1
25 424921 ”T” Connector 1

26 B109A90 Adaptor 1
27 KHI1616 Fitting 1
28 B116A10--2 Pipe 1
29 422140 Filter & Assembly 1

32 425069 Clamp 7
34 K20426 Bolt, Hex 7
35 494989 Fitting 2
36 K71--8 Fitting, Elbow A/R Early Models only
CATALOG B398 - 4 - 23 - R/07-- 2000

R/07-- 2000 - 4 - 24 - CATALOG B398

SECTION 5
TRANSMISSION & SHIFT LEVERS
DESCRIPTION PAGE
2WD/4WD GEAR BOX, CONVERTER & MOUNTINGS . . . . . . . . . . . . . . . . . . . . . . . 5--2
2WD GEAR BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--4
4WD GEAR BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--12
ELECTRICAL CONTROL VALVE, 2WD/4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--20
CATALOG B398 - 5- 1- R/07-- 2000

2WD/4WD GEAR BOX, CONVERTER & MOUNTINGS
TORQUE CONVERTER INSTALLATION NOTICE:

1.) ASSEMBLE TORQUE CONVERTER (ITEM 30) AND FLEX PLATE (ITEM 32) TO TRANSMISSION WITH A
SPACER PLATE (ITEM 31) INSTALLED ON BOTH SIDES OF THE FLEX PLATE.
2.) TEMPORARILY ASSEMBLE TRANSMISSION TO THE ENGINE USING FOUR BOLTS EQUALLY SPACED.
3.) REMOVE THE FLYWHEEL HOUSING ACCESS COVER. IF THE TORQUE CONVERTER CAN BE ROTATED BY
HAND, NO FURTHER ADJUSTMENTS ARE REQUIRED. IF THE TORQUE CONVERTER CANNOT BE ROTATED,
THE SPACER PLATE BETWEEN THE TORQUE CONVERTER AND THE FLEX PLATE MUST BE REMOVED.
20 8
CAB FLOOR
19
9
17
4
16 14
15
22
13
1
10
2
TRANS. 3
BOLT 11
10
12
21
18
23 30
7
31
6
32
27
26
25 34
24 35 31 33
29 29
28 28
APPLY LOCTITE 242
R/07-- 2000 - 5- 2- CATALOG B398

1a 205374 Gear Box, less Converter 1 2WD

Trans. S/N: 156xxx & 157xxx
1b 222572 Gear Box, less Converter 1 2WD
Trans. S/N: 159xxx & above
1c 206974 Gear Box, less Converter 1 4WD
1d 222573 Gear Box, less Converter 1 4WD
2 KN605803 Bolt, Hex 12
4 425895 RH Trans. Mount 1 77” & 81” Cab
4 424860 RH Trans. Mount 1 84” & 95” Cab
5 425896 LH Trans. Mount 1 77” & 81” Cab
5 424861 LH Trans. Mount 1 84” & 95” Cab
6 KN605559 Bolt, Hex 8

10 424193 Washer, Flat 4
11 424194 Mount, Rubber 2
12 K34981 Nut, Lock 2
13 495928 Bracket, Bulkhead 1

14a 425972 Lever, Gear Shift 1 77” & 81” Cab
14b 496809 Lever, Gear Shift 1 84” Cab
14c 495321 Lever, Gear Shift 1 95” Cab
15 K20548 Bolt, Hex 1
17 K33845 Nut, Hex 1
18 78617 Ring, Shifter 1
19 M100A1 Knob 1
20 K20384 Bolt, Hex 4
22 78088 Boot, Shifter 1
23 K33795 Nut, Hex 4
24 495916 Trans. Tube, Modified 1
25 205785 Cap, Oil Tube 1

26 4039 O--Ring 1
27 76333 Dipstick, Transmission 1
28 KN605558 Bolt, Hex 2
30 209372 Torque Converter 1
31 209374 Spacer 2
32 209373 Flex Plate 1
33 209376 Bolt, Hex 6
34 209375 Bolt, Hex 6
35 209573 Washer, Flat 6
CATALOG B398 - 5- 3- R/07-- 2000

2WD GEAR BOX ASSEMBLY
205374 Gear Box, less Converter 1 2WD

1 561840 Transmission Housing 1

2 561841 Trans. Rear Case 1
3 550705 Plug 13
4 189956 O--Ring 13
5 109727 Screw 13
6 109703 Centering Pin 2

7 561833 O--Ring 3
8 561835 Plug 1
9 189956 O--Ring 1
10 473366 Drain Plug 1
11 171155 O--Ring 1
12 109705 Air Breather 1
13 549100 Oil Pressure Switch 1
14a 561832 Control Valve 1 Trans. S/N: 156xxx & 157xxx
14b 563914 Control Valve 1 Trans. S/N: 159xxx & above
R/07-- 2000 - 5- 4- CATALOG B398

15 561829 Screw 4 2WD

16 561837 Filter Housing 1
17 109646 Gasket 1
18 109658 Connection 1
19 561749 Oil Filter 1
20 109728 Screw 2
21 561836 Ball 1
22 561765 Spring 1
23 561827 O--Ring 1
24 561828 Plug 1
25 561822 Plug 2
26 561834 Plug 1
27 109989 Pump, Complete 1
28 109690 Seal 1
29 109676 O--Ring 1
30 561760 Screw 4
31 479270 Washer 4
32 552502 Oil Temp. Sensor 1
33 189956 O--Ring 1
34 109565 Strainer 1
35 550626 Washer 1
36 109712 O--Ring 1
37 473368 Cover 1
38 109732 Screw 2
39 561830 Valve 1
40 561946 Seal Kit 1
41 561823 Pressure Valve 1

42 561945 Seal Kit 1
43 562040 Upper Seat 1
44 561816 Gear Lever Foot 1
45 109681 Pin 1
46 561820 Clamp 1
47 109612 Dust Cover 1
48 561821 Clamp 1
49 561760 Screw 3
50 561761 Washer 3
CATALOG B398 - 5- 5- R/07-- 2000

R/07-- 2000 - 5- 6- CATALOG B398

60 561931 Pump Kit A/R 2WD

(Items 27, 29 & 31)
61 561934 Small Parts Kit A/R

(Includes Items 3, 21, 22, 45, 46, 47, 48,
also on the following pg, Items 54, 55 & 56)
62 562002 Seal Kit A/R

(Includes Items 4, 7, 11, 23, 36,
also on the following pg, Items 8, 10, 49 & 57)

(Includes Items 25, 26, 28, 29, 31,
also on the following pg, Items 6, 7, 9, 40 & 47)
64 562006 Valves Kit A/R

(Includes Items 14, 39 & 41)
65 561942 Repair Kit A/R

(Includes Items 17, 61, 62, 63,
also on the following pg, Items 70, 73, 76, 77, & 78)
CATALOG B398 - 5- 7- R/07-- 2000

2WD GEARBOX ASSEMBLY (CONT.)
1 561791 Reverse Idler Gear 1 2WD

2 109701 Bearing 4
3a 109615 Shim 0.002in. (0.051mm) A/R

3b 109616 Shim 0.003in. (0.076mm) A/R
3c 109617 Shim 0.005in. (0.127mm) A/R
3d 109618 Shim 0.007in. (0.178mm) A/R

3e 109619 Shim 0.015in. (0.381mm) A/R
3f 109620 Shim 0.020in. (0.508mm) A/R
R/07-- 2000 - 5- 8- CATALOG B398

4 109597 Spacer 1 2WD

5 561792 Input Shaft 1
6 109624 Seal 4
7 561805 Seal, Inner 2
8 561806 O--Ring 2
9 561803 Seal, Outer 2
10 561804 O--Ring 2
11 561802 Piston 2
12 561797 Clutch Disc 12
13 561798 Friction Disc 12
14 561796 Plate 2
16 561801 Spring 2
17 561800 Bushing 2
19 561789 Thrustwasher 2
20 561793 Forward Primary Gear 1

22 561809 Spacer 2
23 561762 Bearing 2
24 561764 Bracket 2
25 561794 Reverse Primary Gear 1
26 561790 Countershaft 1
27 976003220871 Bearing 1
28 561786 Bearing 1
29a 109599 Shim 0.002in (0.051mm) A/R

29b 109600 Shim 0.003in (0.076mm) A/R
29c 109601 Shim 0.007in (0.178mm) A/R
29d 109602 Shim 0.022in (0.559mm) A/R
CATALOG B398 - 5- 9- R/07-- 2000

30 109598 Spacer 2 2WD

31 561785 Output Shaft 1
32 561775 3rd Gear 1
33 561776 2nd Gear 1
34 109586 Coupling 2
35 109665 Synchro Assembly 1
37 561774 4th Gear 1
38 561784 Washer 1
39 561788 Bearing 1
40 109679 Plug 1

42 109568 Output Shaft, 1st Gear 1
43 109621 Bearing 2
44 109653 Spacer 1
46 551373 Spacer 1
47 109656 Seal 1
48 561807 End Yoke 1
49 550636 O--Ring 1
50 109798 Washer 1
51 561810 Screw 1
52 561814 1st & 2nd Shift Rod 1
53 561815 3rd & 4th Shift Rod 1
54 109709 Ball 3
55 473920 Spring 2
56 550705 Plug 1
57 189956 O--Ring 1
58 561812 1st & 2nd Shift Fork 1
59 561813 3rd & 4th Shift Fork 1
60 109737 Dog Point Screw 2
R/07-- 2000 - 5 - 10 - CATALOG B398

70 561932 Clutch Pack Kit (Items 7 thru 18) A/R 2WD
71 561933 Clutch Pack Kit (Items 5 & 70) A/R

(Items 54, 55 & 56. Also on page 5 -- 4;
Items 3, 21, 22, 45, 46, 47 & 48)
73 561935 Bearing Kit A/R

(Items 2, 21, 23, 27, 28, 39, 43 & 45)

(Items 8, 10, 49 & 57. Also on page 5 -- 4;
Items 4, 7, 11, 23 & 36)

(Items 6, 7, 9, 40 & 47. Also on page 5 -- 4;
Items 25, 26, 28, 29 & 31)
76 562932 Circlip Kit (Items 15, 18 & 36) A/R
77 561939 Washer Kit (Items 3 & 29) A/R
78 561940 Thrust Washer Kit A/R

(Items 19, 24 & 38)

(Items 70 and 72 thru 78. Also on page 5 --4;
Item 17)
CATALOG B398 - 5 - 11 - R/07-- 2000

4WD GEARBOX ASSEMBLY

1 561757 Transmission Housing 1

2 561758 Transmission Rear Case 1
3 550705 Plug 13
4 189956 O--ring 13
5 561759 Screw 4
6 109703 Centering Pin 2

7 109727 Screw 13
8 561833 O--Ring 4
9 561825 Pipe 1
10 561824 Nut 2
11 561826 Seal 2
12 561835 Plug 1
13 189956 O--Ring 1
14 473366 Drain Plug 1
15 147915 O--Ring 1
R/07-- 2000 - 5 - 12 - CATALOG B398

16 109705 Air Breather 1 4WD

17 549100 Oil Pressure Switch 1
18a 561832 Electric Control Valve 1 Trans. S/N: 156xxx & 157xxx
18b 563914 Electric Control Valve 1 Trans. S/N: 159xxx & above
19 561829 Screw 4
20 561831 Solenoid 1
21 561837 Filter Housing 1

22 109646 Gasket 1
23 109658 Connector 1
24 561749 Oil Filter 1
25 109728 Screw 2
26 561836 Ball 1
27 561765 Spring 1
28 561827 O--Ring 1
29 561828 Plug 1
30 561822 Plug 2
31 561834 Plug 1
32 109989 Pump, Complete 1
33 109690 Seal 1
34 109676 O--Ring 1
35 561760 Screw 4
36 479270 Washer 4
37 552502 Oil Temp Sensor 1
38 189956 O--Ring 1
39 109565 Suction Strainer 1
40 550626 Washer 1
41 109712 O--Ring 1
42 473368 Cover 1
43 109732 Screw 2
44 561830 Valve 1
45 561946 Seal Kit 1
46 561823 Over--Pressure Valve 1

47 561945 Seal Kit 1
48 562040 Upper Seat 1
49 561816 Gear Lever Foot 1
50 109681 Pin 1
CATALOG B398 - 5 - 13 - R/07-- 2000

R/07-- 2000 - 5 - 14 - CATALOG B398

51 561820 Clamp 1 4WD

52 109612 Dust Cover 1
53 561821 Clamp 1
54 561760 Screw 3
55 561761 Washer 3
60 561931 Pump Kit (Items 32, 34 & 36) A/R

(Items 3, 26, 27 & 50 thru 53. Also on the
following page, Items 73, 74 & 75)

(Items 4, 8, 15, 28, 38 & 41. Also on the
following page, Items 8, 10, 49, 62, 64 & 76)

(Items 30, 31, 33, 34 & 36. Also on the
following page, Items 6, 7, 9, 47, 53, 61 & 65)
64 561941 Valves Kit (Items 18, 20, 44 & 46) A/R

(Items 22, 61, 62 &63. Also on the
following page, Items 90, 93, 96, 97 & 98)
CATALOG B398 - 5 - 15 - R/07-- 2000

4WD GEARBOX ASSEMBLY (CONT.)
1 561791 Reverse Idler Gear 1 4WD

2 109701 Bearing 4
3a 109615 Shim 0.002in. (0.051mm) A/R

3b 109616 Shim 0.003in. (0.076mm) A/R
3c 109617 Shim 0.005in. (0.127mm) A/R
3d 109618 Shim 0.007in. (0.178mm) A/R

3e 109619 Shim 0.015in. (0.381mm) A/R
3f 109620 Shim 0.020in. (0.508mm) A/R
4 109597 Spacer 2
5 561792 Input Shaft 1
R/07-- 2000 - 5 - 16 - CATALOG B398

6 109624 Seal 4 4WD

7 561805 Seal, Inner 2
8 561806 O--Ring 2
9 561803 Seal, Outer 2
10 561804 O--Ring 2
11 561802 Piston 2
12 561797 Clutch Disc 12
13 561798 Friction Disc 12
14 561796 Plate 2
16 561801 Spring 2
17 561800 Bushing 2
20 561793 Forward Primary Gear 1

22 561809 Spacer 2
23 561762 Bearing 2
24 561764 Bracket 2
25 561794 Reverse Primary Gear 1
26 561790 Countershaft 1
27 976003220871 Bearing 1
28 561786 Bearing 1
29a 109599 Shim 0.002in (0.051mm) A/R

29b 109600 Shim 0.003in (0.076mm) A/R
29c 109601 Shim 0.007in (0.178mm) A/R
29d 109602 Shim 0.022in (0.559mm) A/R
30 109598 Spacer 2
32 561775 3rd Gear 1
33 561776 2nd Gear 1
CATALOG B398 - 5 - 17 - R/07-- 2000

36 109664 Circlips 1 2WD

37 561774 4th Gear 1
38 561784 Washer 1
39 561788 Bearing 1
40 109679 Plug 1

42 109568 Output Shaft, 1st Gear 1
43 109621 Bearing 2
44 109653 Spacer 1
46 561777 Output Shaft Drive Gear 1

47 109656 Seal 2
48 561807 End Yoke 1
49 550636 O--Ring 2
50 109798 Washer 2
51 561810 Screw 2
53 561778 O--Ring 1
54 561772 Gear, 37 Teeth 1
56 561839 Spacer 1
58 561787 Bearing 2
59a 561780 Shim 0.002in. (0.051mm) A/R

59b 561781 Shim 0.003in. (0.076mm) A/R
59c 561782 Shim 0.007in. (0.178mm) A/R
59d 561783 Shim 0.024in. (0.601mm) A/R
60 561779 Spacer 1
61 561763 Seal 1
62 561766 O--Ring 1
64 561818 O--Ring 1
65 561819 Seal 1
R/07-- 2000 - 5 - 18 - CATALOG B398

66 561769 Spring 1 4WD

67 561770 Spring Bracket 1
69 561808 Spacer 1
70 561807 End Yoke 1
71 561814 1st & 2nd Shift Rod 1

72 561815 3rd & 4th Shift Rod 1
73 109709 Ball 3
74 473920 Spring 2
75 550705 Plug 1
76 189956 O--Ring 1
77 561812 1st & 2nd Shift Fork 1
78 561813 3rd & 4th Shift Fork 1
79 109737 Dog Point Screw 2
90 561932 Clutch Pack Kit (Items 7 thru 18) A/R
91 561933 Clutch Pack Kit (Items 5 & 90) A/R

(Items 73, 74 & 75. Also on page 5 -- 12;
Items 3, 26, 27, 50, 51, 52 & 53)
93 561935 Bearing Kit A/R

(Items 2, 21, 23, 27, 28, 29, 43, 45 & 58)

(Items 8, 10, 49, 62, 64 & 76)

(Items 6, 7, 9, 47, 53, 61 & 65. Also on
page 5 -- 12; Items 30, 31, 33, 34 & 36)
96 562938 Circlip Kit (Items 15, 18, 36 & 68) A/R

97 561939 Washer Kit (Items 3, 39 & 59) A/R
98 561940 Thrust Washer Kit A/R
(Items 19, 24 & 38)
99 562148 Repair Kit (Items 90 & 92 A/R

thru 98. Also on page 5 -- 12; Item 22)
CATALOG B398 - 5 - 19 - R/07-- 2000

ELECTRICAL CONTROL VALVE, 2WD/4WD
1a 561832 Control Valve, Complete 1 Trans. S/N: 156xxx & 157xxx

1b 563914 Control Valve, Complete 1 Trans. S/N: 159xxx & above
2 561944 Solenoid 2
3 561943 Seal Kit 1
4 562043 Plug 4
R/07-- 2000 - 5 - 20 - CATALOG B398

For engine components not found in this section, contact your nearest Perkins or Caterpillar Dealers.
SECTION 6
ENGINE, ALTERNATOR & STARTER
DESCRIPTION PAGE
ENGINE & MOUNTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--2
WATER TEMP. SENDER & MISC. ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . 6--3
STARTER MOTOR & ENGINE FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--4
ENGINE BUILD NO.’S

There are two types of engine “builds” for the “M” Series Forklift Trucks: the Hydrostatic Build and
the 4--Speed Convertor Build. However, there are many engine Build No.’s which are used to dis-
cribe the engines. The Build No.’s shown on the following parts page are the most common, but do
not include all engine Build No.’s. The Build No.’s vary depending on engine specs. and availability.
When ordering a new engine it is important to state the Build No. on your current engine and the Lift
Truck Serial No..
CATALOG B398 - 6- 1- R/07-- 2000

ENGINE & MOUNTINGS

4 1, 2 & 3
see below
8a
11
12
12
5
13
9
Apply Teflon Tape on bolt threads installed into
engine block and Loctite 242 on bolt threads 10
installed in flywheel housing. 8b
1a* 495203 Cat 3054 Diesel Engine, Bosch Electrics 1 Build No.: 145--9239
1b* 494885 Perkins 1004 Diesel Engine, Delco Electrics 1 Build No.: AR70413
1c* 496656 4.2 L Cat Diesel Engine, Bosch Electrics 1 Build No.: 1802732
1d* 496658 4.2 L Perkins Diesel Engine, Magnetti Electrics 1 Build No.: AR70413
1e* 496769 4.2 L Cat Diesel Engine, Magnetti Electrics 1 Build No.: 1802793
2a 494436 Alternator, Bosch 1 Caterpillar

2b 426368 Alternator, Delco 1 Perkins
2c 496325 Alternator, Magnetti 1 requires 3--prong connector
3a 495829 Fan Belt 1 All Perkins (except 4.2L)
3b 496234 Fan Belt 1 All Cats (except 4.2L)
3c 496816 Fan Belt 1 All 4.2L Engines
4a 494438 Water outlet 1 Caterpillar

4b -- -- -- -- Water outlet (see next page) 1 Perkins
5a 424858 Bracket, Front of engine 2 95” & 84” Cabs
5b 425903 Bracket, Front of engine 2 81” & 77” Cabs
6 -- -- -- -- Bracket, Trans. (not shown) 2 see Section 5
7 K304962 Bolt, Hex 4 All
8a K44744 Washer, Flat 4
8b 424193 Washer, Flat 8
9 424194 Rubber Mount 4

10 K34981 Nut, Lock 4
11 KN630360 Washer, Internal Star 16
12a KN605815 Bolt, Hex 16 Current Models
12b 448054 Stud 16 Early Models
13 K34670 Nut, Hex 16 Early Models
* Before ordering a new engine, see Engine Build No’s. on previous page.
R/07-- 2000 - 6- 2- CATALOG B398

WATER TEMP. SENDER & MISC. ENGINE COMPONENTS

APPLY TEFLON TAPE
see Section 8
5
1
2
4 6
CYLINDER HEAD
(REF.) 3
17
7
11
14
10 12
8
13 11
15
20 21
9
19
16
18
1 543672 Sender, Water Temp (Cat/Perkins) 1 All

2 5642 Seal, Sender 1
3* 133755 Oil Filter, Engine 1
4* 495895 Filter Head 1
5* 495896 Gasket 1
6* 495897 Dipstick (approx. 12 3/4” long) 1
7* 495898 Tube (approx. 12 3/4” long) 1
8* 495911 Tube Kit (approx. 25” long) 1

9* 561386 Fuel Lift Pump 1
10* 107353 Kit, Fuel Lift Pump 1
11 -- -- -- -- Filter, Fuel 1 see pg. 5, Filter Chart
12* 495900 Filter Head 1
13* 495901 Bolt 2
14* 495902 Nut 2
15* 495903 Bracket 1

16* 495904 Bolt 2
17 -- -- -- -- Filter Head w/Water--Fuel Filter 1 contact Cat/Perkins Dealer
18* 495905 Water Outlet 1
19* 495906 Bolt 2
20* 495907 Bolt 2
21* 495908 Plug 1
* For Perkins Engines only.
CATALOG B398 - 6- 3- R/07-- 2000

STARTER MOTOR & ENGINE FAN
6
4
3
5 8
APPLY LOCTITE 242
1a 494755 Starter Motor (Delco) 1 Early Perkins

1b (contact Cat Dealer) Starter Motor (Bosch) 1 Early Cat
1c 496326 Starter Motor (Magnetti) 1 Current Perkins/Cat
2 495844 Stud (Delco Starter) 3 Early Perkins

3 495845 Nut (Delco Starter) 3 Early Perkins
4 42232 Washer (Delco Starter) 3 Early Perkins
5a 494756 Solenoid (Delco Starter) 1 Early Perkins

5b (contact Cat Dealer) Solenoid (Bosch Starter) 1 Early Cat
5c 496332 Solenoid (Magnetti Starter) 1 Current Cat/Perkins
6 494743 Fan 1 Cat/Perkins

7 493935 Spacer 1 Cat/Perkins
8 KN630173 Washer, Lock 4 Cat/Perkins
9 KN600215 Bolt, Hex 4 Cat/Perkins
R/07-- 2000 - 6- 4- CATALOG B398

SECTION 7
COOLING SYSTEMS:
ENGINE, TRANSMISSION & DRIVE AXLE
DESCRIPTION PAGE
DRIVE AXLE COOLING SYSTEM (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--2
ENGINE/TRANSMISSION COOLING SYSTEM (RADIATOR) . . . . . . . . . . . . . . . . . 7--4
CATALOG B398 - 7- 1- R/07-- 2000

DRIVE AXLE COOLING SYSTEM (OPTIONAL)
1
7 2
3
6
5
4
12 11
13
14 10
15
31 9 8
32 INSTRUMENT
29
30 PANEL
25
26
28
27
24
23
16
18
19 22 35
17 20 33 34
21
1 424282 Cooler, Axle Oil 1 Poultry

4 K300862 Bolt, Hex 4
5 424472 Washer 4
6 Z2805 Spacer 4
7a 426104 Bracket R.H. (Shown) 1
7b 426105 Bracket L.H. (Opposite) 1
8 R18147--1 Connector 1
R/07-- 2000 - 7- 2- CATALOG B398

9 425487 Pump, Hydraulic 1 Poultry

(for more information, see Section 9, Hydraulic Systems)
10 R18147--6 Connector 1
13 425494 Adapter 2
14 425481 Filter, Flow 1
15 425494 Adapter 1
17 425494 Adapter 1
18 425542 Tee 1
19 B109A34 Reducer 1
20 425497 Switch, Temperature 1
21 425493 Adapter 2
22 425495 Adapter 1
24 B3698--12 Clamp 1
25 R19829--1 Tee, Swivel Nut Run 1

26 425551 Adapter 1
27 425552 Plug 1
28 K224--6 Tee 1
29 B114A3 Plug 1
30 425493 Fitting 1
31 425534 Filter 1
32 425533 Adapter 1
33 -- -- -- -- Wire, Temp. Switch 1
34 -- -- -- -- Wire, Connector 1
35 425496 Temp. Alarm 1
CATALOG B398 - 7- 3- R/07-- 2000

ENGINE/TRANSMISSION COOLING SYSTEM (RADIATOR)

8
7
APPLY TEFLON TAPE
6 12 APPLY LIGHT GREASE
14 13 APPLY LOCTITE 242
5
10
3
4
17
18
17
2
16
15
1
4”
12
11 10 19
13
1 492588 Radiator, Complete 1 All

2 423943 Cap, Radiator 1
3 496084 Radiator Bracket, LH Universal 1
4 496085 Radiator Bracket, RH Universal 1
8 226426 Hose, Upper 1

9* 493729 Hose, Lower 1
10 B2236--10 Clamp, Hose A/R
11 492601 Fitting 2
14 425064 Clamp, 1 piece 4
15 425070 Plate 2
16 K20520 Bolt, Hex 2
17 R18147--5 Fitting 2
18 495841 Shroud, Fan (included w/ Item 1) 1
19 493627 Tank, Lower (included w/ Item 1) 1 (soldering required)
* Cut to fit (as pictured above). Trim, but do not remove the coiled wire provided inside the hose.
R/07-- 2000 - 7- 4- CATALOG B398

SECTION 8
FUEL SYSTEM, AIR INTAKE & EXHAUST SYSTEM
DESCRIPTION PAGE
FUEL TANK, PUMP & FILTERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--2
AIR CLEANER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--4
AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--6
EXHAUST SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--7
ELECTRIC FUEL PUMP (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--8
INJECTION PUMP (See your nearest Perkins/Detroit Diesel Dealer) . . . . . . . . . . . . . . . . . . 8--9
CATALOG B398 - 8- 1- R/07-- 2000

FUEL TANK, PUMP & FILTERING SYSTEM

APPLY TEFLON TAPE
34
33
30 32
31
29
28
1 27
4
3
2
26
25 3 6
24 2 4
23
5
22 11
21 10
20
26
25
32 9
19 12
18
13 35
17
14 36
16 15 8
See
Section 6 37
1 424760 Fuel Tank Assembly 1 All

2 B103A1 Elbow, Street 2
3 B116A1--1 Fitting 2

5 425320 Hose, Return 1
6 K87550 Adapter 1
R/07-- 2000 - 8- 2- CATALOG B398

8 494171 Fuel Filter (w/ drain) 1 Caterpillar

9 425335 Tube Assembly 1 All
10 425321 Hose 1
12 425319 Hose, Suction 1
13 422647 Tube Assembly 1
14 425723 Tap & Strainer Assembly 1

15 B114A2 Plug, Drain 1
16 K34670 Nut, Hex 4
19 K304762 Bolt, Hex 4

20 206302 Seal, Filler Neck 1
21 424835 Fuel Filter Assembly 1
22 B169 Fuel Cap 1
23 B1290 Fuel Sender 1
24 424836 Fuel Sender Cover 1

26 K20388 Bolt, Hex 8
27 424780 Step, Weldment 1
28 K55804 Nut, Lock 3
29 K20468 Bolt, Hex 3
30 425503 Extension, Fender (L.H. shown) 1

30 425502 Extension, Fender (R.H. opposite) 1
31 K20388 Bolt 5
32 K44728 Washer 7
34 K33799 Nut, Hex 5

35 K20311 Bolt, Hex 2
37 425334 Bracket, Fuel Filter 1
CATALOG B398 - 8- 3- R/07-- 2000

AIR CLEANER ASSEMBLY
19
20
18
21 1
17
16 12
13
14
15
2
3
6
4
7
5
8
9
10
11
R/07-- 2000 - 8- 4- CATALOG B398

1 424973 Air Cleaner Assembly 1 All
2 426206 O--Ring 1
3 492503 Safety Element 1
4 426200 Wing Nut 1
5 424974 Air Filter Replacement 1
6 426200 Wing Nut 1
7 426205 Cup Assembly 1

8 426197 Ring 1
9 426196 Washer 1
10 426198 Nut, Wing 1
11 426203 Vaculator Cup Assembly 1
12 424978 Clamp, Mounting 2

15 K33797SS Nut, Hex 4
16 B2236--15 Hose Clamp, 3”--4” A/R
17* 493776 Pre--cleaner, Air Intake, w/ Clamp 1
18** B5966 Hood, Air Intake w/ Clamp 1
19*** 492009 Turbo II, Air Intake, w/ Clamp 1

20 492790 Adapter (use with Item 19) 1
21 K301420 Set Screw (use with Item 20) 4
* Not for use on Trucks with glass installed on the back of the cab.
** For use on Trucks with glass installed on the back of the cab.
*** Not for use on Trucks with glass installed on the back of the cab or with --PXL (77”) cab.
CATALOG B398 - 8- 5- R/07-- 2000

AIR INTAKE SYSTEM (CURRENT)
11 7 6
10
9 6
12 2
ENGINE INTAKE
MANIFOLD (REF) 6
6
6 8
6 3
13
14
15 16 4
6 5 2
1
6 APPLY TEFLON TAPE
1* 424973 Air Cleaner Assembly 1 All

2 424978 Clamp, Air Filter 2
5 K33797 Nut, Hex 4
6 B2236--15 Hose Clamp A/R
7 496475--7.5 Hose, Air Intake 1 All (except 3.9L Cat)

8 496469 Air Intake Tube 1 All (except 3.9L Cat)
9 496474 Air Induction Tube, 450 Elbow 1 All (except 3.9L Cat)
10 B103A1 Elbow Fitting 1
11 B116A1--1 Bushing 1
12 424981 Sending Unit, Vacuum 1
13 425970 Hose, Intake 1 3.9L Cat, 77” & 81” Cab

14 425946 Tube, 2 1/4” Dia. 1 3.9L Cat, 77” & 81” Cab
* See previous pages for individual Nelson Air Cleaner Parts.
R/07-- 2000 - 8- 6- CATALOG B398

EXHAUST SYSTEMS
8a
5.75”
8b
10
7.25”
9
7
11
SEE YOUR ENGINE

DEALERSHIP 5
3 2
4
2 1
1a 423562 Muffler 1 All

1b 496106 Muffler, Catalytic 1
1c 496557 Muffler, Spark Arrest 1
2 424983 Clamp, 6” dia. 2
3 423625 Clamp, 2 1/2” dia. 1
4 494995 Exhaust Pipe 1 84” & 95” Cab

4 496040 Exhaust Pipe 1 77” & 81” Cab
5 77992 Clamp 2 All

6 77386 Flex Pipe 1
7a 495300 Exhaust Flange 1 84” & 95” Cab
7b 495932 Exhaust Flange 1 77” & 81” Cab
8a 496109S Shield, Exhaust 1 Early Models

8b 496640 Shield, Exhaust 1 Current Models
10a K20348 Bolt, Hex 2
10b K20428 Bolt, Hex (for use w/ Item 11) 2
11 496137 Spacer, Heat Shield 2 (early Models only)
CATALOG B398 - 8- 7- R/07-- 2000

ELECTRIC FUEL PUMP (OPTIONAL)
FUEL LINE FROM TANK

TO FUEL PUMP INLET (REF)
3
1
4 2 2
5
8 6
7
2
FUEL LINE FROM
3
FUEL PUMP OUTLET
TO FUEL FILTER
(REF)
FUEL FLOW
APPLY TEFLON TAPE
1 B862 Electric Fuel Pump 1 All (Option)

2 B862--1 Mounting Kit 1
3 B2236--1 Hose Clamp 2
4 B863 Frame Bracket 1
5 K20346 Bolt 4
7 K33797 Nut 4
8* 492582 Block Plate 1
* After removing the Perkins fuel pump, install Item 8 (Block Plate), using the same hardware & gasket.
R/07-- 2000 - 8- 8- CATALOG B398

INJECTION PUMP
See your Engine Dealer
APPLY TEFLON TAPE
1 495909 Fuel Solenoid 1 Perkins only
CATALOG B398 - 8- 9- R/07-- 2000

R/07-- 2000 - 8 - 10 - CATALOG B398

SECTION 9
HYDRAULIC SYSTEMS
(LESS STEERING SYSTEM)
DESCRIPTION PAGE
HYDRAULIC SYSTEM, (TANK, PUMP, VALVES) . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--2
TILT & SIDE SHIFT CYLINDER SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--6
TILT & SIDE SHIFT MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--9
TILT & SIDE SHIFT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--10
HYDRAULIC RETURN LINE, MAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--12
HYDRAULIC CONTROL VALVE, KITS & LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . 9--13
HYDRAULIC CONTROL VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--14
CATALOG B398 - 9- 1- R/07-- 2000

HYDRAULIC SYSTEM (TANK, PUMP, VALVES)
11 16
1
10 12
17
3 13
2 4 14 18
6
7 19
8 20
15
21 24 25
5 23
9 22
38
FOR STEERING CONNECTIONS
50 SEE “STEERING SYSTEMS”
53
49 52 30
37 32
51
46
45 47
39 44 48
43 28
31
40 42
40 24 26
27
55
41 54a
29
58
33 56
67 34
66 57
35 36
65 59
60
64
54b 61
63 62
APPLY LOCTITE 242
FOR POULTRY TRUCKS W/
DRIVE AXLE COOLER ONLY. APPLY LIGHT GREASE
SEE ALSO “COOLING SYSTEMS” APPLY TEFLON TAPE
R/07-- 2000 - 9- 2- CATALOG B398

1 424750 Tank Weldment 1 All

2 424780 Step Weldment 1
4 K55804 Nut, Hex--Lock 3
5a 425502 Extension, Fender R.H. (Shown) 1
5b 425503 Extension, Fender L.H. (Opposite) 1
6 K33799 Nut 5
10 424367 Gauge, Sight 1
11 425501 Cap, Hydraulic Reservoir 1
12 424756 Filler Tube 1

14 K20348 Bolt, Hex 4
15 197930 Gasket 1
16 B114A2 Plug 1
17 K304762 Bolt, Hex 4

20 K34670 Nut, Hex 4
21 424764 Filter, Suction 1
22 B101A12 Elbow 1
23 KHI2424 Nipple 1
24 455200 Clamp, Hose 2
25 425160 Hose 1
26 KOMC--2024--45 Fitting 1
27 K225 O--Ring 1
28a B800 Single Pump Assembly, Hydraulic 1
28b B799 Seal Kit, Primary Pump 1
29 R18147--6 Fitting 1
31 R18147--6 Fitting 2
32 426174 Valve, Flow Divider 1
34 425068 Clamp 5
36 K300858 Bolt, Hex 10
CATALOG B398 - 9- 3- R/07-- 2000

R/07-- 2000 - 9- 4- CATALOG B398

37 R19452--7 Fitting 1 All

38 -- -- -- -- See “Hydraulic Control Valve & Levers”
39 KOMC1216--90 Fitting, Beaded 1
40 425394 Clamp, Hose 2
41a 425158 Hose 1
41b Z4525 x 18” Sleeve, Hose 1
42 KHI1616 Nipple 1
43 B109A90 Bushing, Pipe 1

44 424921 Tee (NPT) 1
45 B116A10--2 Nipple 1
46 K20346 Bolt, Hex 4
48 422140 Filter, Complete Assembly 1
422141 Filter Element 1
49 496083 Check Valve 1

50 455200 Clamp, Hose 2
52 KHI2424 Nipple 2
53 B101A12 Elbow 1
54a 492605 Pump Bracket 1 95” & 84” Cab
54b 424776 Pump Bracket 1 81” & 77” Cab
55 K302264 Screw, Socket Head 4

57 K33799 Nut, Hex 4
58 K304762 Bolt, Hex 2
59 K55826 Nut, Hex--Lock 2
60a 423548 Drive Shaft, Pump 1
60b 424640 Repair Kit (U--Joint) 1
61 K304725 Bolt, Hex 4

63 425487 Dual Pump Assembly, Hydraulic 1
63a 492644 Seal Kit, Primary Pump 1
63b 492645 Seal Kit, Secondary Pump 1
63c 492646 Secondary Pump, Replacement 1
64 K225 O--Ring 1
65 KORF--24--45 Fitting 1
66 K34809 Washer 4
67 K20472 Bolt, Hex 4
CATALOG B398 - 9- 5- R/07-- 2000

TILT & SIDE SHIFT CYLINDER SYSTEMS
10
4 9
3 7 11
2A 6 8
12
13
4
3
2B
21
19
5 22
20
23
27
28
24
2 PLACES
29
25 39 14
26 15
31 16
17
32 18
30
16
33
38
34
37
35 36
43
42
41
40
TO MAST APPLY TEFLON TAPE
44 HYDRAULIC APPLY LOCTITE 242
45 SYSTEM APPLY ANTI--SEIZE LUBRICANT
R/07-- 2000 - 9- 6- CATALOG B398

1 B5505--X Tilt Cylinder Assembly 2 see Tilt & Side Shift

Cylinder Assembly
2A 424890 Pin, Tilt 2 All
2B B6215 Pin, Tilt 2
4 K20348 Bolt 2
5 R18147--3 Adapter 6
6a* 425146 Hose Assembly 1 All except CP--PXL

6b 426083 Hose Assembly 1 CP--PXL Only
7a 425147 Hose Assembly 1 All except CP--PXL
8 425069 Clamp 2
10 K20427 Bolt, Hex 2
12a 425145 Hose Assembly 1 All except CP--PXL

13a** 425144 Hose Assembly 1 All except CP--PXL
14 K20464 Bolt, Hex 4 All

16 425065 Clamp 8
17 425076 Bolt, Stacking 4
18 425075 Lock--Plate 2
19 R19822--2 Union 2
22 -- -- -- -- See “Hydaulic Control Valve & Levers”
23 R18147--3 Adapter 3
25 R18147--3 Adapter 2
26 B6140 Side Shift Cylinder 1
27 K20348 Bolt 1
* On Lift Trucks equipped with the 450 Forward Tilt Mast, use Hose Assembly 426081.
** On Lift Trucks equipped with the 450 Forward Tilt Mast, use Hose Assembly 426084.
CATALOG B398 - 9- 7- R/07-- 2000

28 K34807 Washer, Lock 1 All

29 B5425 Pin, Tilt Cylinder 2
31 R19452--6 Fitting 3
32 R19452--1 Fitting 1
34 425188 Weldment, Fitting 1

35 B7822 Quick Disconnect 1
37a 495301 Fitting (for Item 38a) 1
37b 425132 Fitting (for Item 38b) 1
38a 204220 Accumulator (cast iron, painted) 1 utilizes Item 37a
38b 5373 Accumulator (polished stainless) 1 utilizes Item 37b
39 K301514 Screw, Set 2
41 K300858 Bolt, Hex 2

43 425068 Clamp 1
44 426210 Fitting, Union 1
45 B7860 Tube Assembly (for Mast 1
Models 7600, 7500, 4000 & 3500)
R/07-- 2000 - 9- 8- CATALOG B398

TILT & SIDE SHIFT MOUNTS
FRAME (REF)
MAST OUTER 2
RAIL
3
4
5
6
7
6
5
8
1 B5407 Bar, Mast Support 2 All

2 B6119 Bolt, Cap 4
3 B5795 Mast Mount Assembly 4
4 K87901 Grease Fitting 2
5 R106 Ring, Retaining 4

6 R4584 Wiper 4
7 R7638 Bearing 4
8 R20152 Spacer (use on mast w/o side--shift) 2
CATALOG B398 - 9- 9- R/07-- 2000

HYDRAULIC RETURN LINE, MAST
K4800 MAST
LIFT CYLINDER
(REF)
3
2
7
4
8
5
6
HYDRAULIC TANK
(REF)
APPLY TEFLON TAPE
1 424756 Filler Neck 1 Use with Mast K4800

2 425501 Cap, Hydraulic 1
3 426191 Hose, Return 1
5 R8540--6 Fitting 1
6 B109A32 Reducer 1
R/07-- 2000 - 9 - 12 - CATALOG B398

HYDRAULIC CONTROL VALVE, KITS & LEVERS
8
1
2 9
10
11
12
13
14
3
5
4 6
495117* Kit, 4 Spool to 5 Spool Valve 1 77”-- 84” Cabs only

495123** Kit, 4 Spool to 5 Spool Valve 1 95” Cabs only
1a B1585-- 2 Valve Assembly (Gresen) 1 (3 Spool) All

1b B1585-- 3 Valve Assembly (Gresen) 1 (4 Spool) All
1c B1585-- 4 Valve Assembly (Gresen) 1 (5 Spool) 77”-- 84” Cabs only
1d 492653 Valve Assembly (Comm. Intertech) 1 (5 Spool) 95” Cab only
2a 424925 Plate, Weldment 1 (4 & 5 Spool) 77”--84” Cabs only

2b 425805 Plate, Weldment 1 (3 & 4 Spool) 95” Cab only
2c 492657 Plate, Weldment 1 (5 Spool) 95” Cab only

7 M100A1 Knob A/R
8a 424929 Lever A/R 77”-- 84” Cabs only
8b 425808 Lever A/R 95” Cab only
9 K33942 Nut, Jam A/R

10 424927 Handle, Mounting A/R
11 B5173 Handle, Hub Valve A/R
12a B7251 Shaft, Control Valve (4 & 5 Spool) 1 77”-- 84” Cabs only
12b 425900 Shaft, Control Valve (3 & 4 Spool) 1 95” Cab only
13 K72044 Pin, Cotter A/R
14 425515 Relief Valve, Lift Spool 1 95” Cab w/ K3600 Mast Only
* Add this Kit to the existing 4 Spool Valve (Item 1, B1585-- 4), all hardware and additional Lever included.
** Replace the 4 Spool Valve withthis Kit and the 5 Spool Valve (Item 1, 492653, purchased separately), all hardware and
Levers included.
CATALOG B398 - 9 - 13 - R/07-- 2000

HYDRAULIC CONTROL VALVE ASSEMBLY
CONTENTS
PARTS INDEX
Alphabetical Contents
R/07-- 2000 - 9 - 14 - CATALOG B398

1 B1586 Inlet Section (Includes Items 2 & 3) 1 All

2 B1593 Body 1
3* B1596 Main Relief Valve, Complete 1
4* Ref Cap 1
5* Ref O--Ring 1
6* Ref Spring 1
7* Ref Shim A/R

8* Ref Ring, Piston 1
9* Ref Body and Piston Assy 1
10* Ref Ring, Back Up 1
11* Ref Seal 1
12 B1592--38 Nut 6
13 B1587 Spool Assy, 3 Way Lift Cylinder 1 Includes Items 14 -- 37

14 B1592--56 Seal Kit 1 Includes Items 15 -- 23
15 B1592--25 Wiper, Rod 1
16 B1592--17 Seal, Quad. 1
17 K021 Sectional Seal, Exhaust, .937 Dia. 2
18 K019 Sectional Seal, Pressure, .801 Dia. 2
19 B1592--56 O--Ring 2
20 B1592--8 Ring, Back Up 2
21 B1592--7 O--Ring 2
22 B1592--56 Ring, Back Up 4
23 B1592--4 O--Ring 2
24 B1592--50 Body and Spool Assy (Not Serviced) 1 Order B1587
25 B1592--10 Plug 2
26 B1592--21 Plug 1
27 B1592--6 Spring 1
28 B1592--3 Plug 1
29 B1592--20 Bracket, Handle 1
30 B1592--12 Collar, Stop 2
* Item 3 (B1596 Relief Valve) is an adjustable style Main Relief Valve, it replaces the Early Shimmed Style
components pictured. It utilizes Seal Kit B1592--112. Refer to the Capacity Chart on pg. 9--18 for adjustment.
CATALOG B398 - 9 - 15 - R/07-- 2000

31 B1592--11 Spring 1 All

32 -- -- -- --
33 B1592--65 Collar 1
34 B1592--16 Washer, Lock 1
35 B1592--13 Screw 1
36 B1592--14 Cover 1
37 B1592--15 Screw 4
38 K910 O--Ring 1
39 K64--10 Plug 1 Includes Item 38
40 B1584 Spool Assy, 4 Way Tilt Cylinder 1 Includes Items 42 -- 65
41 B1592--56 Seal Kit 1 Includes Items 42 -- 50
42 B1592--25 Wiper, Rod 1
43 B1592--17 Seal, Quad 1

44 K021 Seal, Sectional Exhaust .937 Dia. 2
45 K019 Seal, Sectional Pressure .801 Dia. 2
46 included w/ Item 41 O--Ring 2
48 B1592--7 O--Ring 2
49 B1592--56 Ring, Back Up 4

50 B1592--4 O--Ring 2
51 B1592--55 Body & Spool Assy (Not Serviced) 1 Order B1584
53 B1592--3 Plug 2
54 B1592--6 Spring 2
55 B1592--67 Retainer, Ball 2

56 B1592--68 Ball 2
57 B1592--66 Body, Check 2
59 B1592--11 Spring 1
60 B1592--65 Collar 1

62 B1592--13 Screw 1
63 B1592--14 Cover 1
64 B1592--15 Screw 4
65 -- -- -- --
66 B1588 Spool Assy, 4Way Side Shift & Acc.1 Includes Items 68 -- 89
67 B1592--56 Seal Kit A/R Includes Items 68 -- 76
R/07-- 2000 - 9 - 16 - CATALOG B398

68 B1592--25 Wiper, Rod 1 All

69 B1592--17 Seal, Quad 2
72 included w/ Item 67 O--Ring 2

74 B1592--7 O--Ring 2
75 included w/ Item 67 Ring, Back Up 4
76 B1592--4 O--Ring 2
77 B1592--55 Body & Spool Assy (Not Serviced) 1 Order B1588

80 B1592--11 Spring 1
81 -- -- -- --
82 B1592--65 Collar, Spool 1
84 B1592--13 Screw 1
85 B1592--14 Cover 1
86 B1592--15 Screw 4
87 B1592--10 Plug 2
88 B1592--6 Spring 2
89 B1592--3 Plug 2
90a B1594 Cover, End Std. 1 Includes Items 91 & 92
90b B1589 Cover, End W / Power Beyond 1 Includes Items 91 & 92

93 B1592--60 Plug Assy, Conversion Power Beyond 1 Includes Items 94 & 97
94 B1592--63 Seal 1
95 B1592--64 Ring, Back Up 1
96 B1592--62 O--Ring 1
97 B1592--61 Sleeve, Power Beyond 1

98a B1592--40 Stud, 2 Spool 3
98b B1592--41 Stud, 3 Spool 3
98c B1592--42 Stud, 4 Spool 3
98d B1592--43 Stud, 5 Spool 3
99 B1592--77 Retainer, Plate Washer 2
100 B1592--75 Washer, Back Up 2

101 K210 Seal, O--Ring 2
CATALOG B398 - 9 - 17 - R/07-- 2000

CAPACITY CHART
MAST TEST PRESSURE ITEM

SERIES WEIGHT SETTING 6
K5300 6000 2050 B1592--100
K5300 5000 1800 N/A
K5300 4000 1500 B1592--30
K4800 3600* 2100 N/A
K4700 6000 2100 N/A
K4700 5000 1800 N/A
K4700 4000 1500 B1592--30
K4500 6000 1900 N/A
K4300 3600* 1975 B1592--36
K4000 8000 1950 B1592--36
K3600 10000 1850** N/A
K3500 8000 1850 N/A
K2300 5000 1600 B1592--30
K2100 5000 1600 B1592--30
K2100 4000 1350 B1592--30
K1400 4500 2200 N/A
* 48” Load Center, all others are 24” Load Centers.

** Set the Main Relief Valve (Item 3, page 9--15) to 2200 psi, then add Relief Valve 425515
(Item 14, page 9 - 13) to the Lift Port. Re--check Lift Pressure.
R/07-- 2000 - 9 - 18 - CATALOG B398

SECTION 10
ELECTRICAL SYSTEMS
DESCRIPTION QTY
BATTERY & CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10--2
WIRING SCHEMATIC, POULTRY/STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10--3
EARLY WIRING HARNESS, POULTRY/STANDARD (BOSCH OR DELCO) . . . . . . 10--4
CURRENT WIRING HARNESS, POULTRY/STANDARD (MAGNETTI) . . . . . . . . . 10--4
BRAKE LIGHTS & TURN SIGNAL KIT (84” 95” CAB) . . . . . . . . . . . . . . . . . . . . . . . 10--6
INSTRUMENT PANEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10--8
LIGHTING, STANDARD/POULTRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10--10
DASH PANEL, FWD/REV LEVER, WARNING LIGHTS, ETC. . . . . . . . . . . . . . . . . . 10--12
TACH & TRANS OIL TEMP GAUGES (OPTIONS) . . . . . . . . . . . . . . . . . . . . . . . . . . . 10--14
BACKUP ALARM & ROTATING RED OR AMBER BEACON . . . . . . . . . . . . . . . . . . 10--15
CAB HEATER & FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10--16
CATALOG B398 - 10 - 1 - R/07-- 2000

BATTERY & CABLES
8 7
TO FRAME 6
GROUND 1 4
TO STARTER
GROUND POST 2 7
TO STARTER
TO ENGINE
9 5
4
5
RIGHT REAR
FENDER WELDMENT
1a See Dealer Battery, Diesel (20”L, 8.25”W, 8”H) 1 Early Models

1b See Dealer Battery, Diesel (13”L, 6 7/8”W, 9 1/2”H) 1 Current Models
2 425022 Cable, Battery (+) (55”) 1 All
3 425023 Cable, Battery (--) (22”) 1
4a 424935 Rod, All Thread 2 Early Models
4b 496687 Bolt, Battery Hold (w/ nut & washers) 1pr Current Models
5 K33799SS Nut 4 Early Models

6a 424932 Strap, Battery 1 Early Models
6b 496684 Bracket, Rectangular Battery 1 Current Models
7a K33897 Nut, Wing 2 Early Models
7b -- -- -- -- Nut, Wing (see Item 4b) 2 Current Models
8 448850 Cable, Starter Ground (18”) 1 All
9 496825 Mat, Rubber (7” x 13 1/2”) 1 Current Models
R/07-- 2000 - 10 - 2 - CATALOG B398

WIRING SCHEMATIC, POULTRY/STANDARD

(R/07-- 00)
NOTES: UNLESS OTHERWISE SPECIFIED
1. ALL CIRCUITS SHOWN DE--ENERGIZED.

2. TRANMISSION MUST BE IN NEUTRAL TO START ENGINE.
495322 3. ALL VACANT CONNECTOR POSITIONS MUST BE PLUGGED.
(W/ 2 KEYS) 4. DASHED TRACES ARE PANEL WIRES, SOLID TRACES ARE
HARNESS WIRES.
CONNECTOR:
(1) -- 22X WEATHER PACK
(2) -- 8X DEUTSCH
(3) (4) (5) -- SEALED SOLENOID PLUGS
(6) -- DELCO ALTERNATOR CONNECTOR
WIRE COLOR CODE:

BK = BLACK
(EARLY PERKINS) BL = BLUE
DELCO STARTER
494755 LTBL = LIGHT BLUE
BN = BROWN
B1290 425402
106389 543672 GN = GREEN
(EARLY CAT) BOSCH ALTERNATOR 494436 ORG = ORANGE
(CURRENT PERKINS 424981 R = RED
& CAT) (CURRENT CAT & PERKINS)
T = TAN
MAGNETI STARTER MAGNETI ALTERNATOR
496326 V = VIOLET
496325
W = WHITE
Y = YELLOW
(EARLY PERKINS) DELCO ALTERNATOR 426368 EXAMPLE . . . BL/BK = BLUE & BLACK STRIPE
495317
425496 425496
423309 493927
B3344 B1335
B6891 494946 494946 494946 B7642
CATALOG B398 - 10 - 3 - R/07-- 2000

EARLY WIRING HARNESS (BOSCH OR DELCO ALTERNATOR), POULTRY/STANDARD 495296

NOTE: SOLID FILLED CONNECTOR SYMBOLS REPRESENT GROUND WIRES.
DIODE INSTALLATION DETAIL
NOTE: EACH DIODE SPLICE IS TO BE SOLDERED WITH ROSIN--CORE SOLDER AND INDIVIDUALLY
HEAT SHRINK WRAPPED. THE ENTIRE SPLICE AREA IS TO BE HEAT SHRINK WRAPPED.
CATALOG B398 - 10 - 4 - R/07-- 2000

CURRENT WIRING HARNESS (MAGNETTI ALTERNATOR/STARTER), POULTRY/STANDARD 496671

NOTE: SOLID FILLED CONNECTOR SYMBOLS REPRESENT GROUND WIRES.
DETAIL “A” DIODE INSTALLATION
NOTE: EACH DIODE SPLICE IS TO BE SOLDERED WITH ROSIN--CORE SOLDER AND INDIVIDUALLY
HEAT SHRINK WRAPPED. THE ENTIRE SPLICE AREA IS TO BE HEAT SHRINK WRAPPED.
CATALOG B398 - 10 - 5 - R/07-- 2000

BRAKE LIGHTS & TURN SIGNAL KIT (FOR NON--POULTRY LIFT TRUCKS ONLY)
(R/02-- 00)
THIS MODEL SWITCH (496111) IS OBSOLETE 7b

AND NO LONGER AVAILABLE
23
7a
26
7c
7b
8
7 24 25
3
9
6 10
4
11
12
25
4
5g 5f 2
5 5e 24
5a
25 26
5b
24
5h 5c
5b
5h
5d
CATALOG B398 - 10 - 6 - R/07-- 2000

496607 Stop & Turn Signal Kit 1 Non--Poultry

(Factory installed)
1 B5797 Switch, Turn Signal 1
2 KN620039 Nut, Hex M5 2
3 496605 Spacer, F--N--R Shifter 1
4 496606 Clamp, Turn Signal 2
5 496115R Rear Light Assembly, Right 1
5a 424178 Light Fixture 2
5b B906 Light, Red w/ hardware 2

5c 496112 Bracket 2
5d K304730 Bolt, Hex 2
5e K44881 Washer 2
5f K34811 Washer, Lock 2
5g K33946 Nut, Hex 2
5h B3344 Light, White w/ hardware 2
6 496115L Rear Light Assembly, Left 1

7 496113R Front Light Assembly, Right 1
7a 424179 Light Fixture 2
7b 496114 Light, Yellow w/ hardware 2
7c K44736 Washer 4
8 496113L Front Light Assembly, Left 1
10 K44728SS Washer, Flat 8

13 Z4000W x 160” Wire, White 1
14 Z4000G x 60” Wire, Green 1
15 Z4000R x 108” Wire, Red 1
16 Z4000BK x 200” Wire, Black 1
17 Z4178 x 400” Loom, 1/2” Split 1

18 496054 Tie Wrap, 3 3/4” lg 20
19 B197 Butt Splice 8
20 B7268 Connector 3
22 B5796 Flasher, Signal 1
23 B6887 Spring 1
24 B196 Connector, Female Bullet 2
25 B194 Connector, Male Bullet 2
26 B6886 Switch, Brake Light 1
CATALOG B398 - 10 - 7 - R/07-- 2000

INSTRUMENT PANEL ASSEMBLY
18
2, 3, 4, 5 & 6
7 8
12 9
13
10
12
13
12 11
12
14
15
[ADD EXTRA RELAY (K7) FOR POULTRY TRUCKS]
16
17
R/07-- 2000 - 10 - 8 - CATALOG B398

495295 Instrument Panel Assembly 1 All
1 494897 Panel 1
2 495325 5 Circuit Light Bar 1
3 495326 Indicator Overlay (Symbols) 1
4 495327 Plexiglass Cover 1
5 K34052 Nut 3
6 K34778 Lock Washer 2

7 495324 Fuel Gauge 1
8 495323 Hour Meter 1
9 495328 Glow Plug Rocker Switch 1
10 495329 4WD Rocker Switch 1
11 495322 Ignition Switch w/ 2 Keys 1

11a 496238 Ignition Key 1
12 495330 Circuit Breaker, 20 Amp 4
13 495352 Circuit Breaker, 10 Amp 2
14 495378 Relay Base 3
15 494946 Relay 2/3
16 495353 Connector, Female (less pins) 1

17 495354 Connector, Male (less pins) 1
18 Z4181 Seal 33” trim to fit
CATALOG B398 - 10 - 9 - R/07-- 2000

LIGHTING, STANDARD/POULTRY
1*
4*
5*
2*
6*
RIGHT FRONT
FENDER (REF) 7*
2
9
3
RIGHT FRONT
FENDER (REF)
LEFT REAR FENDER
(POULTRY, REF)
10
11
12
2, 15 13 SHOWN
14 OPPOSITE SIDE
R/07-- 2000 - 10 - 10 - CATALOG B398

1* 424179 Light Fixture, Front 4/6 Standard/Poultry

2* B3344 Light, White 4/6
3 B1335 Light, Red Poultry 4 Poultry
4* K30468SS Bolt, Hex 8/12 Standard/Poultry
5* K44728SS Washer, Flat 8/12

6* K34807SS Washer, Lock 8/12
7* K33799SS Nut, Hex 8/12
8 424175 Light Fixture, Rear 2 Poultry
9 424178 Guard Assembly, White Light 2

10 K36870SS Screw, Stainless 12 All
12 K33797 Nut, Hex 12
13 B5402 Wire Shield, Right 1

14 B5403 Wire Shield, Left 1
15 R13601 Pedestal, aluminum spacer 1
(required for lamp alignment in front fender)
* This Item also used on Rear Fenders of Standard Lift Truck.
CATALOG B398 - 10 - 11 - R/07-- 2000

DASH PANEL, FWD/REV LEVER, WARNING LIGHTS, ETC.
15
17
16
18
STEERING
COLUMN
POULTRY CAB
DASH PANEL (REF)
7 6
8
10
9
2
4
11 5
1
12
13
95” CAB
14 STEERING COLUMN
COVER (REF.)
R/07-- 2000 - 10 - 12 - CATALOG B398

1 495295 Instrument Panel 1 All

2 K52915SS Screw 4
3 425496 Alarm Indicator 3
4 493219 Heater Switch w/ Knob 1
5 B6147 Toggle Switch, Fan 1
6 B6511 Plate, Boot 1

7 B6512 Rubber Sheet 1
8 B254 Rivet 4
9 B6251 Cap 1
10 K74219 Cap A/R
11 B7642 Horn Assembly 1

15 495317 Shift Lever Assembly 1

(F/N/R, Lights & Horn Switch)
16 495317--1 Lever, Shift 1
17 495317--2 Clamp 1
18 495317--3 Screw 2
CATALOG B398 - 10 - 13 - R/07-- 2000

TACH & TRANS OIL TEMP GAUGES (OPTIONS)
7
8
9
11 10
13
14
12
6
5
4
1 424359 Tach/Hourmeter Kit, Complete 1 All

2 424354 Tachometer only, less Hdwr 1
3 424443 Light Kit 1
4 B194 Connection, Bullet 4
5 Z4176 Loom x 3” 1
6 B3526 Grommet 1
7 423308 Gauge, Oil Temperature 1
8 B3103 Eyelet Connector 3

9 B5764 Light Kit 3
10 552502 Trans Hot Oil Sender 1
11 425190 Adapter 1
12 425192 Tee 1
13 423309 Sender, Temperature 1
14 425193 Adapter 1
R/11--2000 -- 10 -- 14 -- CATALOG B398

BACKUP ALARM AND

ROTATING RED OR AMBER BEACON
2, 3
4
5
6
10
LEFT REAR FENDER
1a B6006 Beacon, Amber w/ Hdwr 1 All

1b B6046 Beacon, Red w/ Hdwr 1
2 Z4169 Loom 110”
3 Z4000 Wire, Red 110”
4 B3698--2 Clamp 7
5 K40919 Screw, Self--tapping 7
6 B6891 Alarm, Backup 1

10 K33797 Nut, Hex 2
CATALOG B398 - 10 - 15 - R/07-- 2000

CAB HEATER & FAN
3 4, 5
8
2 6
11 9
NOTE: 1
RE-- LOCATE TRUCK
ID PLATE HERE
WHEN INSTALLING
7
HEATER OPTION 10
95” CAB
STEERING COLUMN
COVER (REF.)
12**
13**
ORANGE WIRE
RED WIRE FROM MOTOR
FROM MOTOR
LM H
13
HEATER SWITCH B C
CONNECTIONS
APPLY TEFLON TAPE TO FUSED PANEL
1 B6827 Fan Kit (requires additional wire) 1 All

4 K40919 Screw, Self Tapping A/R
5 B3698--2 Clamp, Wire A/R
6* 494960 Heater Installation Kit 1
6a B3354--7 Heater Blower 1
6b 493544 Heater Mount (housing) 1 6.5”x10”x5” deep
7 Z2823 Hose x 72” 2
8 B2236--3 Hose Clamp 4

9 B3522 Valve, Heater 1
10 B109A34 Bushing 2
11 B3521 Fitting, Heater 1
12** 493219 Switch, Heater 1
13** B6147 Toggle Switch, Fan 1
* Includes Items 6a -- 13 and misc. mounting hardware (Items 4 & 5 not included). Remove the Truck ID Plate
and re--locate it as noted above. Mount the heater to the Driver’s right, in place of the ID Plate, using Item 6b as
a mounting pattern.
** On other than 95” Models; locate switch on the dash, to the right of the hydraulic control levers.
R/07-- 2000 - 10 - 16 - CATALOG B398

SECTION 11
FRAME, HOOD, CAB & COUNTER WEIGHTS
DESCRIPTION PAGE
FRAME, REAR FENDERS & FILLER PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11--2
EARLY MODEL HOOD, FIREWALL & SCREEN ASSEMBLY . . . . . . . . . . . . . . . . . 11--4
CURRENT MODEL HOOD, FIREWALL & SCREEN ASSEMBLY . . . . . . . . . . . . . . . 11--6
CAB & MOUNTINGS (MODEL CP & CP--PS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11--8
CAB & MOUNTINGS (MODELS CP--P, - PL & - PXL) . . . . . . . . . . . . . . . . . . . . . . . . . 11--10
ENCLOSED CAB (MODELS CP & CP--PS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11--12
SEMI--ENCLOSED CAB (MODELS CP--P) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11--14
COUNTERWEIGHTS & CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11--16
SEAT & SEAT BELT ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11--18
CAB FRONT GUARD, MIRRORS & TOWING HITCH . . . . . . . . . . . . . . . . . . . . . . . . 11--19
CATALOG B398 - 11 - 1 - R/07-- 2000

FRAME, REAR FENDERS & FILLER PANELS
1
16 19 7
17 8
18
11 12
6
5
15 9
4
14 10
13
1 424680 Frame Assembly 1 All

2a 424768 Right Rear Fender w/out batt. tray 1 std width (16 13/16”)
2b 493343 Right Rear Fender w/ batt. tray 1 extra wide (23 7/16”)
3a 424769 Left Rear Fender 1 std width (16 13/16”)
3b 493344 Left Rear Fender 1 extra wide (23 7/16”)

2c 424767 Tray, Battery (missing the tab) 1 welding required
(20 3/8L x 8 5/8W x 1 1/4H)
R/07-- 2000 - 11 - 2 - CATALOG B398

8 K44732 Washer, Flat 4 All

10 K34670 Nut, Hex 4
11 424778 Filler Panel, Right 1
12 424779 Filler Panel, Left 1
13 K20348 Bolt, Hex 2

16 K20388 Bolt, Hex 4
19 K33799 Bolt, Hex 4
CATALOG B398 - 11 - 3 - R/07-- 2000

EARLY MODEL HOOD, FIREWALL & SCREEN ASSEMBLY

(see also, CURRENT MODEL HOOD)
13 10
14
15 11
16
17 1
12
18, 19, 20 27, 28, 29, 30
23, 24, 25, 26

7
22 8
9
2, 3, 4, 5
31, 32, 33, 34

6
35
37 36
38, 39, 40
41, 42, 43, 44
45, 46,
47, 48
R/07-- 2000 - 11 - 4 - CATALOG B398


- - - See the following pages for One Piece Hood Replacement Kit - - -
1 424880 Weldment, Hood 1 All
2 425863 Firewall Assembly 1
6a 424887 Weldment, Nose 1 81”-- 95” Cab
6b 494400 Weldment, Nose 1 77” Cab
7 424873 Retainer, R.H. 1
8 424874 Retainer, L.H. 1
9 424871 Screen, Grill Cover 1
10 493776 Hood, Air Inlet 1
11 B2236-- 17 Clamp, Hose 1

12a 424879R Hinge, RH (shown) 1
12b 424879L Hinge, LH (not shown) 1
13 K20348SS Bolt, Stainless 6
16 K34807SS Lock Washer, Stainless 4
17 K33799SS Nut, Stainless 4
18 174114 Cylinder, Air 1
20 K55691 Nut, Hex 2
22 B7582-- 3 Seal Strip 2

23 424186 Handle, Grab 4
26 K55691 Nut, Lock 8
27 421564 Hook 4
29 K34805 Washer 8
30 K33795 Nut, Hex 8
31 424870 Weldment, Grill 1

34 K44728SS Washer, Stainless 10
38 424881 Spacer, Nose 4
39 K20468 Bolt, Hex 4
41 421532 Latch 4
43 K34805 Washer 8
44 K33795 Nut, Hex 8
45a 494250 Weldment, Cover 1 84” & 95” Cab
45b 494405 Weldment, Cover 1 81” & 77” Cab
48 K44728SS Flat Washer, Stainless 2
CATALOG B398 - 11 - 5 - R/07-- 2000

CURRENT MODEL HOOD & FIREWALL ASSEMBLY
6 7
5 2
9
1
10
8R
11
12
3
13 4
15
16, 17, 18, 19

14 20, 21, 22, 23
32, 33, 34, 35 28
29
30
24, 25, 26, 27
31
R/07-- 2000 - 11 - 6 - CATALOG B398

496499 One Piece Hood Kit (w/ hardware) 1 All

1a 495210 Weldment, Hood 1
1b 495216 Screen, Hood 1 welding required
2 493776 Hood, Air Inlet 1
3 B2236-- 15 Clamp, Hose 1
4 495994 Cylinder, Air 1
5 495993 Clip 2
6 495992 Stud 2
7 K55691 Nut 2
8R 424879R Hinge, RH (shown) 1
8L 424879L Hinge, LH (not shown) 1

14 Z4117-- 55” Seal Strip 2
15 Z4054-- 47” Seal Strip 1
16 424186 Handle, Grab 2
19 K55691 Nut, Lock 4

20 421564 Hook 2
23 K33795 Nut, Hex 4
24 421532 Latch 2

26 K34805 Washer 4
27 K33795 Nut, Hex 4
28a 424875 Weldment, Cover 1 84” & 95” Cab
28b 425987 Weldment, Cover 1 81” & 77” Cab

32 425863 Firewall Assembly 1
CATALOG B398 - 11 - 7 - R/07-- 2000

CAB & MOUNTINGS (MODELS CP & CP--PS)
8
7 9 12
2 10 13
6 11 1
15
5 14
4
3
16
20 18
19 21 39
22
38
23 41
47 40
24 30
25
48 28 31
26 29
49 32
46 27 42 33 51
50 34
35
43, 44 36
37
1a 425820 Cab 1 CP & CP--PS, 95” Cab

1b 494100 Cab (for suspension seat) 1
2 425668 Cowl Weldment 1
6 B5629--10 Trim 1
7 425836 Door Assembly 1
8 425312 Stud, Wing Head 1
9 425309 Spring, Stud Ejection 1
10 425310 Washer 1
11 425313 Retainer 1
12 425311 Receptacle, Stud 1
13 -- -- -- -- Rivet 2
R/07-- 2000 - 11 - 8 - CATALOG B398

15 K44722SS Washer, Flat 14 CP & CP--PS

16 496042 Cover Weldment, Column 1
17 Deleted
18 425213 Mount, Front Cab 2
19 425212 Pin, Cab Pivot 2
21 77520 Mount, Cab Isolation 2
22 425307 Spacer 2
24 K20552 Bolt, Hex 2
25 K20346 Bolt, Hex 4
28 K20432 Bolt, Hex 2

30 425661 Mount Weldment, Cab 2
32 425307 Spacer 2
34 K20548 Bolt, Hex 2
35 K20346 Bolt, Hex 4

38 78658 Cylinder 2
43 425413 Floormat, L.H. 1

44 425414 Floormat, R.H. 1
45 Deleted
46 425306 Plate, Cover 1 4WD Cab
47 K20324 Bolt 4 4WD Cab
48 K44719 Washer, Flat 4 4WD Cab
49 K34805 Washer, Lock 4 4WD Cab
50 K33795 Nut, Hex 4 4WD Cab

51 426128 Stand Weldment 1 All
CATALOG B398 - 11 - 9 - R/07-- 2000

CAB & MOUNTINGS (MODELS CP--P, --PL & --PXL)
1
2
48 7
49 8
9
5
4 6 10
3 13
11
16 14 12
37
15 17
18 34
35
19 36
44 26
21 20
45 24 27
22 25 28
46 29
43 23 38 39
47 30
31
32
40, 41 33
1a 425302 Cab Assembly 1 84” Cab

1b 425955 Cab Assembly 1 81” & 77” Cab
2 425270 Cowl, Weldment 1 84”, 81” & 77” Cab

6 425269 Panel, Cover 1
7 425312 Stud, Wing Head 2

8 425309 Spring, Stud Ejector 2
9 425310 Washer, Cupped Nylon 2
10 425313 Retainer, Split Ring 2
11 425311 Receptacle, Stud 2
12 -- -- -- -- Rivet, Aluminum 2
13 B5629--10 Trim, Edge 1
R/07-- 2000 - 11 - 10 - CATALOG B398

14 425213 Mount, Front Cab 2 CP--P/--PL/--PXL

15 425212 Pin, Cab Pivot 2
18 425307 Spacer 2

20 K20552 Bolt, Hex 2
21 K20346 Bolt, Hex 4
24 K20432 Bolt, Hex 2

26 425205 Weldment, Cab Mount 2
28 425307 Spacer 2
30 K20548 Bolt, Hex 2
31 K20346 Bolt, Hex 4

34 78658 Cylinder 2

39 425315 Stand Weldment, Tilt 1
40 425975 Floor Mat, L.H. 1 CP--PL/--PXL
41 425976 Floor Mat, R.H. 1 CP--PL/--PXL
43 425306 Plate, Cover 1 CP--P/--PL/--PXL

44 K20324 Bolt, Hex 4
47 K33795 Nut, Hex Plated 4
48 496490 Plate, Floor Cover 1

49 K40919 Screw, Tap 4
CATALOG B398 - 11 - 11 - R/07-- 2000

ENCLOSED CAB (MODELS CP & CP--PS)
25 26
27
L.H. DOOR - TOP VIEW

24
3
1 2
2 5
22
6
4
7
8
23 10
20, 21
11
19
16A
17, 18 9
2
15 12
13A
14 13
1 491713 Front Panel Assembly (Safety Glass) 1 95” Cab only

2 491717 Screw, Self Tapping A/R
3a* 426678 Top Panel (Plexiglass) 1
3b* 494919 Top Panel (Safety Glass) 1
3c 493360 Top Panel, Wire Mesh 1
4 426683 Rear Panel Assembly (Safety Glass) 1

7 K33795 Nut, Hex 5
8 K52927 Screw 2
9 491718 Wiper Motor (Front or Rear) 2
R/07-- 2000 - 11 - 12 - CATALOG B398

10 491714 Wiper Arm (Front or Rear) 2 95” Cab only

11 491719 Wiper Blade (Front or Rear) 2
12 426685 Block, Tapped 4
13 424878 Hinge, 2 Piece Stainless 4 pair
16A 492794 Doorway Post, L.H. (shown) 1
16B 426675 Doorway Post, R.H. (opp. side) 1
17 491712S Door Assembly, L.H. (shown) 1
18 491711S Door Assembly, R.H. (opp. side) 1
19 491715 Side Panel Assembly 2

20 493446 Cab Door Stop 2
21 K40919 Fastener, Cab Door 8
22 426686 Sliding Glass, Front--Side 2
23 426687 Sliding Glass, Rear--Side 2
24 426670 Door Handle, Outside (w/ shaft) 2
25 426669 Door Handle, Inside (w/ set screw) 2
26 424186 Pull Handle (less hardware) 2
27 426668 Door Latch (less hardware) 2
* Silicone required (purchase locally).
CATALOG B398 - 11 - 13 - R/07-- 2000

SEMI--ENCLOSED CAB KIT (MODEL CP--P, 84” CAB)
19
15, 16
13
14 13
17, 18
1
SIDE VIEW
SEAL EDGES WITH SILICONE

(ASTM C920 TYPE S, N, S)
12 10 11 5, 6, 7
FRONT PANEL 8
5, 6, 7
4
3
WIRING KIT
NOT YET RELEASED
9, 6, 7 BACK PANEL
R/07-- 2000 - 11 - 14 - CATALOG B398

496055 Cab Kit, Semi--Enclosed 1 84” Cab
1 496060 Front Panel Assembly 1

2 496059 Rear Panel Assembly 1
3 496063 Front Glass, Safety 1
4 Z4056 x 131” Weather Strip 1
5 K20385 Bolt 13

8 496061 Front Panel Weldment 1
9 K20385 Bolt 8
10 496058 Rear Glass, Safety 1
11 Z4056 x 105” Weather Strip 1

12 496057 Rear Panel Weldment 1
13 491718 Wiper Motor w/ Switch 2
(less Wiper Arm/Blade)
14 K52927 Screw 2
15 491714 Wiper Arm, Front 1
16 491719 Wiper Blade, 18” 1

17 496047 Wiper Arm, Rear 1
18 496048 Wiper Blade, 8 5/8” 1
19 496046 Top Panel, Plexiglass 1
(42.5” x 21.75”)
CATALOG B398 - 11 - 15 - R/07-- 2000

COUNTERWEIGHTS & CHART
1 FRAME, REAR
2 (REF)
3 21
4 20
19
5 18
17 22
13 16
21
20
12 19
11 18
7 8
9 17
6 16
15
10 FRAME, LEFT
14
FRONT (REF)
24” LOAD
TRUCK MAST LIFT HT. UNIT PART NO. REMARKS
CENTER
M230CP 6K 2-- STAGE

TO 168” 6000# K100-- 26.2 B5105A (6K CTWT.)
M430CP K4700
M230CP 6K 3-- STAGE

TO 267” 4000# K100-- 26.2 B5105A (6K CTWT.)
M430CP K5304
K5307 TO 360” 1500# - 26.2 & .8 B5105A & 426281 REAR FRAME CTWTS
M230CPP 3.6K 3-- STAGE 3600# @
M430CPP TO 148” 48” L.C.
K4800 POULTRY TRKS
K100-- 26.2 B5105A
M230CPPL 6K 3-- STAGE (6K CTWT.)
TO 146” 6000#
M230CPPXL K4300
8K 2-- STAGE
M240CP TO 148” 8000#
K3502
K100-- 26.3 B5110A (8K CTWT.)
M440CP K3503 TO 168” 7600#
K3504 TO 192” 7300#
8K 3-- STAGE
TO 181” 8000#
K4002
K4003 TO 220” 6500# K100-- 26.4 B8075 (10K CTWT.)
M240CP
K4004 TO 240” 5800#
M440CP K4005 TO 264” 4500#
K4006 TO 288” 3500# B8075 USES
K100-- 26.4
K4007 TO 336” 2000# & SIDE FRAME
K100-- 26.6 425590 (2)
K4008 TO 360” 1800# CTWT.S
R/07-- 2000 - 11 - 16 - CATALOG B398

1a B5105A Main Counterweight, 3200# 1 See Chart on previous page

1b B5110A Main Counterweight, 4400# 1
1c B8075 Main Counterweight, 5470# 1
4 K304898 Bolt, Hex 2
5 K304911 Bolt, Hex 2
6 425590 Side Counter Weight, 480# 2

9 K33845 Nut, Hex 2
10 K58758 Bolt, Hex 4
12 K34674 Nut, Hex 4
13 425586 Bracket, Mounting 2
14 425588 Bracket, Lower 4
15 426281 Rear Counter Weight, 240# 1

16 K34924 Bolt, Hex 2
18 426274 Bracket 2
21 K34674 Nut, Hex 2
22a 426280 Rear Counter Weight, 920# 1

22b 494840 Rear Counter Weight, 912# 1
CATALOG B398 - 11 - 17 - R/07-- 2000

SEAT & SEAT BELT ASSEMBLIES
1, 3, 4
2
5
10
14
11 9
13 11
8
12 7 6
6 12
7
8
9
1 491746 Seat (adjust rails/remove studs as req’d) 1 95” Cab only

2a 425317 Seat (8”W x 11”L hole pattern) 1 All except 95” Cab
2b 496814 Seat (9.75”W x 11”L hole pattern) 1 All except 95” Cab
3* 493339 Seat, Adjustable Suspension 1 95” Cab only
4** 494297 Seat, Safety (requires Item 4a) 1 95” Cab only
4a 494337 Pressure Switch, Safety 1 95” Cab only
(use w/ Item 4)
5a B6991 Seat Belt, 1 7/8” Wide (less Hdwr) 1 All (Early Models)
5b 495931 Seat Belt, 3” Wide (less Hdwr) 1 All (Current Models)
7 491820 Washer, Square 2

10 K20520 Bolt, Hex 4 95” Cab (Early Models)
11 K34806 Washer, Lock 4 All
12 K33797 Nut, Hex 4
13 425827 Spacer 4 95” Cab (Early Models)
14 K20326 Bolt, Hex 4 All except 95” Cab
* This seat available for replacement only, the original installation must have been made at the factory.
** This seat utilizes a built--in switch that stops the engine when leaving the seat.
R/07-- 2000 - 11 - 18 - CATALOG B398

CAB FRONT GUARD, MIRRORS & TOWING HITCH
4 1
5
3
6 10
7 9
8 11
12
494911 Front Guard Assembly, less mirrors 1 CP & CP--PS (95” Cab)
(hardware included)
494912 Dual Mirror Kit 1 Front Guard required
(hardware included)
1 495423 Front Guard Weldment 1 CP & CP--PS (95” Cab)
2 495422 Guard Mounting Tab 4
3 494914 Mounting Pad (rubber) 8
4 494915 Mirror 2
5 494916 Mirror Mounting Tab 2
6 K45564 Bolt (for Front Guard mounting) 4
8 K33799 Nut, Hex 4
9 B8045 Hitch Bracket 1

10 B8065 Hitch Pin 1
12 K45798 Bolt, Hex 4
CATALOG B398 - 11 - 19 - R/07-- 2000

R/07-- 2000 - 11 - 20 - CATALOG B398

SECTION 12
DECALS
DESCRIPTION PAGE
DECAL & NAME PLATE LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12--2
DECALS & NAME PLATES PICTURED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12--5
CATALOG B398 - 12 - 1 - R/07-- 2000

DECAL & NAME PLATE LOCATIONS

NOTE: DECAL PLACEMENT SHOWN BELOW IS FOR REFERENCE
ONLY AND MAY VARY, DEPENDING ON LIFT TRUCK MODEL.
2
1 12
SEE DETAIL A
14
INNER CAB, SEE
3 13
DETAIL B 15
4a
11
10 DETAIL A
5
9 4a
8
19a, c, d
19b 20
30
21 22
24
23
18 25
17a 26
17b
27 29
16 28
4b
DETAIL B
R/07-- 2000 - 12 - 2 - CATALOG B398

496250 Decal Kit (All Decals except Item 7) 1 All

1 B6109 Plate, OHG 1
2a B6141-- 1 Decal, KDM Logo (17”x 2.5”) 1
2b 495374 Decal, KDM Logo (10”x 2.5”) 1
3a B6111 Plate, KDM Serial No. 1 Early Models
3b 496538 Plate, KDM Serial No. (w/ tire press.) 1 Current Models
4a 422536 Decal, Tire Pressure 4 Earliest Models
4b 496492 Decal, Tire Pressure 4 Early Models
5 420732 Decal, ”No Riders” 2
6 B886 Safety Walk 2
7a 495361 Decal, M2 30 CP 2 2WD, 6K, Perkins

7b 495365 Decal, M2 40 CP 2 2WD, 8K, Perkins
7c 495368 Decal, M2 50 CP 2 2WD, 10K, Perkins
7d 495371 Decal, M2 30 CC 2 2WD, 6K, Caterpillar
7e 495366 Decal, M2 40 CC 2 2WD, 8K, Caterpillar
7f 495369 Decal, M2 50 CC 2 2WD, 10K, Caterpillar
7g 495364 Decal, M4 30 CP 2 4WD, 6K, Perkins

7h 495367 Decal, M4 40 CP 2 4WD, 8K, Perkins
7j 495370 Decal, M4 50 CP 2 4WD, 10K, Perkins
7k 495363 Decal, M4 30 CC 2 4WD, 6K, Caterpillar
7m 495372 Decal, M4 40 CC 2 4WD, 8K, Caterpillar
7n 495373 Decal, M4 50 CC 2 4WD, 10K, Caterpillar
8a 495359 Decal, Manitou Logo (19”x 5”) 2 Red Letters

8b 76600 Decal, Manitou Logo (19”x 5”) 2 White Letters
8c B5867 Decal, ”Chicken Hawk” (19.5”x 6.5”) 2
9a B4832 Decal, ”Diesel Only” 1 Diesel Tank
9b B4794 Decal, Hydraulic Oil 1 Hydraulic Tank
10 423398 Decal, Fan Shroud 1
11 76572 Decal, Anti-- Freeze 1
12 420772 Cable, Catalog 1
13 420774 Case, Literature 1

14 B417 Operator/Owner’s Manual 1
15 420792 Decal, ”Before You Operate” 1
16 B4712 Decal, Diff. Lock 1
17 496654 Decal, Park Brake 1
18a 425357 Decal, Shift Pattern (early models) 1
18b 496653 Decal, Shift Pattern (current models) 1
19a 493981 Decal, Trans. Oil Press 1

19b B293 Decal, Trans. Oil Temp 1
19c 496166 Decal, Trans. Oil Press & Temp 1
19d 496167 Decal, Trans. Oil Press & Temp/Axle Heat 1
20 493980 Decal, Axle Heat 1
21 164091 Decal, Brake Fluid 1
22 423397 Decal, to Protect Engine 1
CATALOG B398 - 12 - 3 - R/07-- 2000

23 493481 Decal, USA 1 All

24 B363 Decal, Lift Levers 1
25a B6512 Rubber Sheet 1
25b B6511 Plate 1
25c B254-- 1 Rivet 4
26 420795 Decal, Warning 1

27 496162 Decal, Backup 1
28 B6143 Decal, Tilt Warning 1
29 497176 Decal, Fwd/Rev 1
30 491779 Decal, Warning 1
31 B6108 Decal, Warning (2.75”x 8.5”) 2 Mast Decal

32 B6146-- 1 Decal, Logo (4.75”x 6.25”) 2 Mast Decal
33 R40 Decal, Safety 1 Mast Decal
34a 426642 Decal, Pinch Point (1.5”x 2.75”) 4 Mast Decal
34b 426643 Decal, Pinch Point (2.5”x 4.5”) 4 Mast Decal
R/07-- 2000 - 12 - 4 - CATALOG B398

DECALS & NAME PLATES PICTURED

2a
1
3a 2b
3b
4a
4b
8a, 8b
5
9a
9b
8c
15 16
11
10
17
21 HOT AXLE 20a
18a
19c 19b 18b

19a
19d
TRANS OIL
PRESS
CATALOG B398 - 12 - 5 - R/07-- 2000

DECALS & NAME PLATES PICTURED

22
23
24
26
27
28
31
32 29
30
33
34a
34b
R/07-- 2000 - 12 - 6 - CATALOG B398




M2/4 30/40/50 CP/ - PS M4 30 CP - P M2 30 CP - P/ - PL/ - PXL Parts Manual

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Alphabetical Contents PARTS INDEX CONTENTS

MANITOU NORTH AMERICA, INC.

M2/4 30/40/50 CP/--PS

      

’M’ SERIES LIFT TRUCK

30=6,000lb. LIFT CAP. M2 30 C P --PS --D

LIFT TRUCK COMPONENT

Truck Model No:

Truck Serial No:

Mast Model No:

Mast Serial No:

Front Drive Axle No:

Attachment Model No:

Attachment Serial No:

For quick reference it is recommended these numbers be recorded as soon as possible.

DESCRIPTION PART NO. CLEAN REPLACE

TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

TIRES & WHEELS

TIRES AND WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--2

CATALOG B398 - 1- 1- R/07-- 2000

TIRES & WHEELS

R/07-- 2000 - 1- 2- CATALOG B398

ITEM PART NUMBER DESCRIPTION QTY MODEL

3a 495973 Drive Tire, 17.5-- 24 R3 12PR 2

5a 176617 Drive Wheel, 15-- 24 2

CATALOG B398 - 1- 3- R/07-- 2000

ITEM PART NUMBER DESCRIPTION QTY MODEL

6a B5497 Steer Wheel, 9-- 16.5 2 2WD only

7a B2257 Stem, Valve 2

8 109480 Nut, Drive Wheel Lug 8/10 Ea. Wheel

R/07-- 2000 - 1- 4- CATALOG B398

BRAKE & ACCELERATOR PEDAL ASSEMBLIES

BRAKE & INCHING PEDAL (95” MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--2

BRAKE & INCHING PEDAL (77”--84” MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--4

PARKING BRAKE LEVER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--6

ACCELERATOR PEDAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--8

BRAKE DISC ASSEMBLIES (See FRONT DRIVE AXLE, Section 3)

CATALOG B398 - 2- 1- R/07-- 2000

BRAKE & INCHING PEDAL (MODELS CP & CP--PS)

R/07-- 2000 - 2- 2- CATALOG B398

ITEM PART NUMBER DESCRIPTION QTY MODEL

1 494580 Bracket Assembly, Brake Cylinder 1 95” Cab only

7 K34806SS Washer, Lock 4

13 B309 Washer, Brass 2

19** R18147--4 Adapter 1

25 K11--6 Adapter, Tee 1

31 K300141 Screw, Set 2

37 K44712 Washer, Flat 2

CATALOG B398 - 2- 3- R/07-- 2000

BRAKE & INCHING PEDAL (MODELS CP--P/--PL/--PXL)

APPLY TEFLON TAPE 23

R/07-- 2000 - 2- 4- CATALOG B398

ITEM PART NUMBER DESCRIPTION QTY MODEL

1 424895 Bracket, Mounting 1 All (except 95” Cab)

7 K20348 Bolt, Hex 1

CATALOG B398 - 2- 5- R/07-- 2000

PARKING BRAKE LEVER ASSEMBLY

R/07-- 2000 - 2- 6- CATALOG B398