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Parts Manual Part No. 40459Rev D4September 2007

(from serial number 0196-101)

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Genie CWP Super Series Part No. 40459

First Edition Fourth Printing

Copyright 1996 by Genie Industries

First Edition: First Printing, July 1996Second Printing, September 1997Third Printing, December 1997Fourth Printing, December 2000

"Genie" and "CWP" are registered trademarks

of Genie Industries in the U.S.A. and many othercountries. "Super Series" is a trademark of GenieIndustries.

Printed on recycled paper

Printed in U.S.A.

ii

This parts manual covers the Genie CWP SuperSeries models introduced in 1996.

Genie Industries has endeavored to deliver thehighest degree of accuracy possible. However,

continuous improvement of our products is a Geniepolicy. Therefore product specifications are subjectto change without notice.

Readers are encouraged to notify Genie of errorsand send in suggestions for improvement. Allcommunications will be carefully considered forfuture printings of this and other manuals. Please

write or fax to the Technical Publications team.

Genie IndustriesPO Box 97030

Redmond, WA 98073-9730, USAFax Number: (425) 867-8890

Technical Publications Department email:[email protected]

http://www.genielift.com

If you have any questions, please call GenieIndustries.

TMTM

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Part No. 40459 Genie CWP Super Series


iii

Table of Contents

Recommended Parts Stocking List .............................................................................................................viHow To Order Parts .................................................................................................................................. viii

Service Parts Fax Order Form .................................................................................................................... ix

Section One Decals and Paint

Figure 1-A Decals and Paint ....................................................................................................... 1 - 2

Figure 1-B Decals and Paint, Models with Utility Platform .......................................................... 1 - 6

Figure 1-C Decals and Paint, Models with Platform Outreach or Fiberglass Platform ............... 1 - 10

Section Two Base Components

Figure 2-A Base Assembly, View 1 ............................................................................................ 2 - 2

Figure 2-B Base Assembly, View 2 (after serial number 0197-490)............................................. 2 - 6

Figure 2-C Base Assembly, View 2 (before serial number 0197-491) ........................................ 2 - 10

Section Three Mast Components

Figure 3-A Number 1 Column and Hydraulic Cylinder Assemblies, All Models............................ 3 - 2

Figure 3-B Number 2 Column Assembly, CWP-8S ..................................................................... 3 - 4

Figure 3-C Number 2 and 3 Column Assemblies, CWP-12S ....................................................... 3 - 6

Figure 3-D Number 2, 3 and 4 Column Assemblies, CWP-15S ................................................... 3 - 8

Figure 3-E Carriage Assembly, CWP-8S .................................................................................. 3 - 10

Figure 3-F Carriage Assembly, CWP-12S ................................................................................ 3 - 12

Figure 3-G Carriage Assembly, CWP-15S ................................................................................ 3 - 14

Figure 3-H Carriage Assembly, Models with Utility Platform ..................................................... 3 - 16

Figure 3-I Lifting Chain Assemblies, CWP-8S ......................................................................... 3 - 18

Figure 3-J Lifting Chain Assemblies, CWP-12S ....................................................................... 3 - 20

Figure 3-K Lifting Chain Assemblies, CWP-15S ....................................................................... 3 - 22

Figure 3-L Sequencing Cables ................................................................................................. 3 - 26

Figure 3-M Mast Covers ........................................................................................................... 3 - 30

Figure 3-N Number 1 Column Attached Parts ........................................................................... 3 - 32

Section Four Power Groups

Figure 4-A Power Unit and Ground Controls Installation ............................................................. 4 - 2

Figure 4-B Hydraulic Power Unit, DC .......................................................................................... 4 - 4

Figure 4-C Hydraulic Power Unit, AC .......................................................................................... 4 - 6

Figure 4-D Ground Controls, DC Powered Models ...................................................................... 4 - 8

Figure 4-E Ground Controls, AC Powered Models .................................................................... 4 - 12

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iv

TABLE OF CONTENTS

Section Four Power Groups, continued

Figure 4-F Control Cable Assembly, CWP-8S and CWP-15S Models withoutPlatform Outreach and CWP-15S Models Equipped with Utility Platform

(Rev A, September 2007) ........................................................................................ 4 - 16

Figure 4-G Control Cable Assembly, CWP-12S Modelswith and without Platform Outreach (Rev A, September 2007) ................................ 4 - 18

Figure 4-H Control Cable Assembly, CWP-8S and CWP-15S Models withPlatform Outreach (Rev A, September 2007) .......................................................... 4 - 20

Figure 4-I Battery and Battery Charger Installation .................................................................. 4 - 22

Figure 4-J Battery Charger, ANSI Models ................................................................................ 4 - 24

Figure 4-K Battery Charger, Worldwide Models......................................................................... 4 - 26

Figure 4-L Battery Charger, CE Models.................................................................................... 4 - 28

Figure 4-M Hydraulic Hoses and Fittings, Models without

Power Wheel Assist Option ..................................................................................... 4 - 30

Figure 4-N Hydraulic Hoses and Fittings, Models withPower Wheel Assist Option ..................................................................................... 4 - 32

Section Five Platform Components

Figure 5-A Aluminum Platform Assembly with Sliding Mid-rail Entry .......................................... 5 - 2

Figure 5-B Aluminum Platform Assembly with Gated Entry(after serial number 0199-827) ................................................................................... 5 - 4

Figure 5-C Aluminum Platform Assembly with Gated Entry

(before serial number 0199-828) ................................................................................ 5 - 8

Figure 5-D Aluminum Extra Large Platform Assembly, Front and Side Entry

(after serial number 0199-827) ................................................................................. 5 - 12

Figure 5-E Aluminum Extra Large Platform Assembly, Front and Side Entry(before serial number 0199-828) .............................................................................. 5 - 14

Figure 5-F Fiberglass Platform Assembly ................................................................................ 5 - 16

Figure 5-G Utility Platform Assembly, CWP-12S ...................................................................... 5 - 18

Figure 5-H Utility Platform Assembly, CWP-15S ...................................................................... 5 - 20

Figure 5-I Utility Platform Assembly with Gated Entry (after serial number 0199-827) ............. 5 - 22

Figure 5-J Utility Platform Assembly with Gated Entry (before serial number 0199-828) .......... 5 - 24

Figure 5-K Platform Controls, Models without Platform Outreach ............................................. 5 - 26

Figure 5-L Platform Controls, Models with Platform Outreach .................................................. 5 - 28

Figure 5-M Platform Controls, Models with Utility Platform ....................................................... 5 - 30

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Section Six Accessories

Figure 6-A Platform Outreach, View 1 ........................................................................................ 6 - 2

Figure 6-B Platform Outreach, View 2 ........................................................................................ 6 - 4

Figure 6-C Power Wheel Assist Option (after serial number 0197-568) ....................................... 6 - 8

Figure 6-D Power Wheel Assist Option (from serial number 0197-491 to

serial number 0197-568) .......................................................................................... 6 - 12Figure 6-E Power Wheel Assist Option (before serial number 0197-491) ................................... 6 - 16

Figure 6-F Power Wheel Assist Manifold Assembly (after serial number 0197-568) .................. 6 - 20

Figure 6-G Power Wheel Assist Manifold Assembly (from serial number 0197-403 toserial number 0197-569) .......................................................................................... 6 - 22

Figure 6-H Power Wheel Assist Manifold Assembly (before serial number 0197-403) ............... 6 - 24

Figure 6-I Power Wheel Assist Battery Installation .................................................................. 6 - 26

Figure 6-J Flashing Beacon and Descent Alarm ...................................................................... 6 - 28

Figure 6-K Platform Accessories .............................................................................................. 6 - 30

Numeric Index ................................................................................................................................. 7 - 1

TABLE OF CONTENTS

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Recommended Parts Stocking List

Group A parts are required to perform maintenanceprocedures as outlined in the Genie CWP Super Series

Service Manual.

Group Bparts solve 75% of machine troubleshooting

issues.

Group C parts affect the safe operation of the machine.

Group D parts are common replacement items.

How To Use This ListThe service parts listed below have been divided into

four priority groups: A, B, C and D. Use the group code

and quantities listed to plan enough inventory to

support your fleet. The quantities shown are

recommended for 1 to 5 machines. Many of these

service parts are common to other Genie products.

Group A

Part No. Description Qty.

38159 Breather Cap........................................................... 2

38018 Battery - Size AA, 1.5V ......................................... 16

90337 Boe-Lube Silicone Wax .......................................... 1

Group B


35733 Pulley - Sequencing ................................................ 5

40549 Sequencing Cable Assembly ................................. 6

69238 Sequencing Cable Assembly, Carriage(after serial number 0199-845) .............................. 2

40548 Sequencing Cable Assembly, Carriage(before serial number 0199-844) ........................... 2

38152 Brush Kit, DC Motor................................................ 2

38153 Solenoid - Motor Starter ......................................... 2

38156 Relief Valve Kit ........................................................ 1

38155 Check Valve Kit ...................................................... 1

36061 Push Button - Black with Seal ................................ 1

33321 Push Button with Base - Red Mushroom Head..... 1

33320 Key Switch with Base (includes 1 pair of keys) .... 121982 Key - Key Switch .................................................... 2

45081 Contact - N.O., Ground Controls ........................... 4

29732 Contact - N.C., Ground Controls ........................... 2

35039 Fuse, 5A .................................................................. 2

38020 Circuit Breaker, 15A, 110V AC Models.................. 2

38021 Circuit Breaker, 8A, 220V AC Models.................... 2

40110 Seal Kit - Hydraulic Cylinder................................... 2

23394 Sheave - Control Cable .......................................... 5

65804 Circuit Breaker, 4A (after 11/30/98) ....................... 2

33551 Fuse, 2A, 250V (before 12/1/98) ........................... 2

38175 Circuit Breaker, 30A ............................................... 1

23380 Switch - Platform Controls...................................... 1

35613 Button - Red, Stop .................................................. 1

36061 Button - Black, Push ............................................... 1

35614 Button - Black, Selector .......................................... 1

11104 Contact - N.O., Platform ......................................... 4

11105 Contact - N.C., Platform ......................................... 2

33584 Relay - Motor Contactor, AC models..................... 1

44997 Valve - Solenoid, 12V DC, N.O., 2 position2 way (after serial number 0197-402) ................... 1

27762 Valve - Solenoid, 12V DC, 2 position 3 way(before serial number 0197-403) ........................... 2

41209 Seal Kit, Power Wheel Assist Motor ....................... 1

Group B, continued


52912 Valve - Solenoid, 12V DC, 3 position, 4 way(after serial number 0197-568) .............................. 1

39346 Valve - Solenoid, 12V, 3 position, 4 way

(from serial number 0197-402 to 0197-569) ......... 1Group C


6714 Level - Bubble ......................................................... 5

38447 Idler Wheel - with Bearings ..................................... 4

35715 Idler Wheel - Small Chain ....................................... 6

Ref. Operators Manual .................................................. 5

38314 Mast Cover, No. 1 and 3 Column .......................... 2

35786 Mast Cover, No. 2 and 4 Column .......................... 2

38315 Carriage Cover ....................................................... 2

38162 Valve - N.O. Solenoid ............................................. 2

40720 Printed Circuit Board ............................................... 1

40571 Valve - N.C. Solenoid, 10V DC............................... 2

35725 Valve - Flow Control, 1 GPM.................................. 1

35726 Valve - Check ......................................................... 1

38068 Knob - Manual Lowering Valve............................... 2

38238 Cable Release Assembly ....................................... 2

37761 Switch - Footpad ..................................................... 6

38576 Switch - Rocker, DPDT Momentary ...................... 2

48614 Switch - Rocker, 4PDT (power wheel assistmodels after serial number 0197-568) ................... 2

38609 Cam Follower.......................................................... 6

44338 Switch - Rocker, Sealed, DPDT Momentary(power wheel assist models from serialnumber 0197-490 to 0197-569) ............................. 2

Group D


38011 Pad - Adjustable Glide ............................................ 8

38026 Roller - Machined ................................................... 8

35706 Bolt - Roller............................................................ 10

35709 Block - Slide Upper, Nylatron ................................. 4

35710 Block - Slide Lower, Nylatron ................................. 4

38005 Block - Slide, Carriage ............................................ 1

11890 Button - Glide .......................................................... 5

35705 Bolt - Rocker ........................................................... 2

38197 Cover - Motor with Decals ..................................... 1

31199 Footpad Cover - Nylon ......................................... 10

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viii

How To Order Parts

Machine Information

Model

Serial Number

Date of Purchase

Authorized Genie Distributor

Phone Number

Manuals

Genie Industries offers the following support

documents for these models:

Title Part No.

Genie CWP Super Series

Operator's Manual, Second Edition .............. 48646

Genie CWP Super Series

Service Manual, First Edition ....................... 40460

Manual of Responsibilities

ANSI / SIA A92.3-1990 ............................... 31587

*Language specific Operator's Manuals and Decalsmay be available for your country.

Please add the appropriate language suffix codeafter the part number when ordering replacement

Operator's Manuals.

How To Order Service PartsPlease be prepared with the following information

when ordering replacement parts for your Genieproduct:

Machine model number

Machine serial number

Genie part number

Part description and quantity

Purchase order number

"Ship to" address

Desired method of shipmentName and telephone number of the authorized

Genie Distributor in your area

Use the Service Parts Fax Order Form on the nextpage and fax your order to our Parts Department.

If you don't know the name of your authorizeddistributor, or if your area is not currently serviced

by an authorized distributor, please call GenieIndustries.

Genie North America

Telephone (425)556-6551

Toll Free (877)367-5606 in U.S.A. and Canada

Fax (425)556-8659

Genie UK

Parts Telephone (44) (0) 1636 614777

Parts Fax (44) (0) 1636 611091

Genie Australia

Parts Telephone (617) 03375 1660

Parts Fax (617) 03375 1002

Genie France

Parts Telephone (33) (0) 237 260 909

Parts Fax (33) (0) 237 315 010

Genie Germany

Parts Telephone (49) 04202 885223

Parts Fax (49) 04202 885225

CS, Chinese SimplifiedCT, Chinese Traditional

DA, DanishDU, Dutch

FR, FrenchGR, GermanIT, Italian

JA, JapaneseKO, Korean

NW, NorwegianPB, Portuguse Brazilian

SP, SpanishSW, Swedish

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c

utoffhereandmakecopies

Part Number Description Quantity Price

All backordered parts will be shipped when available via the same ship method as the original order unlessnoted below:

Ship complete order only - no back orders

Ship all available parts and contact customer on disposition of back ordered parts

Other (please specify)

Please fill out completely

Date _________________________________ Account Number _______________________________

Your Name ______________________________ Your Fax Number _____________________________

_________________________________ Your Phone Number ____________________________

Bill To _________________________________ Ship To ___________________________________

_________________________________ ___________________________________

_________________________________ ___________________________________

_________________________________ ___________________________________

Purchase Order Number ____________________ Ship Via ___________________________________

Model(s) ______________________________________________________ Serial No.(s) _________________

Optional Equipment __________________________________________________________________________

FORGENIEINDUSTRIESUSEONLY

Order Number ______________ Origin Code ________________ Comments _________________________

Date Scheduled ____________ Ship Condition ______________ __________________________________

Order Total ________________ Terms Code________________ __________________________________

Service Parts Order FormFax to (425) 556-8659

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x

Notes

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Part No. 40459 Genie CWP Super Series 1 - 1

Section 1 Decals and PaintFirst Edition Fourth Printing

Section One

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1 - 2 Genie CWP Super Series Part No. 40459

Section 1 Decals and Paint First Edition Fourth Printing

Figure 1-ADecals and Paint

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Language specific operator's manuals and decals may be available for your country. When orderingreplacement decals, please add the appropriate language suffix code after the part number(refer to page viiifor suffix codes).

Index Part No. Description Quantity This Figure

41308 Decal Kit - Safety/Instructional (includes index numbers 1 through 8,

10, 11, 12, 14, 16 through 19, 22 through 27, 30 and 31) ........................................... 41309 Decal Kit - Platform (includes index numbers 2, 9, 26 and 28) ...................................

32150 Paint - Genie Blue, 1 gallon (3.78 liters) ..................................................................... 1484 Paint - Genie Blue, 12 ounces (340.5 grams) Aerosol ................................................

32151 Paint - Genie Grey, 1 gallon (3.78 liters) .................................................................... 1268 Paint - Genie Grey, 12 ounces (340.5 grams) Aerosol ...............................................

1 31070 Danger - Tip-over Hazard (moving machine) ............................................................... 1

2 31071 Warning - Failure to Read/Obey Manual ...................................................................... 1

3 38149 Label - ANSI/Patents .................................................................................................. 1

4 37161 Label - Interlock Display ............................................................................................. 1

5 31068 Danger - Battery Safety .............................................................................................. 1

6 38142 Label - Circuit Breaker ................................................................................................ 1

7 27865 Label - Bubble Level ................................................................................................... 1

8 37141 Notice - Manual Lowering Knob ................................................................................... 1

9 52996 Genie Logo ................................................................................................................. 2

10 31245 Warning - Collision Hazard (runaway machine) ............................................................ 1

11 27857 Caution - Pipe Plug ..................................................................................................... 1

12 28157 Notice - Dexron ATF ................................................................................................... 1

13 33550 Safety Tape - Black / Yellow Striped (roll of 54 feet) (16.5 meters) (CE only).............

14 27863 Caution - Component Damage Hazard ........................................................................ 2

15 62047 Label, CWP-8S ........................................................................................................... 2

62048 Label, CWP-12S ........................................................................................................ 62049 Label, CWP-15S ........................................................................................................

16 38118 Danger/Notice - Safety and Setup, ANSI (Power Wheel Assist models) ..................... 1 48645 Danger/Notice - PWA Safety/Setup (CE models with Power Wheel Assist) ...............

17 31075 Caution - Crushing Hazard .......................................................................................... 2

18 37145 Label - Manual Lowering Valve.................................................................................... 1

This parts list continues. Please turn the page.

FIGURE 1-A

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FIGURE 1-A

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19 40530 Warning - Bodily Injury Hazard .................................................................................... 2

20 38128 Plate - Serial Number .................................................................................................. 1

21 48644 Label - Function Enable Lever (Power Wheel Assist models) ...................................... 1

22 38117 Label - Directional Indication (Power Wheel Assist models) ........................................ 1

23 31077 Caution - Collision Hazard ........................................................................................... 1

24 31076 Caution, 8A Maximum, 115V AC ................................................................................ 1

25 37155 Notice - Operating Instructions.................................................................................... 1

26 37162 Danger - General Safety ............................................................................................. 1

27 44999 Label - Control Activate (CE models) .......................................................................... 1

28 46212 Notice - Maximum Side Force (CE models) ................................................................ 1

29 37144 Notice - Maximum Capacity, 350 lbs (159 kg) (models without Platform Outreach) ..... 1 37143 Notice - Maximum Capacity, 300 lbs (136 kg) (models with Platform Outreach) .........

30 27868 Danger - Relief Valve .................................................................................................. 1

31 38122 Label - Operators Manual Storage Container .............................................................. 1

FIGURE 1-A

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Figure 1-BDecals and Paint, Models with Utility Platform

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FIGURE 1-B

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FIGURE 1-B



21 37141 Notice - Manual Lowering Knob ................................................................................... 1

22 28157 Notice - Dexron ATF ................................................................................................... 1

23 27857 Caution - Pipe Plug ..................................................................................................... 1

24 62048 Label, CWP-12S ......................................................................................................... 2 62049 Label, CWP-15S ........................................................................................................

25 31075 Caution - Crushing Hazard .......................................................................................... 2

26 37145 Label - Manual Lowering Valve.................................................................................... 1

27 38128 Serial Number Plate .................................................................................................... 1

28 38118 Danger/Notice - Safety and Setup, ANSI (models with Power Wheel Assist) .............. 1 48645 Danger/Notice - Safety and Setup, CE (models with Power Wheel Assist).................

29 48644 Label - Function Enable Lever (models with Power Wheel Assist)............................... 1

30 38117 Label - Directional Indication (models with Power Wheel Assist) ................................. 1

31 38142 Label - Circuit Breaker ................................................................................................ 1

32 31077 Caution - Collision Hazard ........................................................................................... 1

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Figure 1-CDecals and Paint, Models with Platform Outreach or FiberglassPlatform

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41319 Decal Kit - Fiberglass Platform

(includes index numbers 1, 2, 4, 5 and 8) ................................................................... 41320 Decal Kit - Platform Outreach (includes index numbers 5, 6, 7, 9, 10 and 11) ............

32150 Paint - Genie Blue, 1 gallon (3.78 liters) ..................................................................... 1484 Paint - Genie Blue, 12 ounces (340.5 grams) Aerosol ................................................

32151 Paint - Genie Grey, 1 gallon (3.78 liters) .................................................................... 1268 Paint - Genie Grey, 12 ounces (340.5 grams) Aerosol ...............................................

1 52996 Genie Logo ................................................................................................................. 1

2 37162 Danger - General Safety ............................................................................................. 1

3 46212 Notice - Maximum Side Force (CE models) ................................................................ 1

4 31071 Warning - Failure to Read/Obey Manual ...................................................................... 1

5 31076 Caution, 8A Maximum, 115V AC ................................................................................ 2

6 37143 Notice - Maximum Capacity, 300 lbs (136 kg) ............................................................. 1

7 44999 Label - Control Activate (CE models) .......................................................................... 1

8 38122 Label - Operator's Manual Storage Container .............................................................. 1

9 38116 Danger - Outreach Option Safety & Instructions ......................................................... 1

10 43657 Danger - Tip-over Hazard ............................................................................................ 1

11 37155 Notice - Operating Instructions.................................................................................... 1

FIGURE 1-C

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Notes

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Section 2 Base ComponentsFirst Edition Fourth Printing

Section Two

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Section 2 Base Components First Edition Fourth Printing

Figure 2-ABase Assembly, View 1

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FIGURE 2-A


1 46027-S Bracket - Terminal Strip (after serial number 0197-491) ............................................... 1

2 38978 Tape - Double Backed Foam (after serial number 0197-491) ......... 4.5 inches (11.4 cm)

3 13098 Strip - Terminal, 10 Pole (after serial number 0197-491) .............................................. 1

4 37761 Switch - Interlock ........................................................................................................ 3

5 57520-S Bracket - Switch Mount (after serial number 0197-491) ............................................... 1

6 6090 Screw - HHC, 1/4-20 x 0.75 inch, GR 5 ...................................................................... 8

7 6356 Washer - Lock, 1/4inch ............................................................................................... 8

8 6091 Nut - Nylock, 1/4-20 ................................................................................................... 6

9 37872 Mast Brace - Right Side, Front .................................................................................... 1

10 6019 Screw - HHC, 3/8-16 x 1.25 inches, GR 5 .................................................................. 4

11 6097 Washer - Flat, 3/8inch (0.438 x 1 x 0.083 inch) (1.11 x 2.54 x 0.21 cm) ..................... 4

12 4828 Nut - Nylock, 3/8-16 ................................................................................................... 4

13 7265 Rivet - Steel, 0.375 x 0.25 inch ................................................................................... 2

14 38071 Mast Brace - Right Side, Rear .................................................................................... 1

15 6889 Nut - Low Profile Nylock,1

/4

-20 ................................................................................. 416 43136 Screw - PHM, 1/4-20 x 0.63 inch, GR 2...................................................................... 4

17 41375-S Door - Battery Box ...................................................................................................... 2

18 37930-S Hinge - Battery Box Door ............................................................................................ 2

19 33674 Snap Pin - Battery Door .............................................................................................. 2

20 37430-S Bracket - Foot Pad Switch .......................................................................................... 2

21 38623 Spring - Post Sensor ................................................................................................... 2

22 37429 Holder - Spring, Post Sensor....................................................................................... 2


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FIGURE 2-A

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FIGURE 2-A


23 29970 Weldment - Foot Pad .................................................................................................. 2

24 8514 Screw - FHS, 1/4-20 x 0.75 inch (after serial number 0197-558) ................................. 4

23903 Screw - FHS, 1/4-20 x 0.5 inch (before serial number 0197-559) ...............................

25 31199 Foot Pad - Nylon ......................................................................................................... 2

26 14815 Pin - Roll, SST, 0.25 x 2.25 inches ............................................................................. 2

27 41307 Base Weldment with Decals (decals are listed in Section One)................................... 1 48333 Base Weldment with Decals, CWP-15S (CE Models)

(decals are listed in Section One) ..............................................................................

28 38070 Mast Brace - Left Side, Rear....................................................................................... 1

29 37873 Mast Brace - Left Side, Front ...................................................................................... 1

30 10006 Screw - HHC, 3/4-10 x 5 inches, GR 5 ....................................................................... 2


32 10258 Nut - Nylock, 3/4-10 ................................................................................................... 2

33 69596 Wheel - Offset Hub, 10 x 2.5 x 0.75 inch (includes bushing and washers) .................. 2

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Figure 2-BBase Assembly, View 2 (after serial number 0197-490)

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FIGURE 2-B


1 38979 Screw - PHM, 1/4-20 x 0.5 inch, GR 2........................................................................ 6

2 6091 Nut - Nylock, 1/4-20 ................................................................................................... 2

3 38456-S Bracket - Cable Wrap .................................................................................................. 1

4 41022 Cover - Latch Box (after serial number 0197-402) ....................................................... 1 Ref. Cover - Latch Box (before serial number 0197-403, refer to Figure 2-C)....................... 1


6 6356 Washer - Lock, 1/4inch ............................................................................................... 8

7 38238 Cable - Release (includes mounting fasteners) ........................................................... 1

8 37456P Plate - Handle Latch ................................................................................................... 1

9 57459 Spring Guide (after serial number 0100-988) ............................................................... 1 40192 Spring Guide (before serial number 0100-989) ............................................................

10 57189 Spring - Handle (after serial number 0100-988) ............................................................ 1

38610 Spring - Handle (before serial number 0100-989) ........................................................

11 40032 Spring - Return ............................................................................................................ 1

12 6035 Washer - Flat, 5/8inch (0.688 x 1.75 x 0.134 inch) (1.75 x 4.45 x 0.34 cm) ................ 1

13 37455-S Handle Latch............................................................................................................... 1

14 37751 Bushing - Bronze, 1 x 1.375 x 0.75 inch (25.4 x 34.9 x 19 mm) .................................. 4

15 44331 Weldment - Steering Shaft Housing ............................................................................ 1

16 44327 Grip - Handle............................................................................................................... 2

17 35464 Tube - Handle, 0.75 x 0.125 x 4.18 inches .................................................................. 2

18 49009-S Hand Guard (after serial number 0199-761)

69281 Hand Guard (from serial number 0197-568 to 0199-762) 44324-S Hand Guard (before serial number 0197-569) .............................................................

19 12461 Screw - HHC, 1/2-13 x 5 inches ................................................................................. 2

20 6086 Nut - Low Profile Nylock, 1/2-13 ................................................................................. 2

21 6878 Screw - Carriage, 1/4-20 x 0.75 inch ........................................................................... 1


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FIGURE 2-B

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FIGURE 2-B


22 49033-S Cover - Steering Handle (after serial number 0199-761)............................................... 1 69283 Cover -Steering Handle (after serial number 0197-569 and

before serial number 0199-762) ..................................................................................

44339-S Cover - Steering Handle (after serial number 0197-517 andbefore serial number 0197-569) ................................................................................... 1

69282 Kit - Steering Handle Update (after serial number 0197-490 andbefore serial number 0197-518) ..................................................................................

23 46681-S Bracket - Cover Mount (after serial number 0197-567) ................................................ 1 46018-S Bracket - Cover Mount (before serial number 0197-568) .............................................. 1

24 11968 Screw - BHHS, 1/4-20 x 1 .......................................................................................... 2


26 44320-S Weldment - Steering Handle (after serial number 0199-761) ........................................ 1

69280 Weldment - Steering Handle (after serial number 0197-569 andbefore serial number 0199-762 ...................................................................................

69279 Weldment - Steering Handle (after serial number 0197-517 andbefore serial number 0197-569) ..................................................................................

69278 Weldment - Steering Handle (after serial number 0197-490 andbefore serial number 0197-518) ..................................................................................

27 38609 Cam Follower .............................................................................................................. 2

28 44330 Block - Cam Follower Mount (3.0 x 2.0 x 1.5 inches) (7.62 x 5.08 x 3.81 cm) ............. 1

29 48512 Washer - Thrust, 0.765 x 1.75 x 0.125 inch (1.94 x 4.45 x 0.32 cm) ........................... 2

30 41007 Screw - Set, Patch, 3/8-16 x 0.75 inch ....................................................................... 2

31 48514 Bushing - Flange, 0.5 x 0.625 x 0.313 inch ................................................................. 2

32 43799 Plate - Wheel Pivot ..................................................................................................... 2

33 57787 Wheel, 8 x 2 inches (20.3 x 5.1 cm)............................................................................ 1

34 6198 Nut - Nylock, 1/2-13 ................................................................................................... 1

35 13775 Washer - Flat, 1 inch (1.062 x 2 x 0.134 inch) (2.7 x 5.08 x 0.34 cm) ......................... 2


37 10107 Screw - HHC, 5/16-18 x 0.75 inch ............................................................................... 6

38 6886 Washer - Lock, 5/16inch ............................................................................................. 6

39 44291 Weldment - Wheel Pivot ............................................................................................. 1

40 11335 Screw - SHS, 3/8-16x 0.50 inch ................................................................................ 2

41 37038 Washer - Shim, 0.51 x 0.8 x 0.125 inch (1.3 x 2.03 x 0.32 cm) ................................... 4

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Figure 2-CBase Assembly, View 2 (before serial number 0197-491)

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FIGURE 2-C


1 37466-S Cover - Drive Manifold (before serial number 0197-403) .............................................. 1 Ref. Cover - Drive Manifold (after serial number 0197-402) (refer to Figure 2-B).................

2 38979 Screw - PHM, 1/4-20 x 0.5 inch, GR 2........................................................................ 3

3 38456-S Bracket - Cable Wrap .................................................................................................. 1

4 38501-S Cover - Switch ............................................................................................................ 1

5 37761 Switch - Interlock (includes mounting fastener) ........................................................... 1


7 6356 Washer - Lock, 1/4inch ............................................................................................... 6

8 38610 Spring - Handle ........................................................................................................... 1

9 40192 Spring Guide ............................................................................................................... 1

10 38238 Cable - Release (includes mounting fasteners) ........................................................... 1

11 37456P-S Plate - Handle Latch ................................................................................................... 1

12 40032 Spring - Return ............................................................................................................ 1

13 37455P-S Handle Latch............................................................................................................... 1

14 37751 Bushing - Bronze, 1 x 1.375 x 0.75 inch (25.4 x 34.9 x 19 mm) .................................. 4

15 37463 Weldment - Steering Shaft Housing ............................................................................ 1

16 41007 Screw - Set, Patch, 3/8-16 x 0.75 inch ....................................................................... 2

17 38514 Block - Cam Follower Mount ....................................................................................... 1

18 40391-S Cover - Steering Handle .............................................................................................. 1

19 21018 Screw - PHM, 10-24 x 0.38 inch ................................................................................. 4

20 37867 Weldment - Steer Handle ............................................................................................ 1

21 38635 Screw - SHS, 5/16-18 x 0.63 inch ............................................................................... 2

22 6002 Nut - Low Profile Nylock, 5/16-18 ................................................................................ 2

23 38609 Cam Follower .............................................................................................................. 2

24 40021 Washer - Shim, 0.39 x 0.625 x 0.075 inch (0.99 x 1.59 x 0.19 cm) ............................. 625 40022 Bushing - Flange, 0.375 x 0.5 inch .............................................................................. 2


27 6198 Nut - Nylock, 1/2-13 ................................................................................................... 1

28 57787 Wheel, 8 x 2 inches (20.3 x 5.1 cm)............................................................................ 1

29 37865 Weldment - Wheel Pivot ............................................................................................. 1

30 41205P Bracket - Switch Mount............................................................................................... 1

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Notes

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Section 3 Mast ComponentsFirst Edition Fourth Printing

Section Three

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Section 3 Mast Components First Edition Fourth Printing

Figure 3-ANumber 1 Column and Hydraulic Cylinder Assemblies, All Models

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1 38013 Nut - Lock, Adjustable Glide Pad ................................................................................ 4

2 40946 Bolt - Adjustable Glide Pad ......................................................................................... 4

3 38011 Pad - Adjustable Glide ................................................................................................ 4

4 6022 Nut - Hex, 3/8-16 ........................................................................................................ 4



7 6052 Washer - Shim, 0.5 x 0.875 x 0.063 inch (1.27 x 2.22 x 0.16 cm) ............................... 2

8 38026 Roller - Machined ........................................................................................................ 2

9 35706 Bolt - Roller ................................................................................................................. 2

10 35709 Block - Slide, Upper, Nylatron ..................................................................................... 1

11 35736 Hydraulic Cylinder ....................................................................................................... 1 40110 Seal Kit - Hydraulic Cylinder ......................................................................................

12 35725 Valve - Flow Control, 1 gpm ........................................................................................ 1

13 35726 Valve - Check ............................................................................................................. 1

14 48905 Fitting - Connector, 4 ORFS x 4 SAE (SAE 520120) ................................................... 2

15 40571 Valve - N.C. Solenoid (includes index numbers 16, 17 and 18) ................................... 1

16 40417 Coil - 10V DC .............................................................................................................. 1

17 19792 Nut - Solenoid Valve ................................................................................................... 1

18 38068 Knob - Manual Lowering Valve .................................................................................... 1

19 35727-S Plate - Cylinder Mount ................................................................................................ 4


21 35728 Screw - HHC, 5/8-11 x 7.5 inches, GR 5 .................................................................... 1

22 6086 Nut - Low Profile Nylock,1

/2-13 ................................................................................. 3


24 35749 Column - Number 1 ..................................................................................................... 1

FIGURE 3-A

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Figure 3-BNumber 2 Column Assembly, CWP-8S

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1 41559 Column - Number 2 ..................................................................................................... 1

2 45425 Screw - FHS, 3/8-16 x 0.75 inch ................................................................................. 2

3 35707 Axle - Idler Wheel ....................................................................................................... 1

4 38709 Shim, 0.825 x 1.375 x 0.05 inch (21 x 35 x 1.3 mm)................................................... 4

5 38447 Idler Wheel .................................................................................................................. 2

6 35711 Spacer, 0.82 x 1 x 0.840 inch (20.8 x 25.4 x 21.3 mm) ............................................... 1

7 35722 Spacer, 0.82 x 1 x 0.310 inch (20.8 x 25.4 x 7.9 mm)................................................. 1

8 35706 Bolt - Roller ................................................................................................................. 2

9 38026 Roller - Machined ........................................................................................................ 2




13 35710 Block - Slide, Lower, Nylatron ..................................................................................... 1

FIGURE 3-B

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Figure 3-CNumber 2 and 3 Column Assemblies, CWP-12S

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Figure 3-DNumber 2, 3 and 4 Column Assemblies, CWP-15S

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1 45425 Screw - FHS, 3/8-16 x 0.75 inch ................................................................................. 6

2 35707 Axle - Idler Wheel ....................................................................................................... 3

3 38709 Washer - Shim, 0.938 x 1.37 x 0.048 inch (2.38 x 3.48 x 0.12 cm) ............................. 7

4 38447 Idler Wheel .................................................................................................................. 4

5 35709 Block - Slide, Upper, Nylatron ..................................................................................... 2


7 6097 Washer - Flat, 3/8inch (0.438 x 1 x 0.083 inch) (1.11 x 2.54 x 0.21 cm) ....................18

8 7713 Nut - Low Profile Nylock, 3/8-16 ................................................................................10

9 35706 Bolt - Roller................................................................................................................10

10 38026 Roller - Machined .......................................................................................................10

11 6052 Washer - Shim, 0.5 x 0.875 x 0.063 inch (1.27 x 2.22 x 0.16 cm) ..............................10

12 35722 Spacer, 0.82 x 1 x 0.310 inch (20.8 x 25.4 x 7.9 mm)................................................. 2

13 35715 Idler Wheel - Small Chain............................................................................................ 2


15 37686 Spacer, 0.825 x 1.375 x 1.4 inches (2.09 x 3.49 x 3.6 cm) ......................................... 116 35752 Column - Number 4 ..................................................................................................... 1

17 35710 Block - Slide, Lower, Nylatron ..................................................................................... 3

18 35751 Column - Number 3 ..................................................................................................... 1

19 35750 Column - Number 2 ..................................................................................................... 1

20 38011 Pad - Adjustable Glide ................................................................................................ 8

21 38012 Bolt - Adjustable Glide Pad ......................................................................................... 8

22 38013 Nut - Lock, Adjustable Glide Pad ................................................................................ 8

23 6022 Nut - Hex, 3/8-16 ........................................................................................................ 8

FIGURE 3-D

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Figure 3-ECarriage Assembly, CWP-8S

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Figure 3-FCarriage Assembly, CWP-12S

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1 40267 Manual Storage Container ........................................................................................... 1 2223 Cable Assembly - Manual Storage Container .............................................................

2 40518 Carriage Assembly with Decals (models without Platform Outreach)(includes index numbers 1, 3, 4 and 13 through 16)(decals are listed in Section One) ............................................................................... 1

41322 Carriage Assembly with Decals (models with Platform Outreach)(includes index numbers 13 through 16)


3 6271 Rivet - Steel, 0.25 x 0.25 inch (6.35 x 6.35 mm) ......................................................... 2

4 6638 Washer - Flat, 1/4inch (0.312 x 0.734 x 0.065 inch) (0.79 x 1.86 x 0.17 cm) .............. 2

5 38988 Spacer - Platform (models without Platform Outreach) ................................................ 1


7 4828 Nut - Nylock, 3/8-16 ................................................................................................... 6



10 35706 Bolt - Roller ................................................................................................................. 4

11 38026 Roller - Machined ........................................................................................................ 4


13 57195 Guide - Carriage Slider ................................................................................................ 2

14 7266 Rivet - Steel, 0.25 x 0.75 inch (0.63 x 1.9 cm) ............................................................ 8

15 8920 Rivet - Aluminum, 0.156 x 0.375 inch ......................................................................... 4

16 38005 Block - Slide, Carriage ................................................................................................ 1

FIGURE 3-F

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Figure 3-GCarriage Assembly, CWP-15S

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1 40267 Manual Storage Container ........................................................................................... 1 2223 Cable Assembly - Manual Storage Container .............................................................. 1

2 40517 Carriage Assembly with Decals (models without Platform Outreach)(includes index numbers 1, 3, 4 and 10 through 13)(decals are listed in Section One) ............................................................................... 1

41321 Carriage Assembly with Decals (models with Platform Outreach)(includes index numbers 10 through 13)



4 6638 Washer - Flat,1

/4inch (0.312 x 0.734 x 0.065 inch) (0.79 x 1.86 x 0.17 cm) .............. 2



7 35706 Bolt - Roller ................................................................................................................. 4

8 38026 Roller - Machined ........................................................................................................ 4

9 6052 Washer - Shim, 0.5 x 0.875 x 0.063 inch .................................................................... 4





FIGURE 3-G

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Figure 3-HCarriage Assembly, Models with Utility Platform

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1 14182 Screw - FHS, 1/4-20 x 1 inch ..................................................................................... 4

2 6091 Nut - Nylock, 1/4-20 ................................................................................................... 4

3 38014 Shim - Carriage ........................................................................................................... 2

4 41295 Carriage Assembly with Decals, CWP-12 (decals are listed in Section One)(includes index numbers 18 through 21) ...................................................................... 1

41296 Carriage Assembly with Decals, CWP-15 (decals are listed in Section One)(includes index numbers 18 through 21) .....................................................................

5 41262 Plate - Platform Reinforcement with Decals (decals are listed in Section One) ........... 1



8 40267 Manual Storage Container ........................................................................................... 1 2223 Cable Assembly - Manual Storage Container .............................................................

9 69495 Platform Control Mount Assembly with Decals (includes index numbers 6, 7 and 8)(decals are listed in Section One) ............................................................................... 1


11 4828 Nut - Nylock, 3/8-16 ................................................................................................... 4

12 6175 Screw - HHC, 3/8-16 x 1 inch, GR 5 ........................................................................... 2



15 35706 Bolt - Roller ................................................................................................................. 4

16 38026 Roller - Machined ........................................................................................................ 4






FIGURE 3-H

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Figure 3-ILifting Chain Assemblies, CWP-8S

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FIGURE 3-I


1 35714 Screw - FHS, 3/8-16 x 2.25 inches ............................................................................. 4

2 5397 Washer - Flat, 5/16inch (0.375 x 0.875 x 0.083 inch) (0.95 x 2.22 x 0.21 cm) ............. 4

3 4828 Nut - Nylock, 3/8-16 ................................................................................................... 4

4 6534 Pin - Grooved, 0.2 x 0.75 inch .................................................................................... 4

6 35699 Chain Terminal - Upper, Number 1 Column ................................................................. 2

5 40550 Chain Assembly - Number 1 Column (includes index numbers 4, 6, and 16) ............... 2 41247 Chain - Leaf, 53.5 inches (135.9 cm) .........................................................................

7 40945 Screw - FHS,1

/4-20 x 2.25 inches ............................................................................. 1

8 35697 Chain Terminal - Clevis, Cylinder ................................................................................ 1

9 Ref. Carriage Assembly (refer to Figure 3-E) ...................................................................... 1

10 11890 Button - Glide.............................................................................................................. 1

11 35712 Nut - Nylock, 3/8-24 ................................................................................................... 2

12 35698 Rocker - Chain Tension............................................................................................... 1

13 35705 Bolt - Rocker............................................................................................................... 1



16 38187 Chain Terminal - Lower, Double Slot (includes index number 4) .................................. 2

17 41559 Number 2 Column Assembly (refer to Figure 3-B) ....................................................... 1

18 35749 Number 1 Column Assembly (refer to Figure 3-A) ....................................................... 1

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Figure 3-JLifting Chain Assemblies, CWP-12S

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3 4828 Nut - Nylock, 3/8-16 ................................................................................................... 6


5 40550 Chain Assembly - Number 1 Column (includes index numbers 4, 6 and 20) ................ 2

41247 Chain - Leaf, 53.5 inches (135.9 cm) .........................................................................


7 40945 Screw - FHS,1

/4-20 x 2.25 inches ............................................................................. 1


9 41246 Chain Assembly - Number 2 Column (includes index numbers 6, 8 and 20) ................ 1 41247 Chain - Leaf, 53.5 inches (135.9 cm) .........................................................................

10 41248 Chain Assembly - Number 2 Column (includes index numbers 6, 11 and 20) .............. 1


11 35695 Chain Terminal - Pulley Support, Double Slot .............................................................. 2

12 Ref. Carriage Assembly (refer to Figure 3-F) .....................................................................

13 35751 Number 3 Column Assembly (refer to Figure 3-C) ....................................................... 1

14 11890 Button - Glide.............................................................................................................. 2

15 35712 Nut - Nylock, 3/8-24 ................................................................................................... 4


17 35705 Bolt - Rocker............................................................................................................... 2



20 38187 Chain Terminal - Lower, Double Slot (includes index number 21) ................................ 4

21 35750 Number 2 Column Assembly (refer to Figure 3-C) ....................................................... 1


FIGURE 3-J

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Figure 3-KLifting Chain Assemblies, CWP-15S

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2 40550 Chain Assembly - Number 1 Column (includes index numbers 1, 3 and 18) ................ 2






7 4828 Nut - Nylock,3

/8-16 ................................................................................................... 8


9 41246 Chain Assembly - Number 2 Column (includes index numbers 3, 8 and 18) ................ 1 41247 Chain - Leaf, 53.5 inches (135.9 cm) .........................................................................

10 41248 Chain Assembly - Number 2 Column (includes index numbers 3, 11 and 18) .............. 1


11 35695 Chain Terminal - Pulley Support, Double Slot .............................................................. 2

12 38980 Chain Terminal - Pulley Support, Single Slot (after serial number 0196-165) ............... 2 35695 Chain Terminal - Pulley Support, Double Slot (before serial number 0196-166)...........

13 41250 Chain Assembly (includes index numbers 14, 12 and 16) ........................................... 2 41249 Chain - Leaf, 53.5 inches (135.9 cm) .........................................................................

14 38986 Pin - Grooved, 0.2 x 0.50 inch (after serial numbers 0196-165) ................................... 4

6534 Pin - Grooved, 0.2 x 0.75 inch (before serial numbers 0196-166) ...............................

15 Ref. Carriage Assembly (refer to Figure 3-G) .....................................................................

16 41224 Chain Terminal - Lower, Single Slot (includes index number 14)(after serial numbers 0196-165) ................................................................................... 2

38187 Chain Terminal - Lower, Double Slot (includes index number 14)(before serial number 0196-166) .................................................................................. 4

17 35752 Number 4 Column Assembly (refer to Figure 3-D) ....................................................... 1

18 38187 Chain Terminal - Lower, Double Slot (includes index number 3) .................................. 4


20 11890 Button - Glide.............................................................................................................. 3

21 35712 Nut - Nylock, 3/8-24 ................................................................................................... 6


FIGURE 3-K

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FIGURE 3-K



23 35705 Bolt - Rocker............................................................................................................... 3





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Figure 3-LSequencing Cables

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2 6091 Nut - Nylock, 1/4-20, CWP-8S .................................................................................... 3

6091 Nut - Nylock, 1/4-20, CWP-12S .................................................................................. 4 6091 Nut - Nylock, 1/4-20, CWP-15S .................................................................................. 5

3 35734 Bracket - Sequencing, Carriage................................................................................... 1

4 44895 Spacer - Tube, 1/4x 3/8x 0.5 inch, CWP-8S .............................................................. 1 44895 Spacer - Tube, 1/4x 3/8x 0.5 inch, CWP-12S............................................................. 2

44895 Spacer - Tube, 1/4x 3/8x 0.5 inch, CWP-15S............................................................. 3

5 35730 Bracket - Sequencing, CWP-8S .................................................................................. 1 35730 Bracket - Sequencing, CWP-12S ................................................................................ 2

35730 Bracket - Sequencing, CWP-15S ................................................................................ 3

6 38979 Screw - PHM, 1/4 -20 x 0.5 inch, GR 2, CWP-8S......................................................... 5

38979 Screw - PHM, 1/4-20 x 0.5 inch, GR 2, CWP-12S .....................................................10 38979 Screw - PHM, 1/4-20 x 0.5 inch, GR 2, CWP-15S .....................................................15

7 35991 Nut - Weld, 1/4-20, CWP-8S ....................................................................................... 6 35991 Nut - Weld, 1/4-20, CWP-12S ....................................................................................12

35991 Nut - Weld, 1/4-20, CWP-15S ....................................................................................18

8 41077 Screw - SHCS, 1/4-20 x 0.88 inch, CWP-8S .............................................................. 1 41077 Screw - SHCS, 1/4-20 x 0.88 inch, CWP-12S............................................................. 2

41077 Screw - SHCS,1

/4-20 x 0.88 inch, CWP-15S............................................................. 3

9 12906 Washer - Fender, 0.285 x 1.28 x 0.063 inch (0.72 x 3.25 x 0.16 cm)........................... 2

12906 Washer - Fender, 0.285 x 1.28 x 0.063 inch (0.72 x 3.25 x 0.16 cm)........................... 4 12906 Washer - Fender, 0.285 x 1.28 x 0.063 inch (0.72 x 3.25 x 0.16 cm)........................... 6

10 35733 Pulley - Sequencing, CWP-8S .................................................................................... 1 35733 Pulley - Sequencing, CWP-12S................................................................................... 2 35733 Pulley - Sequencing, CWP-15S................................................................................... 3


FIGURE 3-L

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FIGURE 3-L

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FIGURE 3-L


11 69238 Sequencing Cable Assembly, Carriage, CWP-8S (after serial number 0199-843)(includes index number 3) ........................................................................................... 1

40548 Sequencing Cable Assembly, Carriage, CWP-8S (before serial number 0199-844)

includes index number 3) ...........................................................................................

11 40549 Sequencing Cable Assembly, CWP-12S (includes index number 5)............................ 1

69238 Sequencing Cable Assembly, Carriage, CWP-12S (after serial number 0199-843)(includes index number 3) ..........................................................................................

40548 Sequencing Cable Assembly, Carriage, CWP-12S (not shown)(before serial number 0199-844) (includes index number 3) ........................................

11 40549 Sequencing Cable Assembly, CWP-15S (includes index number 5)............................ 2

69238 Sequencing Cable Assembly, Carriage, CWP-15S (after serial number 0199-843)(includes index number 3) ..........................................................................................

40548 Sequencing Cable Assembly, Carriage, CWP-15S (not shown)(includes index number 3) (before serial number 0199-844) ........................................

12 57147 Bracket - Sequencing, Upper, CWP-8S (after serial number 0199-843) ....................... 1 38339 Bracket - Sequencing, Upper, CWP-8S (before serial number 0199-844)....................

12 57147 Bracket - Sequencing, Upper, CWP-12S (after serial number 0199-843) ..................... 2

38339 Bracket - Sequencing, Upper, CWP-12S (before serial number 0199-844) ..................

12 57147 Bracket - Sequencing, Upper, CWP-15S (after serial number 0199-843) .................... 3

38339 Bracket - Sequen

cwp 0196-101

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