Section 4 Drive and Brake

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Drive Unit Installation
Figure 4-1 List 4-1 CD-ROM
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Lower Drive Assembly
Figure 4-2 List 4-2
BOOK
Wheel Assembly, Drive HOME
Figure 4-3 List 4-3

Brake Installation BOOK

Figure 4-4 List 4-4
CONTENTS

Travel Brake Assembly

Figure 4-5 List 4-5

DC Lower Hoist Brake Actuator

Figure 4-6 List 4-6

Hoist Brake Assembly

Figure 4-7a Figure 4-7c List 4-7
Figure 4-7b

Auxiliary Brake Assembly

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Figure 4-8 List 4-8
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 Drive Unit Installation
Figure 4-1: Drive Unit Installation CL ICK TO
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T838-012-897-F
 List 4-1: Drive Unit Installation
FIGURE 4-1
QTY PART NUMBER DESCRIPTION USED ON CL ICK TO
ITEM NO.
1 1 410-043 Drive Assembly, Lower (See Figure 4-2.)
GO TO:
2 4 5-018-010 Washer, Flat
3 4 5-002-026 Screw CD-ROM
4 2 5-001-001 Screw HOME
5 2 838-010-288 Clamp
6 1 7-750-920 Nut
7 1 400-188 Gear, Helical Pinion (See Figure 4-2.) item 31 BOOK
8 1 5-026-005 Key, Woodruff HOME
9 1 838-010-011 Plug, Dipstick
10 1 828-009-885/001 Cover, Dipstick BOOK
11 1 530-426 O-Ring R CONTENTS
12 1 570-340/500 Motor, Drive (MD) (See Figure 5-26.)
13 7 5-002-004 Screw SECTION
16 1 838-010-002/001 Wheel Assembly, Drive (See Figure 4-3.) C CONTENTS
1 838-010-002/002 Wheel Assembly, Drive (See Figure 4-3.) A, B
17 9 828-004-578 Bolt, Drive Wheel
18 1 782-422 Plug, Mechanical FIRST
19 AR 771-033 Spacer PAGE
A= Cold Storage
B= Raised/Level Operator Compartment Floor
C= Standard PREVIOUS
R= Recommended Spare PAGE

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 Lower Drive Assembly
Figure 4-2: Lower Drive Assembly CL ICK TO
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25

T410-043
 List 4-2: Lower Drive Assembly (Sheet 1 of 2)
FIGURE 4-2
QTY PART NUMBER DESCRIPTION USED ON CL ICK TO
ITEM NO.
410-043 Drive Assembly, Lower, Rebuilt
GO TO:
1 1 838-010-003 Ring Machining, Pivot
2 1 400-187 Gear, Helical C CD-ROM
3 1 1020548/003 Nut, Clamp C HOME
4 1 400-189 Gear, Spur D
5 1 838-010-010 Cover Machining, Gear
6 1 812-408 Retainer BOOK
7 1 838-010-023 Kit, Ring Set D, R HOME
8 88 850-017 Ball, 9/16 in. D
10 1 410-039 Gear and Pinion Set C BOOK
11 1 838-010-008 Plate, Cover Drive Unit CONTENTS
12 12 5-002-002 Screw C
13 1 1020548/005 Nut, Clamp A, B SECTION
14 1 223-000-701 Plug, Magnetic CONTENTS
15 1 838-010-009 Housing Machining, Gear
16 1 447-092 Bearing, Cone R
17 1 447-569 Bearing, Cup B, R FIRST
19 1 447-081 Bearing, Cone A, B, R PAGE
20 1 447-557 Bearing, Cup A, B, R
21 1 531-601 Seal, Oil A, B, R PREVIOUS
22 1 400-184 Shaft, Axle B PAGE
23 2 447-080 Bearing, Cone C, R
24 2 447-556 Bearing, Cup C, R
NEXT
25 2 840-059 Fitting, Grease D
PAGE
26 7 5-002-004 Screw
27 1 828-004-080 Plug D
LAST
28 2 5-001-006 Screw D
PAGE
29 10 5-018-006 Washer D
30 1 840-035 Fitting, Grease D
31 1 400-188 Gear, Helical Pinion C
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32 1 410-043/50 Kit, Seal (Not Shown) R
INDEX
33 1 410-043/51 Kit, Shaft (Not Shown) R
34 1 410-043/52 Kit, Drive Gear (Not Shown) R
NUMERIC
35 1 410-043/53 Kit, Steer (Not Shown) R
INDEX
36 AR 838-010-012/006 Shim, 5.12 x 0.006
AR 838-010-012/015 Shim, 5.12 x 0.015
AR 838-010-012/002 Shim, 5.12 x 0.002
SEARCH
AR 838-010-012/003 Shim, 5.12 x 0.003
37 AR 838-010-013/002 Shim, 3.12 x 0.002 (Not Shown)
A= Included in Item 32
B= Included in Item 33 HELP
C= Included in Item 34
D= Included in Item 35
R= Recommended Spare
 List 4-2: Lower Drive Assembly (Sheet 2 of 2)
FIGURE 4-2
ITEM NO.
QTY PART NUMBER DESCRIPTION USED ON CL ICK TO
AR 838-010-013/003 Shim, 3.12 x 0.003 (Not Shown) GO TO:
AR 838-010-013/006 Shim, 3.12 x 0.006 (Not Shown)
AR 838-010-013/015 Shim, 3.12 x 0.015 (Not Shown) CD-ROM
A= Included in Item 32 HOME
B= Included in Item 33
C= Included in Item 34
D= Included in Item 35
R= Recommended Spare BOOK
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 Wheel Assembly, Drive
Figure 4-3: Wheel Assembly, Drive CL ICK TO
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T838-010-002-D
NUMERIC
List 4-3: Wheel Assembly, Drive INDEX
FIGURE 4-3
ITEM NO.
QTY PART NUMBER DESCRIPTION USED ON SEARCH
1 838-010-002/001 Wheel Assembly, Drive C
1 838-010-002/002 Wheel Assembly, Drive A, B
1 1 632-145/010 Tire, Poly C, R
1 632-145/021 Tire, Poly A, B, R HELP
2 1 838-010-001 Hub, Wheel
A= Cold Storage
B= Raised/Level Operator Compartment Floor
C= Standard
R= Recommended Spare
Brake Installation
Figure 4-4: Brake Installation CL ICK TO
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S1006881
 List 4-4: Brake Installation
FIGURE 4-4
QTY PART NUMBER DESCRIPTION USED ON CL ICK TO
ITEM NO.
1 1 1005656 Brake Assembly, Travel (B) (See Figure 4-5.)
GO TO:
2 1 838-004-469 Bracket, Motor Cable
3 2 5-002-001 Screw CD-ROM
4 2 810-131 Ring, Snap HOME
5 8 411-079 Shim (Thickness = 0.010)
6 2 411-078 Shim (Thickness = 0.005)
7 2 411-077 Shim (Thickness = 0.002) BOOK
8 1 5-026-006 Key, Woodruff HOME

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Travel Brake Assembly
Figure 4-5: Travel Brake Assembly CL ICK TO
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9 2 3 11 10

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T1005656-A
 List 4-5: Travel Brake Assembly
FIGURE 4-5
QTY PART NUMBER DESCRIPTION USED ON CL ICK TO
ITEM NO.
1 1 1005656/201 Body, Magnet Subassembly (36 Volt)
GO TO:
2 1 605-021/202 Bushing, Snub
3 2 605-021/203 Connector, Tab CD-ROM
4 10 605-021/204 Spring, Compression R HOME
5 1 605-007/211 Armature and Puck Subassembly R
6 1 605-007/212 Rotor, Friction
7 1 605-007/213 Adaptor and Puck Subassembly R BOOK
8 3 605-021/205 Screw, Shoulder HOME
9 3 605-007/218 Spacer
10 3 605-021/206 Screw BOOK
11 3 870-834/126 Washer, Lock CONTENTS
12 1 605-021/207 Screw, Torque Adjusting
R= Recommended Spare SECTION
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 DC Lower Hoist Brake Actuator
Figure 4-6: DC Lower Hoist Brake Actuator CL ICK TO
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11 7 14 2 CD-ROM
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3 BOOK
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T1012634-A
 List 4-6: DC Lower Hoist Brake Actuator
FIGURE 4-6
QTY PART NUMBER DESCRIPTION USED ON CL ICK TO
ITEM NO.
1 4 710-010 Screw
GO TO:
2 4 710-130 Screw
3 4 750-020 Nut, Lock CD-ROM
4 1 760-006 Nut, Lock HOME
5 5 771-016 Washer, Flat
6 4 772-016 Washer, Lock
7 4 772-023 Washer, Lock BOOK
8 1 5-002-005 Screw HOME
9 1 5-016-004 Nut, Lock
10 4 5-018-005 Washer, Flat BOOK
11 4 5-018-007 Washer, Flat CONTENTS
12 1 136-010-529 Lever Alteration (Not Shown) (See Figure 4-7b.) item 26
13 1 136-010-535 Bracket Weldment SECTION
14 1 136-010-538 Support Weldment CONTENTS
15 136-010-541 Cover Alteration (Not Shown) (See Figure 4-7a.) item 5
16 1 1011402 Solenoid, Brake Actuator, DC Lower (B3)
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 Hoist Brake Assembly
Figure 4-7a: Hoist Brake Assembly CL ICK TO
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6 7 5 61 62 49 12 4 HOME

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T1007698-23-1 SHT 1 OF 3
 Hoist Brake Assembly
Figure 4-7b: Hoist Brake Assembly CL ICK TO
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42 47
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47 CONTENTS

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41 42

26
47 FIRST
67 42 PAGE
38 27
34 32 56 33 55
31 PREVIOUS
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49
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47 NEXT
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54 42 NUMERIC
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T1007698-23-2 SHT 2 OF 3
 Hoist Brake Assembly
Figure 4-7c: Hoist Brake Assembly CL ICK TO
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T1007698-23-3, T1007698-23-4, T1007698-23-5 SHT 3 OF 3

 List 4-7: Hoist Brake Assembly (Sheet 1 of 2)
FIGURE 4-7
QTY PART NUMBER DESCRIPTION USED ON CL ICK TO
ITEM NO.
1007698/23 Brake Assembly, Hoist (B1)
GO TO:
1 1 1007698/25 Plate, End with Pins
2 1 570-305/33 Disc, Stationary CD-ROM
3 2 570-305/25 Disc, Brake HOME
4 1 570-305/26 Plate, Pressure
5 1 570-305/45 Housing, Bearing and Seal Assembly (includes:)
1 570-305/113 Bearing, Sleeve R BOOK
1 1007698/15 Seal, Housing HOME
6 6 570-305/87 Screw
7 6 570-305/31 Washer, Lock BOOK
8 1 570-305/46 Hub and Set Screw CONTENTS
9 2 1007698/47 Bushing, Lead Wire (End Plate)
12 1 1007698/48 Plate Assembly, Support SECTION
13 1 1007698/29 Pinion Assembly, Solenoid Lever CONTENTS
14 1 570-305/49 Spring, Pressure (Green) R
15 1 570-305/35 Solenoid Assembly without Coil
20 1 570-305/34 Coil, 600 Volts FIRST
1 570-305/111 Coil, 480 Volts with Leads PAGE
22 1 1007698/41 Solenoid Link and Bearing
24 1 570-305/39 Screw, Cap PREVIOUS
25 1 570-305/40 Nut PAGE
26 1 570-305/53 Arm Assembly, Lever
27 2 570-305/54 Button, Pressure
NEXT
28 1 570-305/55 Sleeve, Eccentric (Lever Arm)
PAGE
29 6 1007698/85 Screw, Set (Lever Arm)
30 1 1007698/57 Nut, Pressure Spring
LAST
31 1 570-305/58 Stop, Solenoid Lever
PAGE
32 1 570-305/59 Tube, Manual Release Spring
33 1 1007698/60 Pin, Roll (Spring Tube)
34 1 570-305/61 Spring, Release R
ALPHA
35 1 570-305/62 Stop, Wrap Spring
INDEX
36 1 570-305/63 Plate, Holding (Spring Stop)
37 2 570-305/64 Screw, Cap
NUMERIC
38 2 570-305/65 Washer
INDEX
39 1 570-305/66 Support Plate and Bearing Assembly
40 1 570-305/67 Pin, Pivot (Lever Arm)
41 1 570-305/68 Pin, Pivot (Solenoid Lever)
SEARCH
42 5 570-305/42 Ring, Retaining
43 4 570-305/69 Screw, Cap
44 2 570-305/70 Plate, Holding
45 2 570-305/71 Plate, Lock HELP
46 1 1007698/11 Spacer, Pressure Spring
47 7 570-305/73 Bearing, Washer Type
48 2 570-305/74 Bearing, Washer Type
49 1 570-305/75 Rod, Release
R= Recommended Spare
 List 4-7: Hoist Brake Assembly (Sheet 2 of 2)
FIGURE 4-7
ITEM NO.
QTY PART NUMBER DESCRIPTION USED ON CL ICK TO
50 1 570-305/76 Bearing, Ball R GO TO:
51 1 570-305/77 Ring, Retaining
52 1 570-305/78 Stud, Pressure Spring CD-ROM
53 1 570-305/79 Pin, Pivot (Spring Stud) HOME
54 2 570-305/80 Ring, Retaining
55 1 570-305/81 Plate, Instruction
56 2 570-305/82 Screw, Drive BOOK
57 1 570-305/83 Plate, Solenoid Mounting HOME
58 3 570-305/84 Grommet
59 3 570-305/85 Screw, Shoulder BOOK
60 3 570-305/86 Washer CONTENTS
61 6 1007698/87 Screw
62 6 1007698/88 Washer, Conical Spring
SECTION
63 1 570-305/89 Knob, Release
CONTENTS
64 1 570-305/99 Kit, Plunger Bracket R
65 3 570-305/36 Pin, Mounting, Vertical (Not Shown)
66 6 570-305/72 Spring, Red (Not Shown) R FIRST
67 3 570-608/24S Spacer, Spring (Stainless Steel) PAGE
68 1 1007698/42 Kit, Brake Release Interlock R
R= Recommended Spare
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 Auxiliary Brake Assembly
Figure 4-8: Auxiliary Brake Assembly CL ICK TO
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1 5 2 6

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TS53-9 (S/N 00100 thru 00107)
TS14-10 (S/N 00108 and Above) BOOK
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TS53-10 (S/N 00100 thru 00107) BOOK

TS14-9 (S/N 00108 and Above) CONTENTS

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13 14 15 12
T605-003, T136-001-729-A
 List 4-8: Auxiliary Brake Assembly
FIGURE 4-8
QTY PART NUMBER DESCRIPTION USED ON CL ICK TO
ITEM NO.
136-001-729 Brake Alteration A
GO TO:
1030630 Brake Alteration B
1 1 605-003 Brake Assembly, Reach (B4) (includes: items 8 thru 20) CD-ROM
1 605-003 Brake Assembly, Shuttle (B6) (includes: items 8 thru 20) HOME
2 21 in. 610-977/001 Wire, Appliance
3 21 in. 610-977/002 Wire, Appliance
4 12 in. 611-024 Insulator, Tubing A BOOK
3 in. 611-024 Insulator, Tubing B HOME
5 4 in. 611-025 Insulator, Tubing, Shrink A
2 in. 611-025 Insulator, Tubing, Shrink B BOOK
6 2 1-010-260 Terminal CONTENTS
7 2 154-006-070 Decal, Label, Specification Plate
8 1 605-003/01 Hub SECTION
9 1 605-003/02 Shaft CONTENTS
10 2 605-003/03 Disc, Stationary
11 1 605-003/04 Disc, Rotating
12 1 605-003/05 Spring, Compression R FIRST
13 1 605-003/06 Magnet Assembly PAGE
14 1 605-003/07 Coil, Shading
15 1 605-003/08 Spring, Torque R PREVIOUS
16 1 605-003/09 Spring, Return R PAGE
17 1 605-003/10 Bearing, Ball R
18 1 605-003/11 Key
19 1 605-003/12 Cover, Wrap
20 1 605-003/13 Ring, Snap
A= Vehicle Serial Numbers 00100 thru 00107
B= Vehicle Serial Numbers 00108 and Above
R= Recommended Spare

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