Yale Mpe 2

PARTS MANUAL
MPE060-F
(D896)
Yale Materials Handling Corporation 550175951

1400 Sullivan Drive ©Yale Corp.
Caller No. 12011 07/2017
Greenville, NC 27834-2011
MODEL NOMENCLATURE
NOTE: This parts manual contains alternate pages for certain assemblies. The truck model code can be used to
determine many of the assemblies on your lift truck (power, tire type, mast type). The complete truck model and
serial number are stamped into the nameplate. See for further information.
SECTIONS
1 FRAME/DRIVE UNIT
2 ELECTRICAL SYSTEM
3 STEER HANDLE/BRAKE SYSTEM
4 LIFT LINKAGE, LOAD WHEELS, AND FORKS
5 OPTIONS
6 NUMERICAL INDEX
7 USER SUPPORT INFORMATION
This Parts Manual is divided into 7 major sections which are listed above. Quick reference to these sections can be
made by placing the right thumb on the tab of the desired section, bending the book back and thumbing the pages
to the corresponding tab.
GENERAL INFORMATION
TABLE OF CONTENTS
DESCRIPTION PAGE
A
AUDIBLE ALARM ............................................................................................................................................ 5-3
AUXILIARY CONTROL BOX AND GRAB RAIL ASSEMBLY ......................................................................... 2-12
B
BATTERY DISCONNECT ............................................................................................................................... 2-11
BATTERY RETENTION .................................................................................................................................. 1-17
BATTERY ROLLER ASSEMBLY .................................................................................................................... 5-6
BATTERY SPACER ........................................................................................................................................ 1-16
BRAKE ASSEMBLY ........................................................................................................................................ 1-10
C
CASTER ASSEMBLY
SPRING LOADED - STANDARD ................................................................................................................ 4-12
SPRING LOADED - HEAVY DUTY ............................................................................................................. 4-14
SPRING LOADED - HEAVY DUTY, SEALED BEARINGS ......................................................................... 4-16
COAST CONTROL
MANUAL STEERING .................................................................................................................................. 3-16
POWER STEERING ................................................................................................................................... 3-17
CONTACTOR ASSEMBLY
SUB-ZERO .................................................................................................................................................. 2-13
CONVENIENCE TRAY .................................................................................................................................... 5-8
COVERS AND FLOORMAT ............................................................................................................................ 1-12
D
DASH DISPLAY .............................................................................................................................................. 2-10
DECALS .......................................................................................................................................................... 1-20
DRIVE WHEEL AND TIRE
AND STATIC STRAP .................................................................................................................................. 1-18
E
ELECTRICAL SYSTEM
STANDARD ................................................................................................................................................. 2-2
SUB-ZERO .................................................................................................................................................. 2-4
F
FORKS ............................................................................................................................................................ 4-4
G
GEAR BOX
MASTER DRIVE UNIT ................................................................................................................................ 1-4
H
HEATER INSTALLATION ............................................................................................................................... 2-14
L
LIFT LINKAGE ................................................................................................................................................. 4-2
LOAD BACKREST
BOLT-ON .................................................................................................................................................... 1-15
PIVOTED ..................................................................................................................................................... 1-14
D896 ©2017 Yale Materials Handling Corporation i

GENERAL INFORMATION
TABLE OF CONTENTS (continued)
DESCRIPTION PAGE
LOAD WHEELS
DUAL WHEEL ............................................................................................................................................. 4-9
DUAL WHEEL - SEALED BEARINGS ........................................................................................................ 4-10
SINGLE WHEEL, FOUR BEARINGS .......................................................................................................... 4-7
SINGLE WHEEL, FOUR BEARINGS - SEALED ........................................................................................ 4-8
SINGLE WHEEL, TWO BEARINGS ........................................................................................................... 4-5
SINGLE WHEEL, TWO BEARINGS - SEALED .......................................................................................... 4-6
M
MANUAL STEERING ELECTRICAL ............................................................................................................... 2-6
MASTER DRIVE UNIT AND ATTACHING PARTS ......................................................................................... 1-2
P
POWER STEERING ELECTRICAL ................................................................................................................ 2-8
R
RF TERMINAL ................................................................................................................................................. 5-2
T
TILLER ARM ASSEMBLY
COMPOSITE HANDLE ............................................................................................................................... 3-2
METAL HANDLE ......................................................................................................................................... 3-4
TILLER HEAD
CONTROL BOX .......................................................................................................................................... 3-14
TILLER HEAD ASSEMBLY
COMPOSITE ............................................................................................................................................... 3-6
METAL HANDLE ......................................................................................................................................... 3-10
TILLER SWIVEL ASSEMBLY
WITH COAST CONTROL - POWER STEERING ....................................................................................... 3-22
WITH COAST CONTROL - MANUAL STEERING ...................................................................................... 3-28
WITHOUT COAST CONTROL OR WITH MANUAL COAST CONTROL - POWER STEERING ............... 3-18
WITHOUT COAST CONTROL OR WITH MANUAL COAST CONTROL - MANUAL STEERING ............. 3-26
TRACTION MOTOR AND BRAKE ASSEMBLY .............................................................................................. 1-6
TRACTION MOTOR ASSEMBLY ................................................................................................................... 1-8
TRANSMISSION DIAGNOSTICS INTERFACE CABLE ................................................................................. 5-10
V
VISIBLE ALARM .............................................................................................................................................. 5-4
W
WIRE HARNESS
ADVANCED COAST CONTROL - MANUAL STEERING ........................................................................... 2-16
ADVANCED COAST CONTROL - POWER STEERING ............................................................................ 2-17
COAST CONTROL - MANUAL STEERING ................................................................................................ 2-18
HANDRAIL .................................................................................................................................................. 2-19
HEATER APPLICATION ............................................................................................................................. 2-20
HEATER ASSEMBLY ................................................................................................................................. 2-21
MANUAL STEERING - PAGE 1 OF 2 ......................................................................................................... 2-22
MICROSWITCH - HEATER INSTALLATION .............................................................................................. 2-28
ii ©2017 Yale Materials Handling Corporation D896

GENERAL INFORMATION
TABLE OF CONTENTS (continued)
DESCRIPTION PAGE
MICROSWITCH - TILLER SWITCH INSTALLATION ................................................................................. 2-29
POWER STEERING - PAGE 1 OF 2 .......................................................................................................... 2-30
RF TERMINAL ............................................................................................................................................ 2-38
SIDE GLIDE ................................................................................................................................................ 2-40
STROBE LIGHT .......................................................................................................................................... 2-41
THERMOSTAT ............................................................................................................................................ 2-42
TILLER HANDLE - COMPOSITE ................................................................................................................ 2-43
TILLER HANDLE - METAL ......................................................................................................................... 2-44
D896 ©2017 Yale Materials Handling Corporation iii

GENERAL INFORMATION
ABBREVIATIONS QUICK REFERENCE SHEET
Listed below are abbreviations used in parts manuals to denote the following expressions:
spacer
TERM DEFINITION TERM DEFINITION
Amp Amperes FRE Freezer Environment
AR As Required in. inches
BDI Battery Discharge Indicators LPG Liquefied Petroleum Gas
BWI Brush Wear Indicator MAP Manifold Absolute Pressure
CE Communicator End mm millimeters
CRE Corrosive Environment MSTS Microprocessor Spark Timing System
D/B Date Break NPT National Pipe Threads
dbA Decibel "A" Scale O/S Oversize
DE Drive End PTO Power Take Off
ECH Empty Container Handler RPM Revolutions per Minute
ECH-3 Empty Container Handler - 3 High S/N Serial Number
Stacking TMM Truck Management Module
ECH-4 Empty Container Handler - 4 High UL Type D Diesel-Powered Safety Rating
Stacking
UL Type DS Diesel-Powered Safety Rating
ECH-5 Empty Container Handler - 5 High
Stacking UL Type E Battery-Powered Safety Rating
ECH-6 Empty Container Handler - 6 High UL Type EE Battery-Powered Safety Rating

Stacking UL Type ES Battery-Powered Safety Rating
ECH-7 Empty Container Handler - 7 High UL Type G Gasoline-Powered Safety Rating
Stacking UL Type GS Gasoline-Powered Safety Rating
ECM Electronic Control Module UL Type LP Gas-Powered Safety Rating
ECN Engineering Change Notice UL Type LPS LP Gas-Powered Safety Rating
EEPROM Electrically Erasable Programmable U/S Undersize
Read Only Memory
UL Underwriters Laboratory
EPA US Environmental Protection Agency
V Volts
EPROM Electrically Programmable Read Only
Memory
iv ©2017 Yale Materials Handling Corporation D896

GENERAL INFORMATION
HOW TO USE THE ILLUSTRATED PARTS MANUAL
This parts manual describes and illustrates assemblies, The different constructions are indicated by keys and
subassemblies, and detail parts needed for service footnotes. The callouts correspond to descriptions
replacement. found on the next page.
D896 ©2017 Yale Materials Handling Corporation v

GENERAL INFORMATION
HOW TO FIND THE DESIRED PART NUMBER

WHEN THE PART NUMBER AND THE NEXT subparts of assemblies. In the example on the
HIGHER ASSEMBLY IS NOT KNOWN: previous page, BEARING CAP (Item 2) is a
1. Determine the function and application of the part subpart of the major assembly CASE.
required. Turn to the Sections Page. Choose the 9. Quantities shown are for one assembly. The
general area of reference most likely to include the quantities of the subpart BEARING CAP are
part. indicated as two and two. This means two per
2. Turn to the section you chose. Use the Section CASE assembly.
Table of Contents to determine the assembly 10. Serial number breaks identify the most current
which would normally contain the part required. parts information and are shown as follows:
Then locate the part on the assembly breakdown → S/N A810N2639
page. Indicates last serial number affected.
S/N A810N2640 →
WHEN THE PART NUMBER IS NOT KNOWN
Indicates the first serial number affected.
AND THE NEXT HIGHER ASSEMBLY IS
S/N A810N1553 ↔ S/N A810N3291
KNOWN:
Indicates a range of serial numbers affected.
3. Determine the assembly the required part is used
on. Turn to the Table of Contents (Page i). ECN numbers for pending serial numbers are
shown to allow for the inclusion of the most current
4. Locate the assembly the required part is used on
parts information and are identified as follows:
and turn to the page indicated for that assembly.
→ S/N Pending Per ECN 63243
Then locate the part on the assembly breakdown
Indicates a pending serial number for last unit
page.
affected.
WHEN THE PART NUMBER IS KNOWN: S/N Pending Per ECN 63243 →
5. Use the Numerical Index (Page 6-1) to find the Indicates a pending serial number for first unit
part number. Turn to the page listed and locate the affected.
part as indicated by the item number. Date breaks are used to indicate when a change
GENERAL: occurred but a subsequent serial number break
was not recorded. This is an arbitrary date usually
The assembly breakdowns include part numbers, based on the ECN release and are identified as
descriptions, quantities required, keys and follows:
footnotes to help in selecting correct parts. → D/B 3/00
6. Parts Supersession Information. Part numbers that Indicates that a change occurred sometime
have this history will be displayed in the parts list within that month for the item affected.
in the order that they were superseded (from oldest D/B 3/00 →
to newest). The superseded part numbers will be Indicates that a change occurred sometime
shown with a line through them. within that month for the item affected.
D/B 3/00 ↔ D/B 4/00
Five periods in the PART NO. column (. . . . .)
Indicates a range of production dates of the item
indicate that the part is either Not Serviced
affected.
Separately or there is a reference to another figure.
A figure reference is denoted by a pointing hand Contact your local dealer for Yale lift trucks for
followed by a parts page number in the serial number information for items with a ECN or
DESCRIPTION column (F7A56) a date break.
7. Keys are used to show two or more similar
ORDERING PARTS:
assemblies, RH and LH assembly parts, etc.
Select the appropriate key, "A", "B", "C", "D", or "E" When ordering replacement parts, give the unit serial
and the corresponding quantity column to find the number, part number, name of part and quantity
required parts. Two periods in the QTY column (..) required.
indicate that the part is not used for that assembly.
8. Indented descriptions under the DESCRIPTION For any further information on parts, service, or
column are used to indicate assemblies and ordering, consult your local dealer for Yale lift trucks.
vi ©2017 Yale Materials Handling Corporation D896

GENERAL INFORMATION
IDENTIFICATION OF TRUCK SERIAL NUMBERS
NOTE: Serial Number breakdown is only for trucks built after 1994.
(1) and (2) The first letter and three numbers indicate the truck unit code.
(3) The second letter indicates the plant of manufacture.
(4) The four or five digit number indicates the production sequence number of the truck.
(5) The final letter indicates the year of manufacture starting with "A" in 1957, 1980, and 2003.
The letters "I", "O", and "Q" will not be used.
For pending serial numbers contact your local dealer for Yale lift trucks.
Parts referred to in this book as right or left hand parts are in accordance with the illustration above.
D896 ©2017 Yale Materials Handling Corporation vii

GENERAL INFORMATION
PUBLICATIONS
Every new lift truck is provided with an OPERATING MANUALS with complete replacement part
MANUAL. This manual has information that the identification, are available at a nominal fee from your
operator must know for inspection and operation of the Yale dealer to assist users in effectively maintaining
lift truck. Yale lift trucks in a safe, useful condition. See the list
below for information on ordering specific publications
SERVICE MAINTENANCE MANUALS, which provide for this model lift truck.
service and overhaul procedures, and PARTS
PUBLICATION YALE PART NUMBER
Operating Manual.................................................................................................................... 550090069
Service Manual (Complete)..................................................................................................... 550175942
Parts Manual........................................................................................................................... 550175951
viii ©2017 Yale Materials Handling Corporation D896

GENERAL INFORMATION
MASTER PART SHEET CROSS-REFERENCE
NOTE: Throughout this manual are references to Part Sheet Numbers. These references are usually found after
the description of a part or assembly. The Part Sheet Number is found on the upper left- or righthand corner of the
parts pages.
EXAMPLE:
ITEM PART NO. DESCRIPTION QTY

31 505965530 Steering Cylinder (F6E67 [Figure 4-3]) .............................................................. 1
32 504224261 Pin........................................................................................................................ 4
Below is a numerical listing of Part Sheet Numbers found in this parts book and what page number they are on.
PART SHEET PAGE PART SHEET PAGE PART SHEET PAGE
G13977...................................1-2 G14000.................................2-19 G14022.................................3-18

G13978...................................1-6 G14001.................................2-20 G14023.................................3-22
G13979...................................1-8 G14002.................................2-21 G14024.................................3-26
G13980.................................1-10 G14003.................................2-22 G14025.................................3-28
G13981.................................1-12 G14004.................................2-26 G14026...................................4-2
G13982.................................1-14 G14005.................................2-28 G14027...................................4-4
G13983.................................1-15 G14006.................................2-29 G14028...................................4-5
G13984.................................1-16 G14007.................................2-30 G14029...................................4-6
G13985.................................1-17 G14008.................................2-34 G14030...................................4-7
G13986.................................1-18 G14009.................................2-38 G14031...................................4-8
G13987.................................1-20 G14010.................................2-40 G14032...................................4-9
G13988...................................2-2 G14011.................................2-41 G14033.................................4-10
G13989...................................2-4 G14012.................................2-42 G14034.................................4-12
G13990...................................2-6 G14013.................................2-43 G14035.................................4-14
G13991...................................2-8 G14014.................................2-44 G14036.................................4-16
G13992.................................2-10 G14015...................................3-2 G14037...................................5-2
G13993.................................2-11 G14016...................................3-4 G14038...................................5-3
G13994.................................2-12 G14017...................................3-6 G14039...................................5-4
G13995.................................2-13 G14018.................................3-10 G14040...................................5-6
G13996.................................2-14 G14019.................................3-14 G14041...................................5-8
G13997.................................2-16 G14020.................................3-16 G14076...................................1-4
G13998.................................2-17 G14021.................................3-17 P33158..................................5-10
G13999.................................2-18
D896 ©2017 Yale Materials Handling Corporation ix

GENERAL INFORMATION
NOTES
x ©2017 Yale Materials Handling Corporation D896

SECTION 1
1 FRAME/DRIVE UNIT
CONTENTS
SECTION 1
FRAME/DRIVE UNIT
DESCRIPTION PAGE
BATTERY RETENTION .................................................................................................................................. 1-17

BATTERY SPACER ........................................................................................................................................ 1-16
BRAKE ASSEMBLY ........................................................................................................................................ 1-10
COVERS AND FLOORMAT ............................................................................................................................ 1-12
DECALS .......................................................................................................................................................... 1-20
DRIVE WHEEL AND TIRE
AND STATIC STRAP .................................................................................................................................. 1-18
GEAR BOX
MASTER DRIVE UNIT ................................................................................................................................ 1-4
LOAD BACKREST
BOLT-ON .................................................................................................................................................... 1-15
PIVOTED ..................................................................................................................................................... 1-14
MASTER DRIVE UNIT AND ATTACHING PARTS ......................................................................................... 1-2
TRACTION MOTOR AND BRAKE ASSEMBLY .............................................................................................. 1-6
TRACTION MOTOR ASSEMBLY ................................................................................................................... 1-8
D896 ©2017 Yale Materials Handling Corporation 1-1

G13977 02-17
MASTER DRIVE UNIT AND ATTACHING PARTS (FIGURE 1-1)

582043788 Master Drive Unit Assembly ............................................................................... 1
1 582069185 Adapter -Chassis ............................................................................................ 1
2 582069190 Gearbox Assembly (FG14076 [Page 1-4]).................................................... 1
3 582069188 Capscrew ....................................................................................................... 8
4 524141080 Nut ...................................................................................................................... 4
5 582068819 Capscrew ............................................................................................................ 4
6 940102909 Washer ............................................................................................................... 4
1-2 ©2017 Yale Materials Handling Corporation D896

02-17 G13977
NOTES

G14076 06-17
GEAR BOX (FIGURE 1-2)

MASTER DRIVE UNIT

06-17 G14076
GEAR BOX
MASTER DRIVE UNIT

582069190 Gearbox Assembly ............................................................................................. 1
1 582072812 Housing .......................................................................................................... 1
2 582072813 Cover .............................................................................................................. 1
3 582072814 Cover .............................................................................................................. 1
4 582072815 Shaft , Flange ................................................................................................. 1
5 582072816 Bevel Gear Set ............................................................................................... 1
6 582072827 Bevel Gear ................................................................................................. 1
7 582048903 Gear ............................................................................................................... 1
8 ..... Nut .................................................................................................................. 1
9 582058724 Wheel Stud ..................................................................................................... 5
10 582072818 Ring (Support) ................................................................................................ 1
11 582072819 Ring (Support) ................................................................................................ 1
12 582072820 Ring (Spacer) ................................................................................................. 1
13 582072821 Ring (Protection) ............................................................................................ 1
14 582072822 Ring (Spacer) ................................................................................................. 1
15 582072823 Washer ........................................................................................................... 1
16 582072824 Ring (Support) ................................................................................................ 1
17 582048902 Pinion ............................................................................................................. 1
18 ..... Steering Bearing ............................................................................................. 1
19 582072826 Bearing (Taper Roller) .................................................................................... 1
23 ..... Shaft Seal ....................................................................................................... 1
24 ..... O-Ring Seal .................................................................................................... 1
25 582072830 Shim ............................................................................................................... 1
26 582072831 Shim (0.15 mm) .............................................................................................. 1
27 582072833 Shim (0.25 mm) .............................................................................................. 1
28 ..... Screw, Hex Head (M16x45) ........................................................................... 1
29 ..... Drain Plug ....................................................................................................... 1
30 ..... Drain Plug ....................................................................................................... 1
31 ..... Ring Seal ........................................................................................................ 2
32 ..... Screw, Socket Head (M8x16) ......................................................................... 8
36 ..... Screw, Socket Head (M10x40) ....................................................................... 3
37 519766808 Lockwasher .................................................................................................... 8
38 582072834 Pin .................................................................................................................. 1
39 582072835 Vent ................................................................................................................ 1
a 582072825 Nameplate ...................................................................................................... 1
582048033 Kit-Seal (Lower Radial Shaft) ............................................................................. 1
582048034 Kit-Plug ............................................................................................................... 1
582048035 Kit-Bearing (Steering) ......................................................................................... 1
582048036 Kit-Gear (Helical) ................................................................................................ 1
FOOTNOTES:
a Not Illustrated

G13978 02-17
TRACTION MOTOR AND BRAKE ASSEMBLY (FIGURE 1-3)

582043995 Traction Motor Assembly .................................................................................... 1
1 582043726 Traction Motor (FG13979 [Page 1-8])........................................................... 1
2 582043992 Locknut ........................................................................................................... 1
3 582050080 O-Ring ............................................................................................................ 1
4 524259238 Brake Assembly , Magnetic (With Diode) (FG13980 [Page 1-10]).................... 1
5 580023467 Capscrew ............................................................................................................ 4

02-17 G13978
NOTES

G13979 02-17
TRACTION MOTOR ASSEMBLY (FIGURE 1-4)

02-17 G13979
TRACTION MOTOR ASSEMBLY

582043726 Traction Motor ..................................................................................................... 1
1 582041898 Kit-Terminal Block (With Screws) ................................................................... 1
2 582064757 Kit-Service (Terminal Bracket, With Screws) ................................................. 1
3 582041897 Kit-Sensor , Speed ......................................................................................... 1
4 582064758 Kit-Service (Bolt, With Washers) .................................................................... 1
5 582064759 Kit-Service (Pulse Wheel Cover, With Screws) .............................................. 1
6 582064760 Kit-Service (Pulse Wheel) .............................................................................. 1
7 582064761 Kit-Service (Bearing) ...................................................................................... 1
8 582064762 Kit-Service (Key, 8 x 10 x 15) ......................................................................... 1
9 582064763 Key (Woodruff, 6 x 9 x 22) .............................................................................. 1
10 582041902 Kit-Sensor , Temperature ............................................................................... 1
11 582064764 Oil Seal ........................................................................................................... 1
12 582064765 Kit-Service (Bearing) ...................................................................................... 1

G13980 02-17
BRAKE ASSEMBLY (FIGURE 1-5)

524259238 Brake Assembly , Magnetic (With Diode) ........................................................... 1
1 a. . . . . Inductor Assembly .......................................................................................... 1
2 580075113 Rotor Assembly .............................................................................................. 1
3 582016358 Flange ............................................................................................................ 1
4 582016351
580075339 Kit-Screw ........................................................................................................ 1
5 580075338 Hub ................................................................................................................. 1
6 524286600 Brake Enclosure Kit (Brake) ............................................................................... 1
FOOTNOTES:
a Supplied complete with items 2, 3, 4, and 5.

02-17 G13980
NOTES

G13981 02-17
COVERS AND FLOORMAT (FIGURE 1-6)

02-17 G13981
COVERS AND FLOORMAT

1 519996802 Information Case ................................................................................................ 1
2 519996803 Cover (Information Case) ................................................................................... 1
3 524140488 Floormat .............................................................................................................. 1
4 524268818 Cover (Front) (Manual Steering) (Shown) .......................................................... 1
4 524268659 Cover (Front) (Power Steering) .......................................................................... 1
5 524141549 Rivet .................................................................................................................... 4

G13982 02-17
LOAD BACKREST (FIGURE 1-7)

PIVOTED

1 524142783 Load Backrest (48 in.) ......................................................................................... 1
1 524143338 Load Backrest (60 in.) ......................................................................................... 1
2 550091938 Plate .................................................................................................................... 2
3 580057482 Capscrew ............................................................................................................ 2
4 524142694 Latch (23 in.) ....................................................................................................... 1
5 524142762 Handle ................................................................................................................ 2
6 524148372 Plate .................................................................................................................... 2
7 504231270 Nut ...................................................................................................................... 4
8 930103907 Capscrew ............................................................................................................ 4
9 ..... Nut ...................................................................................................................... 2

02-17 G13983
LOAD BACKREST (FIGURE 1-8)

BOLT-ON

1 524298403 Load Backrest (48 in.) ......................................................................................... 1
1 524298404 Load Backrest (60 in.) ......................................................................................... 1
1 524298405 Load Backrest (72 in.) ......................................................................................... 1
2 062306700 Capscrew ............................................................................................................ 6
3 016103700 Washer ............................................................................................................... 12
4 580011878 Locknut ............................................................................................................... 6

G13984 02-17
BATTERY SPACER (FIGURE 1-9)

1 524173235 Spacer ................................................................................................................ 1
1 524248291 Spacer (Galvanized) ........................................................................................... 1
2 580041446 Capscrew ............................................................................................................ 2

02-17 G13985
BATTERY RETENTION (FIGURE 1-10)

1 501921200 Bracket (With Stud) ............................................................................................. 2
2 502398904 Washer ............................................................................................................... 2
3 015026600 Washer ............................................................................................................... 2
4 520051895 Nut ...................................................................................................................... 2

G13986 02-17
DRIVE WHEEL AND TIRE (FIGURE 1-11)

AND STATIC STRAP

582044766 Drive Tire Assy (Polyurethane, 90 Durometer) ................................................... 1
582048313 Drive Tire Assy (Polyurethane, 90 Durometer, Siped) ........................................ 1
582044765 Drive Tire Assy (Rubber) .................................................................................... 1
1 501786915 Tire (Polyurethane, 90 Durometer) ................................................................. 1
1 754060300 Cushion Tire (Siped Poly) .............................................................................. 1
1 517580815 Tire (Rubber) .................................................................................................. 1
2 582042092 Wheel ............................................................................................................. 1
3 900126308 Wheel Nut ........................................................................................................... 5
4 580049229 Capscrew ............................................................................................................ 1
5 504574225 Static Strap ......................................................................................................... 1
6 504232256 Lockwasher ......................................................................................................... 1
7 580027573 Nut ...................................................................................................................... 1

02-17 G13986
NOTES

G13987 02-17
DECALS (FIGURE 1-12)

02-17 G13987
DECALS
1 582034783 Label (Greenville Manufacturing) ........................................................................ 1
2 580072749 Label (Operation Warning) ................................................................................. 1
3 580008064 Nameplate Cover ................................................................................................ 1
3 501904907 Rivet .................................................................................................................... 4
3 a b. . . . . Nameplate .......................................................................................................... 1
4 580022643 Label (Battery Discharge Notice - Flooded Battery) (Shown) ............................. 1
4 580032544 Label (Battery Discharge Notice - AGM Battery) ................................................ 1
5 580084552 Label (Cold Storage) (Shown) ............................................................................ 1
5 580084553 Label (Arctic) ....................................................................................................... 1
6 524162256 Label (Patents and Trademarks) ........................................................................ 1
7 524262047 Label (AC Power) ............................................................................................... 2
8 519440800 Label (Pinch Warning) ........................................................................................ 2
9 502157203 Label (Yale) ........................................................................................................ 2
FOOTNOTES:
a Contact your local Yale dealer. b Not Illustrated

G13987 02-17
NOTES

SECTION 2
2 ELECTRICAL SYSTEM
CONTENTS
SECTION 2
ELECTRICAL SYSTEM
DESCRIPTION PAGE
AUXILIARY CONTROL BOX AND GRAB RAIL ASSEMBLY ......................................................................... 2-12

BATTERY DISCONNECT ............................................................................................................................... 2-11
CONTACTOR ASSEMBLY
SUB-ZERO .................................................................................................................................................. 2-13
DASH DISPLAY .............................................................................................................................................. 2-10
ELECTRICAL SYSTEM
STANDARD ................................................................................................................................................. 2-2
SUB-ZERO .................................................................................................................................................. 2-4
HEATER INSTALLATION ............................................................................................................................... 2-14
MANUAL STEERING ELECTRICAL ............................................................................................................... 2-6
POWER STEERING ELECTRICAL ................................................................................................................ 2-8
WIRE HARNESS
ADVANCED COAST CONTROL - MANUAL STEERING ........................................................................... 2-16
ADVANCED COAST CONTROL - POWER STEERING ............................................................................ 2-17
COAST CONTROL - MANUAL STEERING ................................................................................................ 2-18
HANDRAIL .................................................................................................................................................. 2-19
HEATER APPLICATION ............................................................................................................................. 2-20
HEATER ASSEMBLY ................................................................................................................................. 2-21
MICROSWITCH - HEATER INSTALLATION .............................................................................................. 2-28
MICROSWITCH - TILLER SWITCH INSTALLATION ................................................................................. 2-29
RF TERMINAL ............................................................................................................................................ 2-38
SIDE GLIDE ................................................................................................................................................ 2-40
STROBE LIGHT .......................................................................................................................................... 2-41
THERMOSTAT ............................................................................................................................................ 2-42
TILLER HANDLE - COMPOSITE ................................................................................................................ 2-43
TILLER HANDLE - METAL ......................................................................................................................... 2-44

G13988 02-17
ELECTRICAL SYSTEM (FIGURE 2-1)

STANDARD

02-17 G13988
ELECTRICAL SYSTEM
STANDARD

1 582032781 Cable Assy (W) ................................................................................................... 1
1 502535902 Terminal ......................................................................................................... 2
1 524256017 Boot ................................................................................................................ 1
2 582026213 Controller (Combi AC1 PW, Hardware Included) ............................................... 1
3 550041104 Edge Protector .................................................................................................... 1
4 060023800 Clamp ................................................................................................................. 1
5 940600907 Washer ............................................................................................................... 11
6 016337000 Washer ............................................................................................................... 1
7 203756500 Capscrew ............................................................................................................ 1
8 580047200 Screw .................................................................................................................. 2
9 312850034 Strap Clamp ........................................................................................................ 1
10 524245937 Contactor ............................................................................................................ 1
11 582053253 Cable Assy .......................................................................................................... 1
11 502535902 Terminal ......................................................................................................... 2
11 524256017 Boot ................................................................................................................ 1
12 582032782 Cable Assy (Contactor) ....................................................................................... 1
12 502535902 Terminal ......................................................................................................... 2
12 524256017 Boot ................................................................................................................ 1
13 520031801 Fuse (400 Amp) .................................................................................................. 1
14 582032759 Cable Assy (V) .................................................................................................... 1
14 502535902 Terminal ......................................................................................................... 2
14 524256017 Boot ................................................................................................................ 1
15 449001202 Capscrew ............................................................................................................ 4
16 449021003 Washer ............................................................................................................... 4
17 449015135 Nut ...................................................................................................................... 4
18 582035400 Heatsink .............................................................................................................. 1
19 449021010 Washer ............................................................................................................... 6
20 449001068 Capscrew ............................................................................................................ 3
21 524261854 Wire Harness (Handrail) (FG14000 [Page 2-19]).............................................. 1
22 524143269 Horn .................................................................................................................... 1
23 582014103 Hand Rail Assy (FG13994 [Page 2-12])............................................................ 1
24 062151300 Capscrew ............................................................................................................ 2
25 016103500 Washer ............................................................................................................... 2
26 015026000 Lockwasher ......................................................................................................... 2
27 014936500 Nut ...................................................................................................................... 2
28 449001170 Capscrew ............................................................................................................ 2
29 909882405 Nut ...................................................................................................................... 3

G13989 02-17
ELECTRICAL SYSTEM (FIGURE 2-2)

SUB-ZERO

02-17 G13989
ELECTRICAL SYSTEM
SUB-ZERO

1 550041104 Edge Protector .................................................................................................... 1
2 060023800 Clamp ................................................................................................................. 1
3 940600907 Washer ............................................................................................................... 7
4 016337000 Washer ............................................................................................................... 1
5 203756500 Capscrew ............................................................................................................ 1
6 312850034 Strap Clamp ........................................................................................................ 1
7 580047200 Screw .................................................................................................................. 2
8 449001170 Capscrew ............................................................................................................ 2
9 ..... Contactor Assembly (FG13995 [Page 2-13]).................................................... 1
10 524258640 Cable Assy (U) .................................................................................................... 1
10 502535902 Terminal ......................................................................................................... 2
10 524256017 Boot ................................................................................................................ 1
11 582032782 Cable Assy (Contactor) ....................................................................................... 1
11 502535902 Terminal ......................................................................................................... 2
11 524256017 Boot ................................................................................................................ 1
12 520031801 Fuse (400 Amp) .................................................................................................. 1
13 582032759 Cable Assy (V) .................................................................................................... 1
13 502535902 Terminal ......................................................................................................... 2
13 524256017 Boot ................................................................................................................ 1
14 582032781 Cable Assy (W) ................................................................................................... 1
14 502535902 Terminal ......................................................................................................... 2
14 524256017 Boot ................................................................................................................ 1
15 449021010 Washer ............................................................................................................... 6
16 449001068 Capscrew ............................................................................................................ 3
17 909882405 Nut ...................................................................................................................... 3
18 582014103 Hand Rail Assy (FG13994 [Page 2-12])............................................................ 1
19 524143269 Horn .................................................................................................................... 1
20 062151300 Capscrew ............................................................................................................ 2
21 016103500 Washer ............................................................................................................... 2
22 015026000 Lockwasher ......................................................................................................... 2
23 014936500 Nut ...................................................................................................................... 2
24 524261854 Wire Harness (Handrail) (FG14000 [Page 2-19]).............................................. 1
25 582026213 Controller (Combi AC1 PW, Hardware Included) ............................................... 1
26 449001202 Capscrew ............................................................................................................ 4
27 449021003 Washer ............................................................................................................... 4
28 449015135 Nut ...................................................................................................................... 4
29 582035400 Heatsink .............................................................................................................. 1

G13990 02-17
MANUAL STEERING ELECTRICAL (FIGURE 2-3)

02-17 G13990
MANUAL STEERING ELECTRICAL

1 582038712 Wire Harness (Manual Steering) (FG14003 [Page 2-22], FG14004 [Page 2-
26])....................................................................................................................... 1
2 524258644 Cable Assy (Power Cable Negative) .................................................................. 1
2 505968563 E-Ring ............................................................................................................ 2
2 524256016 Boot ................................................................................................................ 1
3 524258643 Cable Assy (Power Cable Pump Positive) .......................................................... 1
3 505968563 E-Ring ............................................................................................................ 2
3 524256016 Boot ................................................................................................................ 1
4 582030754 Retainer , Cable Tie ............................................................................................ 4

G13991 02-17
POWER STEERING ELECTRICAL (FIGURE 2-4)

02-17 G13991
POWER STEERING ELECTRICAL

1 582038711 Wire Harness (Power Steering) (FG14007 [Page 2-30], FG14008 [Page 2-
34])....................................................................................................................... 1
2 524260973 Cable Assy (Power Steering B+) ........................................................................ 1
3 582028474 Cable Assy (Power Steering -) ........................................................................... 1
3 580006553 E-Ring ............................................................................................................ 2
4 524258644 Cable Assy (Power Cable Negative) .................................................................. 1
4 505968563 E-Ring ............................................................................................................ 2
4 524256016 Boot ................................................................................................................ 1
5 524258643 Cable Assy (Power Cable Pump Positive) .......................................................... 1
5 505968563 E-Ring ............................................................................................................ 2
5 524256016 Boot ................................................................................................................ 1
6 582033498 Clip ...................................................................................................................... 1
7 582030754 Retainer , Cable Tie ............................................................................................ 5
a 312850034 Strap Clamp ........................................................................................................ 1
FOOTNOTES:
a Not Illustrated

G13992 02-17
DASH DISPLAY (FIGURE 2-5)

1 ..... Mounting Weldment ............................................................................................ 1
2 582029395 Dash Display (Standard) (24V) ........................................................................... 1
2 582028866 Dash Display (Cooler/Subzero) (24V) ................................................................ 1
3 932729905 Capscrew ............................................................................................................ 3
4 580050169 Nut (U-Type) ....................................................................................................... 3
5 752411301 Ignition Switch (Toggle) (Optional) (Not Shown) ................................................ 1
5 582022975 Ignition Switch (With Key Set) (Shown) .............................................................. 1
6 582022976 Key Set (Two Keys) ........................................................................................ 1
a 550079866 Label (Dash Display) .......................................................................................... 1
FOOTNOTES:
a Not Illustrated

02-17 G13993
BATTERY DISCONNECT (FIGURE 2-6)

1 524259886 Battery Connector Assy (Red) ............................................................................ 1
1 723291304 Battery Connector (Red) ................................................................................ 1
1 012472000 Terminal ......................................................................................................... 2
1 524258641 Battery Connector Assy (Gray) ........................................................................... 1
1 723291300 Battery Connector (Gray) ............................................................................... 1
1 012472000 Terminal ......................................................................................................... 2
2 503954200 Battery Connector Pull Handle ........................................................................... 1
3 014867800 Screw .................................................................................................................. 2
4 580017790 Nut ...................................................................................................................... 2
5 580052728 Capscrew ............................................................................................................ 2
6 449022018 Washer ............................................................................................................... 2
7 449015002 Nut ...................................................................................................................... 2

G13994 02-17
AUXILIARY CONTROL BOX AND GRAB RAIL ASSEMBLY (FIGURE 2-7)

582014103 Hand Rail Assy ................................................................................................... 1
582014102 Control Box Assembly (Auxiliary) ................................................................... 1
a 580026824 Microswitch (On-Off, Molex Connector) ..................................................... 4
a 524144372 Spring (Quick Pick) .................................................................................... 1
1 582016096 Rocker Switch (Lift/Lower) ......................................................................... 1
2 582016097 Rocker Switch (Rabbit) .............................................................................. 1
3 580019800 Front Cover ................................................................................................ 1
4 580019801 Rear Cover ................................................................................................. 1
5 582016098 Rocker Switch (Horn) ................................................................................. 1
6 524143403 Capscrew ....................................................................................................... 4
7 524241406 Rail Assy (With Urethane Grips) .................................................................... 1
FOOTNOTES:
a Not Illustrated

02-17 G13995
CONTACTOR ASSEMBLY (FIGURE 2-8)

SUB-ZERO

1 582047975 Bracket Wldmt .................................................................................................... 1
2 582047894 Contactor (Sub-Zero) .......................................................................................... 1
3 449021002 Washer ............................................................................................................... 2
4 449022021 Washer ............................................................................................................... 2
5 930102901 Capscrew ............................................................................................................ 2

G13996 02-17
HEATER INSTALLATION (FIGURE 2-9)

02-17 G13996
HEATER INSTALLATION
1 582053098 Plate .................................................................................................................... 1
2 582033499 Wire Harness (Microswitch) (FG14005 [Page 2-28])......................................... 1
3 580064578 Wire Harness (Heater Assembly) (FG14002 [Page 2-21])................................ 1
4 582033508 Wire Harness (Thermostat) (FG14012 [Page 2-42])......................................... 1
5 580072790 Wire Harness (Heater Application) (FG14001 [Page 2-20]).............................. 1
6 751191100 Mounting Plate .................................................................................................... 1
7 580017792 Screw .................................................................................................................. 1
8 580040162 Screw .................................................................................................................. 1
9 580021081 Capscrew ............................................................................................................ 1

G13997 02-17
WIRE HARNESS (FIGURE 2-10)

ADVANCED COAST CONTROL — MANUAL STEERING

582033404 Wire Harness (Coast Control) ............................................................................. 1
1 ..... Connector Assembly (CPS122 To Magnet) ................................................... 1
1 580019245 Connector (2 Socket) ................................................................................. 1
1 580019246 Connector (Secondary Lock) ..................................................................... 1
1 580019107 Terminal (Socket) ....................................................................................... 2
2 ..... Connector Assembly (CRP121 To Main Harness) ......................................... 1
2 580056006 Connector (2 Pin) ....................................................................................... 1
2 580019353 Terminal (Pin) ............................................................................................. 2

02-17 G13998

ADVANCED COAST CONTROL — POWER STEERING

1 ..... Connector Assembly (CPS122 To Magnet) ................................................... 1
1 580019107 Terminal (Socket) ....................................................................................... 2
2 ..... Connector Assembly (CRP121 To Main Harness) ......................................... 1
2 580056006 Connector (2 Pin) ....................................................................................... 1
2 580019353 Terminal (Pin) ............................................................................................. 2
3 582033498 Clip ................................................................................................................. 1

G13999 02-17

COAST CONTROL — MANUAL STEERING

1 518445603 Connector ....................................................................................................... 1
2 518445601 Pin .................................................................................................................. 3
3 520202601 Connector (Socket Female) ........................................................................... 1
4 580083893 E-Ring ............................................................................................................ 1
5 580041195 Terminal Pin ................................................................................................... 1
6 580039513 Terminal ......................................................................................................... 1

02-17 G14000

HANDRAIL

524261854 Wire Harness (Handrail) ..................................................................................... 1
1 ..... Connector Assembly (To Main Harness) ....................................................... 1
1 580039499 Connector ................................................................................................... 1
1 580039517 Terminal ..................................................................................................... 5
2 ..... Connector Assembly (To Lift Switch) ............................................................. 1
2 518445601 Pin .............................................................................................................. 2
2 518445603 Connector ................................................................................................... 2
3 ..... Connector Assembly (To Horn Switch) .......................................................... 1
3 518445601 Pin .............................................................................................................. 2
3 518445603 Connector ................................................................................................... 2
4 ..... Connector Assembly (To High Speed Switch) ............................................... 1
4 518445601 Pin .............................................................................................................. 2
4 518445603 Connector ................................................................................................... 2
5 ..... Connector Assembly (To Lower Switch) ........................................................ 1
5 518445601 Pin .............................................................................................................. 2
5 518445603 Connector ................................................................................................... 2

G14001 02-17

HEATER APPLICATION

580072790 Wire Harness (Heater Application) ..................................................................... 1
1 518445608 Connector (6 Way) ......................................................................................... 1
2 524152701 Insulator .......................................................................................................... 1
3 518445602 Socket ............................................................................................................ 6
4 580040456 Wire Seal (Yellow) .......................................................................................... 2
5 518445603 Connector ....................................................................................................... 2
6 518445601 Pin .................................................................................................................. 4
7 524152699 Insulator .......................................................................................................... 2
8 580035031 Connector (2 Way) ......................................................................................... 1

02-17 G14002

HEATER ASSEMBLY

580064578 Wire Harness (Heater Assembly) ....................................................................... 1
1 580064548 Heater (24V) ................................................................................................... 1
2 ..... Connector Assembly ...................................................................................... 1
2 518445604 Connector ................................................................................................... 1
2 518445602 Socket ........................................................................................................ 1
2 524152699 Insulator ..................................................................................................... 1

G14003 02-17

MANUAL STEERING — PAGE 1 OF 2

02-17 G14003
WIRE HARNESS
MANUAL STEERING – PAGE 1 OF 2

582038712 Wire Harness (Manual Steering) ........................................................................ 1
1 ..... Terminal (TS004 MN K Coil) .......................................................................... 1
1 504059730 Terminal ..................................................................................................... 1
2 751194100 Fuse Holder .................................................................................................... 2
2 504061787 Fuse (4 Amp) .................................................................................................. 2
3 ..... Ring Terminal (TS017 MN K Post Connector) ............................................... 1
3 504450739 E-Ring ........................................................................................................ 1
4 ..... Connector Assembly (CRP065 Telemetry Interlock) ...................................... 1
4 582020961 Connector ................................................................................................... 1
4 580038290 Terminal ..................................................................................................... 3
4 580019119 Plug ............................................................................................................ 9
4 505972589 Secondary Lock ......................................................................................... 1
5 ..... Connector Assembly (CPS065 Telemetry Interlock) ...................................... 1
5 580036940 Connector ................................................................................................... 1
5 580062388 Terminal ..................................................................................................... 2
5 580019119 Plug ............................................................................................................ 10
5 505968568 Terminal (Socket) ....................................................................................... 1
6 ..... Connector Assembly (CPS015 Diagnostic Connector) .................................. 1
6 580051703 Connector (DT PLU 3-Socket, With Flange) .............................................. 1
6 580062388 Terminal ..................................................................................................... 3
7 580051704 Dust Cap (For Diagnostic Cable) ................................................................... 1
8 ..... Ring Terminal (TS018 MN K Pre-Charge) ..................................................... 1
8 504450739 E-Ring ........................................................................................................ 1
9 ..... Terminal (TS003 MN K Coil +) ....................................................................... 1
9 505972544 Connector (12 Pin) ..................................................................................... 1
10 ..... Connector Assembly (CPS005 Combi Controller) ......................................... 1
10 520202606 Connector (35-Way) ................................................................................... 1
10 520202601 Connector (Socket Female) ....................................................................... 7
10 520202604 Plug , Socket Contact, Female ................................................................... 28
11 ..... Ring Terminal (TS045 Controller B-) .............................................................. 1
11 582034619 E-Ring ........................................................................................................ 1
12 ..... Connector Assembly (CRP103 Tiller End Switch) ......................................... 1
12 580080890 Connector (DTM REC 3-Pin) ..................................................................... 1
12 580019353 Terminal (Pin) ............................................................................................. 2
12 580019119 Plug ............................................................................................................ 1
13 ..... Connector Assembly (CPS001 Temperature Sensor) ................................... 1
13 580035031 Connector (2 Way) ..................................................................................... 1
13 580062119 Receptacle Contact 20-22 AWG ................................................................ 2
13 580040456 Wire Seal (Yellow) ...................................................................................... 2
14 ..... Connector Assembly (CPS003 Traction Enc) ................................................ 1
14 580035032 Connector (4 Way) ..................................................................................... 1
14 580040456 Wire Seal (Yellow) ...................................................................................... 4
15 ..... Connector Assembly (CRP105 Electric Brake) .............................................. 1
15 580056006 Connector (2 Pin) ....................................................................................... 1
15 580019353 Terminal (Pin) ............................................................................................. 2

G14003 02-17
WIRE HARNESS

16 ..... Thermistor ...................................................................................................... 1

02-17 G14003
NOTES

G14004 02-17

MANUAL STEERING — PAGE 2 OF 2

02-17 G14004
WIRE HARNESS

582038712 Wire Harness (Manual Steering) ........................................................................ 1
1 ..... Connector Assembly (CPP115 Tiller Harness) .............................................. 1
1 518445609 Plug ............................................................................................................ 1
1 518445601 Pin .............................................................................................................. 6
2 ..... Connector Assembly (CPP001 Donut Coast) ................................................ 1
2 518445603 Connector ................................................................................................... 1
2 518445601 Pin .............................................................................................................. 2
3 ..... Connector Assembly (CRP119 Regen Switch) .............................................. 1
3 580056006 Connector (2 Pin) ....................................................................................... 1
3 580019353 Terminal (Pin) ............................................................................................. 2
4 ..... Connector Assembly (CPS121 ACC Harness) .............................................. 1
4 580019107 Terminal (Socket) ....................................................................................... 2
5 ..... Spade Terminal (TS019 Key Switch Battery) ................................................. 1
5 580083893 E-Ring ........................................................................................................ 1
6 ..... Connector Assembly (CRS060 Dash Display) ............................................... 1
6 518445608 Connector (6 Way) ..................................................................................... 1
6 518445602 Socket ........................................................................................................ 6
7 ..... Spade Terminal (TS020 Key Switch Coil) ...................................................... 1
7 580083893 E-Ring ........................................................................................................ 1
8 ..... Connector Assembly (CRP108 Hand Rail Harness) ...................................... 1
8 580039490 Connector ................................................................................................... 1
8 580019353 Terminal (Pin) ............................................................................................. 5
8 580019119 Plug ............................................................................................................ 1
9 ..... Connector Assembly (CRP013 Visible Alarm) ............................................... 1
9 580022893 Connector (2 Pin) ....................................................................................... 1
9 580038290 Terminal ..................................................................................................... 2
10 ..... Connector Assembly (CPS088 Pump Coil) .................................................... 1
10 ..... Connector ................................................................................................... 1
11 ..... Connector Assembly (CPS046 Sped) ............................................................ 1
11 580027206 Connector (DT PLU 8-Socket) ................................................................... 1
11 580019119 Plug ............................................................................................................ 2
11 580062388 Terminal ..................................................................................................... 6
12 ..... Terminal (TS002 Horn -) ................................................................................ 1
12 504059730 Terminal ..................................................................................................... 1
13 ..... Terminal (TS001 Horn +) ................................................................................ 1
13 504059730 Terminal ..................................................................................................... 1
14 ..... Connector Assembly (CPS014 Audible) ........................................................ 1
14 580021087 Connector (2 Way) ..................................................................................... 1
14 580062388 Terminal ..................................................................................................... 2

G14005 02-17

MICROSWITCH — HEATER INSTALLATION

582033499 Wire Harness (Microswitch) ................................................................................ 1
1 ..... Connector Assembly (CPS119) ..................................................................... 1
1 524141478 Switch ......................................................................................................... 1
1 580064545 Heater (24V) ............................................................................................... 1
2 524141478 Switch ......................................................................................................... 1
2 580064545 Heater (24V) ............................................................................................... 1
3 580039513 Terminal ..................................................................................................... 2
3 580022891 Connector (DTM PLU 3-Socket) ................................................................ 1
3 580019119 Plug ............................................................................................................ 1
4 580039513 Terminal ..................................................................................................... 2
5 ..... Connector Assembly (CRP4J) ....................................................................... 1
5 518445604 Connector ................................................................................................... 1
5 518445602 Socket ........................................................................................................ 2
5 524152699 Insulator ..................................................................................................... 1

02-17 G14006

MICROSWITCH — TILLER SWITCH INSTALLATION

582033500 Wire Harness (Microswitch, Power Steering) ..................................................... 1
1 524141478 Switch ......................................................................................................... 1
2 524141478 Switch ......................................................................................................... 1
3 580039513 Terminal ..................................................................................................... 2
3 580019119 Plug ............................................................................................................ 1
4 580039513 Terminal ..................................................................................................... 2

G14007 02-17

POWER STEERING — PAGE 1 OF 2

02-17 G14007
WIRE HARNESS
POWER STEERING – PAGE 1 OF 2

582038711 Wire Harness (Power Steering) .......................................................................... 1
1 ..... Terminal (TS004 MN K Coil) .......................................................................... 1
1 504059730 Terminal ..................................................................................................... 1
2 751194100 Fuse Holder .................................................................................................... 2
2 504061787 Fuse (4 Amp) .................................................................................................. 2
3 ..... Ring Terminal (TS017 MN K Post Connector) ............................................... 1
3 504450739 E-Ring ........................................................................................................ 1
4 ..... Connector Assembly (CRP065 Telemetry Interlock) ...................................... 1
4 582020961 Connector ................................................................................................... 1
4 505972589 Secondary Lock ......................................................................................... 1
4 580038290 Terminal ..................................................................................................... 3
4 580019119 Plug ............................................................................................................ 9
5 ..... Connector Assembly (CPS065 Telemetry Interlock) ...................................... 1
5 580036940 Connector ................................................................................................... 1
5 580062388 Terminal ..................................................................................................... 2
5 580019119 Plug ............................................................................................................ 9
5 505968568 Terminal (Socket) ....................................................................................... 1
6 ..... Terminal (TS010 EPAS Calibration) ............................................................... 1
6 504059730 Terminal ..................................................................................................... 1
7 ..... Connector Assembly (CPS015 Diagnostic Connector) .................................. 1
7 580051703 Connector (DT PLU 3-Socket, With Flange) .............................................. 1
7 580062388 Terminal ..................................................................................................... 3
8 580051704 Dust Cap (For Diagnostic Cable) ................................................................... 1
9 ..... Ring Terminal (TS018 MN K Pre-Charge) ..................................................... 1
9 504450739 E-Ring ........................................................................................................ 1
10 ..... Terminal (TS003 MN K Coil +) ....................................................................... 1
10 504059730 Terminal ..................................................................................................... 1
11 ..... Ring Terminal (TS045 Controller B-) .............................................................. 1
11 582034619 E-Ring ........................................................................................................ 1
12 ..... Connector Assembly (CPS005 Combi Controller) ......................................... 1
12 520202606 Connector (35-Way) ................................................................................... 1
12 520202604 Plug , Socket Contact, Female ................................................................... 29
13 ..... Connector Assembly (CRP804 Torque Sensor) ............................................ 1
13 580086209 Connector ................................................................................................... 1
13 582020052
580063957 Secondary Lock (DTM REC 4-Pin) ............................................................ 1
13 580019353 Terminal (Pin) ............................................................................................. 4
14 ..... Connector Assembly (CRP103 Tiller End Switch) ......................................... 1
14 580080890 Connector (DTM REC 3-Pin) ..................................................................... 1
14 580019353 Terminal (Pin) ............................................................................................. 2
15 ..... Connector Assembly (CPS001 Temperature Sensor) ................................... 1
15 580035031 Connector (2 Way) ..................................................................................... 1
15 580040456 Wire Seal (Yellow) ...................................................................................... 2
16 ..... Connector Assembly (CPS003 Traction Enc) ................................................ 1
16 580035032 Connector (4 Way) ..................................................................................... 1

G14007 02-17
WIRE HARNESS

16 580040456 Wire Seal (Yellow) ...................................................................................... 4
17 ..... Connector Assembly (CRP105 Electric Brake) .............................................. 1
17 580056006 Connector (2 Pin) ....................................................................................... 1
17 580019353 Terminal (Pin) ............................................................................................. 2
18 ..... Thermistor ...................................................................................................... 1

02-17 G14007
NOTES

G14008 02-17

POWER STEERING — PAGE 2 OF 2

02-17 G14008
WIRE HARNESS

582038711 Wire Harness (Power Steering) .......................................................................... 1
1 ..... Connector Assembly (CPP115 Tiller Harness) .............................................. 1
1 518445609 Plug ............................................................................................................ 1
1 518445601 Pin .............................................................................................................. 7
2 ..... Connector Assembly (CPP001 Donut Coast) ................................................ 1
2 518445603 Connector ................................................................................................... 1
2 518445601 Pin .............................................................................................................. 2
3 ..... Connector Assembly (CRP119 Regen Switch) .............................................. 1
3 580056006 Connector (2 Pin) ....................................................................................... 1
3 580019353 Terminal (Pin) ............................................................................................. 2
4 ..... Connector Assembly (CPS121 Acc Harness) ................................................ 1
4 580019107 Terminal (Socket) ....................................................................................... 2
5 ..... Connector Assembly (CPS800 Proximity Switch) .......................................... 1
5 580062118 Connector (3 Way) ..................................................................................... 1
5 580051704 Dust Cap (For Diagnostic Cable) ............................................................... 1
6 ..... Spade Terminal (TS020 Key Switch Coil) ...................................................... 1
6 580083893 E-Ring ........................................................................................................ 1
7 ..... Connector Assembly (CRS060 Dash Display) ............................................... 1
7 518445608 Connector (6 Way) ..................................................................................... 1
7 518445602 Socket ........................................................................................................ 7
8 ..... Spade Terminal (TS019 Key Switch Battery) ................................................. 1
8 580083893 E-Ring ........................................................................................................ 1
9 ..... Connector Assembly (CPS803 EPAS Motor) ................................................. 1
9 580036981 Connector (DTM PLU 12-Socket) .............................................................. 1
9 580019107 Terminal (Socket) ....................................................................................... 3
9 580019119 Plug ............................................................................................................ 9
10 ..... Connector Assembly (CRP108 Handrail Harness) ........................................ 1
10 580039490 Connector ................................................................................................... 1
10 580019353 Terminal (Pin) ............................................................................................. 1
10 580019119 Plug ............................................................................................................ 5
11 580022893 Connector (2 Pin) ....................................................................................... 1
11 580038290 Terminal ..................................................................................................... 2
12 ..... Connector Assembly (CPS088 Pump Coil) .................................................... 1
12 ..... Connector ................................................................................................... 1
13 ..... Connector Assembly (CPS046 Sped) ............................................................ 1
13 580027206 Connector (DT PLU 8-Socket) ................................................................... 1
13 580019119 Plug ............................................................................................................ 2
13 580062388 Terminal ..................................................................................................... 6
14 ..... Terminal (TS002 Horn -) ................................................................................ 1
14 504059730 Terminal ..................................................................................................... 1
15 ..... Terminal (TS001 Horn +) ................................................................................ 1

G14008 02-17
WIRE HARNESS

15 504059730 Terminal ..................................................................................................... 1
16 ..... Connector Assembly (CPS014 Audible Alarm) .............................................. 1
16 580021087 Connector (2 Way) ..................................................................................... 1
16 580062388 Terminal ..................................................................................................... 2

02-17 G14008
NOTES

G14009 02-17

RF TERMINAL

02-17 G14009
WIRE HARNESS
RF TERMINAL

582033509 Wire Harness (RF Terminal) ............................................................................... 1
1 ..... Ring Terminal (To Keyswitch +) ..................................................................... 1
1 012470300 Terminal ..................................................................................................... 1
2 ..... Ring Terminal (To + Battery Side of Connector) ............................................ 1
2 065354400 Terminal ..................................................................................................... 1
3 751194100 Fuse Holder .................................................................................................... 1
4 504061787 Fuse (4 Amp) .................................................................................................. 1
5 ..... Ring Terminal (Positive Contactor 1) ............................................................. 1
5 065353900 Terminal (Ring) .......................................................................................... 1
6 ..... Ring Terminal (Positive Key 2) ....................................................................... 1
6 501997902 Terminal (Ring) .......................................................................................... 1
7 ..... Ring Terminal (Positive Key 1) ....................................................................... 1
7 065353900 Terminal (Ring) .......................................................................................... 1
8 ..... Ring Terminal (To Controller B-) .................................................................... 1
8 501997904 Terminal ..................................................................................................... 1
9 582034620 Strap Clamp ................................................................................................... 4
10 ..... Ring Terminal (Negative B- 1) ........................................................................ 1
10 065353900 Terminal (Ring) .......................................................................................... 1
11 ..... Ring Terminal (Negative B- 2) ........................................................................ 1
11 501997902 Terminal (Ring) .......................................................................................... 1
12 ..... Ring Terminal (Positive Contactor 2) ............................................................. 1
12 501997902 Terminal (Ring) .......................................................................................... 1

G14010 02-17

SIDE GLIDE

582003546 Wire Harness ...................................................................................................... 1
1 ..... Connector Assembly (To Side Glide Switch) ................................................. 1
1 518445603 Connector ................................................................................................... 1
1 518445601 Pin .............................................................................................................. 2
1 524152699 Insulator ..................................................................................................... 1
2 ..... Connector Assembly (To K9) ......................................................................... 1
2 518445604 Connector ................................................................................................... 1
2 518445602 Socket ........................................................................................................ 2
2 524152699 Insulator ..................................................................................................... 1
3 ..... Connector Assembly (To Side Glide Switch) ................................................. 1
3 518445603 Connector ................................................................................................... 1
3 518445601 Pin .............................................................................................................. 2
3 524152699 Insulator ..................................................................................................... 1

02-17 G14011

STROBE LIGHT

582033157 Wire Harness (Strobe Light) ............................................................................... 1
1 ..... Connector Assembly (CPS013 Main Harness) .............................................. 1
1 580021087 Connector (2 Way) ..................................................................................... 1
1 505968568 Terminal (Socket) ....................................................................................... 1
2 505968533 Connector ................................................................................................... 1
2 580038290 Terminal ..................................................................................................... 1

G14012 02-17

THERMOSTAT

582033508 Wire Harness (Thermostat) ................................................................................ 1
1 518445607 Connector ....................................................................................................... 1
2 524152701 Insulator .......................................................................................................... 1
3 518445601 Pin .................................................................................................................. 8
4 317222556 Terminal ......................................................................................................... 2
5 012470300 Terminal ......................................................................................................... 1
6 501997904 Terminal ......................................................................................................... 1
7 524287542 Thermostat ..................................................................................................... 1
8 518445603 Connector ....................................................................................................... 1
9 524152699 Insulator .......................................................................................................... 1

02-17 G14013

TILLER HANDLE — COMPOSITE

580069983 Wire Harness (Tiller Handle) .............................................................................. 1
1 ..... Connector Assembly (CPS56) (To K9) .......................................................... 1
1 518445602 Socket ........................................................................................................ 1
1 518445604 Connector ................................................................................................... 1
2 518445610 Connector (8 Way) ..................................................................................... 1
2 518445602 Socket ........................................................................................................ 2
3 ..... Connector Assembly (CPS114) (To K1) ........................................................ 1
3 518445602 Socket ........................................................................................................ 1
4 518445608 Connector (6 Way) ..................................................................................... 1
4 518445602 Socket ........................................................................................................ 3
5 ..... Connector Assembly (CPS115) (To Main Harness) ....................................... 1
5 518445610 Connector (8 Way) ..................................................................................... 1
5 518445602 Socket ........................................................................................................ 7

G14014 02-17

TILLER HANDLE — METAL

02-17 G14014
WIRE HARNESS
TILLER HANDLE – METAL

582033501 Wire Harness (Tiller Handle) .............................................................................. 1
1 ..... Connector Assembly (CPS058 To Sw Assy Harness) ................................... 1
1 580019107 Terminal (Socket) ....................................................................................... 8
2 ..... Connector Assembly (CPP073 Acc Opt) ........................................................ 1
2 518445629 Terminal ..................................................................................................... 1
2 518445601 Pin .............................................................................................................. 1
2 518445603 Connector ................................................................................................... 1
3 ..... Connector Assembly (CPS145 Hall Sen) ....................................................... 1
3 582004633 Terminal ..................................................................................................... 6
3 580038661 Connector ................................................................................................... 1
4 ..... Connector Assembly (CRS115 To Main Harness) ......................................... 1
4 518445610 Connector (8 Way) ..................................................................................... 1
4 518445602 Socket ........................................................................................................ 7
4 524152702 Insulator ..................................................................................................... 1
5 ..... Connector Assembly (CPP050 Metal Tiller Inline A) ...................................... 1
5 518445603 Connector ................................................................................................... 1
5 518445601 Pin .............................................................................................................. 2
6 ..... Connector Assembly (CRP051 Metal Tiller Inline B) ...................................... 1
6 580056006 Connector (2 Pin) ....................................................................................... 1
6 580019353 Terminal (Pin) ............................................................................................. 2
7 ..... Connector Assembly (CPP052 Metal Tiller Inline C) ...................................... 1
7 518445611 Housing ...................................................................................................... 1
7 518445601 Pin .............................................................................................................. 9
8 ..... Connector Assembly (CRS058 Control Module A) ........................................ 1
8 518445618 Connector Body (Molex) ............................................................................ 1
8 518445602 Socket ........................................................................................................ 11
8 582032914 Insulator ..................................................................................................... 1
9 ..... Connector Assembly (CRS057 Control Module B) ........................................ 1
9 518445608 Connector (6 Way) ..................................................................................... 1
9 518445602 Socket ........................................................................................................ 4
9 524152701 Insulator ..................................................................................................... 1
10 ..... Connector Assembly (CRS059 Control Module C) ........................................ 1
10 518445610 Connector (8 Way) ..................................................................................... 1
10 518445602 Socket ........................................................................................................ 2
10 524152702 Insulator ..................................................................................................... 1
11 ..... Connector Assembly (CRS052 Metal Tiller Inline C) ..................................... 1
11 518445612 Connector ................................................................................................... 1
11 518445602 Socket ........................................................................................................ 1
11 518445630 Terminal ..................................................................................................... 8
11 524165666 Insulator ..................................................................................................... 1
12 ..... Connector Assembly (CRS050 Metal Tiller Inline A) ...................................... 1
12 518445604 Connector ................................................................................................... 1
12 518445630 Terminal ..................................................................................................... 2
13 ..... Connector Assembly (CPS051 Metal Tiller Inline B) ...................................... 1
13 580019107 Terminal (Socket) ....................................................................................... 2

G14014 02-17
NOTES

SECTION 3
3 STEER HANDLE/BRAKE SYSTEM

CONTENTS
SECTION 3
STEER HANDLE/BRAKE SYSTEM
DESCRIPTION PAGE
COAST CONTROL
MANUAL STEERING .................................................................................................................................. 3-16
POWER STEERING ................................................................................................................................... 3-17
TILLER ARM ASSEMBLY
COMPOSITE HANDLE ............................................................................................................................... 3-2
METAL HANDLE ......................................................................................................................................... 3-4
TILLER HEAD
CONTROL BOX .......................................................................................................................................... 3-14
COMPOSITE ............................................................................................................................................... 3-6
METAL HANDLE ......................................................................................................................................... 3-10
WITH COAST CONTROL - POWER STEERING ....................................................................................... 3-22
WITH COAST CONTROL - MANUAL STEERING ...................................................................................... 3-28
WITHOUT COAST CONTROL OR WITH MANUAL COAST CONTROL - POWER STEERING ............... 3-18
WITHOUT COAST CONTROL OR WITH MANUAL COAST CONTROL - MANUAL STEERING ............. 3-26

G14015 02-17
TILLER ARM ASSEMBLY (FIGURE 3-1)

COMPOSITE HANDLE

02-17 G14015
TILLER ARM ASSEMBLY

COMPOSITE HANDLE
KEY:
A: Without Coast Control or With Manual Coast Control
B: With Advanced Coast Control
QTY
ITEM PART NO. DESCRIPTION A B
1 582031269 Tiller Head Assembly (FG14017 [Page 3-6])............................................ 1 ..
1 582031268 Tiller Head Assembly (FG14017 [Page 3-6])............................................ .. 1
2 582030475 Tiller Arm Assembly ................................................................................... 1 ..
2 582030474 Tiller Arm Assembly ................................................................................... .. 1
2 582029729 Tiller Wldmt ............................................................................................ 1 1
3 582029854 Bushing .................................................................................................. 2 ..
3 582029608 Bearing .................................................................................................. .. 2
4 582029677 Rod Seal ................................................................................................ .. 2
5 582035377 Spacer ................................................................................................... .. 1
6 449007018 Screw ......................................................................................................... 1 1
7 449022018 Washer ....................................................................................................... 1 1
8 580021175 Clamp ......................................................................................................... 1 1
9 449015002 Nut .............................................................................................................. 1 1
10 580000119 Plug ............................................................................................................ 2 2
11 582003591 Strap Clamp (Button Head) ........................................................................ 1 1
12 032586000 Lockwasher ................................................................................................ 1 1
13 059863600 Capscrew ................................................................................................... 1 1
14 580069983 Wire Harness (Tiller Handle) (FG14013 [Page 2-43])............................... 1 1
15 580083357
582003113 Gas Spring ................................................................................................. 1 1
16 582018503 Ball Stud ..................................................................................................... 1 1
17 501729905 Capscrew ................................................................................................... 1 1
18 449015014 Nut .............................................................................................................. 1 1
19 582000129 Capscrew ................................................................................................... 2 2
20 582000130 Locknut ....................................................................................................... 2 2
21 620033319 Shim (0.030 in.) .......................................................................................... 2 2
22 449021001 Washer ....................................................................................................... 1 1

G14016 02-17
TILLER ARM ASSEMBLY (FIGURE 3-2)

METAL HANDLE

02-17 G14016
TILLER ARM ASSEMBLY

METAL HANDLE
KEY:
A: Without Coast Control
C: With Manual Coast Control
QTY
ITEM PART NO. DESCRIPTION A B C
1 550028164 Tiller Head Assembly (FG14018 [Page 3-10])................................. 1 .. ..
1 550014959 Tiller Head Assembly (FG14018 [Page 3-10])................................. .. 1 ..
1 550014958 Tiller Head Assembly (FG14018 [Page 3-10])................................. .. .. 1
2 582030478 Tiller Arm Assembly .......................................................................... 1 .. 1
2 582030477 Tiller Arm Assembly .......................................................................... .. 1 ..
2 582029730 Tiller Wldmt ................................................................................... 1 1 1
3 580044860 Insert ............................................................................................. 4 4 4
4 582029854 Bushing ......................................................................................... 2 .. 2
4 582029608 Bearing .......................................................................................... .. 2 ..
4 582029677 Rod Seal (Not Shown) .................................................................. .. 2 ..
5 582003591 Strap Clamp (Button Head) ............................................................... 1 1 1
6 580000119 Plug ................................................................................................... 1 1 1
7 449021001 Washer .............................................................................................. 4 4 4
8 940400908 Washer .............................................................................................. 4 4 4
9 580049229 Capscrew .......................................................................................... 4 4 4
10 449015014 Nut ..................................................................................................... 1 1 1
11 501729905 Capscrew .......................................................................................... 1 1 1
12 582018503 Ball Stud ............................................................................................ 1 1 1
13 582002075 Gas Spring ........................................................................................ 1 1 1
14 582026223 Control Module (CAN) ....................................................................... 1 1 1
15 ..... Bracket .............................................................................................. 1 1 1
16 932200905 Capscrew .......................................................................................... 2 2 2
17 449021003 Washer .............................................................................................. 2 2 2
18 449015002 Nut ..................................................................................................... 2 2 2
19 620033319 Shim (0.030 in.) ................................................................................. 2 2 2
20 032586000 Lockwasher ....................................................................................... 1 1 1
21 059863600 Capscrew .......................................................................................... 1 1 1
a 582033501 Wire Harness (Tiller Handle) (FG14014 [Page 2-44])...................... 1 1 1
FOOTNOTES:
a Not Illustrated

G14017 02-17
TILLER HEAD ASSEMBLY (FIGURE 3-3)

COMPOSITE

02-17 G14017

COMPOSITE
KEY:
QTY
582031269 Tiller Head Assembly ................................................................................. 1 ..
582031268 Tiller Head Assembly ................................................................................. .. 1
1 524180331
524335825 Housing , Lower ..................................................................................... 1 1
2 580096039
524180332 Housing (Upper) .................................................................................... 1 1
2 582019747 Plate .................................................................................................. 1 1
2 582019746 Screw ................................................................................................ 2 2
3 582027529 Printed Circuit Board .............................................................................. 1 1
4 582016090 Knob (RH Butterfly) ................................................................................ 1 1
5 ..... Camshaft ........................................................................................... 1 1
6 582016089 Knob (LH Butterfly) ................................................................................ 1 1
7 940004902 Washer (Butterfly Switch) ...................................................................... 2 2
8 580026296 Capscrew (Butterfly Switch) ................................................................... 2 2
9 580012970 Spring , Directional Control Return ........................................................ 1 1
10 580012962 Bushing (Butterfly Switch) ...................................................................... 2 2
11 582010514
580011991 Cover (Belly Switch) .............................................................................. 1 1
12 580012969 Spring (Horn/Snail) ................................................................................ 1 1
13 524149133 Wire Harness (Quick Pick Switch) ......................................................... 2 ..
14 580026824 Microswitch (On-Off, Molex Connector) ................................................. 2 ..
15 524144372 Spring (Quick Pick) ................................................................................ 2 ..
16 582005203 Horn Button Cover ................................................................................. 1 1
17 582007128 Push Button Switch Assembly (On-Off) ................................................. 4 4
17 582015753 Push Button Switch (On-Off) ............................................................. 1 1
17 524144372 Spring (Quick Pick) ....................................................................... 1 1
17 580055434 Cover , Rubber (On-Off Version) .................................................. 1 1
17 582015754 Cover , Top (For Push Button) ...................................................... 1 1
17 580026824 Microswitch (On-Off, Molex Connector) ........................................ 1 1
18 932200901 Capscrew ............................................................................................... 1 1
19 524180333 Screw ..................................................................................................... 4 4
20 580012967 Label (RH Switch Functions) ................................................................. 1 1
21 580012968 Label (LH Switch Functions) .................................................................. 1 1
22 524144387 Label (Yale Logo, Tiller Handle) ............................................................ 1 1
23 524144374 Actuator (Black) ..................................................................................... 2 2
23 582034277 Actuator (Gray) ...................................................................................... 2 ..
24 580038175 Spring (Cover, Belly) .............................................................................. 1 1
24 580082841 Locking Lever (Belly Spring) .................................................................. 1 1
25 580060389 Spring , Directional Control Return ........................................................ 1 1
26 524292775 Screw ..................................................................................................... 1 1
27 580079167 Support Clip ........................................................................................... 1 1
28 582000129 Capscrew ................................................................................................... 2 2
28 582000130 Locknut ....................................................................................................... 2 2
a 524170074 Button (On/Off Push Button, Tilt Function Select) ..................................... .. 2

G14017 02-17

COMPOSITE
KEY:
QTY
582015387 Kit (Actuator-Side Glide) ............................................................................ 1 ..
FOOTNOTES:
a Not Illustrated

02-17 G14017
NOTES

G14018 02-17
TILLER HEAD ASSEMBLY (FIGURE 3-4)

METAL HANDLE

02-17 G14018

METAL HANDLE
KEY:
B: With Manual Coast Control
C: With Advanced Coast Control
QTY
550028164 Tiller Head Assembly ........................................................................ 1 .. ..
550014958 Tiller Head Assembly ........................................................................ .. 1 ..
550014959 Tiller Head Assembly ........................................................................ .. .. 1
1 550012747 Tiller Head (Control Box) (FG14019 [Page 3-14])....................... 1 1 ..
1 550021665 Tiller Head (Control Box) (FG14019 [Page 3-14])....................... .. .. 1
2 550026837 Pin ................................................................................................. 2 2 2
3 580061791 Snap Ring ..................................................................................... 2 2 2
4 550026784 Bushing ......................................................................................... 2 2 2
5 550026220 Washer .......................................................................................... 2 2 2
6 524335005 Handle Grip ................................................................................... 2 2 2
6 504200200 Handle Grip ............................................................................... 1 1 1
6 524334911 Grip ........................................................................................... 1 1 1
7 550027800 Shaft Assembly ............................................................................. 1 1 1
7 550026136 Shaft ......................................................................................... 1 1 1
7 550026131 Bushing ..................................................................................... 2 2 2
8 585085800 Knob (Rotary Control) ................................................................... 2 2 2
9 550023135 Shim .............................................................................................. 2 2 2
10 550024288 Sleeve (Throttle) ............................................................................ 1 1 1
11 580030111 Pin ................................................................................................. 5 5 5
12 550012083 Control Handle .............................................................................. 1 1 1
13 550030520 Bracket Wldmt .......................................................................... 1 1 1
14 449015002 Nut ............................................................................................ 2 2 2
15 940400907 Washer ..................................................................................... 2 2 2
16 449001056 Capscrew .................................................................................. 2 2 2
17 580095939 Sensor ...................................................................................... 1 1 1
18 582013309 Casting (Throttle Cam) ............................................................. 1 1 1
19 550012709
582054541 Spring ....................................................................................... 1 1 1
20 550013934 Bushing ..................................................................................... 2 2 2
21 580039438 Capscrew ...................................................................................... 2 2 2
22 580001743 Cotter Pin ...................................................................................... 1 1 1
23 550018103 Link ................................................................................................ 1 1 1
24 524337569 Jumper .......................................................................................... .. .. 1
24 518445604 Connector ................................................................................. .. .. 3
24 518445623 Socket ....................................................................................... .. .. 2
24 518445603 Connector ................................................................................. .. .. 2
24 518445601 Pin ............................................................................................. .. .. 4
25 580021175 Clamp ............................................................................................ 1 1 1
26 940400907 Washer .......................................................................................... 1 1 1
27 449021003 Washer .......................................................................................... 1 1 1
28 449015002 Nut ................................................................................................. 1 1 1
29 449001170 Capscrew ...................................................................................... 1 1 1
30 550030894 Screw ............................................................................................ 2 2 2
31 449007018 Screw ............................................................................................ .. 4 4

G14018 02-17

METAL HANDLE
KEY:
B: With Manual Coast Control
C: With Advanced Coast Control
QTY
32 940400907 Washer .......................................................................................... .. 4 4
33 550020857 Bracket .......................................................................................... .. 2 2
34 580083001 Insert ............................................................................................. .. 4 4
35 550021182 Actuator ......................................................................................... .. 2 2
36 501067207 Spring ............................................................................................ .. 4 4
37 550021071 Microswitch ................................................................................... .. 2 2
38 580018749 Screw ............................................................................................ .. 4 4
39 550020859 Bracket Assembly ......................................................................... .. 2 2
39 550020858 Bracket ...................................................................................... .. 1 1
39 503949202 Fastener .................................................................................... .. 2 2
40 550021186 Jumper .......................................................................................... .. 1 1
40 518445604 Connector ................................................................................. .. 1 1
40 518445623 Socket ....................................................................................... .. 2 2
40 518445603 Connector ................................................................................. .. 2 2
40 518445601 Pin ............................................................................................. .. 4 4
41 550024286 Tiller Handle .................................................................................. 1 .. ..
41 550024287 Tiller Handle .................................................................................. .. 1 1
42 524337093 Push Button Switch ....................................................................... .. .. 2

02-17 G14018
NOTES

G14019 02-17
TILLER HEAD (FIGURE 3-5)

CONTROL BOX

02-17 G14019
TILLER HEAD
CONTROL BOX

a 550012747 Tiller Head .......................................................................................................... 1
b 550021665 Tiller Head .......................................................................................................... 1
1 a 550020855 Cover .............................................................................................................. 1
1 b 550020856 Cover .............................................................................................................. 1
2 a. . . . . Handle, Top Cover ..................................................................................... 1
3 ..... Handle, Base Cover ................................................................................... 1
4 550022120 Actuator .......................................................................................................... 1
5 550022122 Actuator .......................................................................................................... 1
6 550022121 Actuator .......................................................................................................... 1
7 505931500 Actuator .......................................................................................................... 1
8 503956200 Stop ................................................................................................................ 1
9 501067206 Spring ............................................................................................................. 2
10 501067207 Spring ............................................................................................................. 6
11 550011383 Plate ............................................................................................................... 1
12 550012711 Support ........................................................................................................... 1
13 449025027 Cotter Pin ....................................................................................................... 1
14 502023904 Screw ............................................................................................................. 4
15 580032494 Washer ........................................................................................................... 1
16 580017101 Washer ........................................................................................................... 1
17 580056589 Clip ................................................................................................................. 1
18 582005051 Switch ............................................................................................................. 1
18 518445603 Connector ................................................................................................... 1
18 518445601 Pin .............................................................................................................. 2
18 524152699 Insulator ..................................................................................................... 1
18 580042219 Connector (8 Pin) ....................................................................................... 1
18 580019353 Terminal (Pin) ............................................................................................. 8
19 524337093 Push Button Switch ............................................................................................. 2
19 524170074 Button (On/Off Push Button, Tilt Function Select) .......................................... 1
19 518445602 Socket ............................................................................................................ 2
20 502023906 Screw .................................................................................................................. 2
FOOTNOTES:
a Standard-Without Coast Control b With Auto Coast Control

G14020 02-17
COAST CONTROL (FIGURE 3-6)

MANUAL STEERING

1 524159395 Bracket ................................................................................................................ 1
2 524142886 Stop .................................................................................................................... 1
3 524158911 Shaft ................................................................................................................... 1
4 502677909 Pin , Coiled ......................................................................................................... 1
5 524294108 Microswitch Assembly ........................................................................................ 1
5 524141478 Switch ............................................................................................................. 1
5 518445602 Socket ............................................................................................................ 2
5 518445604 Connector ....................................................................................................... 1
6 524159394 Cover (With Pem Nuts) ....................................................................................... 1
7 524143897 Screw .................................................................................................................. 2
8 520038861 Capscrew ............................................................................................................ 3
a 524143900 Label (Coast Control) .......................................................................................... 1
a 524285957 Wire Harness (Coast Control) (FG13999 [Page 2-18])..................................... 1
FOOTNOTES:
a Not Illustrated

02-17 G14021
COAST CONTROL (FIGURE 3-7)

POWER STEERING

1 582030193 Bracket (Flip Stop) .............................................................................................. 1
2 582030278 Spacer Block ....................................................................................................... 1
3 524143897 Screw .................................................................................................................. 2
4 524294108 Microswitch Assembly ........................................................................................ 1
4 524141478 Switch ............................................................................................................. 1
4 518445602 Socket ............................................................................................................ 2
4 518445604 Connector ....................................................................................................... 1
5 524280933 Cover (With Nuts) ............................................................................................... 1
5 503949202 Fastener ......................................................................................................... 2
6 524142886 Stop .................................................................................................................... 1
7 524158911 Shaft ................................................................................................................... 1
8 502677909 Pin , Coiled ......................................................................................................... 1
9 580030967 Capscrew ............................................................................................................ 2
a 524143900 Label (Coast Control) .......................................................................................... 1
FOOTNOTES:
a Not Illustrated

G14022 02-17
TILLER SWIVEL ASSEMBLY (FIGURE 3-8)

WITHOUT COAST CONTROL OR WITH MANUAL COAST CONTROL — POWER STEERING

02-17 G14022

WITHOUT COAST CONTROL OR WITH MANUAL COAST CONTROL – POWER STEERING

1 580083871 Capscrew ............................................................................................................ 6
2 582038750 Cover (Steering Swivel, Manual Donut Coast) ................................................... 1
2 582033187 Cover (Steering Swivel, Advanced Coast Control/Power Steering) ................... 1
3 582047063 Bracket (Harness Guard) .................................................................................... 1
4 582031919 Stud .................................................................................................................... 2
5 582034618 Bracket (Harness Mount) .................................................................................... 1
6 940600908 Washer ............................................................................................................... 2
7 580032375 Capscrew ............................................................................................................ 2
8 582029332 Swivel ................................................................................................................. 1
9 449025008 Cotter Pin ............................................................................................................ 1
10 524141162 Shaft ................................................................................................................... 1
11 504574232 Grease Fitting ..................................................................................................... 1
12 582029386 Housing ............................................................................................................... 1
13 449001068 Capscrew ............................................................................................................ 4
14 504225227 Washer ............................................................................................................... 8
15 449022017 Lockwasher ......................................................................................................... 6
16 449015029 Nut ...................................................................................................................... 4
17 505970553 Capscrew ............................................................................................................ 2
18 582033185 Shield (Center Cowl) ........................................................................................... 1
19 580077644 Ball Bearing ........................................................................................................ 1
20 550025497 Spacer ................................................................................................................ 1
21 580069343 Ball Bearing ........................................................................................................ 1
22 582015291 Nut ...................................................................................................................... 1
23 582018677 Sensor (Torque) .................................................................................................. 1
23 580019097 Connector ....................................................................................................... 1
23 580019107 Terminal (Socket) ........................................................................................... 4
23 580019098 Secondary Lock (DTM PLU 4-Socket) ........................................................... 1
24 550028587 Gear , Steer (120 Tooth) ..................................................................................... 1
25 524257337 Cover .................................................................................................................. 1
26 580023890 Capscrew ............................................................................................................ 2
27 449021003 Washer ............................................................................................................... 2
28 580027573 Nut ...................................................................................................................... 2
29 580017792 Screw .................................................................................................................. 1
30 580059974 Shaft , Articulated ............................................................................................... 1
31 580049229 Capscrew ............................................................................................................ 2
32 582042369 Bracket (Bottom Connector) ............................................................................... 1
33 550029660 Bracket Wldmt (Dash Support) ........................................................................... 1
34 580049231 Capscrew ............................................................................................................ 2
35 272342900 Switch (Proximity) ............................................................................................... 1
36 582033500 Wire Harness (Microswitch, Power Steering) (FG14006 [Page 2-29]).............. 1
37 580040162 Screw .................................................................................................................. 2
38 751191100 Mounting Plate .................................................................................................... 1
39 580077646 Dowel .................................................................................................................. 1
40 580060125 Dowel .................................................................................................................. 1
41 080816000 Ball Bearing ........................................................................................................ 1
42 015915600 Snap Ring ........................................................................................................... 1
43 550028540 Baseplate ............................................................................................................ 1
44 580003129 Dowel Pin ............................................................................................................ 2
45 582021324
449001058 Capscrew ............................................................................................................ 2

G14022 02-17

WITHOUT COAST CONTROL OR WITH MANUAL COAST CONTROL – POWER STEERING

46 550028586 Gear , Pinion (26 Tooth) ..................................................................................... 1
47 504057788 Snap Ring ........................................................................................................... 1
48 449051014 Ball Bearing ........................................................................................................ 1
49 015915100 Snap Ring ........................................................................................................... 1
50 504238298 Locknut ............................................................................................................... 2
51 062307300 Capscrew ............................................................................................................ 2
52 582028792 Bar (Torsion) ....................................................................................................... 1
53 580030966 Capscrew ............................................................................................................ 2
54 580021081 Capscrew ............................................................................................................ 1
55 582053098 Plate .................................................................................................................... 1

02-17 G14022
NOTES

G14023 02-17

WITH COAST CONTROL — POWER STEERING

02-17 G14023

WITH COAST CONTROL – POWER STEERING

1 580083871 Capscrew ............................................................................................................ 6
3 582047063 Bracket (Harness Guard) .................................................................................... 1
4 582031919 Stud .................................................................................................................... 2
5 580032377 Capscrew ............................................................................................................ 1
6 940600908 Washer ............................................................................................................... 4
7 582014171 Clip ...................................................................................................................... 1
8 449015014 Nut ...................................................................................................................... 8
9 582031162 Plate (Magnet Mount) ......................................................................................... 1
10 582031425 Stud .................................................................................................................... 3
11 582034618 Bracket (Harness Mount) .................................................................................... 1
12 504235265 Capscrew ............................................................................................................ 2
13 582033309 Disk , Piston ........................................................................................................ 2
14 015914900 Snap Ring ........................................................................................................... 1
15 620033319 Shim (0.030 in.) .................................................................................................. 2
16 582029727 O-Ring ................................................................................................................ 2
17 582033307 Shaft ................................................................................................................... 1
18 582034617
582064507 Bushing ............................................................................................................... 2
19 582029464 Swivel ................................................................................................................. 1
20 582033308 Rod (Clutch Actuator) ......................................................................................... 1
21 582029485 Brake Disk (Stationary) ....................................................................................... 5
22 582029486 Brake Disk (Rotating) .......................................................................................... 5
23 582030783 Bolt ...................................................................................................................... 1
24 580077644 Ball Bearing ........................................................................................................ 1
25 582029386 Housing ............................................................................................................... 1
26 504225227 Washer ............................................................................................................... 8
27 449001068 Capscrew ............................................................................................................ 4
28 751191100 Mounting Plate .................................................................................................... 1
29 580040162 Screw .................................................................................................................. 2
30 582033500 Wire Harness (Microswitch, Power Steering) ..................................................... 1
31 582033405 Wire Harness (Coast Control) (FG13998 [Page 2-17])..................................... 1
32 449022017 Lockwasher ......................................................................................................... 6
33 449015029 Nut ...................................................................................................................... 4
34 505970553 Capscrew ............................................................................................................ 2
36 550025497 Spacer ................................................................................................................ 1
37 580069343 Ball Bearing ........................................................................................................ 1
38 582015291 Nut ...................................................................................................................... 1
39 582018677 Sensor (Torque) .................................................................................................. 1
39 580019097 Connector ....................................................................................................... 1
39 580019107 Terminal (Socket) ........................................................................................... 4
39 580019098 Secondary Lock (DTM PLU 4-Socket) ........................................................... 1
40 550028587 Gear , Steer (120 Tooth) ..................................................................................... 1
41 524257337 Cover .................................................................................................................. 1
42 580023890 Capscrew ............................................................................................................ 2
43 449021003 Washer ............................................................................................................... 2
44 582028792 Bar (Torsion) ....................................................................................................... 1
45 580077646 Dowel .................................................................................................................. 1
46 580060125 Dowel .................................................................................................................. 1

G14023 02-17

WITH COAST CONTROL – POWER STEERING

47 080816000 Ball Bearing ........................................................................................................ 1
48 015915600 Snap Ring ........................................................................................................... 1
49 550028540 Baseplate ............................................................................................................ 1
50 272342900 Switch (Proximity) ............................................................................................... 1
51 582029732 Magnet ................................................................................................................ 1
52 580027573 Nut ...................................................................................................................... 2
53 580049231 Capscrew ............................................................................................................ 2
54 580030966 Capscrew ............................................................................................................ 2
55 580049229 Capscrew ............................................................................................................ 2
56 582042369 Bracket (Bottom Connector) ............................................................................... 1
57 550029660 Bracket Wldmt (Dash Support) ........................................................................... 1
58 580003129 Dowel Pin ............................................................................................................ 2
59 582021324
449001058 Capscrew ............................................................................................................ 2
60 550028586 Gear , Pinion (26 Tooth) ..................................................................................... 1
61 504057788 Snap Ring ........................................................................................................... 1
62 449051014 Ball Bearing ........................................................................................................ 1
63 015915100 Snap Ring ........................................................................................................... 1
64 504238298 Locknut ............................................................................................................... 2
65 062307300 Capscrew ............................................................................................................ 2
66 580059974 Shaft , Articulated ............................................................................................... 1

02-17 G14023
NOTES

G14024 02-17

WITHOUT COAST CONTROL OR WITH MANUAL COAST CONTROL — MANUAL STEERING

02-17 G14024

WITHOUT COAST CONTROL OR WITH MANUAL COAST CONTROL – MANUAL STEERING

1 520038861 Capscrew ............................................................................................................ 3
2 524144590 Cover (Tiller Swivel) ............................................................................................ 1
3 585045700 Locknut ............................................................................................................... 1
4 520012800 Sleeve ................................................................................................................. 2
5 501902908 Lockwasher ......................................................................................................... 1
6 524335288 Swivel ................................................................................................................. 1
7 504574232 Grease Fitting ..................................................................................................... 1
8 524141162 Shaft ................................................................................................................... 1
9 449025008 Cotter Pin ............................................................................................................ 1
10 524149410 Spacer ................................................................................................................ 2
11 519432646 Bearing Cone ...................................................................................................... 2
12 296323263 Bearing Cup ........................................................................................................ 2
13 932728907 Capscrew ............................................................................................................ 2
15 524261860 Center Support (Dash Panel) ............................................................................. 1
16 449001049 Capscrew ............................................................................................................ 4
17 504225227 Washer ............................................................................................................... 8
18 449022017 Lockwasher ......................................................................................................... 4
19 449015029 Nut ...................................................................................................................... 4
20 524149411 Shaft (Standoff) ................................................................................................... 1
21 502172902 Key (Squared) ..................................................................................................... 1
22 580027572 Nut ...................................................................................................................... 2
23 449001302 Capscrew ............................................................................................................ 2
24 582055198 Plate .................................................................................................................... 1
25 449021006 Washer ............................................................................................................... 2
26 580030970 Capscrew ............................................................................................................ 4

G14025 02-17

WITH COAST CONTROL — MANUAL STEERING

02-17 G14025

WITH COAST CONTROL – MANUAL STEERING

1 582029732 Magnet ................................................................................................................ 1
3 582033404 Wire Harness (Coast Control) (FG13997 [Page 2-16])..................................... 1
4 582031919 Stud .................................................................................................................... 2
5 582032716 Bracket (Cover Mount) ........................................................................................ 1
6 940600907 Washer ............................................................................................................... 6
7 580060018 Nut ...................................................................................................................... 2
8 580030970 Capscrew ............................................................................................................ 4
9 500226901 Clamp ................................................................................................................. 1
10 580083871 Capscrew ............................................................................................................ 8
12 580032377 Capscrew ............................................................................................................ 1
13 940600908 Washer ............................................................................................................... 7
14 582014171 Clip ...................................................................................................................... 1
15 449015014 Nut ...................................................................................................................... 6
16 582031162 Plate (Magnet Mount) ......................................................................................... 1
17 582031013 Stud .................................................................................................................... 3
18 504235265 Capscrew ............................................................................................................ 2
19 582033309 Disk , Piston ........................................................................................................ 2
20 582031141 Mounting Plate .................................................................................................... 1
21 900014292 Capscrew ............................................................................................................ 3
22 620033319 Shim (0.030 in.) .................................................................................................. 2
23 015914900 Snap Ring ........................................................................................................... 1
24 582033307 Shaft ................................................................................................................... 1
25 582034617
582064507 Bushing ............................................................................................................... 2
26 582029727 O-Ring ................................................................................................................ 2
27 582033308 Rod (Clutch Actuator) ......................................................................................... 1
28 582029486 Brake Disk (Rotating) .......................................................................................... 5
29 582029485 Brake Disk (Stationary) ....................................................................................... 5
30 582030783 Bolt ...................................................................................................................... 1
31 585045700 Locknut ............................................................................................................... 1
32 501902908 Lockwasher ......................................................................................................... 1
33 520012800 Sleeve ................................................................................................................. 2
34 524149410 Spacer ................................................................................................................ 2
35 519432646 Bearing Cone ...................................................................................................... 2
36 296323263 Bearing Cup ........................................................................................................ 2
37 524261860 Center Support (Dash Panel) ............................................................................. 1
38 449001049 Capscrew ............................................................................................................ 4
39 504225227 Washer ............................................................................................................... 8
40 449022017 Lockwasher ......................................................................................................... 4
41 449015029 Nut ...................................................................................................................... 4
42 524149411 Shaft (Standoff) ................................................................................................... 1
43 502172902 Key (Squared) ..................................................................................................... 1
44 580027572 Nut ...................................................................................................................... 2
45 449001302 Capscrew ............................................................................................................ 2
46 582055198 Plate .................................................................................................................... 1
47 582029432 Casting ................................................................................................................ 1
48 449021006 Washer ............................................................................................................... 2

G14025 02-17
NOTES

SECTION 4
4 LIFT LINKAGE, LOAD WHEELS, AND FORKS

CONTENTS
SECTION 4
LIFT LINKAGE, LOAD WHEELS, AND FORKS
DESCRIPTION PAGE
CASTER ASSEMBLY
SPRING LOADED - STANDARD ................................................................................................................ 4-12
SPRING LOADED - HEAVY DUTY ............................................................................................................. 4-14
SPRING LOADED - HEAVY DUTY, SEALED BEARINGS ......................................................................... 4-16
FORKS ............................................................................................................................................................ 4-4
LIFT LINKAGE ................................................................................................................................................. 4-2
LOAD WHEELS
DUAL WHEEL ............................................................................................................................................. 4-9
DUAL WHEEL - SEALED BEARINGS ........................................................................................................ 4-10
SINGLE WHEEL, FOUR BEARINGS .......................................................................................................... 4-7
SINGLE WHEEL, FOUR BEARINGS - SEALED ........................................................................................ 4-8
SINGLE WHEEL, TWO BEARINGS ........................................................................................................... 4-5
SINGLE WHEEL, TWO BEARINGS - SEALED .......................................................................................... 4-6

G14026 02-17
LIFT LINKAGE (FIGURE 4-1)

02-17 G14026
LIFT LINKAGE
1 524141197 Pin , Pivot (Lower Link Pull Rod) ........................................................................ 2
2 ..... Load Wheel Assy (FG14028 [Page 4-5], FG14029 [Page 4-6],
FG14030 [Page 4-7], FG14031 [Page 4-8], FG14032 [Page 4-9],
FG14033 [Page 4-10])........................................................................................ 2
3 524140887 Rocker Arm Assembly ........................................................................................ 2
4 524140878 Bushing .......................................................................................................... 4
5 502677908 Pin , Chrome Spring ........................................................................................... 14
6 015631500 Grease Fitting ..................................................................................................... 10
7 524140839 Pin , Pivot (Lower Link Fork Frame) ................................................................... 2
8 524140842 Pin , Coiled ......................................................................................................... 6
9 582029845 Pull Rod (For Use With Standard Load Backrest) (36 in.) .................................. 2
9 582029848 Pull Rod (For Use With Bolt-On Load Backrest) (38 in.) .................................... 2
10 524140881 Bushing .......................................................................................................... 2
11 015631300 Grease Fitting ..................................................................................................... 6
12 580015511 Nut ...................................................................................................................... 6
13 524141079 Rod , Threaded ................................................................................................... 2
14 524323505 Washer , Belleville .............................................................................................. 4
15 580017789 Nut ...................................................................................................................... 4
16 015628700 Grease Fitting ..................................................................................................... 2
17 524140885 Yoke Assembly ................................................................................................... 2
18 524140880 Bushing .......................................................................................................... 2
19 550007599 Axle Shaft ........................................................................................................... 2
20 504574232 Grease Fitting ..................................................................................................... 4
21 524140837 Pin , Pivot (Upper Fork Frame Link) ................................................................... 2
22 550007477 Roller Assembly (Pallet Exit) .............................................................................. 2
23 003261800 Bushing .......................................................................................................... 2
24 582029829 Link Assy (Rear) ................................................................................................. 2
25 524302804 Bushing .......................................................................................................... 2
26 524140838 Pin , Pivot (Lower Link Drive Frame) .................................................................. 2
27 524141201 Pin , Pivot (Rear Link/Yoke) ................................................................................ 2
28 524301377 Pin , Pivot ............................................................................................................ 2
29 062960000 Washer ............................................................................................................... 8
30 502677902 Pin ....................................................................................................................... 4
31 524295210 Capscrew ............................................................................................................ 2
32 014937400 Nut ...................................................................................................................... 2
33 582019046 Pin , Lynch .......................................................................................................... 2
34 524141179 Link Assy, Upper ................................................................................................. 2
35 524140879 Bushing .......................................................................................................... 2
36 550030981 Pin , Pivot (Upper Drive Frame Link) .................................................................. 2

G14027 02-17
FORKS (FIGURE 4-2)

1 582034421 Fork Frame (Bolt-On Load Backrest) (48 in.) ..................................................... 1
1 582034414 Fork Frame (Pivot Load Backrest and Battery Removal) (36 in.) ....................... 1
1 582034352 Fork Frame (Standard) (48 in.) ........................................................................... 1
1 582034411 Fork Frame (Battery Removal) (36 in.) ............................................................... 1
1 582034354 Fork Frame (Pivot Load Backrest) (48 in.) .......................................................... 1
1 582034418 Fork Frame (Bolt-On Load Backrest and Battery Removal) (36 in.) ................... 1

02-17 G14028
LOAD WHEELS (FIGURE 4-3)

SINGLE WHEEL, TWO BEARINGS

1 524140950 Load Wheel ......................................................................................................... 2
2 500120903 Bearing ............................................................................................................... 4
3 503480200 Shield , Bearing .................................................................................................. 4
4 121357100 Washer ............................................................................................................... 4
5 524141151 Axle Shaft ........................................................................................................... 2
6 502677902 Pin ....................................................................................................................... 2

G14029 02-17

SINGLE WHEEL, TWO BEARINGS — SEALED

1 524140950 Load Wheel ......................................................................................................... 2
2 582028270 Ball Bearing (Sealed For Life) ............................................................................. 4
3 503480200 Shield , Bearing .................................................................................................. 4
4 121357100 Washer ............................................................................................................... 4
5 524230699 Axle Shaft ........................................................................................................... 2
6 502677902 Pin ....................................................................................................................... 2

02-17 G14030

SINGLE WHEEL, FOUR BEARINGS

1 524140951 Load Wheel ......................................................................................................... 2
2 015119300 Bearing ............................................................................................................... 4
3 524155614 Spacer ................................................................................................................ 4
4 500120903 Bearing ............................................................................................................... 4
5 503480200 Shield , Bearing .................................................................................................. 4
6 121357100 Washer ............................................................................................................... 4
7 524141151 Axle Shaft ........................................................................................................... 2
8 502677902 Pin ....................................................................................................................... 2

G14031 02-17

SINGLE WHEEL, FOUR BEARINGS — SEALED

1 524140951 Load Wheel ......................................................................................................... 2
3 524155614 Spacer ................................................................................................................ 4
4 524230699 Axle Shaft ........................................................................................................... 2
5 121357100 Washer ............................................................................................................... 4
6 503480200 Shield , Bearing .................................................................................................. 4
7 502677902 Pin ....................................................................................................................... 2

02-17 G14032

DUAL WHEEL

1 524140952 Load Wheel ......................................................................................................... 4
2 519433623 Spacer ................................................................................................................ 2
3 503480200 Shield , Bearing .................................................................................................. 8
4 500120903 Bearing ............................................................................................................... 8
5 121357100 Washer ............................................................................................................... 4
6 524187950 Axle Shaft ........................................................................................................... 2
7 502677902 Pin ....................................................................................................................... 2

G14033 02-17

DUAL WHEEL — SEALED BEARINGS

1 524140952 Load Wheel ......................................................................................................... 4
2 519433623 Spacer ................................................................................................................ 2
3 503480200 Shield , Bearing .................................................................................................. 8
5 121357100 Washer ............................................................................................................... 4
6 524230699 Axle Shaft ........................................................................................................... 2
7 502677902 Pin ....................................................................................................................... 2

02-17 G14033
NOTES

G14034 02-17
CASTER ASSEMBLY (FIGURE 4-9)

SPRING LOADED — STANDARD

02-17 G14034
CASTER ASSEMBLY
SPRING LOADED – STANDARD

524267533 Caster Assembly (Spring Loaded) ...................................................................... 1
524275825 Fork Assembly, Swivel ................................................................................... 1
524275826 Swivel Fork (Fork w/o Lower Wheel) ......................................................... 1
1 ..... Cap ........................................................................................................ 1
2 ..... Top Plate ............................................................................................... 1
3 ..... Fork ........................................................................................................ 1
4 524149717 Bearing Pin ............................................................................................ 1
5 524148548 Ball ......................................................................................................... 18
6 524148549 O-Ring ................................................................................................... 1
7 524148564 Locknut ....................................................................................................... 2
8 524148550 Fork (Lower) ............................................................................................... 1
9 524148551 Capscrew ................................................................................................... 1
10 524148552 Tube Assy .................................................................................................. 1
11 524148553 Bushing ...................................................................................................... 2
12 524148554 Locknut ....................................................................................................... 1
13 524148555 Axle Shaft (20 x 90) .................................................................................... 1
14 524148556 Axle Shaft (20 x 115) .................................................................................. 1
15 524148557 Clip ............................................................................................................. 4
16 524148560 Spring ......................................................................................................... 2
17 524148561 Tube Assy .................................................................................................. 2
18 524148562 Washer ....................................................................................................... 2
19 524148563 Capscrew ................................................................................................... 2
20 524149486 Wheel Assembly ............................................................................................. 1
20 524275828 Wheel ......................................................................................................... 1
21 524148567 Bearing ....................................................................................................... 2
22 524148568 Tube ........................................................................................................... 1
23 524149487 Axle Shaft Assembly ...................................................................................... 1
23 524148569 Tube ........................................................................................................... 2
24 524148570 Tube ........................................................................................................... 1
25 524148571 Capscrew ................................................................................................... 1
26 524246177 Tube ........................................................................................................... 1
27 524148554 Locknut ....................................................................................................... 1
28 504057795
449022013 Lockwasher ......................................................................................................... 10
29 524141099 Shim .................................................................................................................... 20
29 524322962 Shim .................................................................................................................... 8
30 449001040 Capscrew ............................................................................................................ 8

G14035 02-17

SPRING LOADED — HEAVY DUTY

02-17 G14035
CASTER ASSEMBLY
SPRING LOADED – HEAVY DUTY

1 524163223 Plate (Assembled) .......................................................................................... 1
2 524246179 Plate (Top) ................................................................................................. 1
3 582056727
524163225 Bearing ....................................................................................................... 1
4 524246180 Fork ................................................................................................................ 1
5 524246291 Bracket (Lower) .............................................................................................. 1
6 524163228 Spacer ............................................................................................................ 1
7 524163229 Capscrew ....................................................................................................... 1
8 524212380 Spring ............................................................................................................. 2
9 524212381 Axle ................................................................................................................ 1
10 524148450 Screw ............................................................................................................. 1
11 524148451 Lockwasher .................................................................................................... 1
12 524246191 Pin .................................................................................................................. 2
13 524149906 Wheel Assy .................................................................................................... 1
14 524148457 Wheel ......................................................................................................... 1
15 524148458 Ball Bearing ................................................................................................ 2
17 524148464 Axle ............................................................................................................ 1
18 524148459 Washer ....................................................................................................... 2
19 524148451 Lockwasher ................................................................................................ 1
20 524148450 Screw ......................................................................................................... 1
21 524148462 Fitting (Grease) .......................................................................................... 1
22 449001302 Capscrew ............................................................................................................ 8
23 504057795
449022013 Lockwasher ......................................................................................................... 10
24 524141099 Shim .................................................................................................................... 8
24 524322962 Shim .................................................................................................................... 8

G14036 02-17

SPRING LOADED — HEAVY DUTY, SEALED BEARINGS

02-17 G14036
CASTER ASSEMBLY
SPRING LOADED – HEAVY DUTY, SEALED BEARINGS

524289326 Swivel Fork ..................................................................................................... 1
1 524289327 Plate ........................................................................................................... 1
2 524289328 Plate ....................................................................................................... 1
3 582056727
524163225 Bearing .................................................................................................. 1
4 524246180 Fork ............................................................................................................ 1
5 524246291 Bracket (Lower) .......................................................................................... 1
6 524163228 Spacer ........................................................................................................ 1
7 524163229 Capscrew ................................................................................................... 1
8 524289329 Spring ......................................................................................................... 2
9 524212381 Axle ............................................................................................................ 1
10 524148450 Screw ......................................................................................................... 1
11 524148451 Lockwasher ................................................................................................ 1
12 524289330 O-Ring ........................................................................................................ 1
13 524246191 Pin .............................................................................................................. 2
14 524289331 Wheel Assy .................................................................................................... 1
15 524148457 Wheel ......................................................................................................... 1
16 015120400 Ball Bearing ................................................................................................ 2
18 524289334 Axle ............................................................................................................ 1
19 524148459 Washer ....................................................................................................... 2
20 524148451 Lockwasher ................................................................................................ 1
21 524148450 Screw ......................................................................................................... 1
22 449001302 Capscrew ............................................................................................................ 8
23 504057795
449022013 Lockwasher ......................................................................................................... 10
24 524141099 Shim .................................................................................................................... 8
24 524322962 Shim .................................................................................................................... 8

G14036 02-17
NOTES

SECTION 5
5 OPTIONS
CONTENTS
SECTION 5
OPTIONS
DESCRIPTION PAGE
AUDIBLE ALARM ............................................................................................................................................ 5-3

BATTERY ROLLER ASSEMBLY .................................................................................................................... 5-6
CONVENIENCE TRAY .................................................................................................................................... 5-8
RF TERMINAL ................................................................................................................................................. 5-2
TRANSMISSION DIAGNOSTICS INTERFACE CABLE ................................................................................. 5-10
VISIBLE ALARM .............................................................................................................................................. 5-4

G14037 02-17
RF TERMINAL (FIGURE 5-1)

1 582033509 Wire Harness (RF Terminal) (FG14009 [Page 2-38])........................................ 1
2 501644104 Terminal Block .................................................................................................... 1
3 582045866 Bracket ................................................................................................................ 1
4 520042842 Plug ..................................................................................................................... 1
5 580044946 Nut ...................................................................................................................... 2
6 940004903 Washer ............................................................................................................... 2
7 449022019 Lockwasher ......................................................................................................... 2
8 449007038 Screw .................................................................................................................. 2

02-17 G14038
AUDIBLE ALARM (FIGURE 5-2)

1 580045132 Back-Up Alarm (82-102 dbA) .............................................................................. 1
2 062151300 Capscrew ............................................................................................................ 2
3 016103500 Washer ............................................................................................................... 4
4 015026000 Lockwasher ......................................................................................................... 2
5 014936500 Nut ...................................................................................................................... 2

G14039 02-17
VISIBLE ALARM (FIGURE 5-3)

02-17 G14039
VISIBLE ALARM
1 449001302 Capscrew ............................................................................................................ 2
2 449021006 Washer ............................................................................................................... 2
3 580027572 Nut ...................................................................................................................... 2
4 582018713 Mounting Weldment ............................................................................................ 1
5 516905800 Clamp ................................................................................................................. 1
6 524295266 Pad ..................................................................................................................... 1
7 580051432 Nut ...................................................................................................................... 2
8 580079613 Strobe Light Assembly ........................................................................................ 1
8 580078920 Strobe Light (Amber LED) .............................................................................. 1
8 505968501 Connector ....................................................................................................... 1
8 505968535 Connector (Secondary Lock) .......................................................................... 1
8 505064713 Terminal ......................................................................................................... 2
8 720098901 Tube ............................................................................................................... AR
9 504232297 Guard (Strobe Light) ........................................................................................... 1
10 580058314 Capscrew ............................................................................................................ 2
11 582033157 Wire Harness (Strobe Light) (FG14011 [Page 2-41])........................................ 1

G14040 02-17
BATTERY ROLLER ASSEMBLY (FIGURE 5-4)

02-17 G14040
BATTERY ROLLER ASSEMBLY

1 524141433 Battery Tray ........................................................................................................ 1
2 504232269 Nut ...................................................................................................................... 2
3 016110000 Washer ............................................................................................................... 2
4 055485000 Capscrew ............................................................................................................ 2
5 504035207 Roller .................................................................................................................. 4
6 524141435 Block ................................................................................................................... 2
7 524308470 Spacer ................................................................................................................ 2
8 524141431 Plate .................................................................................................................... 2
9 065619400 Lockwasher ......................................................................................................... 4
10 580000240 Capscrew ............................................................................................................ 4

G14041 02-17
CONVENIENCE TRAY (FIGURE 5-5)

02-17 G14041
CONVENIENCE TRAY
KEY:
A: Hang-On (With Bolt-On Load Backrest)
B: Bolt-On (With Pivoting Load Backrest)
QTY
1 524143843 Tray , Convenience .................................................................................... 1 1
2 580023206 Strap ........................................................................................................... 1 1
3 524296041 Bracket (Left) .............................................................................................. 1 1
4 524296042 Bracket (Right) ........................................................................................... 1 1
5 580049842 Capscrew ................................................................................................... 4 4
6 524298171 Spacer ........................................................................................................ 4 ..
7 504071785 Washer ....................................................................................................... 8 4
8 909882404 Nut .............................................................................................................. 8 4
9 ..... Bracket ....................................................................................................... 1 ..
10 900014293 Capscrew ................................................................................................... 4 ..

P33158 05-17
TRANSMISSION DIAGNOSTICS INTERFACE CABLE (FIGURE 5-6)

580039670 Cable Assembly (Interface) ................................................................................ 1
1 580039163 Kit-Cable For Laptop Pc ................................................................................. 1
2 580039669 Kit-Cable For Laptop Pc ................................................................................. 1
2 580033802 Body ........................................................................................................... 1
2 580025225 Shroud ........................................................................................................ 1
2 580033803 Terminal ..................................................................................................... 3
2 580042511 Connector ................................................................................................... 1
2 580042782 Connector ................................................................................................... 1
2 580038290 Terminal ..................................................................................................... 3

SECTION 6
6 NUMERICAL INDEX
NUMERICAL INDEX
SECTION 6
NUMERICAL INDEX
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
003261800 4-3 23 065354400 2-39 2 3-5 10 501786915 1-18 1

012470300 2-39 1 065619400 5-7 9 3-23 8 501902908 3-27 5
2-42 5 080816000 3-19 41 3-29 15 3-29 32
012472000 2-11 1 3-24 47 449015029 3-19 16 501904907 1-21 3
2-11 1 121357100 4-5 4 3-23 33 501921200 1-17 1
014867800 2-11 3 4-6 4 3-27 19 501997902 2-39 6
014936500 2-3 27 4-7 6 3-29 41 2-39 11
2-5 23 4-8 5 449015135 2-3 17 2-39 12
5-3 5 4-9 5 2-5 28 501997904 2-39 8
014937400 4-3 32 4-10 5 449021001 3-3 22 2-42 6
015026000 2-3 26 203756500 2-3 7 3-5 7 502023904 3-15 14
2-5 22 2-5 5 449021002 2-13 3 502023906 3-15 20
5-3 4 272342900 3-19 35 449021003 2-3 16 502157203 1-21 9
015026600 1-17 3 3-24 50 2-5 27 502172902 3-27 21
015119300 4-7 2 296323263 3-27 12 3-5 17 3-29 43
015120400 4-17 16 3-29 36 3-11 27 502398904 1-17 2
015628700 4-3 16 312850034 2-3 9 3-19 27 502535902 2-3 1
015631300 4-3 11 2-5 6 3-23 43 2-3 11
015631500 4-3 6 2-9 449021006 3-27 25 2-3 12
015914900 3-23 14 317222556 2-42 4 3-29 48 2-3 14
3-29 23 449001040 4-13 30 5-5 2 2-5 10
015915100 3-20 49 449001049 3-27 16 449021010 2-3 19 2-5 11
3-24 63 3-29 38 2-5 15 2-5 13
015915600 3-19 42 449001056 3-11 16 449022013 4-13 28 2-5 14
3-24 48 449001058 3-19 45 4-15 23 502677902 4-3 30
016103500 2-3 25 3-24 59 4-17 23 4-5 6
2-5 21 449001068 2-3 20 449022017 3-19 15 4-6 6
5-3 3 2-5 16 3-23 32 4-7 8
016103700 1-15 3 3-19 13 3-27 18 4-8 7
016110000 5-7 3 3-23 27 3-29 40 4-9 7
016337000 2-3 6 449001170 2-3 28 449022018 2-11 6 4-10 7
2-5 4 2-5 8 3-3 7 502677908 4-3 5
032586000 3-3 12 3-11 29 449022019 5-2 7 502677909 3-16 4
3-5 20 449001202 2-3 15 449022021 2-13 4 3-17 8
055485000 5-7 4 2-5 26 449025008 3-19 9 503480200 4-5 3
059863600 3-3 13 449001302 3-27 23 3-27 9 4-6 3
3-5 21 3-29 45 449025027 3-15 13 4-7 5
060023800 2-3 4 4-15 22 449051014 3-20 48 4-8 6
2-5 2 4-17 22 3-24 62 4-9 3
062151300 2-3 24 5-5 1 500120903 4-5 2 4-10 3
2-5 20 449007018 3-3 6 4-7 4 503949202 3-12 39
5-3 2 3-11 31 4-9 4 3-17 5
062306700 1-15 2 449007038 5-2 8 500226901 3-29 9 503954200 2-11 2
062307300 3-20 51 449015002 2-11 7 501067206 3-15 9 503956200 3-15 8
3-24 65 3-3 9 501067207 3-12 36 504035207 5-7 5
062960000 4-3 29 3-5 18 3-15 10 504057788 3-20 47
065353900 2-39 5 3-11 14 501644104 5-2 2 3-24 61
2-39 7 3-11 28 501729905 3-3 17 504059730 2-23 1
2-39 10 449015014 3-3 18 3-5 11 2-27 12

NUMERICAL INDEX
NUMERICAL INDEX (continued)
2-27 13 516905800 5-5 5 2-45 2 520202601 2-18 3

2-31 1 517580815 1-18 1 2-45 5 2-23 10
2-31 6 518445601 2-18 2 3-11 24 2-31 12
2-31 10 2-19 2 3-12 40 520202604 2-23 10
2-35 14 2-19 3 3-15 18 2-31 12
2-36 15 2-19 4 518445604 2-21 2 520202606 2-23 10
504061787 2-23 2 2-19 5 2-28 5 2-31 12
2-31 2 2-20 6 2-40 2 524140488 1-13 3
2-39 4 2-27 1 2-43 1 524140837 4-3 21
504071785 5-9 7 2-27 2 2-45 12 524140838 4-3 26
504200200 3-11 6 2-35 1 3-11 24 524140839 4-3 7
504225227 3-19 14 2-35 2 3-12 40 524140842 4-3 8
3-23 26 2-40 1 3-16 5 524140878 4-3 4
3-27 17 2-40 3 3-17 4 524140879 4-3 35
3-29 39 2-42 3 518445606 2-43 3 524140880 4-3 18
504231270 1-14 7 2-45 2 518445607 2-42 1 524140881 4-3 10
504232256 1-18 6 2-45 5 518445608 2-20 1 524140885 4-3 17
504232269 5-7 2 2-45 7 2-27 6 524140887 4-3 3
504232297 5-5 9 3-11 24 2-35 7 524140950 4-5 1
504235265 3-23 12 3-12 40 2-43 4 4-6 1
3-29 18 3-15 18 2-45 9 524140951 4-7 1
504238298 3-20 50 518445602 2-20 3 518445609 2-27 1 4-8 1
3-24 64 2-21 2 2-35 1 524140952 4-9 1
504450739 2-23 3 2-27 6 518445610 2-43 2 4-10 1
2-23 8 2-28 5 2-43 5 524141079 4-3 13
2-31 3 2-35 7 2-45 4 524141080 1-2 4
2-31 9 2-40 2 2-45 10 524141099 4-13 29
504574225 1-18 5 2-43 1 518445611 2-45 7 4-15 24
504574232 3-19 11 2-43 2 518445612 2-45 11 4-17 24
3-27 7 2-43 3 518445618 2-45 8 524141151 4-5 5
4-3 20 2-43 4 518445623 3-11 24 4-7 7
505064713 5-5 8 2-43 5 3-12 40 524141162 3-19 10
505931500 3-15 7 2-45 4 518445629 2-45 2 3-27 8
505968501 5-5 8 2-45 8 518445630 2-45 11 524141179 4-3 34
505968533 2-41 2 2-45 9 2-45 12 524141197 4-3 1
505968535 5-5 8 2-45 10 519432646 3-27 11 524141201 4-3 27
505968540 2-27 9 2-45 11 3-29 35 524141431 5-7 8
2-35 11 3-15 19 519433623 4-9 2 524141433 5-7 1
2-41 2 3-16 5 4-10 2 524141435 5-7 6
505968563 2-7 2 3-17 4 519440800 1-21 8 524141478 2-28 1
2-7 3 518445603 2-18 1 519766808 1-5 37 2-28 2
2-9 4 2-19 2 519996802 1-13 1 2-29 1
2-9 5 2-19 3 519996803 1-13 2 2-29 2
505968568 2-23 5 2-19 4 520012800 3-27 4 3-16 5
2-31 5 2-19 5 3-29 33 3-17 4
2-41 1 2-20 5 520031801 2-3 13 524141549 1-13 5
505970553 3-19 17 2-27 2 2-5 12 524142694 1-14 4
3-23 34 2-35 2 520038861 3-16 8 524142762 1-14 5
505972544 2-23 9 2-40 1 3-27 1 524142783 1-14 1
505972589 2-23 4 2-40 3 520042842 5-2 4 524142886 3-16 2
2-31 4 2-42 8 520051895 1-17 4 3-17 6

NUMERICAL INDEX
524143269 2-3 22 524148571 4-13 25 524241406 2-12 7 3-16

2-5 19 524149133 3-7 13 524244220 4-15 524286600 1-10 6
524143338 1-14 1 524149410 3-27 10 524245937 2-3 10 524287542 2-42 7
524143403 2-12 6 3-29 34 524246177 4-13 26 524289326 4-17
524143843 5-9 1 524149411 3-27 20 524246179 4-15 2 524289327 4-17 1
524143897 3-16 7 3-29 42 524246180 4-15 4 524289328 4-17 2
3-17 3 524149486 4-13 20 4-17 4 524289329 4-17 8
524143900 3-16 524149487 4-13 23 524246191 4-15 12 524289330 4-17 12
3-17 524149717 4-13 4 4-17 13 524289331 4-17 14
524144372 2-12 524149906 4-15 13 524246291 4-15 5 524289333 4-17 17
3-7 15 524149907 4-15 16 4-17 5 524289334 4-17 18
3-7 17 524152699 2-20 7 524248291 1-16 1 524292775 3-7 26
524144374 3-7 23 2-21 2 524256016 2-7 2 524294108 3-16 5
524144387 3-7 22 2-28 5 2-7 3 3-17 4
524144590 3-27 2 2-40 1 2-9 4 524295210 4-3 31
524148372 1-14 6 2-40 2 2-9 5 524295266 5-5 6
524148450 4-15 10 2-40 3 524256017 2-3 1 524296041 5-9 3
4-15 20 2-42 9 2-3 11 524296042 5-9 4
4-17 10 3-15 18 2-3 12 524298171 5-9 6
4-17 21 524152701 2-20 2 2-3 14 524298403 1-15 1
524148451 4-15 11 2-42 2 2-5 10 524298404 1-15 1
4-15 19 2-45 9 2-5 11 524298405 1-15 1
4-17 11 524152702 2-45 4 2-5 13 524301377 4-3 28
4-17 20 2-45 10 2-5 14 524302804 4-3 25
524148457 4-15 14 524155614 4-7 3 524257337 3-19 25 524308470 5-7 7
4-17 15 4-8 3 3-23 41 524322962 4-13 29
524148458 4-15 15 524158911 3-16 3 524258640 2-5 10 4-15 24
524148459 4-15 18 3-17 7 524258641 2-11 1 4-17 24
4-17 19 524159394 3-16 6 524258643 2-7 3 524323505 4-3 14
524148462 4-15 21 524159395 3-16 1 2-9 5 524334911 3-11 6
524148464 4-15 17 524162256 1-21 6 524258644 2-7 2 524335005 3-11 6
524148548 4-13 5 524163223 4-15 1 2-9 4 524335288 3-27 6
524148549 4-13 6 524163225 4-15 3 524259238 1-6 4 524335825 3-7 1
524148550 4-13 8 4-17 3 1-10 524337093 3-12 42
524148551 4-13 9 524163228 4-15 6 524259886 2-11 1 3-15 19
524148552 4-13 10 4-17 6 524260973 2-9 2 524337569 3-11 24
524148553 4-13 11 524163229 4-15 7 524261854 2-3 21 550007477 4-3 22
524148554 4-13 12 4-17 7 2-5 24 550007599 4-3 19
4-13 27 524165666 2-45 11 2-19 550011383 3-15 11
524148555 4-13 13 524170074 3-7 524261860 3-27 15 550012083 3-11 12
524148556 4-13 14 3-15 19 3-29 37 550012711 3-15 12
524148557 4-13 15 524173235 1-16 1 524262047 1-21 7 550012747 3-11 1
524148560 4-13 16 524180332 3-7 2 524267533 4-13 3-15
524148561 4-13 17 524180333 3-7 19 524268340 4-17 550013934 3-11 20
524148562 4-13 18 524187950 4-9 6 524268659 1-13 4 550014958 3-5 1
524148563 4-13 19 524212380 4-15 8 524268818 1-13 4 3-11
524148564 4-13 7 524212381 4-15 9 524275825 4-13 550014959 3-5 1
524148567 4-13 21 4-17 9 524275826 4-13 3-11
524148568 4-13 22 524230699 4-6 5 524275828 4-13 20 550018103 3-11 23
524148569 4-13 23 4-8 4 524280933 3-17 5 550020855 3-15 1
524148570 4-13 24 4-10 6 524285957 2-18 550020856 3-15 1

NUMERICAL INDEX
550020857 3-12 33 580012962 3-7 10 580019353 2-16 2 3-19 28

550020858 3-12 39 580012967 3-7 20 2-17 2 3-24 52
550020859 3-12 39 580012968 3-7 21 2-23 12 580030111 3-11 11
550021071 3-12 37 580012969 3-7 12 2-23 15 580030966 3-20 53
550021182 3-12 35 580012970 3-7 9 2-27 3 3-24 54
550021186 3-12 40 580015511 4-3 12 2-27 8 580030967 3-17 9
550021665 3-11 1 580017101 3-15 16 2-31 13 580030970 3-27 26
3-15 580017789 4-3 15 2-31 14 3-29 8
550022120 3-15 4 580017790 2-11 4 2-32 17 580032375 3-19 7
550022121 3-15 6 580017792 2-15 7 2-35 3 580032377 3-23 5
550022122 3-15 5 3-19 29 2-35 10 3-29 12
550023135 3-11 9 580018749 3-12 38 2-45 6 580032494 3-15 15
550024286 3-12 41 580019097 3-19 23 3-15 18 580032544 1-21 4
550024287 3-12 41 3-23 39 580019800 2-12 3 580033802 5-10 2
550024288 3-11 10 580019098 3-19 23 580019801 2-12 4 580033803 5-10 2
550025497 3-19 20 3-23 39 580021081 2-15 9 580035031 2-20 8
3-23 36 580019107 2-16 1 3-20 54 2-23 13
550026131 3-11 7 2-17 1 580021087 2-27 14 2-31 15
550026136 3-11 7 2-27 4 2-36 16 580035032 2-23 14
550026220 3-11 5 2-35 4 2-41 1 2-31 16
550026784 3-11 4 2-35 9 580021088 2-27 14 580036940 2-23 5
550026837 3-11 2 2-45 1 2-36 16 2-31 5
550027800 3-11 7 2-45 13 2-41 1 580036981 2-35 9
550028164 3-5 1 3-19 23 580021175 3-3 8 580036986 2-35 9
3-11 3-23 39 3-11 25 580038175 3-7 24
550028540 3-19 43 580019119 2-23 4 580022643 1-21 4 580038290 2-23 4
3-24 49 2-23 5 580022891 2-28 3 2-27 9
550028586 3-20 46 2-23 12 2-29 3 2-31 4
3-24 60 2-27 8 580022892 2-28 3 2-35 11
550028587 3-19 24 2-27 11 2-29 3 2-41 2
3-23 40 2-28 3 580022893 2-27 9 5-10 2
550029660 3-19 33 2-29 3 2-35 11 580038661 2-45 3
3-24 57 2-31 4 580023206 5-9 2 580039163 5-10 1
550030520 3-11 13 2-31 5 580023467 1-6 5 580039193 5-10 2
550030894 3-11 30 2-35 9 580023890 3-19 26 580039194 2-23 6
550030981 4-3 36 2-35 10 3-23 42 2-31 7
550041104 2-3 3 2-35 13 580025225 5-10 2 580039438 3-11 21
2-5 1 580019245 2-16 1 580026296 3-7 8 580039490 2-27 8
550061367 4-3 9 2-17 1 580026813 2-23 5 2-35 10
550079866 2-10 2-27 4 2-31 5 580039491 2-27 8
550091938 1-14 2 2-28 4 580026824 2-12 2-35 10
580000119 3-3 10 2-29 4 3-7 14 580039499 2-19 1
3-5 6 2-35 4 3-7 17 580039500 2-19 1
580000240 5-7 10 2-45 13 580027206 2-27 11 580039513 2-18 6
580001743 3-11 22 580019246 2-16 1 2-35 13 2-28 3
580003129 3-19 44 2-17 1 580027207 2-27 11 2-28 4
3-24 58 2-27 4 2-35 13 2-29 3
580006553 2-9 3 2-28 4 580027572 3-27 22 2-29 4
580008064 1-21 3 2-29 4 3-29 44 580039517 2-19 1
580011878 1-15 4 2-35 4 5-5 3 580039669 5-10 2
580011991 3-7 11 2-45 13 580027573 1-18 7 580039670 5-10

NUMERICAL INDEX
580040162 2-15 8 580056589 3-15 17 580083001 3-12 34 582019746 3-7 2

3-19 37 580057482 1-14 3 580083871 3-19 1 582019747 3-7 2
3-23 29 580058314 5-5 10 3-23 1 582020961 2-23 4
580040456 2-20 4 580059974 3-19 30 3-29 10 2-31 4
2-23 13 3-24 66 580083893 2-18 4 582022975 2-10 5
2-23 14 580060018 3-29 7 2-27 5 582022976 2-10 6
2-31 15 580060125 3-19 40 2-27 7 582026213 2-3 2
2-32 16 3-23 46 2-35 6 2-5 25
580041195 2-18 5 580060389 3-7 25 2-35 8 582026223 3-5 14
580041446 1-16 2 580061791 3-11 3 580084552 1-21 5 582027529 3-7 3
580042219 3-15 18 580062118 2-35 5 580084553 1-21 5 582028270 4-6 2
580042220 3-15 18 580062119 2-23 13 580086209 2-31 13 4-8 2
580042221 2-45 1 2-23 14 580095939 3-11 17 4-10 4
580042222 2-45 1 2-31 15 582000129 3-3 19 582028474 2-9 3
580042511 5-10 2 2-32 16 3-7 28 582028792 3-20 52
580042782 5-10 2 2-35 5 582000130 3-3 20 3-23 44
580044860 3-5 3 580062388 2-23 5 3-7 28 582028866 2-10 2
580044946 5-2 5 2-23 6 582002075 3-5 13 582029332 3-19 8
580045132 5-3 1 2-27 11 582003113 3-3 15 582029386 3-19 12
580047200 2-3 8 2-27 14 582003546 2-40 3-23 25
2-5 7 2-31 5 582003591 3-3 11 582029395 2-10 2
580049229 1-18 4 2-31 7 3-5 5 582029432 3-29 47
3-5 9 2-35 13 582004633 2-45 3 582029464 3-23 19
3-19 31 2-36 16 582005051 3-15 18 582029485 3-23 21
3-24 55 580063957 2-31 13 582005203 3-7 16 3-29 29
580049231 3-19 34 580064545 2-28 1 582007128 3-7 17 582029486 3-23 22
3-24 53 2-28 2 582013309 3-11 18 3-29 28
580049842 5-9 5 580064548 2-21 1 582014102 2-12 582029608 3-3 3
580050169 2-10 4 580064578 2-15 3 582014103 2-3 23 3-5 4
580051432 5-5 7 2-21 2-5 18 582029677 3-3 4
580051703 2-23 6 580069343 3-19 21 2-12 3-5 4
2-31 7 3-23 37 582014171 3-23 7 582029727 3-23 16
580051704 2-23 7 580069983 2-43 3-29 14 3-29 26
2-31 8 3-3 14 582015291 3-19 22 582029729 3-3 2
2-35 5 580072749 1-21 2 3-23 38 582029730 3-5 2
580052728 2-11 5 580072790 2-15 5 582015387 3-8 582029732 3-24 51
580055434 3-7 17 2-20 582015753 3-7 17 3-29 1
580056004 2-16 2 580075113 1-10 2 582015754 3-7 17 582029829 4-3 24
2-17 2 580075338 1-10 5 582016089 3-7 6 582029845 4-3 9
2-23 15 580077644 3-19 19 582016090 3-7 4 582029846 4-3 9
2-27 3 3-23 24 582016096 2-12 1 582029847 4-3 9
2-32 17 580077646 3-19 39 582016097 2-12 2 582029848 4-3 9
2-35 3 3-23 45 582016098 2-12 5 582029849 4-3 9
2-45 6 580078920 5-5 8 582016351 1-10 4 582029850 4-3 9
580056006 2-16 2 580079167 3-7 27 582016358 1-10 3 582029851 4-3 9
2-17 2 580079613 5-5 8 582018503 3-3 16 582029854 3-3 3
2-23 15 580080890 2-23 12 3-5 12 3-5 4
2-27 3 2-31 14 582018677 3-19 23 582030193 3-17 1
2-32 17 580080891 2-23 12 3-23 39 582030278 3-17 2
2-35 3 2-31 14 582018713 5-5 4 582030474 3-3 2
2-45 6 580082841 3-7 24 582019046 4-3 33 582030475 3-3 2

NUMERICAL INDEX
582030477 3-5 2 3-23 30 582042092 1-18 2 582072818 1-5 10

582030478 3-5 2 582033501 2-45 582042369 3-19 32 582072819 1-5 11
582030754 2-7 4 3-5 3-24 56 582072820 1-5 12
2-9 7 582033508 2-15 4 582043726 1-6 1 582072821 1-5 13
582030783 3-23 23 2-42 1-9 582072822 1-5 14
3-29 30 582033509 2-39 582043788 1-2 582072823 1-5 15
582031013 3-29 17 5-2 1 582043992 1-6 2 582072824 1-5 16
582031141 3-29 20 582034277 3-7 23 582043995 1-6 582072825 1-5
582031162 3-23 9 582034352 4-4 1 582044765 1-18 582072826 1-5 19
3-29 16 582034354 4-4 1 582044766 1-18 582072827 1-5 6
582031268 3-3 1 582034403 4-4 1 582045866 5-2 3 582072828 1-5 21
3-7 582034404 4-4 1 582047063 3-19 3 582072829 1-5 22
582031269 3-3 1 582034405 4-4 1 3-23 3 582072830 1-5 25
3-7 582034406 4-4 1 582047894 2-13 2 582072831 1-5 26
582031425 3-23 10 582034407 4-4 1 582047975 2-13 1 582072833 1-5 27
582031919 3-19 4 582034408 4-4 1 582048033 1-5 582072834 1-5 38
3-23 4 582034409 4-4 1 582048034 1-5 582072835 1-5 39
3-29 4 582034410 4-4 1 582048035 1-5 582072869 1-5 20
582032716 3-29 5 582034411 4-4 1 582048036 1-5 585045700 3-27 3
582032759 2-3 14 582034412 4-4 1 582048313 1-18 3-29 31
2-5 13 582034413 4-4 1 582048902 1-5 17 585085800 3-11 8
582032781 2-3 1 582034414 4-4 1 582048903 1-5 7 620033319 3-3 21
2-5 14 582034415 4-4 1 582050080 1-6 3 3-5 19
582032782 2-3 12 582034416 4-4 1 582053098 2-15 1 3-23 15
2-5 11 582034417 4-4 1 3-20 55 3-29 22
582032914 2-45 8 582034418 4-4 1 582053253 2-3 11 720098901 5-5 8
582032954 3-27 14 582034419 4-4 1 582054541 3-11 19 723291300 2-11 1
582033157 2-41 582034420 4-4 1 582055198 3-27 24 723291304 2-11 1
5-5 11 582034421 4-4 1 3-29 46 751191100 2-15 6
582033185 3-19 18 582034422 4-4 1 582058724 1-5 9 3-19 38
3-23 35 582034423 4-4 1 582064507 3-23 18 3-23 28
582033186 3-29 11 582034424 4-4 1 3-29 25 751194100 2-23 2
582033187 3-19 2 582034618 3-19 5 582064757 1-9 2 2-31 2
3-23 2 3-23 11 582064758 1-9 4 2-39 3
3-29 2 582034619 2-23 11 582064759 1-9 5 752411301 2-10 5
582033307 3-23 17 2-31 11 582064760 1-9 6 754060300 1-18 1
3-29 24 582034620 2-39 9 582064761 1-9 7 900014292 3-29 21
582033308 3-23 20 582034783 1-21 1 582064762 1-9 8 900014293 5-9 10
3-29 27 582035377 3-3 5 582064763 1-9 9 900126308 1-18 3
582033309 3-23 13 582035400 2-3 18 582064764 1-9 11 909882404 5-9 8
3-29 19 2-5 29 582064765 1-9 12 909882405 2-3 29
582033404 2-16 582038711 2-9 1 582068819 1-2 5 2-5 17
3-29 3 2-31 582069185 1-2 1 930102901 2-13 5
582033405 2-17 2-35 582069188 1-2 3 930103907 1-14 8
3-23 31 582038712 2-7 1 582069190 1-2 2 932200901 3-7 18
582033498 2-9 6 2-23 1-5 932200905 3-5 16
2-17 3 2-27 582072812 1-5 1 932728907 3-27 13
582033499 2-15 2 582038750 3-19 2 582072813 1-5 2 932729905 2-10 3
2-28 582041897 1-9 3 582072814 1-5 3 940004902 3-7 7
582033500 2-29 582041898 1-9 1 582072815 1-5 4 940004903 5-2 6
3-19 36 582041902 1-9 10 582072816 1-5 5 940102909 1-2 6

NUMERICAL INDEX
940400907 3-11 15 940400908 3-5 8 3-29 6 3-23 6

3-11 26 940600907 2-3 5 940600908 3-19 6 3-29 13
3-12 32 2-5 3

NUMERICAL INDEX
NOTES

SECTION 7
7 USER SUPPORT INFORMATION

CONTENTS
SECTION 7
USER SUPPORT INFORMATION
DESCRIPTION PAGE
SERVICE PARTS ORDERING INSTRUCTIONS ........................................................................................... 7-2

TECHNICAL SERVICE PUBLICATIONS ........................................................................................................ 7-2
OPERATOR TRAINING .................................................................................................................................. 7-2
SERVICE TRAINING COURSE ...................................................................................................................... 7-2
SERVICE TRAINING MATERIALS ................................................................................................................. 7-2

USER SUPPORT INFORMATION
Your investment in a Yale Industrial Truck is important to you and to your Yale Dealer. You measure the return on
that investment through the performance of these trucks and the drivers who operate and the mechanics who service
them safely and efficiency. The following information is intended to help you to achieve your investments objectives:
SERVICE PARTS ORDERING INSTRUCTIONS operators manual is missing from any Yale Industrial
Truck, it should be replaced. Replacement copies are
HOW TO ORDER SERVICE PARTS available for a nominal fee from your Yale Dealer.
In order to prevent delay, too much communication and OPERATOR TRAINING
to have your orders filled correctly, quickly, and at the
least possible cost, the following is the correct procedure The Yale "Basic Operator Training" program helps
to use to order replacement parts. industrial truck users increase their materials handling
production and safety through correct lift truck operation,
WHEN ORDERING PARTS training, and motivation. The Yale program is based
upon real life experience – not theoretical concepts. We
Contact your authorized Yale Industrial Truck Dealer
developed a "complete" program that is totally self-
giving them the following information:
contained – incorporating the most modern instructional
1. Your Purchase order number. techniques including elements of self-study, audio-visual
support (both video and slides), and classroom study.
2. Complete addresses for sending the invoice and
parts. SERVICE TRAINING COURSE
3. Tell us how you want your parts sent. If we do not Operators and Yale dealer service technicians can
get this information, we will send the parts using the improve their technical ability for maintaining and
lowest priced method. repairing Yale Industrial Trucks, which decreases repair
time and cost, by taking Yale Service Training courses.
4. Correct part number(s) and description(s). Use your Different types of mechanical, electric, and electronic
parts manual as a reference. subjects are available. Courses can be held at customer
or Dealer locations in addition to regularly scheduled
5. Model and serial number of the truck. courses which are held at Yale Corporate Headquarters
in Greenville, NC.
TECHNICAL SERVICE PUBLICATIONS
SERVICE TRAINING MATERIALS
Technical literature, with detailed information, is
available at a nominal fee to assist users to effectively Your own service training can be supported through a
maintain Yale Industrial Trucks in a safe, useful complete line of Yale Service Training materials. An
condition. Part Manuals with complete replacement parts Index is available from your Yale Dealer which lists
identification, Service Maintenance Manuals which textbooks, audio-visual programs and films. These
provide service and overhaul procedures and additional materials will provide your training staff with everything
copies of the Operating Manual can be obtained from necessary for training your group.
your Yale Industrial Truck Dealer.
For additional information or assistance in obtaining
To provide instructions for safely operating and servicing these user support publications and programs, contact:
Yale Industrial Trucks, each truck is equipped with an
operators manual. It describes various operating Yale Materials Handling Corporation
techniques and safety warnings to the operator. It 1400 Sullivan Drive
contains a guide to safe maintenance practices and Caller No. 12011
recommended schedules for maintenance. if the Greenville, NC 27834-2011

Yale Materials Handling Corporation 550175951
1400 Sullivan Drive ©Yale Corp.
Caller No. 12011 07/2017
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Yale Mpe 2

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Yale Mpe 2

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PARTS MANUAL

Yale Materials Handling Corporation 550175951

3 STEER HANDLE/BRAKE SYSTEM

4 LIFT LINKAGE, LOAD WHEELS, AND FORKS

7 USER SUPPORT INFORMATION

D896 ©2017 Yale Materials Handling Corporation i

TABLE OF CONTENTS (continued)

ii ©2017 Yale Materials Handling Corporation D896

TABLE OF CONTENTS (continued)

D896 ©2017 Yale Materials Handling Corporation iii

ABBREVIATIONS QUICK REFERENCE SHEET

ECH-6 Empty Container Handler - 6 High UL Type EE Battery-Powered Safety Rating

iv ©2017 Yale Materials Handling Corporation D896

HOW TO USE THE ILLUSTRATED PARTS MANUAL

D896 ©2017 Yale Materials Handling Corporation v

HOW TO FIND THE DESIRED PART NUMBER

vi ©2017 Yale Materials Handling Corporation D896

IDENTIFICATION OF TRUCK SERIAL NUMBERS

D896 ©2017 Yale Materials Handling Corporation vii

PUBLICATION YALE PART NUMBER

Operating Manual.................................................................................................................... 550090069

Service Manual (Complete)..................................................................................................... 550175942

Parts Manual........................................................................................................................... 550175951

viii ©2017 Yale Materials Handling Corporation D896

MASTER PART SHEET CROSS-REFERENCE

ITEM PART NO. DESCRIPTION QTY

PART SHEET PAGE PART SHEET PAGE PART SHEET PAGE

G13977...................................1-2 G14000.................................2-19 G14022.................................3-18

D896 ©2017 Yale Materials Handling Corporation ix

x ©2017 Yale Materials Handling Corporation D896

BATTERY RETENTION .................................................................................................................................. 1-17

D896 ©2017 Yale Materials Handling Corporation 1-1

MASTER DRIVE UNIT AND ATTACHING PARTS (FIGURE 1-1)

ITEM PART NO. DESCRIPTION QTY

1-2 ©2017 Yale Materials Handling Corporation D896

D896 ©2017 Yale Materials Handling Corporation 1-3

GEAR BOX (FIGURE 1-2)

1-4 ©2017 Yale Materials Handling Corporation D896

ITEM PART NO. DESCRIPTION QTY

D896 ©2017 Yale Materials Handling Corporation 1-5

TRACTION MOTOR AND BRAKE ASSEMBLY (FIGURE 1-3)

ITEM PART NO. DESCRIPTION QTY

1-6 ©2017 Yale Materials Handling Corporation D896

D896 ©2017 Yale Materials Handling Corporation 1-7

TRACTION MOTOR ASSEMBLY (FIGURE 1-4)

1-8 ©2017 Yale Materials Handling Corporation D896

TRACTION MOTOR ASSEMBLY

D896 ©2017 Yale Materials Handling Corporation 1-9

BRAKE ASSEMBLY (FIGURE 1-5)

ITEM PART NO. DESCRIPTION QTY

1-10 ©2017 Yale Materials Handling Corporation D896

D896 ©2017 Yale Materials Handling Corporation 1-11

COVERS AND FLOORMAT (FIGURE 1-6)

1-12 ©2017 Yale Materials Handling Corporation D896

COVERS AND FLOORMAT

D896 ©2017 Yale Materials Handling Corporation 1-13

LOAD BACKREST (FIGURE 1-7)

ITEM PART NO. DESCRIPTION QTY

1-14 ©2017 Yale Materials Handling Corporation D896