31-Easi2 16806-18296 PM PDPM-0035

MODEL 31 EASI 2
REACH
PARTS CATALOG
SIN 16806 THRU 18296
PDPM-0035
DATED FEB 15, 1993
MODEL 31 EASi2 REACH PARTS MANUAL
TABLE OF CONTENTS
S/N 16806 to 18296
Page 1of2 Date: February 15, 1993
Description Serial No.
POWER 100
Power Section Basic • 828-003·100/ (Q) .•..•.•.••.••....•...••......••.•...••...•••••..•.•.•.......• 16806 to 17950 101

Power Section Basic· 828-004-023/ (B) .............................................................. 17951to18296 101.1
Finish Instructions· 828-003-322/ (K) - Sh. 1...................................................... 16806 & Up 103
Finish lnstructlons-828-003-322/ (K) ·Sh. 2...................................................... 16806 & Up 105
Finish Instructions (Bilingual) - 828-003-657/ (J) - Sh. 1..................................... 16806 & Up 107
Finish Instructions (Bilingual)· 828-003-657/ (J) - Sh. 2..................................... 16806 & Up 109
Gate Installation - 828-003-564/ ........................................................................... 16806 to 17950 111
Gate Installation - 828-003-925/ ........................................................................... 17951 & Up 111.1
Roller Assembly-828-001-430/ (D) ..................................................................... 16806 & Up 113
Power Section to Mast· 828-003-278/ (D) .......................................................... 16806 & Up 115
Rear Post Installation· 828-003-369/ (B)............................................................. 16806 & Up 117
Back Gate Assembly (Full/Half Height) -828-003-569/...................................... 16806 & Up 119
Platform Extension Installation -828-003-702...................................................... 16806 & Up 121
Fire Extinguisher Installation -828-003-727/ ....................................................... 16806 & Up 123
BRAKES AND STEERING 200
Mech. Steering Installation -828-003-228 (F) ...................................................... 16806 to 18296 201

Brake Assembly - 828-003-209 (E) ....................................................................... 16806 & Up 203
Idler Steer Wheel Installation - 828-003-039/ (G) ................................................ 16806 to 17950 205
Idler Steer Wheel Installation -828-003-923/ (C)................................................. 17951 & Up 205.1
Idler Steer Wheel Assembly - 828-003-057/ (G) .................................................. 16806 & Up 207
Steering Wheel Assembly - 828-003-11 o (D) ....................................................... 16806 to 17738 209
Steering Wheel Assembly - 828-003-110 (E) ........................................................ 1n39 & Up 209.1
Hydraulic Brake - 870-834/001 (Early Version) ................................................... 16806 to__ 211
Hydraulic Brake • 870-834/001 (Current Version)............................................... & Up 211.1
DRIVE UNIT 300
Drive Unit Installation - 828-003-181 (L) ............................................................... 16806 to 18296 301

Drive Motor-570-262/500.................................................................................... 16806 & Up 303
Drive Unit Gear Reducer- 410-022 ....................................................................... 16806 to 305
Drive Unit Gear Reducer- 410-026.......................................................................
Drive Unit Gear Reducer- 410-029....................................................................... -=- to
& Up
305.1
307
ELECTRICAL 400
Standard Electrical Symbols................................................................................ 401

Electric System Schematic - 828-003-414 (A) Sh. 1 ............................................ 16806 to 17002 403
Electric System Schematic - 828-003-414 (A) Sh. 2 ............................................ 16806 to 17002 405
Electric System Schematic - 828-003-414 (E) Sh. 1 ............................................ 17003 & Up 403.1
Electric System Schematic -828-003-414 (E) Sh. 2............................................ 17003 & Up 405.1
Electrical System - 828-003-349 (E) Sh. 1 ............................................................ 16806 to 17002 407
Electrical System -828-003-349 (E) Sh. 2 ............................................................ 16806 to 17002 409
Electrical System - 828-003-349 (F) Sh. 1 ............................................................ 17003 to 17169 407.1
Electrical System - 828-003-349 (F) Sh. 2 ............................................................ 17003 to 17169 409.1
Electrical System - 828-003-349 (M) Sh. 1 ........................................................... 17170 to 18296 407.2
MODEL 31 EASF REACH PARTS MANUAL
TABLE OF CONTENTS
S/N 16806 to 18296
Page2of2 Date: February v 1993
Description Serial No.
ELECTRICAL (Cont'd.)
Electric Control System - 828-003-442 (A1) ......................................................... 16806 to 1nos 411

Electric Control System - 828-003-955/ (A) ......................00................................. 1no7 & Up 411.1
Contactor Assembly - 828-003-421 /001 (H) ........................;............................... 16806 & Up 413
Detector Assembly-828-003-420/ (E)................................................................. 16806 & Up 415
Encoder Bracket Assembly - 828-003-382/ (F) ................................................... 16806 & Up 41 I
Handle Assembly- 828-003-476/ (F) ................................................................... 16806 & Up 419
Elec. Connector Assembly- 828-003-432/ (A).................................................... 16806 & Up 421
Resistor Assembly Installation -828-000-980/ (H) .............................................. 16806 to 18296 423
Resistor Assembly - 828-003-719 ......................................................................... 16806 to 18296 425
Working Lights lnstallation-828-003-729/ .......................................................... 16806 & Up 427
Working Light Rework-828-003-728/ ................................................................. 16806 & Up 42S
Strobe Light Installation - 828-003-731/............................................................... 16806 & Up 431
Strobe Light Assembly - 828-003-730 / ................................................................ 16806 & Up 433
Warning Light Installation - 828-003-735/ (B) ...................................................... 16806 & Up 435
Warning Light Assembly-154-005-638/ (G) ....................................................... 16806 & Up 437
Back-Up Alarm Installation -828-003-780/ .......................................................... 16806 & Up 439
Back-Up Light Installation -828-003-785 (A)....................................................... 16806 & Up 441
All Travel Alarm Installation - 828-003-788/ (A)................................................... 16806 & Up 443
Fan Assembly Installation- 828-003-796/ ............................................................ 16806 & Up 445
HYDRAULIC 5<.
Standard Hydraulic Symbols................................................................................ 501

Hydraulic Schematic - 828-003-067 (A) ............................................................... 16806 to 18296 503
Hydraulic System - 828-003-286/ (!<) ................................................................... 16806 to 18296 505
Lift Manifold Assembly - 828-003-287 (C) ............................................................ 16806 & Up 507
Lift Manifold -520-854........................................................................................... 16806 & Up 509
Auxiliary Manifold Assembly - 828-003-288 ......................................................... 16806 to 18296 511
Auxiliary Manifold - 520-855 .................................................................................. 16806 to 18296 513
Auxiliary Pump & Motor Assembly - 828-003-229 (F) .......................................... 16806 to 18296 515
Auxiliary Pump Assembly - 500-435 ..................................................................... 16806 to 18296 517
Auxiliary Motor - 570-264/200 .............................................................................. 16806 to 18296 519
Lift Pump & Motor Assembly- 828-003-283 (C) .................................................. 16806 to 18803 521
Lift Motor- Prestolite -570-236/100..................................................................... 16806 & Up 523
Lift Motor- G.E. -570-236/200............................................................................. 16806 & Up 525
Lift Motor-Advanced DC- 570-236/500 ............................................................. 16806 & Up 527
Hydraulic Motor Assembly - 828-003-325 (C) ...................................................... 16806 & Up 529
Steer Motor-550-024 ........................................................................................... 16806 & Up 531
Orbit Valve Assembly- 828-003-326 (A) ............................................................... 16806 to 18296 533
Orbit Metering Valve - 870"'841 ............................................................................. 16806 to 18296 535
Reservoir Assembly - 828-003-161 (E) ................................................................. 16806 to 17896 537
Reservoir Assembly - 828-003-161 (H) ................................................................. 17897 & Up 537.1
Lift Motor Assembly- 570-236/400 ...................................................................... 16806 & Up 539
Lift Pump and Motor lnstal. (Dual Stage) -828-003-989/ (A) .............................. 16806 to 18803 541
MODEL31 POWER
AS Pag0101
Revised 10/~5/92
S/N 16806 to 17950

POWER SECTION BASIC
Figure 828-003-100/ (Q)
THE RAYMOND CORPORATION
POWER SECTION BASIC Page 102

Figure 828-003-100/ (Q) MODEL 31 EASi2
Item No. ~ Part Number Description
1 1 (REF) 828-003-039/ Steer Idler Wheel Installation

2 1 828-003-000I Frame Weldment
3 1 (REF) 828-003-161 Reservoir Assembly
4 5 (REF) 828-001-430/ Roller Assembly
5 1 828-003-679 Door Weldment
6 1 (REF) 828-003-181 Drive Unit Assembly
7 4 710..:373P Hex Hd. Cap Screw 5/8-11 x 3.00
8 1 (REF) 828-003-228 Steering Installation
9 1 (REF) 828-003-209 Brake Assembly
11 2 760-048 Jam Nut5/8-11
12 1 828-003-914 Pedal Weldment
13 2 812-005-174 Latch Pin
14 1 861-013 Yoke Pin
15 1 810-910 Cotter Pin
16 1 828-003-136 Rod
17 1 900-263 Steering Shaft Assembly
18 4 740-134 Carriage Bolt 5/16-18 x 1.0
19 11 750-013 Nut 5/16-18
20 2 462-009 Ollite Bearing
21 2 735-011 Shoulder Bolt 5/16-18 x 3/8
22 2 810-764 Spirol Pin 1/4 x 2-1/2
23 1 828-003-085 Steering Stop
24 1 810-110 Retainer Ring
25 1 860-114 Knob
26 7 771-116 Flat Washer 1/4
27 7 750-006 Nut 1/4-20
28 1 828-003-131 Battery Connector Bracket
29 2 710-040 Hex Hd. Cap Screw 1/4-20 x 3-1 /2
30 1 828-003-339I Drive Wheel Assembly: (See Chart) includes
1 632-131/ Tire
1 828-003-073 Hub Mach. Casting
31 7 828-003-193 Lug Bolt
32
33
34 4 710-065 Hex Hd. Cap Screw 5/16-18x1/2
35 8 771-052 Flat Washer 5/16
36 1 828-003-095 LH. Dust Cover Plate
37 1 828-003-096 R. H. Dust Cover Plate
38 1 828-003-216 Middle Dust Cover Plate
39 7 701-182 Rd. Hd. Mach. Screw 1/4-20 x 1/2
40 1 030-602-043 /004 Hose Assembly
41 2 828-003-599 Reservoir Hold Down Bracket
42 2 750-012 Nut5/16=24
43 1 710-257P Hex Hd. Cap Screw 1/2-20 x 2-1 /2
44 1 750-033 Nut 1/2-20
Page 102 (Conrd.) POWER SECTION BASIC

MODEL 31 EASi2 Figure 828-003-100/ (Q)
P/N ITEM 30 P/N DESCRIPTION
001 001 16.5" Batt. compt.
002 002 16.5 11 Batt. compt.
003 003 16.5 11 Batt. compt.
004 001 21.5 11 Batt. Compt.
005 002 21.5" Batt. Compt.
006 003 21.5 11 Batt. Compt.

MODEL 31 POWER
~~
11
....
................
11 .... ....
.... ........
!ii ....
....
6 ........
.... ....
S/N 17951to18296
POWER SECTION BASIC
Figure 828-00«123/ (B)
POWER SECTION BASIC Page 102.1

Figure 828-004-023/ (B) MODEL 31 EASi2
1 1 (REF) 828-003-923/ Steer Idler Wheel Installation

2 1 828-Q04-QOO/ Frame Weldment
3 1 (REF) 828-003-161 Reservoir Assembly
4 5 (REF) 828-001-430/ Roller Assembly
5 1 828-003-679 Door Weldment
6 1 (REF) 828-003-181 Drive Unit Assembly
7 4 710-373P Hex: Hd. Cap Screw 5/8-11 x 3.00
8 1 (REF) 828-003-228 Steering Installation
9 1 (REF) 828-003-209 Brake Assembly
10 2 750-012 Nut5/16-24
11 2 760-048 Jam Nut 5/8-11
12 1 828-003-914 Pedal Weldment
13 2 812-005-174 Latch Pin
14 1 861-013 Yoke Pin
15 1 810-910 Cotter Pin
16 1 828-003-136 Rod
17 1 900-263 Steering Shaft Assembly
18 4 740-134 Carriage Bolt 5 /16-18 x 1.0
19 11 750-013 Nut 5/16-18
20 2 462-009 Oilite Bearing
21 2 735-011 Shoulder Bolt 5/16-18 x 3/8
22 2 810-764 Spirol Pin 1/4 x 2-1 /2
23 1 828-003-085 Steering Stop
24 1 810-110 Retainer Ring
25 1 860-114 Knob
26 7 n1-116 Flat Washer 1/4
27 7 750-006 Nut 1/4-20
28 1 828-003-131 Battery Connector Bracket
29 2 710-040 Hex: Hd. Cap Screw 1/4-20 x 3-1 /2
30 1 828-003-339/ Drive Wheel Assembly: (See Chart) includes
1 632-131/ Tire
1 828-003-073 Hub Mach. Casting
31 7 828-003-193 lug Bolt
32 1 710-257P Hex: Hd. Cap Screw 1/2-20 x 2-1 /2
33 1 750-033 Nut 1/2-20
34 4 710-065 Hex Hd. Cap Screw 5/16-18x 1/2
35 7 n1-052 Flat Washer 5/16
36 1 828-003-095 LH. Dust Cover Plate
37 1 828-003-096 R. Ho Dust Cover Plate
38 1 828-003-216 Middle Dust Cover Plate
39 7 701-182 Rd. Hd. Mach. Screw 1/4-20x1/2
40 1 030-602-043/004 Hose Assembly
41 2 828-003-599 Reservoir Hold Down Bracket
Page 102.1 (Cont'd.) POWER SECTION BASIC

MODEL 31 EASi2 Figure 828-004-023/ (B)
P/N ITEM 30 P/N DESCRIPTION
001 001 16.5 11 Batt. Compt.

.
002 002 16.5 11 Batt. Compt.
003 003 16.5" Batt. Compt~
004 001 21.5 11 Batt. Compt.

005 002 21.5" Batt. Compt.
006 003 21.5" Batt. Compt.

MODEL 31 POWER
A9 P~g~ H"l3
Revised 2/15/93
Sheet 1 of 2
ANISH INSTRUCTIONS
Figure 828-003-322/ (K)
MODEL 31 POWER
A11,A12 Page 105
Revised 2/15/93
MAST GUARD
(REF) (GLASS)
MAST
TRACTOR
(REF)
(2) LEC. PANEL

CONTROL (REF)
COVER
(REF) (2) c:> /1
(2) DETAIL E
VIEW F-F
TRACTOR
FRAME
DETAIL H (REF) DETAIL A
DETAIL A GLASS MAST
DETAIL B GUARD ONLY
CENTER ABOUT
(2)BATTERY ,...---_ ,..--..__
COMP ARTMENT
[.../""" MAST
~ MAST GUARD
(SCREEN)
I= I=
I:= =
==
F ==
IW ~-i c:> 11
II~ / ;J1
l D< \ ~
(2) (REF)
TOP COVER
(REF)
DETAIL B
CONTRll. COVER (REF)
BRACKET KEY
(REF)
KEY SWITCH
(REF)
RONT PAD
RACKET KEY
(REF)
'
5
SCREEN MAST
GUARD ONLY
c DETAIL D (REF)
Sheet 2 of 2
FINISH INSTRUCTIONS
Flaure 828-003-322/ (K)
FINISH INSTRUCTIONS Page 10~
Figure 828-003-322/ (K) MODEL 31 EASI
ltemNo. ~ Part Number oescrlptlon

ltemNo. ~ Part Number oescrlotlon
6 813-570/002 Stud
2 2 411-511/021 Raymond Decal 46 7 771-054 Flat Washer 5/16
3 1 411-529 Lubrication Decal 47 1 828-003-116 Spring Cllp
4 1 411-528 Patent No. Decal 48 1 828-001-066 Battery Plug Kit
5 411-530 Cold Storage Decal 49 1 828-003-800 Switch Cover
6 1 412-148 Basic Plate 50 4 813-570/002 Stud
7 1 850-111 Woodruff Key 51 2 411-682/001 EE Decal
8 1 (REF) 828-003·110 Steering Wheel Assembly 52 1 412-144 Type EE Spec. Plate
9 1 760-147 Nut 53 411-534 Emergency Disconnect Decal
10 1 828-003·186 Floor Pad
11 1 828-003-918 Pedal Pad
828-003-322/
12 1 411-785 Traction Motor Warning Decal - -T
13 1 411-756/001 General Warning Decal
14 1 411-754 Reach Decal
15 1 412-326 UL "E" Plate
16 1 411-753 Tiit Decal
17 2 411-784 Battery Warning Decal
18 1 900-262/002 Plug Button OPTIONS AUX. FUNCTIONS
19 1 411-730 Operator Display Decal
Left Pad Assembly P/N DESCRIPTION W/O ITEM P/N DESCRIPTION W/ITEM
20 1 828-003-747
21 828-003-749 Right Pad Assembly l Standard 5,51,52 l Reach 14
22 1 828-003-748 Front Pad Assembly
23 1 828-003-076 Top Cover 2 Cold Storage 51,52 2 Tilt 16
24 1 828-003-857 Control Cover
25 1 411-737/001 General Warning Decal 3 EE Standard 5,6 3 Shift 31
26 1 411-735 Reach Tiit Shift Decal
27 1 411-736 Reach Tiit Decal 4 EE Cold Stor. 6 4 Reach, Tilt 27
28 9 812-029/002 Retainer Nut
5 Reach, Shift 32
29 8 701-244 Tr. Hd. Mach. Screw 1/4-20 x 1/2 (Black)
30 5 701-247 Tr. Hd. Mach. Screw 1/4·20 x 1-1/4 (Black) 6 Tilt, Shift 33
31 1 411-752 Shift Decal
32 .1 411-751 Reach Shift Decal 7 Reach, Tilt, Shift 26
33 1 411-750 Shift Tiit Decal P/N OACH W/ITEM
34 1 411-755 No Aux. Decal 8 No Aux. 34
35 2 701-220 Tr. Hd. Mach. Screw 1/4·20 x 5/8 l 72-75 13
37 1 828-003-284 Electrical Cover (S/N 16806 to 18640)
2 76 & Up 25
1 828-005-035 Electrical Cover (S/N 18641 and Up)
39 2 828-003-612 Standoff Control Cover
40 3 701-246 Tr. Hd. Mach. Screw 1/4·20 x 3/4 (Black)
41 1 828-003-876 Mounting Block
42 1 740-128 Carriage Bolt 5/16·18 x 1-1 /2
43 1 771-019 Flat Washer 5/16
44 AR 412-150 Aux. Spec. Plate
45 1 750-013 Nut 5/16·18
MODEL 31 POWER
61
Pag® -W1
Revised 2/15/93
~
.....
.....
..... .....
.....
.....
.....
10
..>heet 1 of 2
BILINGUAL
FINISH INSTRUCTIONS
Figure 828-003-657I (J)
MODEL31 POWER
Page 109
83,84 Revised 2/15/93
MAST GUARD
~(REF) (GLASS)
MAST
/
/ (REF)
TRACTOR
/! AD g. ELEC. COVER
(REF)
(I CONTROL
COVER
(REF) (2)
(REF)
(2) LEC. PANEL

(2) (REF)
28 CREF)
TRACTOR
FRAME
DETAR. H (REF) DETAIL E
VIEW F·F
DETAIL A
DETAIL A GLASS MAST
DETAIL B GUARD ONLY
CENTER ABOUT
(2)BATTERY
COMP ARTMENT ,.---__
- - VMAST
MAST GUARD
(SCREEN)
48
I== ,,,,,,.,,.., v 37
== 38
I= I=
47
I== 51
4
==
I= ='
!
:1
~~;1
~
"--, ~ j1
K (XI /
(2) (REF) I \ I EBJ I
~
TOP COVER
(REF) 13
BRACKET KEY 25
DETAIL B
(REF) RONT PAD SCREEN MAST 6
(REF) GUARD OtJ~Y
I
KEY SWITCH
(REF)
Sheet 2 of 2
BILINGUAL FINISH INSTRUCTIONS
Figure 828-003-657 / (J)
FINISH INSTRUCTIONS Page 11~

Figure 828-003-657I (J) MODEL 31 EASI
ltemNo. ~ Part Number oescrlptlon Item No. .Ql:i, Part Nymber Descriotlon
1 6 813-570/002 Stud 45 AR 411-778 French Warning Decal

2 2 411-511/021 Raymond Decal 46 AR 411-779 French Warning Decal
3 411-641 Lubrication Decal 47 1 828-003-656/001 Plate Assembly
4 1 828-003-800 Switch Cover 48 2 828-003-655 Clip
5 1 411-632 Cold Storage Decal 49 1 771-019 Flat Washer 5/16
6 1 412-151 Basic Plate 50 1 750-013 Hex Nut 5/16-18
7 1 850-111 Woodruff Key 51 1 828-003-656/002 Plate Assembly
8 1 (REF) 828-003-110 Steering Wheel Assembly 52 1 411-645 Patent Decal
9 1 760-147 Nut 53 1 828-003-116 Spring Clip
10 1 828-003-186 Floor Pad 54 1 828-001-066 Battery Plug Kit
11 1 828-003-918 Pedal Pad 55 1 411-787 Traction Motor Decal
12 1 828-003-284 Electrical Cove_r (S/N 16806 to 18640) 56 2 411-682/001 EE Decal
1 828-005-035 Electrical Cover (S/N 18641 and Up) 57 1 412-145 Type EE Spec. Plate
13 1 411-756/001 General Warning Decal 58 1 411-638 Emergency Disconnect Decal
14 1 411-754 Reach Decal
15 1 412-326 UL •E• Plate
828-003-657/
16 1 411-753 Tilt Decal - -T
17 2 411-786 Battery Warning Decal
18 900-262/002 Plug Button
19 411-730 Operator Display Decal
20 828-003-747 Left Pad Assembly
21 1 828-003-749 Right Pad Assembly
22 1 828-003-748 Front Pad Assembly OPTIONS AUX. FUNCTIONS
23 828-003-076 Top Cover
24 1 828-003-857 Control Cover P/N DESCRIPTION W/O ITEM P/N DESCRIPTION W/ITEM
25 AR 411-737 /001 General Warning Decal
Reach, Tiit, Shift Decal
1 Standard 5,56,57 1 Reach 14
26 AR 411-735
27 AR 411-736 Reach, Tilt Decal 2 Cold Storage 56,57 2 Tilt 16
28 9 812-029/002 Retainer Nut
29 8 701-244 Tr. Hd. Mach. Screw 1/4-20 x 1/2 (Black) 3 EE Standard 5,6 3 Shift 31
30 5 701-247 Tr. Hd. Mach. Screw 1/4-20 x 1-1/4 (Black)
31 1 411-752 Shift Decal 4 EE Cold Stor. 6 4 Reach, Tilt 27
32 1 411-751 Reach, Shift Decal
33 1 411-750 Tilt, Shift Decal 5 Reach, Shift 32
34 1 411-755 No Aux. Decal
6 Tilt, Shift 33
35 2 701-220 Truss Hd. Mach. Screw 1/4-20 x 1/2
36 7 771-054 Flat Washer 5/16 7 Reach, Tilt, Shift 26
37 4 771-016 Flat Washer P/N OACH W/ITEM
38 6 760-006 Hex Nut 1/4-20 Nylock 8 No Aux. 34
39 2 828-003-612 Control Cover Standoff 1 72-75 13
40 3 701-246 Truss Hd. Mach. Screw 1/4-20x3/4 (Black)
41 1 828-003-876 Mounting Block 2 76 & Up 25
42 1 740-128 Carriage Bolt 5 /16-18 x 1-1 /2
43 AR 412-152 Aux. Spec Plate - Canadian
44 AR 813-570/002 Stud
MODEL31 POWER
87 PagG~ i 11
Revised 10/15/92
.__---A•__- - - -
FIGURE C
----A•------~
FIGURE B
.__---A•__-----i 8
----A•_----1 7
FIGURE A FIGURE D
S/N 16806 to 17950
GATE INSTALLATION
Figure 828-003-564/
GATE INSTALLATION Page 112

Figure 828-003-564/ MODEL 31 EASi 2
B8
Item No. .Qty, Part Number Description
1 1 828-003-003 /002 Battery Gate

2 1 828-003-003 /003 Battery Gate
3 1 828-003-003 /005 Battery Gate
4 1 828-003-003 /006 Battery Gate
5 2 828-003-003 /002 Battery Gate
6 2 828-003-003 /003 Battery Gate
7 2 828-003-003 /005 Battery Gate
8 2 828-003-003 /006 Battery Gate
Batt. See
P/N Compt. Figure W/O ITEMS
001 16.5 c 1,2,3,4,6,7 & 8

002 16.5 D 1,2,3,4,5,6 & 8
003 16.5 Std. B 2,4,5,6 7 & 8
004 16.5 A 1,2,3,4,6,7 & 8

005 21.5 c 1,2,3,4,5,7 & 8
006 21.5 Std. 0 1,2,3,4,5,6 & 7

007 21.5 B 1,3,5,6,7 & 8
008 21.5 A 1,2,3,4,5,7 & 8

MODEL 31 POWER
Page n1.1
Added 10/iG
t-----A•-------~--i
FIGURE C
i-----A•---------i
FIGURE 8
i-----A•-------- ----A•---------1
FIGURE A FIGURE D
S/N 17951 and Up
GATE INSTALLATION
Figure 828-003-925 /
GATE INSTALLATION Page 112.1

Figure 828-003-925/ MODEL 31 EAS12
Item No. _Qty, Part Number Description
1 1 828-003-924/002 Battery Gate

2 1 828-003-924/003 Battery Gate
3 1 828-003-924/005 Battery Gate
4 1 828-003-924 /006 Battery Gate
5 2 828-003-924 /002 Battery Gate
6 2 828-003-924/003 Battery Gate
7 2 828-003-924/005 Battery Gate
8 2 828-003-924/006 Battery Gate
Batt. See
P/N Compt. Figure W/O ITEMS
001 16.5 c 1,2,3,4,6,7 & 8
002 16.5 Std. D 1,2,3,4,5,6 & 8
003 16.5 B 2,4,5,6,7 & 8
004 16.5 A 1,2,3,4,6,7 & 8
005 21.5 c 1,2,3,4,5,7 & 8
006 21=5 Std. D 1,2,3,4,5,6 & 7

007 21.5 B 1,3,5;6,7 & 8
008 21.5 A 1,2,3,4,5,7 & 8

MODEL 31 POWER
Pago 113
Revised 2/15/93
-
i - - - - - - - A = _ _ MAX. (REF)-----1
i--~~~~~~~-B= MAX. (REF)~------;~
Batt.
P/N Compt. A= B=
-- --
004 16.5 14.74 16.50
005 21.5 19.74 21.50

009 16.5 14.50 16.31
010 21.5 19.50 21.31
011 14.5 12~50 14.31
1 2 123-001-382 Battery Roller

2 1 828-001-429/ Spacer Pipe
3 1 828-001-335I Roller Shaft
4 2 810-488/014 Push-On Retaining Ring
S/N 16806 and Up

ROLLER ASSEMBLY
Figure 828-001-430/ (D)
MODEL 31 POWER
811,812 Page 115
Revised 3/15/92
MAST ASSEM REF
PWR SECT REF
YEW A-A
c )
VIEWl-a
POWER SECTION TO MAST

Figure 828-003-278/ (D)
POWER SECTION TO MAST Page 11~

Figure 828-003-278/ (D) MODEL 31 EASi
813
Item No. ~ Part Number Descrlotlon

3 1 828-001-175 Main Frame Alter.
2 710-368P Hex Hd. Cap Screw 5/8-11 x 2-1 /2
4 2 7-771-500/016P Wash·er
5 4 710-357P Hex Hd. Cap Screw 5/8-11x1-1/4
6 4 710-359P Hex Hd. Cap Screw 5/8-11x1-1/2
7 4 710-355P Hex Hd. Cap Screw 5/8-11 x 1
8 8 710-373P Hex Hd. Cap Screw 5/8-11x3
9 4 7-771-500/016P Washer
11 4 710-361P Hex Hd. Cap Screw 5/8-11 x 1/3/4
13 4 7-771-500/016P Washer
P/N CONDITION USE MOUNTING HARDWARE

001 3000# 4 9 1 5 10
002 Deep Reach 4 9 13 1 6 11
003 4500# 4 9 13 3 8
004 4000#, All 4 9 13 1 6 11

M Trucks
MODEL 31 POWER
C1, C2 Page 117
Added 9/15/91
828-003-369
~
.--.
A A BATTERY
16
21
P/N
0
I
GACH
72.79,85,91
73,80,86,92
74. 81 . 87. 93. 95
75,82,88,94,96
P/N
01
02
03
04
76,83,89,97 05
77,84,90,98 06
78,99 07
VIEW A-A 100+ 08
c
r
I
)
VIEW B-B VIEW C-C VIEW D-D
REAR POST INSTALLATION

Figure 828-003-369/ (B)
REAR POST INSTALLATION Page 11~

Figure 828-003-369/ (8) MODEL 31 EASI
C3
Item No. ~ Part Nymber Description
1 2 020-003-364 / Rear Post Tube

2 828-003-366 Door Alter
3 828-003-376 R.S. Plate Alter.
4 020-003-367 I Overhead Guard Alter.
5 2 710-129 Hex Hd. Cap Screw 3/8-16 x 7/8
6 1 861-209 Spring Plunger
7 1 811-866/002 Lock Pin
8 1 710-153 Hex Hd. Cap Screw 3/8-16 x 3.00
9 1 760-020 Locknut 3/8-16
10 3 771-023 Flat Washer 3/8
MODEL 31 POWER
cs.cs Page 119
Added 9/15/91
II
II
REF ~ II
REF
FRAME WELD
FRAME WELD \ II
I I
I 1001 I
_L _ _
1001
-----..,-------_J
I
-+-
I
Full/ Half Height

BACK GATE ASSEMBLY
Figure 828-003-569/
BACK GATE ASSEMBLY Page 12~

Figure 828-003-569 / MODEL 31 EASi
C7
1 1 828-003-555 /001 Guard Hinge Weldment

2 1 828-003-555 /002 Guard Hinge Weldment
3 1 828-003-556/001 Back Pad Assembly
4 1 828-003-556/002 Back Pad Assembly
5 3 900-137 Single Action Hinge
6 2 900-137 Single Action Hinge
7 1 828-003-590 /001 Back Bumper Guard
MODEL31 POWER
Pa!J,C l 21
C9 Added 9/E>/91
=1=-,=;i=== =f 9=::c:;
_J - J_
~-----+-+--f--~
~ - +-~~~'I -:- J l
PLATFORM EXTENSION INSTALLATION

Figure 828-003-702
PLATFORM EXTENSION INSTALLATION Page 122

Figure 828-003-702 MODEL 31 EASi2
C10
Item No. ..Qn!. Part Number Description
1 1 828-003-704 Platform Extension Weldment

2 1 828-003-703 Platform Extension Pad
3 2 772-115 Lockwasher 1/2
4 2 710-241 Hex Hd. Cap Screw 1/2-20 x 1
5 AR 990-569 Cement
C11 MODEL31 POWER
Page 123
Added 3/15/92
FRONT VIEW
R.H. SIDE VIEW

OPTION ON MCOEL 20 ONLY
L.H. SIDE VIEW

STNllARD MOUNTING
FIRE EXTINGUISHER INSTALLATIONS

Figure 828-003-727 /
FIRE EXTINGUISHER INSTALLATIONS Page 124

Figure 828-003-727 / MODEL 31 EASi2
C12
Item No. ..Q!Y: Part Number Description
1 1 870-111 Extinguisher - 5.0# C02

2 1 870-116 Extinguisher - 2.5# Dry Chemical
3 1 870-117 Extinguisher - 5.0# Dry Chemical
4 4 710-007 Hex Hdo Cap Screw 1/4-28 x 1/2
5 4 n2-11s Lockwasher1/4
6 4 701-117 Rd. Hd. Mach. Screw #10-32x1/2
7 4 n2-112 Lockwasher #1 O
P/N MODELS MTG. POSITION W/O ITEM

001 20/21 2, 3, 6 & 7
002 & L.H. Side 1, 3, 4 & 5

003 3li 1, 2, 4 & 5
004 20 2, 3, 6 & 7
005 Only R.H. Side 1, 3, 4 & 5
006 1, 2, 4 & 5
MODEL 31 BRAKE & STEERING
Page201 REF HYO MOTOR
F5,F6
Revised 2/15/93
ETAIL B
DETAIL A
D
___-@
§
DETAIL 8 DETAIL C
2r--s;;~~~------LI
See View A-A
460-678 VIEW A-A

REF.
S/N 16806 to 18296
MECH. STEERING INSTALLATION

Figure 828-003-228 (F)
MECH. STEERING INSTALLATION Page20~

Figure 828-003-228 (F) MODEL 31 EASI
1 1 907-004-140 Washer
2 828-003-921 /001 Steer Shaft Weldment
3 900-207 Mounting Pad
4 1 828-003-205 Steer Mtg. Bracket
5 1 7-812-506/040 Encoder Shaft
6 1 828-003-162 Timing Belt Pulley
7 1 828-003-200 Steering Mounting Spacer
8 1 828-003-204 Spacer
9 1 710-140 Hex Hd. Cap Screw 3 /8-24 x 1-1 /2
10 1 830-160 Compression Spring
11 1 771-123 Flat Washer 3 /8
12 REF 828-003-382 Encoder Bracket Assembly
13 1 872-007/006 Timing Belt
14 4 710-015 Hex Hd. Cap Screw 1/4-20 x 1.00
16 1 828-003-246 Bracket
17 1 828-001-457 Ring
18 3 760-006 Lock Nut 1/4-20
19 1 828-003-242 Bracket Weld
20 1 154-000-345 Bracket
21 2 710-010 Hex Hd. Cap Screw 1/4-20 x .75
22 710-135 Hex Hd. Cap Screw 3 /8-24 x 1-1/4
23 2 724-290 Soc. Hd. Set Screw #10-24 x 3/16
Pape 203
Revised 10/I G/92
BRAKE ASSEMBLY
Figure 828-003-209 (E)
BRAKE ASSEMBLY Page204

Figure 828-003-209 (E) MODEL31 EASi2
1 1 870-630 Master Cylinder W /Reservoir

2 1 828-003-206 Brake Mounting Bracket
3 1 828-003-167 Brake Cam
4 1 710-014 Hex Hd. Cap Screw 1/4-28 x 1
5 4 750-005 Hex Nut 1/4-28
6 1 821-005-090 Spacer
8 1 828-003-207 Turnbuckle Body Bar
9 1 828-003-208 Shaft
10 6 750-012 Hex Nut 5/16-24
11 1 735-011 Shoulder Screw
13 1 1-150-355 Switch
14 1 828-003-221 Shaft
15 2 860-813 aevis Link
16 2 701-016 Rd. Hd. Mach. Screw #4-40 x 3/4
17 1 462-009 Bearing
18 1 828-003-305 Actuator Switch
19 1 828-003-327 Switch Bracket
20 2 701-130 Rd. Hd. Mach. Screw #10-32 x 5/16
21 1 828-003-306 Brake Stud
23 2 861-013 Yoke Pin 5/16x1-1/16
24 2 810-910 Cotter Pin 3/32 x 3/4
25 1 812-001-347 Hydraulic Connector
26 1 750-411 Jam Nut 5/16-24- LH.
27 2 n4-105 Lockwasher #4
28 2 750-025 Hex Nut #4-40
F11, F12 MODEL 31 BRAKE & STEERING
Page205
Revised 10/15/92
ITEM 24 ITEM I ITEM 2 ITEM 3

DRIVE
UNIT
SECTION A-A
.------. G
SECTION B-8 SECTION C-C
VIEW E-E
DRIVE UNIT
- - - --ri'
II
II
II
II
''~ -
)r ' ~,-I!.
II
l"'---
1
I
--- I
I I
't::~=========::=== =/~ j=
~ ) \ 1 J
$_!.~_?: ==1'== == == ~,
\
/ =d:::?==irr'lii
==t.~-=--=- \ ~-=--=-ls;::===~~:t'""t---6
I
I
,...-..._. I I
I
I
A
I 0
I
L...~~~L:..rtt:::::tt~~~~-"
VIEW 8-G YEW D-D
4 2
S/N 16806to17950
IDLER STEER WHEEL INSTALLATION
Figure 828-003-039/ (G)
IDLER STEER WHEEL INSTALLATION Page20H

Figure 828-003-039/ (G) MODEL 31 EASI P/N BATT. COMPT. ITEM 24
Item No. ~ part Number pescdotlon 001 14.50 001
REF 828-003-057 /001 Steer Idler Wheel Assembly 002 16.50 002
2 1 828-003-064 Steer Link Assembly: Includes
003 21.50 003
1 828-003-060 Right Steer Link
2 840-030 Grease Fitting
2 460-680 Bearing
3 1 828-003-065 Steer Link Assembly: Includes
1 828-003-061 Left Steer Link
2 460-680 Bearing
4 828-003-066 Center Link Assembly: Includes
1 828-003-063 Center Steer Link
1 445-118 Bearing
5 1 828-003-078 Pivot
6 AR 828-000-225 /001 Spacer
7 AR 828-000-225 /002 Spacer
8 AR 828-000-225 /003 Spacer
9 2 710-134 Hex Hd. Cap Screw 3/8-16 x 1
10 4 824-000-382 Bolt
11 12 824-000-390 Spacer
12 1 760-147 Hex Nut 3/4-16
13 1 771-128 Flat Washer
14 2 750-020 Hex Nut 3/8-16
15 AR 771-040 Spacer
17 2 828-000-250 Spring Bolt
18 2 828-000-229 Spring Boss
19 1 710-365 Hex Hd. Cap Screw 5/8-18
21 1 828-003-182 Lock Plate
22 2 714-117 Soc. Hd. Cap Screw 3/8-16 x 1/2
23 1 464-092 Olllte Bearing
24 1 828-003-165/ Steer Bracket Weld
25 2 828-003-021 Steer Mounting Bracket
26 4 710-252 Hex Hd. Cap Screw 1/2-13 x 2
28 2 710·248P Hex Hd. Cap Screw 1/2-20
29 2 750-031 Hex Nut 1/2-20
30 1 750-434 Hex Nut 1/2-13
31 1 822-002-663 Bolt 1/2·13 UNC-2A
32 3 828-003·701 Spacer
33 1 841-056 Grease Fitting
Page2«'i5.1
Revised 2/15/93
ITEM 4 ·
VIEW E-E
ITEM 3
DRIVE
UNIT
VIEW 0-0
SECTION C-C
ITEM 26 ITEM I
12
G G
SECTION
.---------. SECTION B-B
DRIVE UNIT
VIEW G-G
E E
4 2
S/N 17951 and Up
IDLER STEER WHEEL INSTALLATION

Figure 828-003-923 / (C)
IDLER STEER WHEEL INSTALLATION Page206.1

Figure 828-003-923/ (C) MODEL 31 EASi2
item No. ~ Part Number Qescriotion
1 (REF) 828-003-057/001 Steer Idler Wheel Assembly

2 1 . 828-003-064 Steer Link Assembly: includes
1 828-003-060 Right Steer Unk
2 460-680 Bearing
3 1 828-003-065 Steer Link Assembly: includes
1 828-003-061 Left Steer Unk
2 460-680 Bearing
4 1 828-003-066 Center Unk Assembly: includes
1 828-003-063 Center Steer Link
445-118 Bearing
5 1 828-003-078 Pivot
6 AR 828-000-225/001 Spacer
7 AR 828-000-225/002 Spacer
8 AR 828-000-225/003 Spacer
9 2 710-134 Hex Hd. Cap Screw 3/8-16 x 1
10 4 824-000-382 Bolt
11 12 824--000-390 Spacer
12 1 760-147 Hex Nut 3/4-16
14 2 750-020 Hex Nut 3/8-16
15 AR 771-040 Spacer
17 2 828-000-250 Spring Bolt
18 2 828-000-229 Spring Boss
19 1 710-367 Hex Hd. Cap Screw 5/8-18 x 2-1/4
20 771-127 Flat Washer
21 1 828-003-182 Lock Plate
22 2 714-117 Soc. Hd. Cap Screw 3/8-16 x 1/2
23 1 464-092 Oilite Bearing
24 1 828-004-021 / Steer Bracket Weld
25 2 828-003-021 Steer Mounting Bracket
26 4 710-252 Hex Hd. Cap Screw 1/2-13 x 2
28 2 710-248P Hex Hd. Cap' Screw 1/2-20
29 2 750-031 Hex Nut 1/2-20
30 1 750-434 Hex Nut 1/2-13
31 1 822-002-663 Bolt 1/2-13 UNC-2A
32 3 828-003-701 Spacer
34 AR 828-000-225 /004 Spacer
P/N BATT. COMPT. ITEM 24

001 14.50 001
002 16.50 002
003 21.50 003

Page. 207
Revised 2/~5/93
DETAIL A
IDLER STEER WHEEL ASSEMBLY

Figure 828-003-057/ (G)
IDLER STEER WHEEL ASSEMBLY Page20~

Figure 828-003-057 / (G) MODEL 31 EASi
1 1 444-326 Thrust Bearing

2 1 761-882 Castle Nut
3 1 447-077 Tappered Bearing
4 1 828-005-046 Frame Assembly: includes
1 447-533 Sleeve Bearing
2 460-690 Spherical Bearing
1 828-005-045 Frame Mach.
5 1 828-003-053 Wheel Frame Mach.
6 1 828-000-234/ Caster Wheel Assembly: includes
1 632-078/ Poly Wheel
2 441-128 Ball Bearing
7 1 810-947 Cotter Pin
8 1 828-003-059 Caster Axle
10 AR 828-000-260/001 Caster Spacer
11 AR 828-000-260 /002 Caster Spacer
12 AR 828-000-260 /003 Caster Spacer
13 1 810-930 Cotter Pin
14 1 701-186 Rd. Hd. Mach. Screw 1/4-20 x 3/4
15 1 812-000-112 Spacer Washer
P/N ITEM 6 P/N TIRE NO. - COLOR

001 001 001 RED-ORANGE
002 002 002 NEUTRAL
003 003 003 BLACK
007 007 007 TAN
008 008 008 YELLOW
G3
Page209
Revised 10/15/92
SECTION A-A
A
Item No. Qty. Part Number Description
1 1 828-003-215 Wheel Hub Weldment (S /N 16806 to 17083)

1 828-003-862 Wheel Hub Weldment (S/N 17084 to 17738)
2 1 828-003-733 Knob
3 1 716-137 Shoulder Screw 3/8-16 x 2 11 /16
4 1 828-003-508 Steering Knob Cap
5 1 828-003-600 Steering Wheel Cover (S /N 16806 to 17738)
6 4 702-113 Flat Head Screw #10-32 x 3/8
S/N 16806 to 17738

STEERING WHEEL ASSEMBLY
Figure 828-003-11 O (D)
Pag~ 209.1
Added 10/15/92
8ECT10N A-A
A
Item No. .Qrt: Part Number Description
1 1 828-003-642 Wheel Hub Weldment

2 1 828-003-733 Knob
3 1 716-137 Shoulder Screw 3/8-16 x 2 11/16
4 1 828-003-508 Steering Knob Cap
5 1 828-003-926 Steering Wheel Cover
6 4 702-113 Flat Head Screw #10-32 x 3/8
S/N 1n39 and Up

STEERING WHEEL ASSE.MBLY
Figure 828-003-11 O (E)
G5,G6 . MODEL 31 BRAKE & STEERING
Page 211
Revised 2/15/93
Section B-B
r-20·1
\
\
I
'--- TORQl£ ADJUST

SPANt{R HQ.ES
\
l-20·~
Early Version
HYDRAULIC BRAKE
Fiaure 870-834/001
HYDRAULIC BRAKE Page 21~

Figure 870-834/001 MODEL 31 EASI
Item No. ~ Part Number Pescdotlon
1 1 870-834/111 Piston Body

2 24 870-834/112 Compression Spring
3 1 870-834/113 0-Ring 4-3/4" x 1/8"
4 870-834/114 0-Ring 5-1 /2" x 1/8"
5 1 870-834/115 Outer Body
7 1 870-834/117 Adjusting Plate
8 24 870-834/118 Pins
9 1 870-834/136 Friction Plate & Puck Sub-Assembly: Includes
6 Pucks
12 Rivets
1 Friction Plate
10 1 870-834/120 Friction Rotor (High Heat Dissipation)
11 1 870-834/121 Adaptor & Friction Puck Assembly: Includes
6 Pucks
12 Rivets
1 Adaptor Plate
12 3 870-834/122 Hex Hd. Bolt 5/16-18x1-1/4
13 3 870-834/123 Spacer
14 3 870-834/124 Spacer
15 3 870-834/125 Soc. Hd. Cap Screw 5/16-18 x 2-3/4
16 3 870-834/126 Serrated Washer 5/16
17 1 870-834/127 Relief Fitting
18 3 870-834/128 Hex Hd. Screw
To determine whether your brake assembly is current version or early version check the Friction Puck Assembly.
Vehicles with the early version brake have 6 pucks and 12 rivets, current brake assemblies have 4 pucks and 8 rivets.
G9, G10
Page211.1
Revised 2/15/93
20·~
~
Section B-B
\
~\
\\ \ I
-~1
I
\
\ I
\____ TORQUE ADJUST

SPANNER rKlLES
5/ 16-18 H.H .C .S .
t.llUNTING BOLTS
Current Version
HYDRAULIC BRAKE
FinurA A70-R.~4/001
HYDRAULIC BRAKE Page 212.i
Figure 870-834/001 MODEL 31 EASI
Item No. ~ Pan Number oescrlDtlon
1 1 870-834/111 Piston Body

3 1 870-834/113 0-Rlng 4-3/4" x 1/8"
4 1 870-834/114 0-Rlng 5-112· x 1/8•
5 1 870-834/115 Outer Body
6 1 870-834/117 Adjusting Plate
7 1 870-834/119 Friction Plate &Puck Sub-Assembly: Includes
4 Pucks
8 Rivets
1 Friction Plate
8 1 870-834/120 Friction Rotor (High Heat Dissipation)
9 1 870-834/121 Adaptor & Friction Puck Assembly: Includes
4 Pucks
8 Rivets
1 Adaptor Plate
10 3 870-834/130 Hex Hd. Screw 5/16-18x1
11 3 870-834/123 Spacer
12 3 870-834/124 Spacer
13 3 870-834/125 Soc. Hd. Cap Screw 5/16-18 x 2-3/4
14 3 870-834/126 Serrated Washer 5/16
15 1 870-834/127 Bleeder Screw
16 1 870-834/131 Pipe Plug
17 4 870-834/132 Fl. Hd. Soc. Cap Screw #10-24 x 1/2
18 1 870-843/133 Fitting (Cap Plug)
19 1 870-834/134 Cap Plug (Sleeve Cap)
To determine whether your brake assembly Is current version or early version check the Friction Puck Assembly.
Vehicles with the early version brake have 6 pucks and 12 rivets, current brake assemblies have 4 pucks and 8 rivets.
MODEL 31 DRIVE UNIT
F5, F6 Page301
Revised 2/15/93
AD REF
8
__
\._
S/N 16806 to 18296
DRIVE UNIT INSTALLATION

Figure 828-003-181 (L)
DRIVE UNIT INSTALLATION Page30~

Figure 828-003-181 (L) MODEL31 EASI
Item No. lltt: Part Number Descrlotlon
1 1 (REF) 570-262/500 Drive Motor

2 1 (REF) 410-022 Drive Unit Gear Reducer (S/N 16806 to_)
1 (REF) 410-026 Drive Unit Gear Reducer (S/N _ t o _ )
1 (REF) 410-029 Drive Unit Gear Reducer (S/N _ & Up)
3 1 (REF) 870-834/001 Brake Assembly
4 1 850-115 Woodruff Key
5 1 750-454P Nut 3/4-16
6 1 7-850-100/018 Woodruff Key
7 4 714-102 Soc. Hd. Cap Screw 5/16-18x1.0
8 2 810-132 Snap Ring
9 1 828-003-211 Dipstick Plug
10 1 828-003-212 Dipstick Cover
11 4 771-019 Flat Washer 5/16
12 1 460-678 Bearing
13 2 411-078 Shim
14 2 411-079 Shim
15 1 792-502 90 Degree Elbow
16 REF 710-074 Hex Hd. Cap Screw 5/16-18 x 1
17 REF 870-834/123 Spacer
18 REF 410-175 Pinion Gear
19 1 114-009-503 Motor Spec. Plate
20 1 782-422 Pipe Plug 3/8
MODEL31 DRIVE UNIT
P~g0303
Revised 2/15/93
Item No. .Qty. Part Number Description
1 1 570-262/511 Drive End Head

2 1 570-251 /514 Bearing
3 1 570-427/513 Retaining Ring
4 1 570-262/512 Fan
5 1 570-262/513 Armature and Fan Assembly
6 1 570-262/514 Field Coil Kit
7 4 570-236/514 Brush
8 4 570-446/516 Brush Spring
9 1 570-236/515 Brush Box and Plate Assembly
10 1 570-427 /512 Bearing
11 1 570-262/515 Wavey Washer
12 1 570-262/516 Commutator End Head
13 1 570-252/520 Lead Assembly Kit
14 1 570-262/218 Seal (Not Illustrated)
15 1 570-262/217 EE Motor Band (Not Illustrated)
DRIVE MOTOR
Figure 570-262/500
F11 MODEL 31 DRIVE UNIT
Pag~305
Revised 10/'15/92
S/N 16806to _ _
DRIVE UNIT GEAR REDUCER
Figure 410-022
DRIVE UNIT GEAR REDUCER Page30~

Figure 410-022 MODEL 31 EASi
1 1 410-022/01 Hellcat Pinion

2 1 410-022/02 Main Cover
3 1 410-022/05 Output Bearing Spacer
4 1 410-022/06 Flanged Output Drive Shaft
5 1 410-022/07 Bearing Cup
6 1 410-022/08 Bearing Cone
7 1 410-022/09 Bearing Cup
8 1 410-022/10 Bearing Cone
9 1 410-022/18 Output Up Seal
10 1 410-022/11 External Retaining Ring
11 12 410-022/12 Soco Hd. Cap Screw 3/8-16x1-1/4
12 1 410-022/13 Cover Shim Set
13 1 850-135-001 /19 Pipe Plug 1/2-14
14 1 828-003-191 Drive Ring Assembly
15 2 410-022/16 Grease Fitting
16 1 410-022/04 Bearing Filler Plug
17 1 410-022/03 Pivot Ring
18 2 810-717 Spiro! Pin
19 79 850-015 Ball (1 /2 Diameter)
·20 1 820-000-069 Ring Set: includes
21 2 820-000-091 Outer Thrust Ring
22 2 820-000-090 Inner Thrust Ring
23 1 820-000-092 Outer Radial Ring
24 1 820-000-089 Inner Radial Ring
25 1 410-022/17 Grease Fitting
26 1 412-343 l.D. Tag (Spec. Plate)
27 4 410-022/14 Drive Screw
28 1 400-149 Steering Ring Gear
29 1 410-022/15 Pipe Plug 3/8-18
30 2 410-022/19 Bearing Cup
31 2 410-022/20 Bearing Cone
MODEL 31 DRIVE UNIT
Page305.1
Revised 2/'15/93
INFORMATION NOT AVAILABLE

AT TIME OF PUBLICATION
S/N _ to
Figure 410-026
DRIVE UNIT GEAR REDUCER Page306.1

Figure 410-026 MODEL 31 EASi2
ltemNo. ~ Part Number Description

MODEL 31 DRIVE UNIT
Pags307
Added 2/15/93

S/N_andUp
Figure 410-029
DRIVE UNIT GEAR REDUCER Page30~

ltemNo. ~ Part Number Descriotion

STANDARD ELECTRICAL SYMBOLS Page 401
March 31, 1987
+_fl I t-= Battery
+ Suppreaor
SWcon
.
-Ir Capacitor
Power Line
Controlled
*-
Rectifier
*
R.ectifter
Control Lin•
(SCR)
~ DJ
Zener
*
Diode Hom
Diode
J'\.r FUN
@ 1'henniater
9 Licht
..,,/\/\/\r Raiator
6 Tramiator 0
TP
D
TP
Standoff'
Terminal
i
?>J
(plur) Oact)
Connector
!
Twisted.
Pair r11::r:
L. - - - -~
Terminal
Strip
~1 ~
Wirinc
Variable
Resiat:or
Shielded
Pair
? Ham-
-c::J-
Wire Coded
Sleeve -e- Solenoid
Coil
\..A...l....U
rrm
TranaCormer
Page 402 ELECTRICAL SYMBOLS
March 31, 1987
9 Bourmet:er
Sincl• Pole ·
;
-o'--c.- Sincl• Throw
G Dilcharp
Indicator
Switch
_-.t._
Cont:act:or
J "L.. Coat:acta Thermoatu
xCh- Coatact:or
Coil
-·r
- - ~ - 2 a
Sincl• Pole
Tl T Drive. Double Throw
'~~·
Motor Switch
,....,- - -
T T T Pump ~ Relay
] >c -o
~LG--·
Motor
-l - l T-- -
Awcillary
r~L@--., Motor
-
-1 "['.___
Cont:actor Tipa
Normally
. Open
Normally
_}-L CloMd
g I gN.O. Switch
0 ON.C. ....
0 I 0 N.C Swit:ch
~N.O
Normally Open
{shown act:ivat:ed)
ELECTRICAL SYMBOLS 402.1
March 31, 1q87
17. HOW TO READ THE RAYMOND CORPORATION ELECTRICAL WIRING DIAGRAMS

Each end of every wire in a Raymond truck is identified with the component
and terminal to which that wire should be connected. Small wires have a
coded sleeve as shown in Figure 1 to identify where it connects. Large
cables have the identification stamped on the outer covering. This system
tells the assembler or serviceman exactly where each wire should be
connected.
Sl
KEY-
/ SWITCH CODED SLEEVES
.,---~~
[il:l:::§:=::(~~==~~fil
WIRING HARNESS
Figure 1
Figure 2 shows how the parts in Figure 1 would appear on a Raymond wiring
diagram. In addition to the coded sleeve or stampinq identifying where
each wire connects, the wiring diagram also shows the destination of the
wire's other end.
WIRING HARNESS
THESE DESIGNATIONS
INDICATE COMPONENT
ANO TERMINAL T!)
WHICH OTHER END OF
WIRES CONNECT.
Figure 2
MODEL 31 ELECTRICAL
A5,A6 Page 403
Revised 3/15/92
JPS4-
JPI-
!3-----T-1-T--
JPSI-
! ~ CONTRa.CAllLE
- •12V - l!5
THROTTLEM~......,m.._-;..~-----L.-~~~
11
~----------------------------------,
I
•+- ,---..:-~--MEMORY LAT1 VAi
~::-,4=========1r::i1:4::i~l: ~TCH >-j

Alil'D -- 13
I PC FUS OPERATOR .;CONTROL HANDLE
...----+--"""'"';;;;;--;;; ~SOA
TP2 DISPLAY
(CIC) ..+-----++-~7....._.SHIFT CLOCK
i. l.IFTf4-,l~l--+-'1--'_ _ _ __.____,~
VAa / JPNl-
I a :,....-----'--'--~~-~--.~~~
.... OUT !c + 12Vl+'''---,..,-------1---~
I
I FU•
I LI a
19-W-~----+. .-+--,..l.--o'""+laV
L.._ _ __Jl..,;l..:.o_ _ _4'.,;l-:_'.:::il--~,SHIELD

~ALARM J VEHICLE REACH .. I
1 -----1---'-.__ 53
HORNl+-7' ---+1+-
I I _._
__ S4
1
B•PCF i.--------.
I JO~ MANAGER RETRACT .. I I _._- SS DIRll sa. - '- - DIRll

~_,_1_ _-1--.Lf'7 TP7 (VM)
I
~ :::rl.~---- - - ---L------~- - -----, TILT UP ~ 3 I I _.__ 5'
I a
w i I 11L.-----.J-..-'--
TILT OOWNl+'4'---"-
I I JPH2- I e S7
I
1
""-a
I FU7"~ I
JLx J~P~U6
1
r---
1
I
--- -MD~: -s - . ,L_I__,.-·~:·,.
,1_ ~~~G
,I,
JPDI- JPHl-
~==:J~l:~--~~~~:
1 I
i.;;:----=-+«=·DRIVE
l:lf:::=::t~ .a-DRIVE
H-BRIDGE
CONTRa.
MOOULE
-'_..,I~-JP_sa_ _..:!-.i~~j~gs~==~~ t.IMIJ §
-.,
a ..
FORWARD
FIEl.D PWM
I!!
a~
SSHIFT LEFT ~ !5
SSHIFT RIGHT \
AGNll
SHIELD'"~..__
II
II
__,
_.__
_.__
51
5'
DIRA SCI..-·- -
7
EQ SOL- - - 1111
I
DW
a
.JS3- I a
I 70A
! 7/TP:J
450A I
I
RI Al sa I FW-1 f CRI l:!=o=::t:t··l~~:~VE (HCM) I '-----~-..-~r~D !~ ~ INPUTfl ~ I 2-------.
B•KEY J-.
a TS ~r---+.0:M:aE I•DRIVE
INPUTfa
TILT UP 3
2
LIL SOL-'0---<11 .!.":\.. I
~-----J ,--.,..1--oiFW-11-
1
' COP
...._.T~1-~·~-T~~~--..__ _...,..._r-_1.~I-'MI~T_ _ _ ___J
I
1 Rl.N
.\.• PROGRAM z
S
TILT DOWN 4
SSHIFT LEFT ~ 5
SSHIFT RIGHT ' 3
ll•KEYi.=--- ~~a
I~
IQ OUTPUTfl 7 PN3•
TPa
I
I Ill Ill Ila·~
I
I
3
JPSl j
~
1!o
OUTPUTla
OUTPUTf3
I
9 E
l l+KEY
B+PCF
;
Ila y ]
~Ir ~MD~ !...._;; x-~= ..

I
a , Lil ANALOG fl IO B-PCF LIHSOL 5
ANALOG fa II
Ir {......
i--'---a~
I
ii Ml( '*'
a
1
1
r ™' T TMa J,1-----+----~
• ~:~ ENTER
AGNll~
!~~I~
13
aND SCI..
I I .____.......SHIELD SHIELD
~-----
I
--------J I
I
VEHICLE
Fl.N:TION
I
I
,.....__........ EATSINK .JPT1-
r.....-------''"!L+1-11•KEY
I
I
I CONTRQ.LER
(VFC) I HYDRAULIC
jii
DRIVER
~_ _ _ _ _ _ ~ ~1---_-,--- . . - ------< ==~ .JPTa- 1 .. .JPs1- AAEMllLY
~ ~.:. ;~ ~ ~r-------'-r-l.---4\-+1~ jj:!~

1 (lllA)
....,~ llJ'a
; JI 1-1 : TPS RECI
I QI
:P6 :
~--:11--r----+-+-+-----'-+1"- c-DRIVE
1
s
~=ri'l(~~ATURE e
.. LIMIT
JPS9- JPN 14,- I REACH I
'N ' I °I>-,...., "'\ • - a-DRIVE _- ::=;PER PWM
~"'-------+-Y:---..z...+1-· 1av
- +12Vt+!l!--f+----------..J..I
DE~l4~'"!--rT""-----------ti4l ~11- z- ~
.JP1
I TP4 : ,_,fHT\C!HTD.:_Ef\~;;;;;;;;;;:::+T:::;-;-;r--r-r-----l""+l_E_-DR_I_V_E_ _...J I ~SHIELD aND ENt+ii--rr----------~
~~ g14..!-f---L~----------i~
PGND ...----!..,!.-J.-"...l.~
LIFT TEMP " - 2 \_prj j ~
: I I \_'j I I S/IENt+lt--tt----------~
DIRllEN •- ~ ~Nt
: L - - - - - - -.. -;s:;'l~ .. J ~ , UPF4- :
l.M£STED~~ll==========d:l
L::_j
===t:;===:::~:::;-v
I
5
r--~w_l-lS----&-•,.-tm~.g.....,i!----.
2 1
I ~
..:=-
l.IFT IIHIT
~
L.::_j
PRESSUIE M---__;0~+11'
+laV
LRESS
~~~~--~~=~+====================~;: JPN4- SI
1
I
I JPFa
,-
'--------'A41111-PC
'.. 11-
•
"
JPF3 -
~~~===========================~ti:i====!=:J--:11-CONTACTOR
1-
I
JPS 1o-
" " ; ! ; - - - - - - - - - - - - - - 1 1 . . . . . . __ __J,l.....J, --~
.. PC-CONTACT""
c
u
~
TEMP14·-~~:::==========:il~
TRAC TEMP
LIFT 14 8 ll+l<EY ...'----'-'.....,, .!,
REMOTE .,~
•'-------1
ll+F 11,,.-'I"
~
FUI Di~ gl'4!-i-fi-++----------~~
L.----t,_....-------.l.".l.Jll+PC
:I
ll•PC - " - 11-PCF
11- ~ 11-1"
~r---------------h..;....--4-~;j:~:=:g::
~;;---------------...l..,----!-6l""i!~
~r--------------..+JLI---!.,-61··11+KEY
L/LEN~-"iii~7-----------.J.!~
TILT ENt't-~~t----------~ot4l
~~:t't-1-ti-rT""----------i.I~
EJ
0 TSlt·J~r:I~;----------~
1. -----T---------~•I...! ~~ ~=t~===========================b~===:i:~:Ill•KEY
t111--ti0f--------------~--J.2-..611P11~~ REMOTE EPO~-t'fir-1;-----------io~ sf/ I
I 7 l•IENIE REMOTELWR1'4~f-Ml-77----------~~
G
11
'-------~1 --------~P-IENIE
'---------::---------.L.,"llX-IENIE
•-
ll+PC - " - ll•PCI" ~H~t---------------iJ.W-.:....ji.=;j•:::=
~ POWER SUPPLY
(PS) _
REMOTE LFT14
SHIELD~
1 -:~-4:·rl-----------i~ ll•PCF 13 ~1:
'----:------~l-------~•i....ipc-1EN1E ~H..r----------------::.+.+---1~~;!11-F ~ REACH SOL 3 ' a fMl!OI\ I I
~ll+F ~11-F
! la
I I" I+ II+ " I -.._·_ __,-.,.sH~ELD
- L:.:J '-J I
.------'•t.-i l+KEY
I sIDESHIFT SOL 1"""'"-7...=.-----_;2:_faiiK\~am;;;;;J.:1~ I
)( y POWEii PANEL I I&. j:; ~ I ~ I
DRIVER AA'I' I + -+ ID
+ m
2~1
PC PC
y
CNTA (PPDA)
I
I
m
a
+
3 4 15 '
I! I
~~ ~ ~:4==~·==4t_ _ _ _ __;:.j\..._/H;::..;i.:.-__J I
:
)(
p I JPPI-
P CNTR
I , I , I
x y I JPSI 1- 11-PCF Joo=--;-,__;::.. I
)( )( CNTA
, 5 4 3 a I
I
~ ~ ~ ____ ~ -=A~R=-A~ - ___ J
)(
II
y
I
I
r I
l ......
I
I&.
'!54321
0 +
JPNl5-
I
I
I
I
I
J
S/N 16806 to 17702

Sheet 1of2
ELECTRIC SYSTEM SCHEMATIC
Figure 828-003-414 (A)
MODEL 31 ELECTRICAL
A7,A8 Page 405
Revised 3/15/92
STANDARD MAST SPEED LIMIT SWITCH LIFT INHIBIT WITH BYPASS BACKUP ALARM
JPN7- SI 0 Sl2 •
----1.._
--------~--. I
MASTSW I :>---.....:C::O::.;M~oA~-c-O~N~C:.........,
HYDRAULIC
DRIVER +12V 2
ASSEMBLY
:J
(HOA) 3 JPNl2- Sl 3
B-PCF JPS3-
I:~:~ :~
..-----------. 7
LIFT OUTPUT#I K~---+---~cf--4~
•MAST IN FULLY LOWERED POSITION COM VEHICLE
MANAGER OUTPUT#2 1-<~-8--1---
(VM)
B-PCF >--- - - - - - - - - '
OTHER THAN STANDARD MAST SPEED LIMIT SWITCH

•REMOVE Sl2 TO ELIMINATE BYPASS CAPABILITY TSl9-
JPN8- SI I ..-----------. 5
...-~~----~~ B+PcFn----'
MASTSW2 f?.:>-___c_oM_~ "O NC HYDRAULIC
DRIVER 6
HYDRAU-IC B-PCF ·!""\-..;;....----'
DRIVER +12V ~
ASSEMBLY
ASSEMBLY LIGHTS I!.. FAN CHDAl
(HDAl B-PCF~~~'~-------
LIGHT •USE JPS3-7 TO Kl- FOR FORWARD TRAVEL ALARM

•MAST IN FULLY LOWERED POSITION USE JPS3-8 TO Kl- FOR REVERSE TRAVEL ALARM
CONNECT BOTH JPS3-7 ~ JPS3-8 FOR ALL TRAVEL ALARM
HYDRAULIC
DRIVER
ASSEMBLY
(HOA)
WARNING LIGHT
JPN2- WL
--~~~~~B+_P_C~F~:~1~~-+~(})
HYDRAULIC
DRIVER
ASSEMBLY
(HOA) B-PCF ~~
2 --------'
REMOTE LIFT/LOWER
JPN4- SI
.-------~ I
B+KEY14>---..-!.<Y' NESTED SWITCH
NORMAL
B+F i-:...,_.;;:2- - POSITION
REMOTE
HYDRAULIC HYDRAULIC
DRIVER DRIVER
ASSEMBLY REMOTE• ASSEMBLY
POSITION (HOA) 6
CHDAl B-PCFh------------'
TSl9- Sl6 Sl7
__L_ __L_
TS21-2 2 I R3 2 LIFT
SIDESHIFT SOL 2 ~
Sl4 Sl5 •REACH CARRIAGE IN RETRACTED (NESTED) POSITION
__L_ __L_
TS21-3 I R2 2
REACH SOL 3 ~
I LOWER
4 TS21-4 Sl8 I
REMOTE EPO
6 TS21-6
B-PCF
•REMOVE TPI ON PPDA
S/N 16806 to 17702
Sheet 2 of 2
. ELECTRIC SYSTEM SCHEMATIC
Figure 828-003-414 (A)
MODEL 31 ELECTRICAL
Page405.1
Revised 2/15/93
BACKUP ALARM
STANDARD MAST SPEED LIMIT SWITCH LIFT INHIBIT WITH BYPASS
JPN7- SIO JPNl3- Sl2 •
_L..
~-------------~ I I
MASTSW I H:;------....;CO~M<~~on,.:..:;NC:......, INHBTBYP ))
HYDRAULIC
DRIVER
ASSEMBLY
+12V ~ 2
HYDRAULIC
DRIVER
ASSEMBLY B-PCF »2
0
I
JPNl2- OUTPUTf I K~-------i-----~H-\
, 3- - - - - - - - - - ' (HOA)
::
(K>A) B-PCFH'»-- Sl3 VEHICLE OUTPUTf2 i-c.,_e____
• I COM ()d 0 NC
MANAGER
LIFT INHBT CVM)
•MAST IN FlLLY LOWERED POSITION +12V
B-PCF I TSl9-
OTHER THAN STANDARD MAST SPEED LIMIT SWITCH -------------------~ e
•REMOVE Sl2 TO ELIMINATE BYPASS CAPABILITY B+PCF o-------'
HYDRAULIC
.JPN8- DRIVER 6 -------"
B-PCF o-.;;..
SI I ASSEMBLY
-------------~ COM O'*'ONC (I-DA)
+12V I~ 2I
HYDRAULIC MASTSW2
1
DRIVER '":·
ASSEMBLY LIGHTS g. FAN •USE .JPS3-7 TO Kl- FOR FORWARD TRAVEL ALARM
(I-DA) B-PCF 1-'! 3
, .-------------'
!'i>-·
1
USE JPS3-8 TO Kl- FOR REVERSE TRAVEL ALARM
CONNECT BOTH JPS3-7 lo JPS3-8 FOR ALL TRAVEL ALARM
LIGHT
•MAST IN FlLLY LOWERED POSITION
HYDRAULIC REMOTE LIFT/LOWER WITH UNNESTEO SWITCH
DRIVER
ASSEMBLY JPN4-
WARNING LIGHT (HOA) .-----------~ I •REMOVE TPI ON PPDA
.JPN2- WL
B+F ~>-""----.
________...... NORMAL
POSITION
__I_C____B_+_PC-F~:~~-1-----•~~~----~
---HYDR----AUL
REMOTE
DRIVER
ASSEMBLY 2 HYDRAULIC
(HOA) B-PCFH'»-----------'
1 DRIVER
I ~
ASSEMBLY
(HOA)
SIDESHIFT SOL 2
REMOTE LIFT/LOWER
..PN4-
I
2
SI •REMOVE TPI 00
NORMAL
=.1
I
I
NESTED SWITCH
REACH SOL
B+F POSITION
REMOTE ..--------~.o
HYDRAULIC I Sl9
HYDRAULIC DRIVER 4 TS2 I-4 COM .1. NC
--
JPN'5-J
DRIVER ~REMOTE• ASSEMBL y REMOTE EPO r;.,;__-T..:S2~1--6-~~-~'t'l-,.:.;j
ASSEMBLY POSITION PPDA
(I-DA) 816 (HOA) B-PCF r-)6;....__-o-o-------"
TSl9- 817
-l.._ R3 _ L . . LIFT
TPI
TS21-2
SIDESHIFT SOL 2 2 ~I 00
S14 Sl'5 JPF I- I'V"._____COM-<~.-(----'
A
TS21-3 -l.._ R2 _L.. •REACH CARRIAGE IN RETRACTED (NESTED) POSITION
REACH SOL 3 ~ I LOWER
REMOVE WIRE FROM JPNe-1 TO JPFl-1
TS21-4
REMOTE EPO 4
6 TS21-6
B-PCF
S/N 17003 and Up

Sheet2of2
ELECTRIC SYSTEM SCHEMATIC
Figure 828-003-414 (E)
ELECTRIC SYSTEM SCHEMATIC Page40~

Figure 828-003-414 (A) MODEL 31 EASI
A9, A10
~ Description Key Description
8 Maximum Speed Contactor (ByPass) JPS1 Vehicle Manager Connector for Chopper Control Module
CCM Chopper Control Module JPS2 Vehicle Manager Connector for H-Bridge Module
CR1 Diode on Field Wiring Assembly JPS3 Vehicle Manager Connector for Expansion (optional)
DA1 Diode Assembly for Backup Alarm JPS4 Vehicle Manager Connector for Control Handle
DE Drive Motor Encoder JPS6 Vehicle Manager Connector for Diagnostics
DIRA Solenoid for Aux. OH Direction Control JPS8 Vehicle Manager Connector for Operator Display
DIRB Solenoid for Aux. OH Direction Control JPS9 Vehicle Manager Connector for Hydraulic Driver
DT Drive Motor Temperature Sensor JPS10 Vehicle Manager Connector for Power Panel Driver
EO Solenoid for Aux. Pressure Equalizing Control JPS11 Vehicle Manager Connector for Power Supply (Inside Box)
FU1 Control Fuse for 8- to HOA (15 Amp) JPS12 Vehicle Manager Connector for Optional RS232 Port
FU2 Control Fuse for B- to PPDA (15 Amp) JPS13 Vehicle Manager Connector for Drive Motor Encoder
FU3 Control Fuse for B + to HOA (1 SAmp) JPP1 Connector on Power Supply
FU4 Control Fuse for B+ to PPDA (15 Amp) JPM Connector on Drive Motor Temperature Sensor
FUS Power Fuse for Travel (350 Amp) JPT1 Chopper Control Module (CCM) Connector to Transistor & PPDA
FUS Power Fuse for Lift (450 Amp) JPT2 Chopper Control Module (CCM) Connector to Vehicle Manager
FU7 Power Fuse for Aux. (70 Amp) JPZ Connector on Lift Motor Temperature Sensor (optional)
FUS Power Fuse for Field (70 Amp) K1 Relay for Backup Alarm
FW Field Wiring Card L/L Solenoid for Load Holding
H1 Horn L/H Solenoid for Lift Lower Proportioning
HCM H-Bridge Control Module MD Drive Motor
HT Heatslnk Temperature Sensor MP Lift Pump Motor
JPS+ Connector to Battery Positive MX Aux. Pump Motor
JPB- Connector to Battery Negative p Lift Pump Contactor
JPD1 Connector on Field Wiring Card for H-Brldge Module PC Power Disconnect Contactor
JPF1 Connector on Power Panel Driver Card for Hydraulic Driver Assembly PRESS Pressure Sensor
JPF2 Connector on Power Panel Driver Card for Contactor Panel PT Lift Pump/Motor Temperature Sensor
JPF3 Connector on Power Panel Driver Card for Vehicle Manager Control and Power 01 Chopper Transistor
JPF4 Connector on Power Panel Driver Card for Temp. Sensor In Heatslnk REACH Solenoid for Reach
JPFS Connector on Fuse Board for Chopper Driver REC1 Free Wheeling Rectifier
JPH1 Connector on H-Brldge Card for H-Brldge Module R1 Resistor for Field Wiring Card
JPH2 Connector on H-Bridge Module for Vehicle Manager R2 Resistor for Remote Lift/Lower
JPI Connector on Operator Display R3 Resistor for Remote Lift/Lower
JPN1 Connector on Hydraulic Driver Card for Solenoid R4 Resistor for Unnested Switch
JPN2 Connector on Hydraulic DrlverCard for Warning Light S1 Key Switch
JPN3 Connector on Hydraulic Driver Card for Optional Power S2 Deadman Switch
JPN4 Connector on Hydraulic Driver Card for Keyswitch S3 Horn Switch
JPNS Connector on Hydraulic Driver Card for Power Panel Driver Card S4 Reach Switch
JPN6 Connector on Hydraulic Driver Card for Deadman and Horn $5 Retract Switch
JPN7 Connector on Hydraulic Driver Card for Standard Mast Switch S6 Tiit Up Switch
JPN8 Connector on Hydraulic Driver Card for Other than Standard Mast Switch S7 Tiit Down Switch
JPN9 Connector on Hydraulic Driver Card for Pressure Sensor Sa Sldeshlft Left Switch
JPN10 Connector on Hydraulic Driver Card for Temp. Sensor Traction Motor $9 Sldeshlft Right Switch
JPN11 Connector on Hydraulic Driver Card for Temp. Sensor Lift Motor $10 Speed Limit Switch
JPN12 Connector on Hydraulic Driver Card for Lift Inhibit Switch S11 Speed Limit Switch
JPN13 Connector on Hydraulic Driver Card for Lift Inhibit ByPass S12 Lift Inhibit Bypass Switch
JPN14 Connector on Hydraulic Driver Card for Vehicle Manager S13 Lift Inhibit Switch
S14 Remote Lift/Lower
ELECTRIC SYSTEM SCHEMATIC Page 406 (Conrd~

Figure 828-003-414 (A) MODEL31 EASi
A11
K§y Description

S18 Remote EPO
S19 Unnested Carriage Switch
S/S Solenoid for Sideshift
T1 Terminal for Base Drive to TM1-B1
TS Terminal for Cathode for CR1
TILT Solenoid for Tiit
TM1 Dual Transistor Module for Field Wiring Assembly
TS19 Terminal Strip for Mast Cable on Hydraulic Driver Card
TS21 Terminal Strip for Mast Cable on Carriage
TP1 Tie Point on Aux. Fuse
TP2 Tie Point on Travel Fuse
TP3 Tie Point on Lift Fuse
TP4 Tie Point for B-
TP5 Tie Point on Heat Sink (Bottom Side)
TP6 Tie Point on Heat Sink (Top Side)
TP7 Tie Point on Field Fuse
TP8 Tie Point for Plugging Resistor (R1)
VR 1 Variable Resistor for Throttle
VR2 Variable Resistor for Lift/Lower
WL Warning Light
X Auxiliary Pump Contactor
2ND Solenoid for 2nd Stage Pump (Lift)
NOTES:
1. Schematic shows truck switched off, deadman switch off and carriage fully lowered.
2. For System Electrical, see 828-003-349.
...... ~. ..
•••'-"'• ...,. ...,.,.,.. .. ....... ...
.--- '-"'• ,.,..
ELECTRIC SYSTEM SCHEMATIC Page406.i

Figure 828-003-414 (E) MODEL 31 EASI
oescrlotlon ~ Description
CCM Chopper Control Module JPS10 Vehicle Manager Connector for Power Panel Driver
CR1 Diode on Field Wiring Assembly JPS11 Vehicle Manager Connector for Power Supply (Inside Box)
DA1 Diode Assembly for Backup Alarm JPS12 Vehicle Manager Connector for Optional RS232 Port
DE Drive Motor Encoder JPS13 Vehicle Manager Connector for Drive Motor Encoder
DIRA Solenoid for Aux. 011 Direction Control JPP1 Connector on Power Supply
DIRB Solenoid for Aux. Oil Direction Control JPM Connector on Drive Motor Temperature Sensor
OT Drive Motor Temperature Sensor JPT1 Chopper Control Module (CCM) Connector to Transistor & PPDA
EQ Solenoid for Aux. Pressure Equalizing Control JPT2 Chopper Control Module (CCM) Connector to Vehicle Manager
FU1 Control Fuse for B- to HOA (1S Amp) JPZ Connector on Lift Motor Temperature Sensor (optional)
FU2 Control Fuse for B- to PPDA (1S Amp) K1 Relay for Backup Alarm
FU3 Control Fuse for B + to HOA (1 S Amp) L/L Solenoid for Lift Lower Proportioning
FU4 Control Fuse for B+ to PPDA (1S Amp) L/H Solenoid for Load Holding
FUS Power Fuse for Travel (3SO Amp) MD Drive Motor
FUS Power Fuse for Lift (450 Amp) MP Lift Pump Motor
FUS Power Fuse for Field Wiring and Aux Motor (1SO Amp) MX Aux. Pump Motor
FW Fleld Wiring Card p Lift Pump Contactor
H1 Hom PC Power Disconnect Contactor
HCM H-Brldge Control Module PRESS Pressure Sensor
HT Heatslnk Temperature Sensor PT Lift Pump/Motor Temperature Sensor
JPB+ Connector to Battery Positive 01 Chopper Transistor
JPB- Connector to Battery Negative REACH Solenoid for Reach
JPD1 Connector on Field Wiring Card for H-Brldge Module REC1 Free Wheeling Rectifier
JPF1 Connector on Power Panel Driver Card for Hydraulic Driver Assembly R1 Resistor for Field Wiring Card
JPF2 Connector on Power Panel Driver Card for Contactor Panel R2 Resistor for Remote Lift/Lower
JPF3 Connector on Power Panel Driver Card for Vehicle Manager Control and Power R3 Resistor for Remote Lift/Lower
JPF4 Connector on Power Panel Driver Card for Temp. Sensor In Heatslnk 1S Shorting Contactor
JPFS Connector on Fuse Board for Chopper Driver S1 Key Switch
JPH1 Connector on H-Brldge Card for H-Brldge Module S2 Deadman Switch
JPH2 Connector on H-Brldge Module for Vehicle Manager S3 Hom Switch
JPI Connector on Operator Display S4 Reach Switch
JPN1 Connector on Hydraulic Driver Card for Solenoid SS Retract Switch
JPN2 Connector on Hydraulic Driver Card for Warning Light S6 Tiit Up Switch
JPN3 Connector on Hydraulic Driver Card for Optional Power S7 Tiit Down Switch
JPN4 Connector on Hydraulic Driver Card for Keyswltch sa Sldeshlft Left Switch
JPNS Connector on Hydraulic Driver Card for Power Panel Driver Card S9 Sldeshlft Right Switch
JPN6 Connector on Hydraulic Driver Card for Deadman and Hom S10 Speed Limit Switch
JPN7 Connector on Hydraulic Driver Card for Standard Mast Switch S11 Speed Limit Switch
JPN8 Connector on Hydraulic Driver Card for Other than Standard Mast Switch S12 Lift Inhibit Bypass Switch
JPN9 Connector on Hydraulic Driver Card for Pressure Sensor S13 Lift Inhibit Switch
JPN10 Connector on Hydraulic Driver Card for Temp. Sensor Traction Motor S14 Remote Lift/Lower
JPN11 Connector on Hydraulic Driver Card for Temp. Sensor Lift Motor S1S Remote Lift/Lower
JPN12 Connector on Hydraulic Driver Card for Lift Inhibit Switch S16 · Remote Lift/Lower
JPN13 Connector on Hydraulic Driver Card for Lift Inhibit ByPass S17 Remote Lift/Lower
JPN14 Connector on Hydraulic Driver Card for Vehicle Manager S18 RemoteEPO
JPS1 Vehicle Manager Connector for Chopper Control Module S19 Unnested Carriage Switch
JPS2 Vehicle Manager Connector for H-Brldge Module S/S Solenoid for Sldeshlft
JPS3 Vehicle Manager Connector for Expansion (optional) T1 Terminal for Base Drive to TM1-B 1
JPS4 Vehicle Manager Connector for Control Handle T2 Terminal for Base Drive to TM1-B2
JPS6 Vehicle Manager Connector for Diagnostics T3 Terminal for Base Drive to TM2-B1
JPS8 Vehicle Manager Connector for Operator Display T4 Terminal for Base Drive to TM2-B2
JPS9 Vehicle Manager Connector for Hydraulic Driver TS Terminal for Cathode for CR1
ELECTRIC SYSTEM SCHEMATIC Page 406.1 (Conrd~

Figure 828-003-414 (E) MODEL 31 EASi
~ Description
TllT Solenoid for Tilt

TS19 · Terminal Strip for Mast Cable on Hydraulic Driver Card
TS21 Terminal Strip for Mast Cable on Carriage
TP2 Tie Point on Travel Fuse
TP3 Tie Point on Lift Fuse
TP4 Tie Point for B-
TP5 Tie Point on Heat Sink (Bottom Side)
TP6 Tie Point on Heat Sink (Top Side)
TP7 Tie Point on Field Fuse
TP8 Tie Point for Plugging Resistor (R1)
VR1 Variable Resistor for Throttle
VR2 Variable Resistor for Lift/Lower
WL Warning Light
2ND Solenoid for 2nd Stage Pump (Lift)
NOTES:
1 Schematic shows truck switched off, deadman switch off and carriage fully lowered.
o
2. For System Electrical, see 828-003-349.

MODEL 31 ELECTRICAL
89 Page407
Revised 3/15/92
S/N 16806 to 17002

Sheet 1 of 2
ELECTRICAL SYSTEM
Figure 828-003-349 (E)
810 MODEL 31 ELECTRICAL
Page409
Revised 3/15/92
'l'P6 TO HD-Al
TP2 TO RI-I
TP<& TO 8-
""'ITO ...... I
V-2 TO HD-II
30
40
TO Sl1ENOIOS
'TO
PRESSl.11£
SENSOR ON
VIEW B-B HANXFllLO
..PN<& TO SI
S/N 16806 to 17002

Sheet2 of 2
ELECTRICAL SYSTEM
Figure 828-003-349 (E)
MODEL 31 ELECTRICAL
C1 Page 407.1
Added 3/15/92
MD-A2 TO TP2 24
3/N 17003 to 17169

Sheet 1 of 2
ELECTRICAL SYSTEM
Figure 828-003-349 (F)
MODEL 31 ELECTRICAL
C2 Page 409.1
Added 3/15/92
TP6 TO IC>-AI
TP4 TD 8-
'°'
VIEW B-B
S/N 17003 to 17169
Sheet 2 of 2
ELECTRICAL SYSTEM
Figure 828-003-349 (F)
C5 MODEL 31 ELECTRICAL
Page407.2
Revised 2/15/93
PRESSURE SENSOR A
2NO
OIRA
MX-S TO TP7 20
M0-A2 TO TP2
TO TPG
S/N 17170 to 18296

Sheet 1 of 3
ELECTRICAL SYSTEM
Figure 828-003-349 (M)
C7,C8 MODEL 31 ELECTRICAL
Page409.2
Revised 2/15/93
TO JPN4
PC-I TO B+
TP8 TO Rl-2 TP6 TO MD-Al
TP2 TO MD-A2
REMOTE KEY AND WIRING
HARNESS INSTALLATION
TP4 TO MP-A
TP2 TO RI-I
TP4 TO B-
JPFI TO JPN5
-----.. ..,.,..?------
Ill
-.;r '?- -
Ill
~t"·~..-
Ill
- - - - - - -t '.!t~r- -
1111 1
---
10
FW-2 TO MD-S2
FW-1 TO MD-SI MAST CABLE 0 0 ooo 0
PNI I TO TEMP
SENSOR ON LIFT
MOTOR
PNIO TO TEMP
SENSOR ON
JPNI TO SOLENOIDS TRACTION MOTOR
JPN6 TO S2 g. HI N9 TO
PRESSURE
JPN5 TO JFI SENSOR ON
VIEW B-B MANIFOLD
S4 TO CONTROL HANDLE
S/N 17170 to 18296

Sheet2of3
ELECTRICAL SYSTEM
Figure 828-003-349 (M)
MODEL 31 ELECTRICAL
Page409.3
Revised 2/15/93
CREFl
..JSl4 TO
ENCODER
CREFI
~oa•-E
TP4 TO FW-B- (REF)
TP8 TO Rl-2 TP4 TO B- TP2 TO MOA2
VIEW D-D
VIEW C-C
ITEM 61 NOT SHOWN
IN THIS VIEW
S/N 17170 to 18296

Sheet3of3
ELECTRICAL SYSTEM
Figure 828-003-349 (M)
ELECTRICAL SYSTEM Page41~

Figure 828-003-349 (E) MODEL 31 EASi
B11
1 REF 828-003-421 /001 Contactor Assembly

2 4 760-920 Nut3/8-16
3 4 771-123 Flat Washer 3 /8
4 REF 828-003-476/001 Handle Assembly - Standard
5 1 828-003-487 Wiring Housing Support
6 1 828-003-613 Cover Support
7 REF 828-003-442 Electric Control System
8 1 828-003-691 Wiring Harness
9 1 828-003-440 Cable Assembly
14 REF 590-534/001 Fuse-70Amp
15 REF 590-534/013 Fuse - 350 Amp
16 REF 590-534/015 Fuse - 450 Amp
17 1 022-027-615/148 Cable Assembly
18 1 022-046-610/147 Cable Assembly
19 1 024-029-420/254 Cable Assembly
20 1 024-020-570 /255 Cable Assembly
21 1 025-021-840 /106 Cable Assembly
22 1 025-021..SSO /105 Cable Assembly
23 1 023-021-970 I 445 Cable Assembly
24 1 023-021-sso / 444 Cable Assembly
25 1 828-003-358 Wire Assembly
26 1 590-610/002 Hom
27 1 701-182 Screw 1/4-20 x 1/2
29 1 828-003-435/001 Hyd. Driver Card Assembly
30 7 1-074-195 /003 PC Board Spacer
31 1 828-003-033 Bracket
32 5 771-116 Flat Washer 1/4
33 2 701-180 Rd. Hd. Mach. Screw 1/4-20x3/8
34 1 1-150-065 Lock Switch
35 1 828-003-459 Display Card Assembly
36 4 702-066 Fl. Hd. Mach. Screw #6-32 x 1/2
37 1 828-003-494/001 Cable Assembly
38 - REF 828-003-420 /002 Temperature Sensor (Detector Assembly)
39 9 114-008-096 Coil Driver
40 9 701-023 Rd. Hd. Mach. Screw #4-40 x 1-1 /2
41 1 724-494 Set Screw 3/8-16 x 3/8
42 810-767 Spiral Pin 5/16 x 1
43 1 828-003-443 Elec. Cover Mounting Bracket
44 31.56 370-637/005 Tape
Page 410 (Conrd.) ELECTRICAL SYSTEM

MODEL 31 EASl2 Figure 828-003-349 (E)
612
Item No. _Q!y, Part Number Descriotion
45 1 828-003-584 Elec. Plate

46 2 710-004 Hex Hd. Cap Screw 1/4-20 x3/8
47 1 828-003-692/001 Wiring Harness
48 1 828-003-494 /002 Cable Assembly
49 REF 828-003-420 /004 Detector Assembly
50 REF 828-003-476/002 Handle Assembly - Cold Storage
51 6.00 611-038 Heat Shrink - Black
52 1 590-136/13 Insulator
53 1 724-399 Screw 1/4-20x5/8
54 1 n4-116 Shakeproof Ext. Washer 1/4
55 REF 590-534 /004 Fuse-100 Amp (FU7)
56 20.00 370-618 Tape 1/8x3/8
ELECTRICAL SYSTEM Page 410.1

Figure 828-003-349 (F) MODEL 31 EASi2
C3
Item No. .Qr£. Part Number Description
1 REF 828-003-421 /001 Contactor Assembly

2 4 760-920 Nut3/8-16
3 4 n1-123 Flat Washer 3 /8
4 REF 828-003-476/001 Handle Assembly - Standard
5 1 828-003-487 Wiring Housing Support
6 1 828-003-613 Cover Support
7 REF 828-Q03-442 Electric Control System
8 1 82S-003-691 Wiring Harness
11 1 82S-003-454 Cable Assembly
13 1 828-003-455 . Cable Assembly
14 REF 590-534/001 Fuse-70Amp
15 REF 590-534/013 Fuse - 350 Amp
16 REF 590-534/015 Fuse - 450 Amp
17 1 022-027-615/148 Cable Assembly
18 1 022-046-610/147 Cable Assembly
19 1 024-029-420 /254 Cable Assembly
20 1 024-020-570 /255 Cable Assembly
21 025-021-840/118 Cable Assembly
22 1 025-021-860 /119 Cable Assembly
23 1 023-021-910 / 445 Cable Assembly
24 1 023-021-aso I 444 Cable Assembly
26 1 590-610 /002 Horn
27 1 701-182 Screw 1/4-20 x 1/2
29 1 828-003-435 /001 Hyd. Driver Card Assembly
30 7 1-074-195 /003 PC Board Spacer
31 1 828-003-033 Bracket
33 2 701-180 Rd. Hd. Mach. Screw 1/4-20x3/8
34 1 1-150-065 Lock Switch
35 828-003-459 Display Card Assembly
36 4 702-066 Fl. Hd. Mach. Screw #6-32 x 1/2
37 1 828-003-494 /001 Cable Assembly
38 REF 828-003-420 /002 Temperature Sensor (Detector Assembly)
39 9 114-008-096 CoU Driver
40 9 701-023 Rd. Hd. Mach. Screw #4-40 x 1-1 /2
41 724-494 Set Screw 3/8-16 x 3/8
42 1 810-767 Spiral Pin 5/16 x 1
44 31.56 370-637 /005 Tape
Page 410.1 (Cont'd.) ELECTRICAL SYSTEM

MODEL31 EASi2 Figure 828-003-349 (F)
C4
'tern No. .Q!Y: Part Number Description
45 1 828-003-584 Elec. Plate

46 2 710-004 Hex Hd. Cap Screw 1/4-20 x 3/8
47 1 828-Q03-692/001 Wiring Harness
48 1 828-003-494/002 Cable Assembly
49 REF 828-003-420 /004 Detector Assembly
50 REF 828-003-476/002 Handle Assembly - Cold Storage
51 11.00 611-038 Heat Shrink - Black
52 1 590-136/13 Insulator
53 1 724-399 Screw 1/4-20x5/8
54 1 n4-116 Shakeproof Ext. Washer1/4
55 REF 590-534/004 Fuse - 100 Amp (FU7)
56 20.00 370-618 Tape 1/8 x 3/8
.......,..,. .......,. .... ...,. ...,....,. ... .
'-"'• .., ...........
ELECTRICAL SYSTEM Page410~
Figure 828-003-349 (M) MODEL31 EAS
Item No. _Qty, Part Number Descrlotion Item No. _Qty, Part Number Descriotlon
1 (REF) 828-003-421 /001 Contactor Assembly 45 1 828-003-584 Elec. Plate

2 4 760-920 Nut 3/8-16 46 2 710-004 Hex Hd. Cap Screw 1/4-20x3/8
3 4 771-123 Flat Washer 3/8 47 828-003-692/001 Wiring Harness
4 1 (REF) 828-003-476/001 Handle Assembly - Standard 48 1 828-003-494 /002 Cable Assembly
5 1 828-003-937 Wiring Housing Support 49 1 (REF) 828-003-420 /004 Detector Assembly
6 1 828-003-938 Cover Support 50 1 (REF) 828-003-476/002 Handle Assembly - Cold Storage
7 1 (REF) 828-003-442 Electric Control System (S /N 16806 to 17706) 51 11.00 611-037 Heat Shrink - Black
1 (REF) 828-003-955 /001 Electric Control System (S/N 17707 & Up) 52 1 Insulator
590-136/13
8 1 828-003-691 Wiring Harness 53 1 724-399 Screw 1/4-20 x 5 /8
9 828-003-440 Cable Assembly 54 1 774-116 Shakeproof Ext. Washer 1/4
10 1 828-003-441 Cable Assembly 55 REF 590-534/004 Fuse - 100 Amp (FU7)
11 828-003-454 Cable Assembly 56 20.00 370-618 Tape 1/8x3/8
12 1 828-003-434 Cable Assembiy 57 1 828-003-692/002 Harness, Key Switch
13 1 828-003-455 Cable Assembly 58 1 1-150-001 Key Switch
14 REF 590-534 /007 Fuse - 150 Amp 59 1 023-030-sso I 444 Cable Assembly
15 REF 590-534/013 Fuse - 350 Amp 60 1 022-030-615 /148 Cable Assembly
16 REF 590-534/015 Fuse - 450 Amp 61 1 114-008-018/013 Cable Assembly
17 1 02?-027-615/148 Cable Assembly 62 1 (REF) 828-003-421 /003 Contactor Assembly
18 1 022-046-610/147 Cable Assembly 63 1 023-031-940 / 445 Cable Assembly
19 024-029-420 /254 Cable Assembly 64 2 600-915 /003 Lock Nut
20 1 024-020-570 /255 Cable Assembly
21 1 025-021-840/118 Cable Assembly
22 1 025-021-860/119 Cable Assembly
23 1 023-021-910 / 445 Cable Assembly P/N DESCRIPTION W/O ITEMS
24 1 023-021-s50 / 444 Cable Assembly
001 W/O Remote 57-64
26 1 590-610/002 Horn
002 W/Remote 34, 47, 59-64
27 1 701-182 Screw 1/4-20x1 /2
28 1 828-003-399 Wiring Harness 003 EE - W/O Remote .1,18,19,23,24,57,58
29 1 828-003-792/001 Hyd. Driver Card Assembly
30 7 1-074-195 /003 PC Board Spacer
31 1 828-003-033 Bracket
32 5 771-116 Flat Washer 1I4
33 2 701-180 Rd. Hd. Mach. Screw 1/4-20x3/8
34 1 1-150-065 Lock Switch
35 1 828-003-459 Display Card Assembly
36 4 702-066 Fl. Hd. Mach. Screw #6-32 x 1/2
37 1 828-003-494 /001 Cable Assembly
38 1 (REF) 828-003-420 /002 Temperature Sensor (Detector Assembly)
39 9 114-008-096 Coll Driver
40 9 701-023 Rd. Hd. Mach. Screw #4-40 x 1-1 /2
41 1 724-524 Set Screw 3/8-16 x 3/4
42 1 810-767 Splrol Pin 5/16x1
44 31.56 370-637/005 Tape
c11, c12 · MODEL 31 ELECTRICAL
Page411
Revised 10/15/92
(':;'\ ON EACH END OF

DETAIL A-A \:::_) CARD RACK LEGS
15
*
8
S/N 16806to 1noe
ELECTRIC CONTROL SYSTEM

Figure 828-003-442 (A1)
ELECTRIC CONTROL ASSEMBLY Page 41~

Figure 828-003-442 (A 1) MODEL 31 EASi
1 1 828-003-359 Card Rack Alteration

2 1.2 811-861 /016 Flexible Latch
3 1.2 811-861/006 Flexible Latch
4 828-003-419/001 End Plate
5 114-007-944 Power Supply Cable Assembly
6 1 154-012-024/002 Power Supply Card Assembly
7 4 742-034 Pan Hd. Set Screw #6-32 x 3 /8
8 4 701-018 Rd. Hd. Mach. Screw #4-40 x 7 /8
9 1 828-003-397 /001 VFC Carel Assembly
10 4 742-035 Pan Hd. Screw #6-32 x 1/2
11 1 828-003-425 Screened Plate
12 1 411-423/001 Label Decal
13 9 1-074-076 Female Screw
14 1 1-074-191/001 Bezel
15 1 828-003-345 Lat. VFC Card Assembly
MODEL 31 ELECTRICAL
Page411.1
Added 10/15/92
DETAii. A-A
/
4
S/N 1no1 and Up

ELECTRIC CONTROL SYSTEM
Figure 828-003-955/001 (A)
ELECTRIC CONTROL ASSEMBLY Page412.~

Figure 828-003-955/001 (A) MODEL31 EASI
1 1 300-426 Card Rack

2 1.2 811-861 /016 Flexible Latch
3 1.2 811-861/006 Flexible Latch
4 1 828-003-419/001 End Plate
5 1 114-007-944 Power Supply Cable Assembly
6 1 154-012-060 Power Supply Card Assembly
7 4 742-035 Pan Hd. Screw #6-32 x 1/2
8 4 701-018 Rd. Hd. Mach. Screw #4-40 x 7/8
9 1 828-003-397/008 VFC Card Assembly
10 4 742-034 Pan Hd. Set Screw #6-32 x 3/8
11 1 828-003-425 Screened Plate
12 1 411-423/001 Label Decal
13 9 1-074-076 Female Screw
14 1 1-074-191 /001 Bezel
15 1 828-003-950 Lat. VFC Card Assembly
MODEL 31 ELECTRICAL
Page413
Revised 2/15/93
@
G
B
SECTION A-A
ROTATED 90' CW
CABLE TERMINAL REF
LEAD
PC
@
@)
S/N 16806 and Up

CONTACTOR ASSEMBLY
Flaure 828-003-421 /001 (H)
CONTACTOR ASSEMBLY Page414

Figure 828-003-421 /001 (H) MODEL31 EASl2
Item No. ~ Part Number Description Item No. ~ Part Number Description
2 4 052-005-020 Wire Assembly 66 1 590-534/013 Fuse

3 1 828-003-426/ Wiring Harness 79 AR 990-508 Heat Sink Compound
4 1 114-007-668/011 HCM Module Assembly 80 AR 990-427 Oxide Inhibiting Seal
5 6 701-087 Rd. Hd. Mach. Screw 82 1 600-915/002 Locknut
6 4 774-009 Lockwasher #8 83 1-105-124 B Contactor: Includes
7 16 701-119 Rd. Hd. Mach. Screw #10-32x1/2 1 1-105-112/01 Tip Kit
8 12 772-112 Lockwasher 84 1 828-003-416 Buss Bar
9 2 1-085-127/001 Thermal Conductor 85 1 828-003-842 Buss Bar
10 2 1-125-012 Semi-Conductor 86 8 701-115 Rd. Hd. Mach. Screw #10-32 x 3/8
12 20 771-116 Flat Washer 1/4 87 1 828-003-423 Buss Bar
13 4 710-031 Hex Hd. cap Screw 1/4-20 x 2-1 /2 88 1 828-003-394 PPD Card Assembly
14 4 154-005-011 Bearing Sleeve · 89 1 025-019-080/103 Cable Assembly
16 1 750-019 Hex Nut 3/8-24 90 1 025-019-124/104 Cable Assembly
17 1 (REF) 828-003-420/001 Detector Assembly 91 1 811-306 Clamp
18 4 774-012 Shakeproof Lockwasher #1 o 92 1 023-067-076/443 Cable Assembly
19 1 1-125-011 Semi-Conductor 93 1 828-003-321 /001 Plate Panel
22 1 828-003-458 Wiring Harness 94 1 025-019-220/007 Cable Assembly
23 9 771-112 Flat Washer #1o 95 2 710-006 Hex Hd. Cap Screw 1/4-20 x 1/2
24 5 1-105-123 Contactor: includes 96 710-012 Hex Hd. Cap Screw 1/4-20 x 7 /8
1 154-008-740/416 Tip Kit 97 724-401 Soc. Hd. Set Screw 1/4-20 x 5/8
26 3 611-029 Strap 98 1 774-116 Ext. Tooth Lockwasher
27 411-422/001 Label Decal 99 1 023-265-060 /449 Cable Assembly
31 1 023-019-037 /450 Cable Assembly 100 154-012-017/ FW Card Assembly
37 1 1-142-027 Choke Coll
38 2 772-104 Lockwasher
39 3 411-421/001 Label Decal
43 2 710-008 Hex Hd. Cap Screw 1/4-20x5/8
45 1 1-085-123/001 Thermal Conductor
46 1 828-003-415 Buss Bar
47 1 114-008-154/012 Chopper Module Assembly
49 1 1-085-124/002 Thermal Conductor
50 4 701-023 Rd. Hd. Mach. Screw #4-40 x 1-1 /2
51 4 114-008-096 Coll Driver Module Assembly
53 1 1-135-103 Diode Semi-Conductor
55 4 1-085-128/007 Spacer
56 1 828-003-365 Heat Sink
58 1 1-105-112 X Contactor: includes
1 1-105-112/01 Tip Kit
59 1 1-105-122 P Contactor: Includes
1 154-008-740/416 Tip Kit
60 1 590-534/015 Fuse
61 6 724-389 Soc. Hd. Set Screw 1/4-20 x 1-3/4
62 26 750-006 Hex Nut
63 5 1-074-104/001 Standoff Insulator
64 3 724-409 Soc. Hd. Set Screw 1/4-20x2.00
65 590-534 /007 Fuse
MODEL 31 ELECTRICAL
Pag~415
Revised 2/~6/93
__.f!._
1--~~~~...c.-=--=-=-=-=....;;;i._~~~~1
--------
1 1 1-012-313/001 Reep. Elec. Connector

2 1 1-187-050 Sensor Detector
3 2 154-Q06-170 Identification Sleeve
4 2 1-012-314/002 Socket Contact
5 1 1-012-057/02 Elec. Housing Pin Connector
6 2 1-012-253/032 Pin Contact
7 .20 611-032 Shrink Tubing Insulator
8 1 1-012-339/002 Elec. Housing Connector
9 2 1-012-340/002 Socket Contact
P/N A= B= W/O Items

001 JF5-1 JF5-2 5,6,7,8,9
002 PM-1 PM-2 1,4,8,9
003 JF12-1 JF12-2 5,6,7,8,9
004 JZ-1 JZ-2 1,4,8,9

005 JY2-1 JY2-2 1,4,5,6
S/N 16806 and Up

DETECTOR ASSEMBLY
Figure 828-003-420 / (E)
MODEL 31 ELECTRICAL
D7
Pag® 417
Revised 2/~5/93
ENCODER BRACKET ASSEMBLY

Figure 828-003-382/001 (F)
ENCODER BRACKET ASSEMBLY Page41~

Figure 828-003-382/001 (F) MODEL 31 EAS"
1 1 828-003-244 Nylatron Spacer

2 1 828-003-243 Bracket
3 1 828-003-241 Bracket
4 1 830-048 Tension Spring
5 1 ,750-003 Hex Nut #10-24
6 1 714-031 Soc. Hd. Cap Screw #10-24 x 1-1/4
7 1 n1-104 Flat Washer #1 O
8 1 1-185-006/002 Rotary Encoder
9 1 828-003-162 Timing Belt Pulley
10 1 828-003-304 Nylatron Spacer
11 4 7-703-003/008 Rd. Hd. Screw M3 x 0.5 x 8
12 1 411-846 Decal - Label
MODEL 31 ELECTRICAL
Pag~419
Revised 2/15/93
HANDLE ASSEMBLY
Figure 828-003-476/ (F)
HANDLE ASSEMBLY Page42~

Figure 828-003-476/ (F) MODEL31 EASi
1 1 828-003-601 Pot. Connector

2 1 82S-003-149 Shaft Handle
3 1 828-003-596 Pot. Bracket
4 1 828-003-103 Handle-LH.
5 1 828-003-104 Handle- R.H.
6 1 1-120-112/007 Variable Resistor
7 1 828-003-592 Aux. Button - Standard
8 1 714-020 Bd. Hd. Set Screw #10-32 x 1/2
9 3 724-306 Soc. Hd. Set Screw #10-32x1/4
10 3 714-008 Soc. Hdo Cap Screw #10-32 x 1/2
12
13 1 1-150-165 Hom Switch
15 1 611-028 Ty-Rap
17 2 7-590-001 /001 Pushbutton Switch
18 1 830-415 Lift Spring
19 1 830-414 Travel Spring
20 1 828-003-620 Lift Cap
21 1 1-120-100 Variable Resistor
22 1 828-003-593 Switch Card Assembly
23 1 828-003-633 Actuator Button
24 1 714-038 Soc. Hd. Cap Screw #10-32 x 2
25 2 7-590-002/001 Pushbutton Switch
26 1 828-003-806 Aux. Button - Cold Storage
27 2 1-120-114 Knob Adapters
P/N DESCRIPTION W/O ITEMS
001 Standard 25, 26
003 Cold Storage 7, 17

MODEL 31 ELECTRICAL
011 Page 421
Revised 10/15/92
ELEC. CONNECTOR ASSEMBLY

Figure 828-003-432/ (A)
ELEC. CONNECTOR ASSEMBLY Page4~

Figure 828-003-432/ (A) MODEL31 EAS
1 1 590-724 Battery Connector (Gray): includes

1 590-724/01 Contact Tips
2 1 022-0()4..320/146 Cable Assembly
3 1 022-003-380/046 Cable Assembly
4 1 022-004-370/146 Cable Assembly
5 1 022-003-430 /046 Cable Assembly
6 1 590-725 Battery Connector (Yellow): Includes
1 590°725/01 Shell
7 1 590°726 Battery Connector (Red): includes
1 590°726/01 Shell
8 1 590-739 Battery Connector (Blue): Includes
1 590-739/01 Shell
9 2 590-735 Bushing
10 1 022-003"310 /146 Cable Assembly
11 1 114-008-018/012 Cable Assembly
12 1 114-008-018/014 Cable Assembly
13 1 022-003420 /146 Cable Assembly
B.C. CONNECTOR
P/N WIDTH COLOR W/O ITEMS
001 16.5 Gray 4-8,10-13
002 21.5 Gray 2,3,6-8,10-13
003 16.5 Yellow 1,4,5,7,8,10-13
004 21.5 Yellow 1-3,7,8,10-13
005 16.5 Red 1,4-6,8,10-13
006 21.5 Red 1-3,6,8,10-13
007 16.5 Blue 1,4-6,7,10-13
008 21.5 Blue 1-3,6,7,10-13
009 16.5 Gray 2-8,11,13
010 21.5 Gray 2-8,10,12
011 16.5 Yellow 1-5,7,8,11,13
012 21.5 Yellow 1-5,7,8,10,12
013 16.5 Red l-6,8,11,13
014 21.5 Red 1-6,8,10,12
015 16.5 Blue 1-7,11,13
016 21.5 Blue 1-7,10,12
013 MODEL 31 ELECTRICAL
Page; 423
Revised 2/15/93
REACH (STD.)
/001, /005 & /006
MAST
ASH PANEL
DEEP REACH (STD.)

/002
REACH (EE) / DEEP REACH (EE)

/003, /007 & /008
S/N 16806 to 18296
RESISTOR ASSEMBLY INSTALLATION

Figure 828-000-980 / (H)
RESISTOR ASSEMBLY INSTALLATION Page424

Figure 828-000-980 / (H) MODEL 31 EASi2
2 3 750-414 Nut 5/16-18

3 3 n2-119 Lockwasher 5/16
11 2 850-133-006 Clamp
12 2 701-180 Rd. Hd. Macho Screw 1/4-20x3/8
13 2 n2-116 Lockwasher1/4
14 3 n1-119 Flat Washer 5 /16
18 AR 611-029 Ty-Rap
19 1 828-003-700/001 Cable Assembly
20 1 828-003-700 /002 Cable Assembly
21 1 (REF) 828-003-719 Resistor Assembly
22 828-003-700 /004 Cable Assembly
23 1 828-003-700 /003 Cable Assembly
24 1 (REF) 812-003-915/004 Resistor Assembly - EE
25 1 (REF) 812-003-915/005 Resistor Assembly - EE

005 21.5" Batt. Compt. 22-25
006 16.5" Batt. Compt. 19,20,24,25
007 EE - 21.5" Batt. Compt. 19-23, 25
008 EE - 16.5" Batt. Compt. 19, 21-24

E1 MODEL 31 ELECTRICAL
F'ai~@425
Revised 2/i 5/93
5 B B
A
SECTION A- A
SECTION B - B
S/N 16806 to 18296
RESISTOR ASSEMBLY
Figure 828-003-719
RESISTOR ASSEMBLY Page 426
E2
1 1 812-002-910 Bracket Weldment

2 2 710-127 Hex Hd. Cap Screw 3/8-16 x 3/4
5 1 590-417 Resistor
6 600-203 Grommet
E3 MODEL 31 ELECTRICAL
Page 427
Added 3/15/92
VIEW A-A
(LIGHTS NOT SHOWN)
~~~~~~~[jl
---~·-U
.___.....,......... ,,
I
11
11
I
I
I I I I
i II I I
I I
·1
I I I
I I I
I I I
I ••
SIDE VIEW (TYPICAL)
WORKING LIGHTS INSTALLATION

Figure 828-003-729 /
WORKING LIGHTS INSTALLATION Page 42~

Figure 828-003-729/ MODEL31 EASi
E4
1 (REF) 828-003-728/001 Light Rework

2 1 828-003-715 Bracket
3 1 710-134 Hex Hd. Cap Screw 3/8-16x1-1/4
4 1 750-020 Hex Nut 3/8-16
5 2 771-123 Flat Washer 3/8
6 1 (REF) 828-003-728/001 Light Rework
7 1 828-003-715 Bracket
8 1 710-134 Hex Hd. Cap Screw 3/8-16x1-1/4
9 1 750-020 Hex Nut 3/8-16
10 2 771-123 Flat Washer 3/8
11 1 828-003-734/003 Wire Assembly
13 AR 811-402 Clip
14 AR 813-570/004 Grip Nail Stud

001 Single Light - overhead Guard Mounted 6, 7, 8, 9, 10, 12
002 Dual Lights - Overhead Guard Mounted

MODEL 31 ELECTRICAL
ES Pag~429
Added 3/i5/92
n1u
.
A= B= W/O ITEM
P/N
-- --
001 14.00 4.00 2
002 14.00 4.00 1
ltemNo. ~ Part Number Description
1 591-575/001 Working Light - 36 v.

2 1 591-575/002 Working Light - 24 V.
3 1 1-012-070/04 Connector
4 2 1-012-071 Contact Pin
5 AR 611-013 Shrink Tubing
WORKING LIGHT REWORK

Figure 828-003-728/
MODEL 31 ELECTRICAL
E7
Page 431
Added 3/15/92
.:;.;-:...:-_
11
-----
Ir
11 II
11 II
11 II
11 II
11 II
11 II
11 II
•• II
TOP VIEW
(LIGHTS NOT SHOWN)
STROBE LIGHT INSTALLATION

Figure 828-003-731 /
STROBE LIGHT INSTALLATION Page432

Figure 828-003-731 / MODEL 31 EASi2
ES
1 1 (REF) 029-003-730 I Strobe Light Assembly

2 1 591-570 Strobe Light Guard
3 3 701-128 Rd. Hd. Mach. Screw #10-32 x 1
4 3 750-008 Hex Nut #10-32
5 3 n1-112 Flat Washer #1 O
6 1 828-003-734/002 Wire Assembly
7 1 828-003-734/001 Wire Assembly
8 1 828-003-726 Mounting Plate
10 3 828-003-725 Square Hook
11 3 750-006 Hex Nut 1/4-20
13 AR 811-402 Clip
ITEM LIGHT
P/N #1 COLOR MOUNTING W/O ITEMS
001 001 Red
002 002 Amber Above
003 003 Blue Overhead 6 &8
004 004 Green Guard
005 005 Clear
006 001 Red
007 002 Amber Below
008 003 Blue Overhead 7 &9
009 004 Green Guard
010 005 Clear

MODEL 31 ELECTRICAL
Page433
Added 3/15/92
,...
I
I
I D
n
1 1 591-569/ Strobe Light

2 1 1-012-070/04 Connector
3 2 1-012-071 Contact Pin
4 AR 611-025 Shrink Tubing
ITEM LIGHT
P/N #1 COLOR A= B=
001 001 Red 10.00 9.50
002 002 Amber 10.00 9.50
003 003 Blue 10.00 9.50
004 004 Green 10.00 9.50
005 005 Clear 10.00 9.50
STROBE LIGHT ASSEMBLY

Figure 828-003-730 /
MODEL 31 ELECTRICAL
E11
Page435
Revised 10/15/92
11 {
11 II
11 II
11 II
7
i~
11 II
11 II
11 II
11 II
REF
•• II I
I
I
I
11hl----
~
,i .
.JI'
I
-~ru..-.-,~
I
TOP VIEW
(LIGHTS NOT SHOWN)
WARNING LIGHTS INSTALLATION

Figure 828-003-735/ (B)
WARNING LIGHTS INSTALLATION Page43~

Figure 828-003-735/ (B) MODEL31 EAS"
1 1 (REF) 154-005-638/ Warning Light Assembly

2 1 812-001-857 Warning Light G'uard
3 2 701-184 Rd. Hd. Cap Screw 1/4-20x5/8
4 See Chart 750-006 Hex Nut 1/4-20
5 See Chart n1-116 Flat Washer 1/4
6 1 828-003-734 /002 Wire Assembly
7 1 828-003-734/001 Wire Assembly
10 3 828-003-725 Square Hook
11 AR 811-402 Oip
13 1 100-024-489 Finish Instructions
ITEM LIGHT QTY. QTY.

" P/N #1 COLOR MOUNTING W/O ITEMS ITEM 4 ITEM 5
001 002 Red Above

overhead 6,8,13 5 5
002 001 Amber Guard
003 002 Red Below

overhead 2,3,7,9 3 3
004 001 Amber Guard
Page437
MODEL 31 ELECTR\CAL Added 3/15/92
E13
~~
··~:=@
WARN\NG UGHT ASSEMBLY

Figure 154-005-638/ (G)
WARNING LIGHT ASSEMBLY Page43~

Figure 154-005-638/ (G) MODEL 31 EASi
E14
1 1-012-070/04 Connector
2 *1-012-071 Contact Pin
2 1 591-501 Light. - Complete (Amber)
3 1 591-502 Light - Complete (Red)
4 1 591-501/01 ·Flasher
5 1 591-501/02 Lens - Amber
6 1 591-501/03 Gasket
7 1 591-501/04 Bulb
8 1 591-502/01 Lens-Red
9 1 701-100 Rd. Hd. Mach. Screw #8-32 x 1
10 1 750-002 Hex Nut #8-32
11 1 774-112 Shakeproof Lockwasher #8
12 1 870-643 Fiber Washer
13 AR 611-025 Heat Shrink Tubing
001 Amber 3, 8
002 Red 2, 5
MODEL 31 ELECTRICAL
Page439
Added 3/15/92
ACK OF BRACKET
121-003-033
----------------------------
0
0
SECTION A-A
SECTION B-B
B
t ______tB ~=====::::?' NOT TO SCALE
BACK-UP ALARM INSTALLATION

Figure 828-003-780 I
BACK-UP ALARM INSTALLATION Page44~

Figure 828-003-780/ MODEL31 EASi
F2

3 1 590-622/001 Hom Alarm
4 2 750-013 Hex Nut 5/16-18
5 2 701-225 Rd. Hd. Mach. Screw5/16-18x3/4
6 2 n1-019 Flat Washer 5 /16
7 AR 813-570/004 Stud Grip Nail
8 AR 811-402 Cable Clamp
9 1 828-003-795 /00.1 Cable Assembly
11 1 1-100-013 Relay
12 1 154-010-242 Diode Module Assembly
18 3 611-044 Ty-Mount Self-Adhesive
19 3 611-029 Ty-Rap Self-Locking 4.0 Long
20 1 771-007 Flat Washer #6
21 1 701-070 Rd. Hd. Mach. Screw #6-32 x 3/4
22 3 772-107 Lockwasher #6
23 2 701-060 Rd. Hd. Mach. Screw 6-32 x 5/16
24 828-003-781 Attachment Plate
25 1 828-003-782 Bracket
26 2 724-399 Cup Pt. Set Screw 1/4-20 x 5/8
P/N LOCATION
005 Above Overhead Guard
006 Below Overhead Guard

MODEL 31 ELECTRICAL
F3 Page441
Revised 10/15/92
ACK OF BRACKET
&2&-003-033
0
0
0 0
-------------------------------
,,,,
J_LI - - - - - - - - - ..
I ---------"'
'==========
BACK-UP LIGHT INSTALLATION

Figure 828-003-785 (A)
BACK-UP LIGHT INSTALLATION Page442

Figure 828-003-785 (A) MODEL 31 EASl2
1· 1 154-008-963 Light Rework

2 1 828-003-715 Bracket
3 1 710-134 Hex Hd. Gap Screw 3/8-16x1-1/4
4 1 750-020 Hex Nut 3/8-16
6 AR 811-402 Clamp
7 AR 813-570/004 Stud
8 1 828-003-787 Gable Assembly
9 3 n2-104 Lockwasher #8
10 1 701-060 Rd. Hd. Mach. Screw #6-32 x 5/16
11 1 701-070 Rd. Hd. Mach. Screw #6-32 x 3/ 4
12 1 n1-009 Flat Washer #8
13 1 1-100-013 Relay - 36 Volt
15 1 828-003-795/001 Cable Assembly
17 3 611-029 Ty-Rap Mount Self-Locking 4• Long
F5 MODEL 31 ELECTRICAL
Page443
Revised 2/15/93
ACK OF BRACKET
S2S-003-033
12 0
0
0 0
!0r~~~3 j§~~~~§~-~-:.::-:..:-:..:-:..:-:..:-:..:-:..:-:..:-:..:-:..:-:..:-:..:-:..:-:..:-:..:-:..:-:..:-:..:-:..:-:..:-:..:-:..:-:..:-:..:-:..:-:..:-.::::-.::..:i-
SECTION A-A
B B
f --~t '===="
SECTION B-B
NOT TO SCALE
ALL TRAVEL ALARM INSTALLATION

Figure 828-003-788/ (A)
ALL TRAVEL ALARM INSTALLATION Page444

Figure 828-003-788/ (A) MODEL 31 EASi2
Item No. ~ Part Number Descriotion
1 1 828-003-784 Back-Up Alarm Cable Assembly

3 1 590-622/001 Hom Alarm
4 2 750-013 Hex Nut 5/16-18
5 2 701-225 Rd. Hd. Mach. Screw5/16-18x3/4
6 2 771-019 Flat Washer 5/16
8 AR 811-402 Cable Clamp
9 1 828-003-795 /002 Cable Assembly
11 1 1-100-013 Relay - 36 Volt
19 3 611-029 Ty-Rap Self-Locking 4• Long
20 1 771-007 Flat Washer #6
21 1 701-070 Rd. Hd. Mach. Screw #6-32 x 3/4
22 3 772-107 Lockwasher #6
23 2 701-060 Rd. Hd. Mach. Screw #6-32 x 5/16
24 1 828-003-781 Attachment Plate
25 1 828-003-782 Bracket
26 2 724-399 Cup Pt. Set Screw 1/4-20 x 5/8
P/N LOCATION
005 Above Overhead Guard
006 Below overhead Guard
F7 MODEL 31 ELECTRICAL
Page 445
Added 3/15/92
MODEL 20 g. 21
MODEL 31
it-------,
.. -------~
"'T
-!+I-
-------
------
TYPICAL SIDE VIEW

FAN ASSEMBLY INSTALLATION
Figure 828-003-796/
FAN ASSEMBLY INSTALLATION Page44~

Figure 828-003-796/ MODEL 31 EASi
Fa
Item No. .Q!y, Part Number Description
1 1 710-134 Hex Hd. Cap Screw 3/8-16x1-1/4

2 1 828-003-715 Bracket
3 2 750-020 Hex Nut 3/8-16
4 4 771-123 Flat Washer 3/8
5 1 100-027-109/001 Blower Assembly - 36 Volt
6 1 100-027-109/00?. Blower Assembly - 24 Volt
7 1 710-127 Hex Hd. Cap Screw 3/8-16 x 3/4
8 1 828-003-734/004 Cable Assembly
10 AR 811-402 Brass Single Tube Cip
11 AR 813-570/004 Grip Nail
P/N MODEL VOLT W/O ITEMS

001 20 24 5 & 8
002 21 36 6 & 8
003 31 36 6 & 9
THE RAYMOND tORPORATION
STANDARD HYDRAULIC SYMBOLS Page 501
March 31 , 1987
Pnaun
.*
Line Sinrl•
Manual
----
--~-.---
Pilot Line
Drain Lin•
On/Oil
Valns
ZJ Pump,
Variable
Diaplacement
• Connection Variable
r:o· Power Dilplacement
J_ Line
Connection
Steer
Unit
r4'5 R.ennibl•
Motor
nmbl• Check
'-._/ -<)--
)(
Lin•
Pluaed
Conaect:ion w
ValYe
Sprinc
u() Preuun
Compensated
Line To Relervoir
ili Abcwe Fluid

Lnel ----,
L __ Subauembly Tl° Pulh/Pull
W.er
LlJ Betownwd
Lne1
Tr Pedal/Treadle
- ...
Double
-
Fixed
ffi
0
Actinc
Raaic:tioa Orbiml Cylinder
+
ValYe
Variable
a..Uic:tion [E Sincl•
Amnc
Cylinder
~
B.eMrYoir
Vent:
0
Slncl•
Pump,
Fixed
Diaplaceme1rt
0( Preaun
Switch
Fixed
0
Pilot:
-
Displacement:,
Filter/ -Q; ... , •
--<>-
llnenibl• Operated
Strainer Check
Mowr ~
Valve
B.eMrYoir
Fixed Displace- now Control,
u
0 tt:r
Vented meat, non• Adjuatabl•
llnenible Temperature &
D Preuurised Motor Pnaure
Compensated
P~ge 502 STANDARD HYDRAULIC SYMBOLS
11arc:h 31 , 1987
rr[]Zl
Solenoid,
Sincle
Windinc
y{Q,
1.:1
I
.I
Pnuun
a.ducinc
Valve
~--, Pr.aun
~
Two Position I
ltellef
Two Conaedion Vw •
.J Valve
•/Pilot.
I
m
Two Posit.ion
Three
Connection
.
TwoPosi~on
[]IXJ Four
Con.nection .
A '! •
0 t7J
Elect.rical Solenoid Valve,
Normally Open
.
I• ir.
• j ....
Three Position
·X
Four Way
\Iv '. • T T
Valve Capable of
J. J.
I I
xD
Irdinit.e Poamoninr
4IIth
Electrical Solenoid Valve,
Normally C10Md
IVIVLll:.L. u I n I 1•.n1nv ..1v
A5,A6
Page503
Revised 2/15/93
LEGEND
P2 CV2 PRESSURE LINES
------ RETURN LINES
---- WORKING LINES
Pl I
I
CVI
--- SUCTION LINES
LIFT/LOWER -... TI'~ SOLJ

. VALVE LL~
FLOW
CONT.
wwJ_Th
I SOL2
I
I
I
I H.P.REL. .,
I LIFT CONTROL J. n_j
I MANIFOLD L~
T I I
l ~:r-------~---------+-------•----------------J
"' -- - - ---------- ~
-~~
ARI r-----
RESERVOIR - - - - - - - - - - T-------SR_______________ J 3i
STEER
TO AUX.
------------~--------------------------------------FUNCTIONS
A2
TO AUX.
~--4--~---._---------t--'Ll-----...._---4--------------------- FUNCTIONS
Al
S/N 16806 to 18296
HYDRAULIC SCHEMATIC
Figure 828-003-067 (A)
A7 MODEL 31 HYDRAULIC
Page505
Revised 2/15/93
-TO LIFT CYLINDER
16
Il
S /N 16806 to 18296
HYDRAULIC SYSTEM
Figure 828-003-286/ (K)
HYDRAULIC SYSTEM Page50~

Figure 828-003-286/ (K) MODEL 31 EASI
1 1 (REF) 828-003-229 Auxiliary Pump and Motor Assembly

2 1 (REF) 828-003-989/001 Lift Pump and Motor Assembly
3 1 (REF) 828-003-287 Lift Manifold Assembly
4 1 (REF) 828-003-288 Auxiliary Manifold Assembly
·5 1 (REF) 828-003-325 Hydraulic Motor Assembly
6 1 (REF) 828-003-326 Orbit Valve Assembly
7 1 828-003-097 /001 Formed Return Hose ·
8 1 828-003-098 Formed Lift Hose
9 1 828-003-329 SP Tubing Assembly
10 1 828-003-330 SR Tubing Assembly
11 1 828-003-332/ Lift Hose Assembly
12 1 812-002-914 /004 Hose
13 2 041-908-018/553 Lift Hose
14 1 031-908-018/511 Aux. Pressure Hose
15 1 031-706-009/527 Steer Motor Hose
16 1 031-706-009 /565 Steer Motor Hose
17 2 811-925/006 Hose Clamp
18 2 811-926 Hoseaamp
19 1 812-002-914/001 Hose
20 2 710-096 Hex Hd. Cap Screw 5/16-18 x 3-1 /4
21 2 740-135 Carriage Bolt 5/16-18 x 3-1 /2
22 2 760-913 Thin locking Hex Nut 5/16-18
23 2 740-134 Carriage Bolt 5/16-18 x 1
24 2 750-013 HexNut5/16
25 4 710-134 Hex Hd. Cap Screw 3/8-16x1-1/4
26 4 714-127 Soc. Hd. Cap Screw 3/8-16 x 3/4
27 2 811-925/004 Hoseaamp
29 2 n1-019 Flat Washer 5/16
30 1 811-710 Hoseaamp
31 1 710-005 Screw 1/4-28 x 3/8
32 1 n1-11s Flat Washer 1/4
33 1 360-028/001 Cable Guard
34 2 811-925/005 Hoseaamp
P/N ITEM 11 P/N BATTERY COMPT.
001 828-003-332/001 16.50
002 828-003-332/002 21.50

MODEL 31 HYDRAULIC
A9,A10 Page507
Revised 10/15/92
SOL I
LIFT MANIFOLD ASSEMBLY

Figure 828-003-287 (C)
LIFT MANIFOLD ASSEMBLY Page SO~

Figure 828-003-287 (C) MODEL31 EASi
Item No. ~ Part Number Descriotlon
1 1 (REF) 520-854 Uft Manifold

3 2 792-358 90 Degree Elbow Tube Fitting
4 1 792-571 0-Ring Connector
5 1 792-327 Tube Fitting Cap
6 1 828-003-614 /001 Pressure Transducer Module Assembly: includes
1 591-567 Pressure Tranducer Module
1 1-012-339/002 Connector Plug
4 1-012-340/002 Socket Contact
4 154-006-170 Identification Sleeve
1 611-025 Shrink Tubing
7 1 792-551 90 Degree Elbow Tube Fitting
8 1 802-017 Hydraulic Connectqr, Beaded
MODEL 31 HYDRAULIC
Page509
Revised 10/15/92
LIFT MANIFOLD
Figure 520-854
LIFT MANIFOLD Page51~

1 1 520-854/01 Plated Manifold

2 2 520-854/02 Plug-SAE6
3 4 520-854/03 Plug-SAE8
4 1 520-854/05 Solenoid Valve: includes
5 1 520-835/02 24VDCCoU
6 1 520-854/04 Solenoid Cartridge
7 1 520-854/06 Solenoid Valve: includes
8 1 520-835/02 24VDCCoil
9 1 520-848/02 Solenoid Cartridge
10 2 520-835/08 Check Valve
11 1 520-835/03 Relief Valve
12 1 520-844/01 Proportional Valve: includes
13 1 520-844/02 24 VDCColl
14 1 520-854/07 Seal Repair Kit
15 1 802-023/004 90 Degree Elbow, Beaded Insert
83,84. MODEL 31 HYDRAULIC
Page511
Revised 2/15/93
S4
S/N 16806 to 18296
AUXILIARY MANIFOLD ASSEM8LY

Figure 828-003-288
AUXILIARY MANIFOLD ASSEMBLY Page 512

BS
REF 520-855 Auxiliary Manifold

2 1 792-327 Tube Fitting - Cap
3 1 792-521 90 Degree Elbow
5 1 802-023/004 90 Degree Elbow, Beaded Insert
MODEL 31 HYDRAULIC
87 Page513
Revised 2/15/93
SR A4
r+-------
r
I
_______________lsp
S1 -------~A2
I I
P 1.---e-----4.__+' 1-+--------.;KA1
L_ x
S2 _J
X = (PLUGGED PORT)
S1 S2
S /N 16806 to 18296
AUXILIARY MANIFOLD
Figure 520-855
AUXILIARY MANIFOLD Page514

1 1 520-840/01 Solenoid Valve: contains

2 1 520-855/01 Solenoid cartridge
3 2 520-835/02 24 voe Coil (1 o size)
4 1 520-840/03 Solenoid Valve: contains
5 1 520-855/02 Solenoid cartridge
6 1 520-420 /212 24 voe Coil cos Size)
7 2 520-840/02 Relief Valve
8 1 520-855/03 Orifice Disk W/.045 Centered Hole (See Note)
1 520-855/05 Orifice DlskW/.046 Offset Hole (See Note)
9 1 520-855/04 Seal Repair Kit
NOTE: Orifice disk with centered hold was used on early vehicles. The change to the offset hole eliminated a lock-up
condition that occurred in some vehicles.
MODEL 31 HYDRAULIC
Page515
Revised 2/15/93
INLET
(l I
I lJ lJ I
I
I
0 0
1 1 (REF) 570-264/200 Auxiliary Motor

2 1 (REF) 500-435 Auxiliary Pump
3 4 710-069 Hex Hd. Cap Screw 5/16 x 3/4
4 1 792-511 90 Degree Elbow Tube Fitting 3/ 4-16 x 1/2
5 1 114-009-503 Motor Spec Plate
S/N 16806 to 18296

AUXILIARY PUMP AND MOTOR ASSEMBLY
Figure 828-003-229 (F)
MODEL 31 HYDRAULIC
Page 517
Revised 2/15/93
ILLUSTRATION NOT AVAILABLE

S /N 16806 to 18296
AUXILIARY PUMP ASSEMBLY
Figure 500-435
AUXILIARY PUMP ASSEMBLY Page 518

812
1 4 500-435/01 Bearing
2 1 500-435/02 Ball Bearing
3 1 500-435/03 Oil Seal
4 8 500-417/220 Screw 1/4-20 x 2-1/4
5 500-435/04 Washer (.960IDx1.25 OD x .15 W)
6 500-435/05 Gear
7 1 560-204/32 Shear Pin (.219 D x .50 L)
8 1 500-435/06 Shear Pin (.093 D x .75 L)
9 1 500-435/07 Internal Snap Ring
10 2 500-435/08 External Snap Ring
11 1 500-417/215 Lee Plug
12 500-435/09 Spacer (.037 W x 1.13 ID x 1.37 OD)
13 500-435/10 Drive Shaft
MODEL31HYDRAUUC Page519
Revised 2/15/93
ILLUSTRATION NOT AVAILABLE

S/N 16806 to 18296

AUXILIARY MOTOR
Figure 570-264/200
Page 52~
MODEL 31 EASi
Part Number Description
570-436/01 Armature Assembly

570-205/07 C.E. Sealed Ball Bearing
570-264/211 Frame and Field Assembly
570-436/02 Field Coil Package
570-205/10 Pole Shoe Screw Package
570-204/113 Commutator End Head Assembly
570-205/04 Brush Set
570-402/11 Bearing Cover
570-432/04 Brush Plate Assembly
570-414/08 Brush Spring Set
570-205/05 Drive End Head Assembly
570-414/11 Sealed Ball Bearing
570-432/112 Retainer Ring Package
570-205/06 Terminal Stud Package
570-414/02 C.E. Bearing Spring Washer
570-426/111 Enclosure Kit (EE Motor Only)
MODEL 31 HYDRAULIC
Page521
Revised 2/15/93
0 0
S/N 16806 to 18803
1 1 (REF) 570-236/ Lift Motor

2 1 500-434 Lift Pump: includes
1 500-434/01 Front Seal Kit
1 500-434/02 Rear Seal Kit
3 2 710-034 Hex Hd. Cap Screw 3/8x1-1/4
4 4 710-188 Hex Hd. Cap Screw 7/16-14x1-1/4
5 2 792-358 Elbow
6 1 802-022 Hydraulic Connector, Beaded
7 1 530-431 0-Ring Packing
LIFT PUMP AND MOTOR ASSEMBLY

Figure 828-003-283 (C)
MODEL 31 HYDRAULIC
Page 523
C5 Revised 9/15/91
©r---~
@~----
©------;=;--
@1--------:-
-d!!!f.~-
,Jrestolite
LIFT MOTOR
Figure 570-236/100
LIFT MOTOR Page 524

Figure 570-236/100 MODEL 31 EASi2
C6
1 1 570-236/115 Armature & Fan Assembly: includes

2 1 570-235/112 Spline & Pin Package
3 1 570Q235/113 Fan
4 1 442-227 Sealed Ball Bearing
5 1 - 570-236/111 Field Coil Package
6 570-236/112 C.E. Head Assembly: includes
7 1 570-236/113 Brush Spring Set
8 1 570-236/114 Service Brush Set
9 1 570-235/117 Brush Plate Assembly
10 570-235/118 D.E. Head Assembly: includes
11 1 442-227 Sealed Ball Bearing
12 810-476 Retainer
13 1 570-205/10 Pole Shoe Screw Package
14 1 570-235/119 Terminal Stud Package (Hdwe. Incl.)
15 830-406 C.E. Bearing Spring Washer
16 570-235/120 Enclosing Kit
MODEL 31 HYDRAULIC
Page525
C7 Added 9/15/91
,---------..,.
VIEW AT "A"
Item No. .Q!y. Part Number Description
1 1 570-217/123 C.E. Ball Bearing

2 1 570-236/211 Yoke & Bearing Support
3 2 570-215/118 Stud & Nut
4 1 570-235 /214 C.E. Cover
5 1 570-235/222 Cross Connector
6 1 570-235/223 Cross Connector
7 1 570-236/213 Armature
8 1 570-236/214 Field Wound
9 1 570-236/215 D.E. Cover
10 570-236/216 D.E. Bearing Bracket
11 570-026/04 D.E. Ball Bearing
12 1 570-235/221 C.E. Cover
13 1 570-235/219 Yoke & Holder
14 4 570-236/218 Brush
15 8 570-242/112 Spring
16 1 .570-235/224 Foot
17 1 570-235/211 Enclosure Kit (Not illustrated)
GENERAL ELECTRIC
36 Volt
LIFT MOTOR
Figure 570-236/200
MODEL 31 HYDRAULIC
Page 527
Revised 3/15/92
Item No. .Qty. Part Number Description
1 1 570-236/511 Drive End Head Casting

2 1 570-427/512 Drive End Bearing
3 1 570-427 /513 Retaining Ring
4 1 570-446/512 Fan
5 1 570-236/512 Armature & Fan Assembly
6 1 570-236/513 Field Coil Kit
7 8 570-236/514 Brush
8 1 570-236/515 Brush Box Assembly
9 1 570-446/518 C.E. Bearing
10 1 570-236/516 Commutator End Head Casting
11 1 570-236/517 Lead Assembly Kit
12 1 570-252/518 Wavey Washer
13 1 set 570-446/516 Brush Spring Set
ADVANCED DC
36 Volt
LIFT MOTOR ASSEMBLY
Figure 570-236/500
MODEL 31 HYDRAULIC
C11 Page 529
Added 9/15/91
1 REF 550-024 Steer Motor

2 2 792-507 Tube Fitting - Connector
HYDRAULIC MOTOR ASSEMBLY

Figure 828-003-325 (C)
MODEL 31 HYDRAULIC
R . Page531
ev1sed 10/15/92
s:EER MOTOR
Figure 550-024
STEER MOTOR Page53~

Figure 550-024 MODEL31 EAS
1 4 550-004/01 Cap Screw 12 Pt. Dr. 5/16-24 x 7 /8

2 1 550-004/03 Mounting Flange 4 Bolt
0
3 1 550-003/03 Back-Up Ring

4 1 550-004/06 Thrust Bearing Race
5 1 550-004/07 Thrust Needle Bearing
6 1 550-015/02 Keyed Straight Output Shaft
7 1 850-113 Woodruff Key
8 1 550-022/01 Housing
9 1 550-024/02 Drive
10 1 550-015/05 Spacer Plate
11 1 550-024/01 Geroler
12 1 550-015/17 End Cap
13 7 550-024/03 Cap Screw 12 Pt. Dr. 5/16-24
14 1 550-015/09 Seal Kit- Standard: includes
1 550-015/01 Seal Kit ° Cold Storage: includes
1 Exclusion Seal (550-004/02)
1 Shaft Pressure Seal (550-004/04)
1 Seal (550-013/06)
3 Seals (550-015/04)
MODEL 31 HYDRAULIC
Page533
Revised 2/15/93
1 1 (REF) 870-841 Orbitrol Metering Valve

4 1 792-343 Connector Tube Fitting
S/N 16806 to 18296

ORBIT VALVE ASSEMBLY
Figure 828-003-326 (A)
MODEL 31 HYDRAULIC
Page535
Revised 2/15/93
ILLUSTRATION NOT
AVAILABLE AT
TIME OF PUBLICATION
s/N 16806 to 18296

ORBIT METERING VALVE
Figure 870-841
ORBIT METERING VALVE Page 53~

Figure 870-841 MODEL31 EASi
06
Item No. .Q!Y.. Part Number Descriotion
7 550-008/02 Cap Screw

2 1 870-822/04 End Cap
3 3 870-820/14 Seal
4 1 870-841/01 Gerotor Sub-Assembly
5 1 550-008/16 Spacer Plate
6 1 550-008/17 Drive
7 1 870-841/02 Control Parts Assembly: Includes
8 1 550-008/15 Centering Pin
9 4 870-841/03 Centering Spring
10 2 550-008/07 Bearing Race
11 550-008/08 Thrust Needle Bearing
12 1 550-008/05 0-Rlng
13 1 870-691/01 Dust Seal
14 870-841/04 0-Ring
15 1 870-841/05 Back-Up Ring
16 1 870-841/06 Seal
17 1 550-008/03 Retaining Ring
18 1 870-841/07 Front Retainer
19 1 550-008/12 Check Ball Retainer
20 1 550-008/21 Check Ball
21 1 550-008/11 Check Ball Seat
22 1 550-008/19 0-Rlng
23 1 550-008/10 0-Ring
24 1 550-008/09 Set Screw
25 870-841/08 Seal Kit
26 500-008/06 Needle Bearing Kit
MODEL 31 HYDRAULIC
Page537
Revised 10/15/92
2 8
ORIENTATION OF CAP
A
---------J----.,
YEW B-B YEW A-A
Description
Item No. ~ Part Number
1 1 520-509/01 Filter
2 1 828-003-141 Nut
3 1 850-019 Ball
5 1 828-003-068 Filter Adapter
6 1 530-490/011 0-Rlng
7 2 742-095/102 Hex Hd. Self-Tapping Screw 1/4-20 x 1/2
8 1 828-003-146 Reservoir Weldment
9 1 850-521 Filler Breather Cap
10 6 701-119 Rd. Hd. Mach. Screw #10-32 x 1/2
11 1 828-003-041 /001 Funnel Tray
12 1 828-003-802 Bracket Key
13 1 828-003-801 Bracket Switch
14 2 701-192 Tr. Hd. Cap Screw 1/4-20 x 3/4
S/N 16806 to 17896

RESERVOIR ASSEMBLY
. Figure 828-003-161 (E)
MODEL 31 HYDRAULIC
Page 537.1
Revised 2/15/93
2 a
ORIENTATION OF CAP
A
0
17
B B
0
VIEW B-B
1 1 520-509/01 Filter
2 1 828-003-141 Nut
3 1 850-019 Ball
5 1 828-003-068 Filter Adapter
6 1 530-490/011 0-Rlng
7 2 742-095/102 Hex Hd. Self-Tapping Screw 1/4-20x1/2
8 1 828-003-940 Reservoir Weldment
9 1 850-523 Filler Breather Cap
10 6 701-119 Rd. Hd. Mach. Screw #10-32 x 1/2
11 1 828-003-041 /001 Funnel·Tray
12 1 828-003-942 Bracket Key
13 1 828-003-801 Bracket Switch
14 2 701-192 Tr. Hd. Cap Screw 1/4-20x3/4
15 1 828-003-939 Cover Flange
16 1 531-140 Gasket
17 6 702-117 Fl. Hd. Mach. Screw #10-32x1/2
S/N 17897 and Up

RESERVOIR ASSEMBLY
Figure 828-003-161 (H)
09, 010·
Page539
AddecJ 9/15/91
t
37 21,
38
10 13
l/F; MOTOR ASSEMBL y

Figure 570-236/400
LIFT MOTOR ASSEMBLY Page 54~

Figure 570-236/400 MODEL 31 EASi
011
1 4 570-236/411 Bolt M5 x 14-5.6

2 12 570-236/412 Washer
3 12 570-236/413 Washer
4 1 570-236/414 Housing
5 9 570-236/415 Bolt MS x 20-5.6
6 570-236/416 Safety Washer
7 1 570-236/417 Thrust Washer
a 1 570-236/418 Fan
9 1 570-236/419 Protective Motor Shield
10 3 570-236/420 Bolt M6 x 30-5.6
11 3 570-236/421 Washer
12 1 570-236/422 Bearing Cap
13 1 570-236/423 Bearing
14 570-236/424 Bearing Cap
15 1 570-236/425 Shield With Brush Holder: Includes
16 8 570-236/426 Bolt MS x 25-5.6
17 1 570-236/427 Rear End Shield
18 1 570-236/428 Conductor
19 1 570-236/429 Conductor
20 4 570-236/430 Brush Holder
21 8 570-236/431 Brush
22 8 570-236/432 Nut
23 8 570-236/433 Washer
24 570-236/434 Stator: includes
25 4 570-236/435 Pole
26 1 570-236/436 Series Connected Coil Assembly
27 1 570-236/437 Terminal
28 1 570-236/438 Pressboard Foil
29 1 570-236/439 Bush
30 1. 570-236/440 Body
31 10 570-236/441 Washer
32 8 570-236/442 Bolt M10 x 20-5.6
33 570-236/443 Sealing
34 1 570-236/444 Base
35 ~ 570-236/445 Washer
36 4 570-236/446 Nut
37 2 570-236/447 Screw M6 x 14-5.8
38 2 570-236/448 Washer
39 1 570-236/449 Key
40 1 570-236/450 Rotor
41 1 570-236/451 Bearing
42 1 570-236/452 Ring
MODEL 31 HYDRAULIC
Page541
Revised 2/15/93
P/N DESCRIPTION W/O ITEM
001 Standard 7
003 EE 1
1 1 (REF) 828-003-283 Lift Pump & Motor Assembly

2 4 740-134 Carriage Bolt 5/16-18 x 1
3 4 750-013 Hex Nut 5/16-18
4 1 114-009-503 Motor Spec. Plate
7 1 (REF) 828-005-011 Lift Pump & Motor Assembly (EE)
S/N 16806 to 18803
LIFT PUMP AND MOTOR ASSEMBLY INSTALLATION

Figure 828-003-989 / (A)

31-Easi2 16806-18296 PM PDPM-0035

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MODEL 31 EASI 2

Page 1of2 Date: February 15, 1993

Description Serial No.

Power Section Basic • 828-003·100/ (Q) .•..•.•.••.••....•...••......••.•...••...•••••..•.•.•.......• 16806 to 17950 101

BRAKES AND STEERING 200

Mech. Steering Installation -828-003-228 (F) ...................................................... 16806 to 18296 201

DRIVE UNIT 300

Drive Unit Installation - 828-003-181 (L) ............................................................... 16806 to 18296 301

Standard Electrical Symbols................................................................................ 401

Page2of2 Date: February v 1993

Description Serial No.

Electric Control System - 828-003-442 (A1) ......................................................... 16806 to 1nos 411

Standard Hydraulic Symbols................................................................................ 501

S/N 16806 to 17950

POWER SECTION BASIC Page 102

Item No. ~ Part Number Description

1 1 (REF) 828-003-039/ Steer Idler Wheel Installation

Page 102 (Conrd.) POWER SECTION BASIC

P/N ITEM 30 P/N DESCRIPTION

001 001 16.5" Batt. compt.

002 002 16.5 11 Batt. compt.

003 003 16.5 11 Batt. compt.

004 001 21.5 11 Batt. Compt.

005 002 21.5" Batt. Compt.

006 003 21.5 11 Batt. Compt.

POWER SECTION BASIC Page 102.1

Item No. ~ Part Number Description

1 1 (REF) 828-003-923/ Steer Idler Wheel Installation

Page 102.1 (Cont'd.) POWER SECTION BASIC

P/N ITEM 30 P/N DESCRIPTION

001 001 16.5 11 Batt. Compt.

003 003 16.5" Batt. Compt~

004 001 21.5 11 Batt. Compt.

006 003 21.5" Batt. Compt.

(2) LEC. PANEL

ltemNo. ~ Part Number oescrlptlon

(2) LEC. PANEL

FINISH INSTRUCTIONS Page 11~

1 6 813-570/002 Stud 45 AR 411-778 French Warning Decal

S/N 16806 to 17950

GATE INSTALLATION Page 112

1 1 828-003-003 /002 Battery Gate

001 16.5 c 1,2,3,4,6,7 & 8

003 16.5 Std. B 2,4,5,6 7 & 8

004 16.5 A 1,2,3,4,6,7 & 8

006 21.5 Std. 0 1,2,3,4,5,6 & 7

008 21.5 A 1,2,3,4,5,7 & 8

S/N 17951 and Up

GATE INSTALLATION Page 112.1

Item No. _Qty, Part Number Description

1 1 828-003-924/002 Battery Gate

003 16.5 B 2,4,5,6,7 & 8

004 16.5 A 1,2,3,4,6,7 & 8

005 21.5 c 1,2,3,4,5,7 & 8

006 21=5 Std. D 1,2,3,4,5,6 & 7

008 21.5 A 1,2,3,4,5,7 & 8

i--~~~~~~~-B= MAX. (REF)~------;~

005 21.5 19.74 21.50