CONTENTS

MANITOU NORTH AMERICA, INC.

6401 IMPERIAL DRIVE
Waco, TX 76712--6803

NOTE: Manitou Forklift Manuals are continually updated and subject to change
without prior notice. If your Forklift Mast Model or parts are not found in this manual,
please contact your dealer or the Manitou North America Parts Department
for the latest information and parts availability.

3500 SERIES
2 RAIL MAST
2,500 -- 8,000 LB. CAPACITY
MODELS K3501 THRU K3507

PARTS MANUAL

For Parts Orders contact your Manitou North America Dealer or call:
Manitou North America, Parts Dept. 800--425--3727 or (254) 799--0232
Parts Dept. Fax: (254) 867--6504 Website: www.manitou--na.com

CATALOG R384
R10--94
CONTENTS

GENERAL INFORMATION

The purpose of this catalog is to provide illustrations for identifying and ordering Mast components/parts.
Because of the multitude of Mast Models and components utilized, the illustrations provide a general descrip-
tion and therefore may not show the exact shape or detail of the components/parts represented.
The Mast parts are identified by an Item Number on the illustration or picture page. Find the Item Number
for the part desired, then locate that Item Number under the ”Items” column following the illustration. The Part
Number will be located directly to the right of the Item Number. Also provided is a part Description, Quantity of
parts required and the mast Model number.
Most important when ordering parts, is providing the correct serial number as assigned to the mast at the
factory. Keep accurate records of all modifications or improvements made to the mast after manufacture. (All
Mast modifications must be authorized by K--D Manitou.) Notify the Parts Dept. of any changes that may affect
your parts order.

When ordering Mast parts or requesting technical information, the following numbers are required:

Mast Model Number:_____________________________________________

Mast Serial Number:______________________________________________

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

The Mast Model Number is stamped on the Identification Plate located on the right side (as viewed
from the driver’s seat) of the Outer Rail, at or above eye level.

MAST MODEL NO. DESCRIPTION

(SAMPLE)
MODEL NO. OF MAST RAILS MODEL NO. OF OPTIONAL EQUIPMENT

K5705 -- K5797 -- K5755 -- K1479

MODEL NO. OF CARRIAGE MODEL NO. OF MOUNTING

To order Mast Parts, contact the K- D MANITOU DEALER in your area or

K- D Manitou, Parts Division, Waco, Texas.

1--800--425--3727
CONTENTS

CONTENTS

MAST RAIL ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CHAIN ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

HOSE KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

CARRIAGE ASSEMBLY, 42”, 60” & 72” HOOK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

CARRIAGE ASSEMBLY, 42”, 60” & 72” SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

DECALS

CATALOG R394 -- 1 -- R/10--94

CONTENTS

MAST RAIL ASSEMBLIES

2
1

3
4

5* 3
4

6*
7*
8*
7*
9 6*

10

R/10--94 -- 2 -- CATALOG R384

CONTENTS

ITEM PART NUMBER DESCRIPTION QTY MODEL

1 R8360--5 Outer Rail Assembly 1 K3501

1 R8362--6 Outer Rail Assembly 1 K3502
1 R8360--7 Outer Rail Assembly 1 K3503
1 R8360--8 Outer Rail Assembly 1 K3504
1 R8360--16 Outer Rail Assembly 1 K3507

2 R65--2 Inner Rail Assembly 1 K3501

2 R65--3 Inner Rail Assembly 1 K3502
2 R65--4 Inner Rail Assembly 1 K3503
2 R65--5 Inner Rail Assembly 1 K3504
2 R65--16 Inner Rail Assembly 1 K3507

3 R22 Shim A/R ALL

4 R2 Roller 4
5* K87901 Fitting, Grease 2
6* R106 Ring, Retaining 4
7* R4584 Wiper 4
8* R7638 Bearing, Mast Mounting 4

9 R63 Bolt, Cylinder Restraining 1

10 K33845 Nut 1

* For use on Masts mounted to K--D Manitou M--Series Forklift Trucks only.

CATALOG R384 -- 3 -- R/10--94

CONTENTS

CYLINDER ASSEMBLY

8*

19
7
18
6
17

5*

21
22

20
23
9*
16 1

10* TO
24 MAST
25
11 12
13
14
15 TO
TRUCK

R/10--94 -- 4 -- CATALOG R384

CONTENTS

ITEM PART NUMBER DESCRIPTION QTY MODEL YEAR

1 R2150--1 Cylinder Assembly 1 K3501

1 R2150--2 Cylinder Assembly 1 K3502
1 R2150--3 Cylinder Assembly 1 K3503
1 R2150--4 Cylinder Assembly 1 K3504
1 R2150--12 Cylinder Assembly 1 K3507

2 R2160--1 Barrel Assembly 1 K3501

2 R2160--2 Barrel Assembly 1 K3502
2 R2160--3 Barrel Assembly 1 K3503
2 R2160--4 Barrel Assembly 1 K3504
2 R2160--19 Barrel Assembly 1 K3507

3 R2165--1 Piston Assembly 1 K3501

3 R2165--2 Piston Assembly 1 K3502
3 R2165--3 Piston Assembly 1 K3503
3 R2165--4 Piston Assembly 1 K3504
3 R2165--12 Piston Assembly 1 K3507

4 R2554 Ring, Wear 1 ALL

5* -- -- -- -- Seal 1
6 R347 Retainer, Seal 1
7 R346 Snap Ring 1
8* -- -- -- -- Wiper 1
9* -- -- -- -- O--Ring 1
10* -- -- -- -- Ring, Back Up 1

11 R2158 Plug 1
12 K306401 Screw, Cap 1
13 R348 Control, Flow 1
14 K914 O--Ring 1
15 K62--12--14 Adapter (Includes Item 14) 1
16 R2156 Wear Ring 1

17 R2233--1 Spacer 1 K3501, K3502

17 R2233--2 Spacer 1 K3503
17 R2233--3 Spacer 1 K3504
17 R2233--15 Spacer 1 K3507

18 R102 Washer 1
19 R13453--1 Ring, Snap 1
20 R2211--2 Lock Wire 1
21 R2551 Screw, Button Hd 1
22 R2552 Washer, Seal 1
23 R2190 Seal Kit 1

24 426210 Union 1 (M230/430CP, w/out 450 tilt)

25 426593 Tube Assembly 1 (M230/430CP, w/out 450 tilt)

* Included in Seal Kit, Item 23.

CATALOG R384 -- 5 -- R/10--94

CONTENTS

CHAIN ASSEMBLY
9

UPPER
INNER RAIL
(REF)

4
2
3 HYDRAULIC
CYLINDER
(REF)

4
6
3
5
7

CARRIAGE
(REF)

R/10--94 -- 6 -- CATALOG R384

CONTENTS

ITEM PART NUMBER DESCRIPTION QTY MODEL

1* R194--2 Chain Assembly (7 Leaf thickness) 2 K3501

1* R194--3 Chain Assembly (7 Leaf thickness) 2 K3502
1* R194--4 Chain Assembly (7 Leaf thickness) 2 K3503
1* R194--5 Chain Assembly (7 Leaf thickness) 2 K3504

1** R9481--26 Chain Assembly (8 Leaf thickness) 2 K3501

1** R9481--32 Chain Assembly (8 Leaf thickness) 2 K3502
1** R9481--38 Chain Assembly (8 Leaf thickness) 2 K3503
1** R9481--44 Chain Assembly (8 Leaf thickness) 2 K3504
1** R9481--66 Chain Assembly (8 Leaf thickness) 2 K3507

2* R193 Anchor, Chain 2

2** R9482 Anchor, Chain 2

3* R189--2 Pin, Chain 4

3** R189--3 Pin, Chain 4

4 K72016 Pin, Cotter 8

5 R32 Nut, Hex Lock 4
6 R213 Nut, Rocker 2

7* R192 Anchor, Chain 2

7** R9483 Anchor, Chain 2

8 R186 Sheave 2
9 K97541 Ring, Snap 2

* For use on Mast Serial No. R280--01 thru R280--86. Add additional 14” to chain length when supplying Item
1 Chain, if used with Carriage Model K3589.
** For use on Mast Serial No. R280--87 & above. Add additional 14” to chain length when supplying Item 1
Chain, if used with Carriage Model K3589.

CATALOG R384 -- 7 -- R/11--00

CONTENTS

HOSE KITS

11
7

6
12
8
13
9
10

4
3

5
2

INNER RAIL

16 14

15

WELDS TO
BACK OF
INNER RAIL
17
14
16
15 WELDS TO
CARRAGE

R/10--94 -- 8 -- CATALOG R384

CONTENTS

ITEM PART NUMBER DESCRIPTION QTY MODEL

1 B760--1734 Hose Assembly, R.H. (Shown) 1 Waco ’M’ Series Trucks

1 B760--1733 Hose Assembly, L.H. 1 Waco ’M’ Series Trucks

1 B760--989 Hose Assembly 2 K3561--1

1 B760--990 Hose Assembly 2 K3561--2
1 B760--991 Hose Assembly 2 K3561--3
1 B760--992 Hose Assembly 2 K3561--4

2 R9064 Sheave, Hose 2 ALL

3 R2362 Bearing 2
4 R7332 Snap Ring, Internal 4
5 R7333 Snap Ring, External 2
6 R5271 Bracket Assembly, R.H. (Shown) 1
6 R5272 Bracket Assembly, L.H. 1

7 K33799 Nut, Hex 4

8 K33924 Jam Nut, Hex 4
9 R5283 Sleeve, Retainer 4
10 K304796 Bolt, Hex 4
11 K20472 Bolt, Hex 4

12 R5284 Block 2
13 K20526 Bolt, Hex 4
14 K108--8 Fitting, Bulkhead 4
15 R10413 Plate, Mounting 4
16 K22--8 Nut, Lock 4
17 R5268 Fitting, Adaptor 2

CATALOG R384 -- 9 -- R/10--94

CONTENTS

CARRIAGE ASSEMBLY, 42”, 60” & 72” HOOK

7
6
5
4

2
3

8
9
10

14

11

13 12

R/10--94 -- 10 -- CATALOG R384

CONTENTS

ITEM PART NUMBER DESCRIPTION QTY MODEL

1 R3825--1 Carriage Assembly, 42” 1 K3596

1 R23190--1 Carriage Assembly, 60” 1 K3595
1 R3825--3 Carriage Assembly, 72” 1 K3594

2 R22 Shim A/R ALL

3 R2* Roller 4
4 R3564 Bolt 2
5 R3561 Shaft 2
6 R1** Roller 2

7 K97535 Ring, Snap 2

8 R3712 Shim A/R
9 R3711 Block, Thrust 2
10 K302282 Screw, Socket Head Cap 4
11 R2393 Washer 8

12 R4095 Roller, Inside Thrust 4

13 R4099 Shaft 2
14 K305135 Pin, Roll 4

* Available for replacement of the R2 Roller is a 0.015” over--sized Roller, order Part No. R446.
** Available for replacement of the R1 Roller is a 0.015” over--sized Roller, order Part No. R442.

CATALOG R384 -- 11 -- R/10--94

CONTENTS

CARRIAGE ASSEMBLY, 42”, 60” & 72” SHAFT

15
1

2
3

16

8
9
10

17
14

18

11

13 12 7
6
5

R/10--94 -- 12 -- CATALOG R384

CONTENTS

ITEM PART NUMBER DESCRIPTION QTY MODEL

1 R130 Carriage Assembly, 42” 1 K3599

1 R155 Carriage Assembly, 60” 1 K3598
1 R550 Carriage Assembly, 72” 1 K3597

2 R22 Shim A/R

3 R2* Roller 4
4 R3564 Bolt 2
5 R3561 Shaft 2
6 R1** Roller 2

7 K97535 Ring, Snap 2

8 R3712 Shim A/R
9 R3711 Block, Thrust 2
10 K302282 Screw, Socket Head Cap 4
11 R2393 Washer 8

12 R4095 Roller, Inside Thrust 4

13 R4099 Shaft 2
14 K305135 Pin, Roll 4

15 R1187--1 Bar, Implement, 42” 1

15 R1187--2 Bar, Implement, 60” 1
15 R1187--3 Bar, Implement, 72” 1

16 K45548 Bolt, Hex 1

17 K34807 Washer, Lock 1
18 K33799 Nut, Hex 1

* Available for replacement of the R2 Roller is a 0.015” over--sized Roller, order Part No. R446.
** Available for replacement of the R1 Roller is a 0.015” over--sized Roller, order Part No. R442.

CATALOG R384 -- 13 -- R/10--94

CONTENTS

DECALS

1
1

ROUGH TERRAIN
MAST 48” 2, 3

INDUSTRIAL
MAST 57”

2, 3

ITEM PART NUMBER DESCRIPTION QTY MODEL

1 426641 Decal, ”Fork Safety” 2 ALL

2 426642 Decal, ”Pinch Point” (Small) A/R
3 426643 Decal, ”Pinch Point” (Large) A/R