Catálogo de Peças 190VX - A909
Catálogo de Peças 190VX - A909
Catálogo de Peças 190VX - A909
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 GENERAL TRUCK
2 ENGINE ASSEMBLY
4 EXHAUST SYSTEM
5 COOLING SYSTEM
6 FUEL SYSTEM
7 ELECTRICAL SYSTEM
8 TRANSMISSION
9 DRIVE AXLE
10 STEERING SYSTEM
11 BRAKE SYSTEM
12 HYDRAULIC SYSTEM
15 OPTIONS
17 NUMERICAL INDEX
This Parts Manual is divided into 18 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.
18 USER SUPPORT INFORMATION
This Parts Manual is divided into 18 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
ACCUMULATOR ............................................................................................................................................. 15-11
ADD ON OPTION KITS ................................................................................................................................... 16-2
ADD ON TELEMETRY KITS ........................................................................................................................... 16-4
AIR INTAKE ..................................................................................................................................................... 6-2
AIR INTAKE AND FILTER
GM 5.7 LPG ................................................................................................................................................ 6-16
AIR INTAKE MANIFOLD
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-40
ALTERNATOR AND MOUNTING
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 7-16
ARMREST ASSEMBLY
MINI-LEVER MODULES ............................................................................................................................. 1-52
AUXILIARY FUNCTION HOSES ..................................................................................................................... 13-18
AUXILIARY ONE SECTION
THREE AND FOUR FUNCTION ................................................................................................................. 12-24
AUXILIARY TWO SECTION
FOUR FUNCTION ....................................................................................................................................... 12-26
B
BACK-UP ALARM ........................................................................................................................................... 15-5
BATTERY AND CONTROL CABLE DISCONNECT SWITCH ........................................................................ 7-26
BATTERY CABLES
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 7-22
GM 5.7L LPG .............................................................................................................................................. 7-24
BRAKE AND INCHING PEDAL CONVERSION .............................................................................................. 16-3
BRAKE COOLING SYSTEM
SINGLE AND DUAL PEDAL ....................................................................................................................... 11-10
BRAKE PEDAL
DUAL PEDAL .............................................................................................................................................. 11-4
SINGLE PEDAL .......................................................................................................................................... 11-2
BRAKE PEDAL MOUNTING ........................................................................................................................... 11-14
ALTERNATE MOUNTING ........................................................................................................................... 11-16
BRAKE VALVE ASSEMBLY ........................................................................................................................... 11-18
BUZZER GROUP ............................................................................................................................................ 7-54
C
CAB
ATTACHING PARTS - SHEET 1 OF 2 ....................................................................................................... 1-20
ATTACHING PARTS - SHEET 2 OF 2 ....................................................................................................... 1-22
LEFT HAND DOOR ASSEMBLY ................................................................................................................ 1-28
MAIN ASSEMBLY ....................................................................................................................................... 1-18
RIGHT HAND DOOR ASSEMBLY .............................................................................................................. 1-30
WINDOW WIPER SYSTEM ........................................................................................................................ 1-26
WINDOWS .................................................................................................................................................. 1-24
CAMSHAFT
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-22
CAMSHAFT AND TIMING
GM 5.7 LPG ................................................................................................................................................ 3-24
DESCRIPTION PAGE
CARRIAGE ...................................................................................................................................................... 13-14
CHARGE PUMP .............................................................................................................................................. 8-20
COMPARTMENT PLATFORM ........................................................................................................................ 1-14
CONTROL VALVE
THREE SPEED TRANSMISSION ............................................................................................................... 8-18
CONTROL VALVE AND STEERING UNIT ASSEMBLY
FOUR FUNCTION ....................................................................................................................................... 12-14
THREE FUNCTION ..................................................................................................................................... 12-12
COOLING SYSTEM
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 5-2
GM 5.7 LPG ................................................................................................................................................ 5-10
COUNTERWEIGHTS AND FENDERS ........................................................................................................... 1-56
COWL ELECTRICAL
ELECTRIC HYDRAULIC ............................................................................................................................. 7-12
COWL MOUNT ................................................................................................................................................ 1-16
ALTERNATE PART ..................................................................................................................................... 1-17
CRANKCASE BREATHER
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-32
CRANKSHAFT
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-30
CYLINDER BLOCK
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-8
GM 5.7 LPG ................................................................................................................................................ 3-20
CYLINDER HEAD
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-10
CYLINDER HEAD AND EXHAUST MANIFOLD
GM 5.7 LPG ................................................................................................................................................ 3-14
D
DIFFERENTIAL ............................................................................................................................................... 9-6
DIPSTICK AND BREATHER ........................................................................................................................... 12-38
DRIVE AXLE AND ATTACHING PARTS
WET BRAKE ............................................................................................................................................... 9-4
DRIVE AXLE HOUSING AND HUB ................................................................................................................ 9-8
DRIVE TIRE AND WHEEL .............................................................................................................................. 9-2
DUAL MIRRORS
WITH CAB ................................................................................................................................................... 15-7
WITH OVERHEAD GUARD ........................................................................................................................ 15-8
E
E-HYDRAULIC CONTROL CONVERSION KITS
ELECTRICAL ARRANGEMENT
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 7-4
GM 5.7L LPG .............................................................................................................................................. 7-6
ELECTRICAL SYSTEM
RIGHT HAND CHASSIS - CUMMINS QSB 3.3L DIESEL .......................................................................... 7-8
RIGHT HAND CHASSIS - GM 5.7L LPG .................................................................................................... 7-10
ELECTRO HYDRAULIC POPPET VALVE
THREE AND FOUR FUNCTION ................................................................................................................. 12-22
DESCRIPTION PAGE
ELECTRONIC CONTROL LEVERS
MINI-LEVER MODULE (FOUR FUNCTION) (→ S/N A909V01507H) ....................................................... 7-42
MINI-LEVER MODULES (THREE FUNCTION) (→ S/N A909V01507H) .................................................. 7-44
ELECTRONIC CONTROL MODULE AND SENSORS
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 7-20
ELECTRONIC MINI LEVER LABELS
SINGLE FUNCTION .................................................................................................................................... 1-42
ENGINE ELECTRICAL SYSTEM
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 7-14
ENGINE MOUNTING
(CUMMINS QSB 3.3L DIESEL) .................................................................................................................. 2-3
GM 5.7L LPG .............................................................................................................................................. 3-2
EXHAUST MANIFOLD
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-38
EXHAUST SYSTEM
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 4-2
WITH CATALYTIC CONVERTER - GM 5.7 LPG ........................................................................................ 4-4
F
FAN ASSEMBLY
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 5-6
GM 5.7 LPG ................................................................................................................................................ 5-13
FENDERS ....................................................................................................................................................... 1-66
FIRE EXTINGUISHER
WITH CAB ................................................................................................................................................... 15-3
WITH OVERHEAD GUARD ........................................................................................................................ 15-4
FLOORPLATES AND COVERS ...................................................................................................................... 1-10
FLYWHEEL HOUSING
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-6
GM 5.7 LPG ................................................................................................................................................ 3-4
FOOT DIRECTIONAL CONTROL PEDAL ...................................................................................................... 6-24
FORK POSITIONER ....................................................................................................................................... 13-12
FORKS ............................................................................................................................................................ 1-62
FORWARD CLUTCH HIGH AND OUTPUT SHAFT
THREE SPEED TRANSMISSION - FWD2 ................................................................................................. 8-14
FORWARD CLUTCH LOW AND SECOND SHAFT
THREE SPEED TRANSMISSION - FWD1, RANGE2 ................................................................................ 8-12
FREE LIFT CYLINDER ................................................................................................................................... 14-15
FRONT GEAR HOUSING
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-21
FUEL FILTER
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 6-8
FUEL FILTER PLUMBING
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 6-6
FUEL INJECTION PUMP
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 6-10
FUEL INJECTOR AND INJECTOR PLUMBING
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 6-14
DESCRIPTION PAGE
FUEL PUMP PLUMBING
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 6-12
FUEL SYSTEM
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 6-4
GM 5.7 LPG - SHEET 1 OF 2 ..................................................................................................................... 6-18
GM 5.7L LPG - SHEET 2 OF 2 ................................................................................................................... 6-22
FULL SUSPENSION SEAT
(ELECTRO-HYDRAULIC) (SWIVEL AND NON SWIVEL) - SHEET 1 OF 3 (S/N A909V01508H →) ....... 1-44
RECLINER AND DAMPER KITS - SHEET 2 OF 3 ..................................................................................... 1-48
SERVICE KITS FOR NON SWIVEL AND SWIVEL - SHEET 3 OF 3 ......................................................... 1-50
WITH ELECTRONIC CONTROLS (→ S/N A909V01507H) ....................................................................... 1-38
FULL SUSPENSION SWIVEL SEAT
WITH ELECTRONIC CONTROLS (→ S/N A909V01507H) ....................................................................... 1-40
FUSE BOX
GM 5.7 LPG ................................................................................................................................................ 3-16
G
GEAR PUMP ................................................................................................................................................... 12-10
GEAR PUMP ASSEMBLY ............................................................................................................................... 12-8
H
HEADER HOSES ............................................................................................................................................ 13-16
HEATER .......................................................................................................................................................... 1-32
HEATER CONTROL ....................................................................................................................................... 1-37
HEATER HOSE ............................................................................................................................................... 1-34
HEATER HOSES
GM 5.7 LPG ................................................................................................................................................ 1-36
HOIST HOSE AND ATTACHING PARTS ....................................................................................................... 12-36
HOOD ASSEMBLY ......................................................................................................................................... 1-2
HYDRAULIC FILTER ...................................................................................................................................... 12-4
HYDRAULIC SUPPLY AND RETURN ............................................................................................................ 12-2
I
INNER MAST .................................................................................................................................................. 13-6
INSTRUMENT CLUSTER ............................................................................................................................... 7-31
INTAKE MANIFOLD AND ATTACHING PARTS
GM 5.7 LPG ................................................................................................................................................ 3-6
INTERIOR PANELS AND COVERS ............................................................................................................... 1-6
INTERMEDIATE MAST ................................................................................................................................... 14-6
L
LABELS
EXTERIOR .................................................................................................................................................. 1-60
INTERIOR ................................................................................................................................................... 1-58
LIFTING BRACKET
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-4
LIFTING EYE ................................................................................................................................................... 15-9
LIGHT CONVERSION KITS ............................................................................................................................ 16-4
LIGHTS
AMBER LIGHTS - WITH THREE STAGE MAST ........................................................................................ 7-40
DESCRIPTION PAGE
BRAKE, TAIL, BACKUP, SIDE, TURN SIGNALS, WORK, STROBE - WITH CAB .................................... 7-32
BRAKE, TAIL, BACKUP, SIDE, TURN SIGNALS, WORK, STROBE - WITH OVERHEAD GUARD ......... 7-34
LOAD WEIGH ELECTRICAL .......................................................................................................................... 7-52
M
MAIN LIFT CYLINDER .................................................................................................................................... 13-9
MAST ELECTRICAL ....................................................................................................................................... 7-50
MID INLET SECTION
THREE AND FOUR FUNCTION ................................................................................................................. 12-16
MINI LEVER MODULE LABELS
HYDRAULIC CONTROL FUNCTIONS ....................................................................................................... 1-54
MINI-LEVER CONTROLS
WITH ARMREST - THREE FUNCTION (S/N A909V01508H →) .............................................................. 7-46
WITH ARMREST - FOUR FUNCTION (S/N A909V01508H →) ................................................................ 7-48
MISCELLANEOUS CONVERSION KITS ........................................................................................................ 16-4
O
OIL FILLER ARRANGEMENT ......................................................................................................................... 2-20
OIL FILTER AND COOLER
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-19
OIL LEVEL GAUGE
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-18
OIL PAN
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-16
GM 5.7 LPG ................................................................................................................................................ 3-18
OIL PUMP
GM 5.7 LPG ................................................................................................................................................ 3-26
OIL PUMP AND FRONT GEAR COVER
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-14
OUTER MAST ................................................................................................................................................. 13-2
OUTLET SECTION
THREE AND FOUR FUNCTION ................................................................................................................. 12-28
OVERHEAD GUARD ...................................................................................................................................... 1-64
P
PARK BRAKE ASSEMBLY
→ S/N A909V01557J ................................................................................................................................. 11-6
S/N A909V01558K → ................................................................................................................................. 11-8
PISTON AND CONNECTING ROD
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-28
POWER DISTRIBUTION MODULE ................................................................................................................ 7-28
PULLEY SYSTEM
GM 5.7 LPG ................................................................................................................................................ 3-10
PUMP DRIVE .................................................................................................................................................. 8-22
R
RADIATOR ASSEMBLY .................................................................................................................................. 5-4
WITH OIL COOLER .................................................................................................................................... 5-14
RADIATOR MOUNTING
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 5-8
DESCRIPTION PAGE
GM 5.7 LPG ................................................................................................................................................ 5-12
REMOTE KEY SWITCH .................................................................................................................................. 7-30
RETURN TO SET TILT KITS .......................................................................................................................... 16-2
REVERSE CLUTCH AND FIRST SHAFT
THREE SPEED TRANSMISSION - REV1, RANGE 1 ................................................................................ 8-16
ROCKER ARM ASSEMBLY
GM 5.7 LPG ................................................................................................................................................ 3-22
ROCKER ARM SHAFT
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-26
S
SEALED ALTERNATOR AND MOUNTING
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 7-18
SEAT CONVERSION KITS ............................................................................................................................. 16-3
SEAT PAN AND COVERS .............................................................................................................................. 1-8
SOUND ABATEMENT ..................................................................................................................................... 1-12
STARTER MOTOR
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 7-19
STARTING AID
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-42
STEER AXLE .................................................................................................................................................. 10-10
STEER COLUMN AND ATTACHING PARTS ................................................................................................. 10-2
STEER CYLINDER ......................................................................................................................................... 10-13
STEER TIRE AND WHEEL ............................................................................................................................. 10-14
STEERING COLUMN ASSEMBLY ................................................................................................................. 10-4
STEERING CONTROL UNIT .......................................................................................................................... 10-6
STEERING LINES ........................................................................................................................................... 10-8
STROBE LIGHT
LED ............................................................................................................................................................. 15-2
T
THERMOSTAT
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-12
THROTTLE PEDAL ASSEMBLY AND ATTACHING PARTS
STANDARD PEDAL .................................................................................................................................... 6-26
TILT CYLINDER AND MAST INSTALLATION ................................................................................................ 12-30
TILT CYLINDERS ............................................................................................................................................ 12-32
TILT HYDRAULICS ......................................................................................................................................... 12-34
TILT SECTION
THREE AND FOUR FUNCTION ................................................................................................................. 12-20
TORQUE CONVERTER
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 8-4
TORQUE CONVERTER AND FLYWHEEL
GM 5.7L LPG .............................................................................................................................................. 3-5
TRANSMISSION ASSEMBLY
THREE SPEED - SHEET 1 0F 2 ................................................................................................................. 8-6
THREE SPEED - SHEET 2 OF 2 ................................................................................................................ 8-8
TRANSMISSION COOLING
WITH EXTERNAL OIL COOLER ................................................................................................................ 8-10
DESCRIPTION PAGE
TRANSMISSION ELECTRICAL SYSTEM
THREE SPEED TRANSMISSION ............................................................................................................... 7-38
TRANSMISSION MOUNT ............................................................................................................................... 8-2
TURBOCHARGER
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-34
TURBOCHARGER PLUMBING
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-36
U
UNLOADER VALVE ........................................................................................................................................ 12-6
V
VALVE ASSEMBLY, LIFT AND LOWER
ELECTRONIC CONTROL VALVE - THREE AND FOUR FUNCTION ....................................................... 12-18
VALVE COVER
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-24
VIBRATION DAMPER
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-43
W
WATER OULET CONNECTION
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-46
WATER PUMP AND PULLEY
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-44
WATER SEPARATOR
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 6-9
WET BRAKE ASSEMBLY ............................................................................................................................... 9-10
WIRE HARNESS
ALTERNATOR-D - CUMMINS QSB 3.3L DIESEL ...................................................................................... 7-90
AMBER LIGHTS - 3 STAGE MAST ............................................................................................................ 7-106
BUZZER ...................................................................................................................................................... 7-110
ELECTRONIC CONTROL VALVE - THREE FUNCTION ........................................................................... 7-100
ELECTRONIC CONTROL VALVE - FOUR FUNCTION ............................................................................. 7-102
ENGINE - CUMMINS QSB 3.3L DIESEL .................................................................................................... 7-56
JUMPER - HEAD/WORK LIGHTS, 3 STAGE MAST .................................................................................. 7-108
LIGHTS WITH OVERHEAD GUARD .......................................................................................................... 7-104
REAR - CUMMINS QSB 3.3L DIESEL ........................................................................................................ 7-78
REAR - GM 5.7L LPG ................................................................................................................................. 7-80
RIGHT HAND CHASSIS - CUMMINS QSB 3.3L DIESEL (→ S/N A909V01525H) ................................... 7-58
RIGHT HAND CHASSIS - CUMMINS QSB 3.3L DIESEL (S/N A909V01526H →) ................................... 7-66
RIGHT HAND CHASSIS - GM 5.7L LPG .................................................................................................... 7-72
SEALED ALTERNATOR-DS - CUMMINS QSB 3.3L DIESEL .................................................................... 7-92
SEAT JUMPER (→ S/N A909V01525H) .................................................................................................... 7-64
TRANSMISSION - THREE SPEED ............................................................................................................ 7-96
WIRE HARNESS (COWL)
WITH FOOT DIRECTIONAL CONTROL PEDAL - WITH RETURN TO SET TILT AND MODULATED
BRAKES ...................................................................................................................................................... 7-86
WITH FORWARD AND REVERSE LEVER - WITHOUT RETURN TO SET TILT AND MODULATED
BRAKES ...................................................................................................................................................... 7-82
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
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.
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.
(1) and (2) The first letter and number indicates the mast 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 mast.
(5) Carriage travel in millimeters stamped just below the serial number.
Mast Group identification consists of mast unit code (1) and (2) plus carriage travel (5).
For pending production sequence numbers contact your local dealer for Yale lift trucks.
(1) and (2) The first letter and three numbers indicate the attachment unit code.
(3) The second letter indicates the plant of manufacture.
(4) The four or five digit number indicates the production sequence number.
For pending production sequence numbers contact your local dealer for Yale lift trucks.
Side-shift carriages and attachments have nameplates. Use the serial number found on the nameplate to identify
the attachment.
Always refer to the group, serial, or part number when ordering service parts.
Modifications of attachments and side-shift carriages by SPED (Special Products Engineering Department) are
identified by a model prefix code beginning with the letter "S". Contact your dealer for Yale lift trucks for information
on these assemblies.
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
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:
Below is a numerical listing of Part Sheet Numbers found in this parts book and what page number they are on.
1 GENERAL TRUCK
CONTENTS
SECTION 1
GENERAL TRUCK
DESCRIPTION PAGE
ARMREST ASSEMBLY
MINI-LEVER MODULES ............................................................................................................................. 1-52
CAB
ATTACHING PARTS - SHEET 1 OF 2 ....................................................................................................... 1-20
ATTACHING PARTS - SHEET 2 OF 2 ....................................................................................................... 1-22
LEFT HAND DOOR ASSEMBLY ................................................................................................................ 1-28
MAIN ASSEMBLY ....................................................................................................................................... 1-18
RIGHT HAND DOOR ASSEMBLY .............................................................................................................. 1-30
WINDOW WIPER SYSTEM ........................................................................................................................ 1-26
WINDOWS .................................................................................................................................................. 1-24
COMPARTMENT PLATFORM ........................................................................................................................ 1-14
COUNTERWEIGHTS AND FENDERS ........................................................................................................... 1-56
COWL MOUNT ................................................................................................................................................ 1-16
ALTERNATE PART ..................................................................................................................................... 1-17
ELECTRONIC MINI LEVER LABELS
SINGLE FUNCTION .................................................................................................................................... 1-42
FENDERS ....................................................................................................................................................... 1-66
FLOORPLATES AND COVERS ...................................................................................................................... 1-10
FORKS ............................................................................................................................................................ 1-62
FULL SUSPENSION SEAT
(ELECTRO-HYDRAULIC) (SWIVEL AND NON SWIVEL) - SHEET 1 OF 3 (S/N A909V01508H →) ....... 1-44
RECLINER AND DAMPER KITS - SHEET 2 OF 3 ..................................................................................... 1-48
SERVICE KITS FOR NON SWIVEL AND SWIVEL - SHEET 3 OF 3 ......................................................... 1-50
WITH ELECTRONIC CONTROLS (→ S/N A909V01507H) ....................................................................... 1-38
FULL SUSPENSION SWIVEL SEAT
WITH ELECTRONIC CONTROLS (→ S/N A909V01507H) ....................................................................... 1-40
HEATER .......................................................................................................................................................... 1-32
HEATER CONTROL ....................................................................................................................................... 1-37
HEATER HOSE ............................................................................................................................................... 1-34
HEATER HOSES
GM 5.7 LPG ................................................................................................................................................ 1-36
HOOD ASSEMBLY ......................................................................................................................................... 1-2
INTERIOR PANELS AND COVERS ............................................................................................................... 1-6
LABELS
EXTERIOR .................................................................................................................................................. 1-60
INTERIOR ................................................................................................................................................... 1-58
MINI LEVER MODULE LABELS
HYDRAULIC CONTROL FUNCTIONS ....................................................................................................... 1-54
OVERHEAD GUARD ...................................................................................................................................... 1-64
SEAT PAN AND COVERS .............................................................................................................................. 1-8
SOUND ABATEMENT ..................................................................................................................................... 1-12
HOOD ASSEMBLY
ITEM PART NO. DESCRIPTION QTY
1 580086801 Seal ..................................................................................................................... 2
2 524298575 Hood (LH) (With Overhead Guard) ..................................................................... 1
2 524317908 Hood (LH) (With Cab) ......................................................................................... 1
3 504235245 Handle ................................................................................................................ 2
4 449001121 Capscrew ............................................................................................................ 4
5 580017101 Washer ............................................................................................................... 4
6 580055650 Nut ...................................................................................................................... 4
7 580078722 Sound Liner (LH) ................................................................................................ 1
8 580083675 Sound Liner (LH) ................................................................................................ 1
9 580078724 Sound Liner (LH) (With Overhead Guard) .......................................................... 1
9 582000029 Liner (LH) (With Cab) .......................................................................................... 1
10 580067512 Seal ..................................................................................................................... 1
11 580060019 Nut ...................................................................................................................... 12
11 449021001 Washer (Not Illustrated) ...................................................................................... 8
12 582004516 Ball Stud ............................................................................................................. 4
12 580049915 Ball Stud (Alternate Part) .................................................................................... 4
13 580072744 Gas Spring .......................................................................................................... 2
13 582005653 Gas Spring (Alternate Part) ................................................................................ 1
14 580049231 Capscrew ............................................................................................................ 18
15 580088049 Hinge .................................................................................................................. 2
16 580026621 Nut (Fold Over) ................................................................................................... 8
17 580056624 Pin (Rod End) ..................................................................................................... 4
18 580000868 Locking Cotter Pin .............................................................................................. 4
19 580044861 Insert ................................................................................................................... 8
20 580088048 Hinge (Base) ....................................................................................................... 2
21 580027572 Nut ...................................................................................................................... 4
22 080143400 Mount .................................................................................................................. 4
23 518796686 Washer ............................................................................................................... 4
24 580032011 Capscrew (DSL) ................................................................................................. 4
24 580077405 Capscrew (LPG) ................................................................................................. 4
25 580093086 Hood Support ...................................................................................................... 1
26 580084838 Hinge (Base) ....................................................................................................... 2
27 580082458 Hinge .................................................................................................................. 1
28 580058383 Bumper (Hood) ................................................................................................... 4
29 524298546 Hood (RH) (With Overhead Guard) .................................................................... 1
29 524317909 Hood (RH) (With Cab) ........................................................................................ 1
30 580078720 Sound Liner (RH) ................................................................................................ 1
31 580083674 Sound Liner (RH) ................................................................................................ 1
32 580078725 Sound Liner (RH) (With Overhead Guard) ......................................................... 1
32 582000028 Liner (RH) (With Cab) ......................................................................................... 1
33 580065933 Seal ..................................................................................................................... 1
34 524317907 Side Plate Wldmt ................................................................................................ 1
35 524317829 Hood Support ...................................................................................................... 1
36 524317906 Side Plate Wldmt ................................................................................................ 1
37 580083673 Sound Liner (LH) ................................................................................................ 1
38 580096723 Bracket ................................................................................................................ 2
39 580056530 Screw .................................................................................................................. 6
40 504225257 Nut , Foldover ..................................................................................................... 4
41 580039438 Capscrew ............................................................................................................ 2
42 580041704 Insert ................................................................................................................... 4
43 580044860 Insert ................................................................................................................... 2
HOOD ASSEMBLY
ITEM PART NO. DESCRIPTION QTY
44 580089962 Seal ..................................................................................................................... 2
45 580089963 Seal (With Cab) .................................................................................................. 2
46 580089961 Seal ..................................................................................................................... 1
46 580067529 Seal ..................................................................................................................... 1
47 582001850 Liner (RH) ........................................................................................................... 1
48 524318403 Plate .................................................................................................................... 1
49 524318400 Plate .................................................................................................................... 1
50 580021461 Spacer (LPG) ...................................................................................................... 1
NOTES
FOOTNOTES:
a With Cab c With Swivel Seat
b With Overhead Guard d Without Swivel Seat
FOOTNOTES:
a Diesel Option b LPG Option
SOUND ABATEMENT
KEY:
A: Cab
B: Over Head Guard
QTY
ITEM PART NO. DESCRIPTION A B
1 580078726 Sound Liner (Cowl Plate) ........................................................................... 1 1
2 a b 580059607 Seal ............................................................................................................ 1 ..
3 a b 580046349 Seal ............................................................................................................ 1 ..
4 a 580046392 Seal ............................................................................................................ 1 ..
5 a 580046391 Seal ............................................................................................................ 1 ..
6 a 580078576 Seal ............................................................................................................ 1 ..
7 580068007 Sound Liner ................................................................................................ 1 1
8 580078727 Sound Liner (Cowl Plate) ........................................................................... 1 1
9 580068081 Sound Liner (Dash) (LH) ............................................................................ 1 1
10 580067860 Sound Liner ................................................................................................ 1 1
11 580068080 Sound Liner (Foam) (RH) ........................................................................... 1 1
12 580091418 Sound Liner (Frame Cowl) ......................................................................... .. 1
13 580091415 Sound Liner (Frame Cowl) ......................................................................... .. 1
14 580078733 Sound Liner (Front Floor Plate) .................................................................. 1 1
15 580091419 Sound Liner (RH) (Frame) ......................................................................... .. 1
16 580091631 Sound Liner (RH) (Frame) ......................................................................... .. 1
17 580091630 Sound Liner (RH) (Frame) ......................................................................... .. 1
18 580093813 Sound Liner (RH) (Frame) ......................................................................... .. 1
19 580093066 Sound Liner (LH) (Frame) .......................................................................... .. 1
20 580091416 Sound Liner (Rear Floor Plate) .................................................................. .. 1
21 580091417 Sound Liner (Cover Plate) .......................................................................... .. 1
22 580078728 Sound Liner (LH) (Frame) .......................................................................... 1 1
23 580078729 Sound Liner (LH) (Frame) .......................................................................... 1 1
24 580078739 Sound Liner (Seat Support LH) .................................................................. 1 1
25 580078737 Sound Liner ................................................................................................ 1 1
26 580078738 Sound Liner (Seat Support RH) ................................................................. 1 1
27 580078735 Sound Liner (Seat Support) ....................................................................... 1 1
28 580078736 Sound Liner (Seat Support) ....................................................................... 1 1
29 580078734 Sound Liner (Seat Support) ....................................................................... 1 1
30 580078740 Sound Liner (Seat Pan) .............................................................................. 1 1
31 580091413 Sound Liner (LH) (Frame) .......................................................................... .. 1
32 580078731 Sound Liner (Rear Floor Plate) .................................................................. 1 ..
33 580093812 Sound Liner ................................................................................................ 2 2
34 580078732 Sound Liner (Rear Floor Plate) .................................................................. 1 ..
35 580083106 Plug (LH) .................................................................................................... 1 ..
36 580083107 Plug (RH) ................................................................................................... 1 ..
37 580085400 Seal ............................................................................................................ 2 ..
38 580085401 Seal ............................................................................................................ 2 ..
39 580003442 Fastener ..................................................................................................... 2 ..
FOOTNOTES:
a With Electronic Hydraulics b With Manual Hydraulics
COMPARTMENT PLATFORM
ITEM PART NO. DESCRIPTION QTY
1 524337907 Operator Module ................................................................................................. 1
2 909882405 Nut ...................................................................................................................... 2
3 504233271 Washer ............................................................................................................... 4
4 505966562 Washer ............................................................................................................... 4
5 580082448 Isolator ................................................................................................................ 4
6 504323759 Stud .................................................................................................................... 2
7 931015915 Capscrew ............................................................................................................ 2
501702903 Loctite ................................................................................................................. AR
CAB
MAIN ASSEMBLY
CAB
ATTACHING PARTS – SHEET 1 OF 2
CAB
ATTACHING PARTS – SHEET 2 OF 2
CAB
WINDOWS
FOOTNOTES:
a Not Illustrated
CAB
WINDOW WIPER SYSTEM
FOOTNOTES:
a Not Illustrated
CAB
LEFT HAND DOOR ASSEMBLY
FOOTNOTES:
a Not Illustrated
CAB
RIGHT HAND DOOR ASSEMBLY
FOOTNOTES:
a Not Illustrated
HEATER
ITEM PART NO. DESCRIPTION QTY
580077680 Heater ................................................................................................................. 1
1 580083258 Heater (Blower) .............................................................................................. 1
2 580083259 Heater (Coil) ................................................................................................... 1
3 580083260 Adapter (2.0 inch) ........................................................................................... 1
4 580083261 Adapter (2.5 inch) ........................................................................................... 1
5 580083262 Adapter (3.5 inch) ........................................................................................... 1
6 580083263 Heater (Blower Plate) ..................................................................................... 1
7 ..... Casing ............................................................................................................ 1
8 580083264
582035767 Cover .............................................................................................................. 1
9 580083265
582035768 Bracket ........................................................................................................... 1
10 580083266
582035769 Cover .............................................................................................................. 1
11 580083267 Bracket ........................................................................................................... 1
12 580083268
582035770 Bracket ........................................................................................................... 1
13 580083269 Flange ............................................................................................................ 1
14 580083270
582035772 Flange ............................................................................................................ 1
15 580083271 Flange ............................................................................................................ 1
16 580083272 Wire Harness .................................................................................................. 1
17 580083273 Valve .............................................................................................................. 1
18 580083274 Filter ............................................................................................................... 1
19 580020184
582024764 Hose-Bulk (M) ................................................................................................ 1
20 580083275 Clamp ............................................................................................................. 1
21 580083276 Gasket ............................................................................................................ 1
22 502632907 Screw ............................................................................................................. 4
23 580083278 Screw ............................................................................................................. 15
24 580083279 Screw ............................................................................................................. 6
25 203756500 Capscrew ....................................................................................................... 9
26 504231213 Rivet ............................................................................................................... 2
27 021197300 Nut .................................................................................................................. 4
28 580083277 Screw (Plastic) ............................................................................................... 2
29 504063761 Screw ............................................................................................................. 6
HEATER HOSE
ITEM PART NO. DESCRIPTION QTY
1 013378900 37 Deg Flared Ftg ............................................................................................... 1
2 013378800 Fitting .................................................................................................................. 1
3 580086609 Tube Assy ........................................................................................................... 1
4 580086608 Tube Assy ........................................................................................................... 1
5 580073148 Hose Clamp (Dual Hose) .................................................................................... 1
6 580030967 Capscrew ............................................................................................................ 1
7 580026621 Nut (Fold Over) ................................................................................................... 3
8 580049231 Capscrew ............................................................................................................ 2
9 580092998 Bracket ................................................................................................................ 1
10 062159500 Clamp ................................................................................................................. 4
11 580086628 Hose ................................................................................................................... 2
a 505970592 Sealant ................................................................................................................ AR
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Not Illustrated
NOTES
ARMREST ASSEMBLY
MINI-LEVER MODULES
LABELS
INTERIOR
FOOTNOTES:
a Contact Your Local Yale Dealer c Not Illustrated
b Electronic Transmission d UL Type DS
LABELS
EXTERIOR
FOOTNOTES:
a Contact Your Local Yale Dealer d Without Cab
b Diesel e → 2/2013
c With Cab f 2/2013 →
NOTES
OVERHEAD GUARD
ITEM PART NO. DESCRIPTION QTY
1 524294779 Overhead Guard ................................................................................................. 1
2 258979300 Plug (Black) ........................................................................................................ 4
3 524240692 Plug (Black) ........................................................................................................ 1
4 524208883 Grommet ............................................................................................................. 1
5 b 580058212 Capscrew ............................................................................................................ 2
6 b 580051747 Handle (Assembly) (Alternate Horn Button) ....................................................... 1
7 580050959 Handle ............................................................................................................ 1
8 580058447 Push Button Switch ........................................................................................ 1
9 580022893 Connector (2 Pin) ........................................................................................... 1
10 505968540 Connector (Secondary Lock) .......................................................................... 1
11 505968514 Terminal (Pin) ................................................................................................. 2
12 b 580026812 Clip ...................................................................................................................... 1
13 b 580056613 Fastener .............................................................................................................. 1
14 449001400 Capscrew ............................................................................................................ 10
15 580058194 Nut ...................................................................................................................... 2
16 580044861 Insert ................................................................................................................... 2
17 524201323 Grommet ............................................................................................................. 2
18 518801683 Washer ............................................................................................................... 10
19 580041704 Insert ................................................................................................................... 2
a 580083174 Grommet ............................................................................................................. 1
FOOTNOTES:
a Not Illustrated b Optional
KEY:
A: Pneumatic (Solid)
B: Pneumatic (Non-Solid)
QTY
ITEM PART NO. DESCRIPTION A B
1 550000044 Fender Extension (LH) (Solid) .................................................................... 1 ..
1 550000045 Fender Extension (LH) ............................................................................... .. 1
2 550000046 Fender Extension (RH) (Solid) ................................................................... 1 ..
2 550000047 Fender Extension (RH) .............................................................................. .. 1
3 932731906 Capscrew ................................................................................................... 6 6
4 580058192 Nut .............................................................................................................. 8 8
5 580058271 Capscrew ................................................................................................... 2 2
2 ENGINE ASSEMBLY
CONTENTS
SECTION 2
ENGINE ASSEMBLY
DESCRIPTION PAGE
SECTION 2
ENGINE ASSEMBLY
DESCRIPTION PAGE
NOTES
FLYWHEEL HOUSING
CUMMINS QSB 3.3L DIESEL
CYLINDER BLOCK
CUMMINS QSB 3.3L DIESEL
CYLINDER HEAD
CUMMINS QSB 3.3L DIESEL
NOTES
OIL PAN
CUMMINS QSB 3.3L DIESEL
NOTES
VALVE COVER
CUMMINS QSB 3.3L DIESEL
NOTES
CRANKSHAFT
CUMMINS QSB 3.3L DIESEL
CRANKCASE BREATHER
CUMMINS QSB 3.3L DIESEL
TURBOCHARGER
CUMMINS QSB 3.3L DIESEL
TURBOCHARGER PLUMBING
CUMMINS QSB 3.3L DIESEL
EXHAUST MANIFOLD
CUMMINS QSB 3.3L DIESEL
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Water pump part 580091791 is an optional water
pump that could be included in this kit.
SECTION 3
ENGINE ASSEMBLY - LPG
DESCRIPTION PAGE
ENGINE MOUNTING
GM 5.7L LPG
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Not Illustrated
NOTES
PULLEY SYSTEM
GM 5.7 LPG
FOOTNOTES:
a Not Illustrated
NOTES
FOOTNOTES:
a Not Illustrated
NOTES
OIL PAN
GM 5.7 LPG
CYLINDER BLOCK
GM 5.7 LPG
FOOTNOTES:
a Not Illustrated
OIL PUMP
GM 5.7 LPG
NOTES
4 EXHAUST SYSTEM
CONTENTS
SECTION 4
EXHAUST SYSTEM
DESCRIPTION PAGE
EXHAUST SYSTEM
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 4-2
WITH CATALYTIC CONVERTER - GM 5.7 LPG ........................................................................................ 4-4
EXHAUST SYSTEM
CUMMINS QSB 3.3L DIESEL
EXHAUST SYSTEM
WITH CATALYTIC CONVERTER – GM 5.7 LPG
NOTES
5 COOLING SYSTEM
CONTENTS
SECTION 5
COOLING SYSTEM
DESCRIPTION PAGE
COOLING SYSTEM
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 5-2
GM 5.7 LPG ................................................................................................................................................ 5-10
FAN ASSEMBLY
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 5-6
GM 5.7 LPG ................................................................................................................................................ 5-13
RADIATOR ASSEMBLY .................................................................................................................................. 5-4
WITH OIL COOLER .................................................................................................................................... 5-14
RADIATOR MOUNTING
CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 5-8
GM 5.7 LPG ................................................................................................................................................ 5-12
COOLING SYSTEM
CUMMINS QSB 3.3L DIESEL
RADIATOR ASSEMBLY
ITEM PART NO. DESCRIPTION QTY
580088534 Radiator .............................................................................................................. 1
1 580097308 Radiator .......................................................................................................... 1
2 580097309 Air Cooler ....................................................................................................... 1
3 580097310 Oil Cooler ....................................................................................................... 1
4 580097312 Bracket ........................................................................................................... 1
5 580097311 Bracket ........................................................................................................... 1
NOTES
RADIATOR MOUNTING
CUMMINS QSB 3.3L DIESEL
COOLING SYSTEM
GM 5.7 LPG
FOOTNOTES:
a → 9/2011 c 9/2011 →
b → S/N A909E01526K d S/N A909E01527K →
RADIATOR ASSEMBLY
WITH OIL COOLER
NOTES
6 FUEL SYSTEM
CONTENTS
SECTION 6
FUEL SYSTEM
DESCRIPTION PAGE
AIR INTAKE
ITEM PART NO. DESCRIPTION QTY
1 580082074 Pre-Cleaner ........................................................................................................ 1
2 504058787 Hose Clamp ........................................................................................................ 1
3 502056905 Clamp ................................................................................................................. 2
4 580085163 Air Filter .............................................................................................................. 1
4 580088196 Filter Element ................................................................................................. 1
4 580090343 Kit-Cover ........................................................................................................ 1
4 580095336 Plug ................................................................................................................ 1
5 580083958 Bracket Wldmt .................................................................................................... 1
6 580033885 Nut ...................................................................................................................... 2
7 931015903 Capscrew ............................................................................................................ 2
8 580030966 Capscrew ............................................................................................................ 4
9 580083960 Hose ................................................................................................................... 1
10 580093111 Hose ................................................................................................................... 1
FUEL SYSTEM
CUMMINS QSB 3.3L DIESEL
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Fuel Inlet b Mounting location: Fuel Pump Side Middle Mount
NOTES
FUEL SYSTEM
GM 5.7 LPG – SHEET 1 OF 2
FUEL SYSTEM
GM 5.7 LPG – SHEET 1 OF 2
FOOTNOTES:
a Not Illustrated
NOTES
FUEL SYSTEM
GM 5.7L LPG – SHEET 2 OF 2
KEY:
A: With Premium Low Fuel Sensor
B: Without Premium Low Fuel Sensor
QTY
ITEM PART NO. DESCRIPTION A B
1 582007179 Hose Assy .................................................................................................. 1 1
2 060023600 Clamp ......................................................................................................... 1 1
3 580049231 Capscrew ................................................................................................... 1 1
4 580027573 Nut .............................................................................................................. 1 1
5 056623800 Fitting ......................................................................................................... 2 2
6 582001213 Sensor ........................................................................................................ 1 ..
7 505970580 Fitting ......................................................................................................... 1 ..
7 580017034 Fitting ......................................................................................................... .. 1
8 580090374 Fuel Filter (LPG) ......................................................................................... 1 1
8 580090387 Kit-Filter Element ................................................................................... 1 1
9 582041056
580047714 Capscrew ................................................................................................... 2 2
10 580074250 Bracket ....................................................................................................... 1 1
11 580026621 Nut (Fold Over) .......................................................................................... 5 5
12 580049229 Capscrew ................................................................................................... 3 3
13 019930000 Fitting ......................................................................................................... 1 1
14 580008220 Capscrew ................................................................................................... 2 2
15 580008353 Clamp ......................................................................................................... 1 1
16 580064997 Hose Assy .................................................................................................. 1 1
17 580077921 Bracket ....................................................................................................... 1 1
18 505970592 Sealant ....................................................................................................... AR AR
NOTES
7 ELECTRICAL SYSTEM
CONTENTS
SECTION 7
ELECTRICAL SYSTEM
DESCRIPTION PAGE
SECTION 7
ELECTRICAL SYSTEM
DESCRIPTION PAGE
NOTES
ELECTRICAL ARRANGEMENT
CUMMINS QSB 3.3L DIESEL
ELECTRICAL ARRANGEMENT
GM 5.7L LPG
ELECTRICAL SYSTEM
RIGHT HAND CHASSIS – CUMMINS QSB 3.3L DIESEL
FOOTNOTES:
a Not Illustrated c S/N A909V01526H →
b → S/N A909V01525H
ELECTRICAL SYSTEM
RIGHT HAND CHASSIS – GM 5.7L LPG
FOOTNOTES:
a Not Illustrated
COWL ELECTRICAL
ELECTRIC HYDRAULIC
KEY:
A: With Return to Set Tilt
B: Without Return to Set Tilt
QTY
ITEM PART NO. DESCRIPTION A B
1 580093227 Wire Harness (Cowl) (With Foot Directional Control Pedal) (FP20944
[Page 7-86])................................................................................................ 1 1
1 580093229 Wire Harness (Cowl) (With Forward/Reverse Lever) (FP20944 [Page 7-
86]).............................................................................................................. 1 1
1 582004774 Wire Harness (Cowl) (With Foot Directional Control Pedal)(Alternate Part)
(FP20944 [Page 7-86]).............................................................................. 1 1
1 582004775 Wire Harness (Cowl) (With Forward/Reverse Lever) (Alternate Part)
(FP20943 [Page 7-82]).............................................................................. 1 1
2 580047200 Screw ......................................................................................................... 2 2
3 580062311 Bracket ....................................................................................................... 1 1
3 580096475 Bracket (Right Hand) (Alternate Part) ........................................................ 1 1
4 580037180 Capscrew ................................................................................................... 2 2
4 580037180 Capscrew (Alternate Part) .......................................................................... 2 2
5 580038826 Bracket ....................................................................................................... 1 1
6 a 580038751 Wire Harness (Control Valve) (FP20949 [Page 7-102])............................ 1 1
6 c 580040090 Wire Harness (Control Valve) (FP20948 [Page 7-100])............................ 1 1
7 e 580049609 Vehicle System Manager (VSM) (w/ Electro-Hydraulics) -8525420 ........... 1 1
7 d 580049610 Vehicle System Manager (VSM) (w/ Cab and with or without Electro-
Hydraulics) -8525421 ................................................................................. 1 1
8 580026812 Clip ............................................................................................................. 3 1
9 580056613 Fastener ..................................................................................................... 3 1
10 580056614 Bracket ....................................................................................................... 1 1
11 580030968 Capscrew ................................................................................................... 3 3
12 580037180 Capscrew ................................................................................................... 2 2
13 580042794 Clamp (Swivel) ........................................................................................... 1 1
13 580064599 Clamp (Swivel) (Alternate Part) .................................................................. 1 1
14 580075968 Clamp ......................................................................................................... 1 1
15 580053484 Clamp (Swivel) ........................................................................................... 1 1
16 580096474 Bracket (Left Hand) (Alternate Part) ........................................................... 1 1
b 580050194 Dust Cap .................................................................................................... 1 1
FOOTNOTES:
a Four Function d With Cab
b Not Illustrated e With Overhead Guard
c Three Function
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Not Illustrated
BATTERY CABLES
CUMMINS QSB 3.3L DIESEL
BATTERY CABLES
GM 5.7L LPG
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Remove Panels From Overlay as Required For c S/N A909V01507H →
Truck Configuration.
b → S/N A909V01506H
LIGHTS
BRAKE, TAIL, BACKUP, SIDE, TURN SIGNALS, WORK, STROBE – WITH CAB
LIGHTS
BRAKE, TAIL, BACKUP, SIDE, TURN SIGNALS, WORK, STROBE – WITH OVERHEAD GUARD
LIGHTS
BRAKE, TAIL, BACKUP, SIDE, TURN SIGNALS, WORK, STROBE – WITH OVERHEAD GUARD
NOTES
FOOTNOTES:
a 5.7L LPG c S/N A909V01508H →
b → S/N A909V01507H
LIGHTS
AMBER LIGHTS – WITH THREE STAGE MAST
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Kit Includes: 1 Interlock Mini-Lever (must be used c Kit Includes: 1 Momentary Switch, 1 Lockwasher,
in combination with a Momentary Interlock Switch), 1 Gasket, 1 Nut (parts are NSS)
1 Gasket, 4 Screws (parts are NSS)
b Kit Includes: 1 Momentary Switch Hole Plug, 1
Gasket (parts are NSS)
FOOTNOTES:
a Kit Includes: 1 Interlock Rocker (must be used in c Kit Includes: 1 Momentary Interlock Switch Plug, 1
combination with a Momentary Interlock Switch), 1 Gasket (parts are NSS)
Gasket, 4 Screws (parts are NSS) d Kit Includes: 1 Momentary Switch, 1 Lockwasher,
b Kit Includes: 1 Mini-Lever Plug, 1 Gasket (parts are 1 Gasket, 1 Nut (parts are NSS)
NSS)
MINI-LEVER CONTROLS
WITH ARMREST – THREE FUNCTION (S/N A909V01508H →)
KEY:
A: Without Directional Control Switch
B: With Directional Control Switch
QTY
ITEM PART NO. DESCRIPTION A B
1 582001049 Mini-Lever Assembly .................................................................................. 1 ..
1 c 582001128 Mini-Lever Assembly .................................................................................. 1 ..
1 a 582001053 Mini-Lever Assembly .................................................................................. 1 ..
1 b 582001055 Mini-Lever Assembly .................................................................................. 1 ..
1 582001057 Mini-Lever Assembly .................................................................................. .. 1
1 c 582001060 Mini-Lever Assembly .................................................................................. .. 1
1 a 582001062 Mini-Lever Assembly .................................................................................. .. 1
1 b 582001064 Mini-Lever Assembly .................................................................................. .. 1
2 ..... Lever Position 1 ..................................................................................... 1 1
2 580096227 Lever (Single Function) ..................................................................... 1 1
3 ..... Lever Position 2 ..................................................................................... 1 1
3 580096227 Lever (Single Function) ..................................................................... 1 1
3 a 580096229 Lever (With Override) ........................................................................ 1 1
4 ..... Lever Position 3 ..................................................................................... 1 1
4 580096227 Lever (Single Function) ..................................................................... 1 1
4 c 580096228 Lever (Clamping) ............................................................................... 1 1
5 580093297 Plug ........................................................................................................ 1 1
6 580097446 Armrest (Without Push Buttons Holes) .................................................. 1 1
6 a c 582003674 Armrest (With Push Buttons) ................................................................. 1 1
7 580097388 Cushion (Armrest) .................................................................................. 1 1
8 580097432 Nut ......................................................................................................... 5 5
9 580093745 Capscrew ............................................................................................... 6 6
10 582005939 Wire Harness ......................................................................................... 1 1
11 c 580095849 Push Button (Position 3) ........................................................................ 1 1
11 b 580095849 Push Button (Position 2 and 3) .............................................................. 2 2
11 a 580095849 Push Button (Position 2) ........................................................................ 1 1
12 c 580096147 Cover (Push Button) .............................................................................. 1 1
12 b 580096147 Cover (Push Button) .............................................................................. 1 1
13 580095850 Wire Harness (Forward/Reverse Switch in the MLM) (Push
Buttons) ................................................................................................. 1 1
14 580097449
582005940 Printed Circuit Board .............................................................................. 1 1
15 580097447 Cover (Bottom Armrest) ......................................................................... 1 1
16 582001086 Plug ........................................................................................................ 1 1
17 580097389 Horn Button ............................................................................................ 1 1
18 580096412
582098594 Switch - Directional Control ................................................................... .. 1
19 580096411 Plug (Directional Control Switch) ........................................................... 1 ..
20 580093745 Capscrew ................................................................................................... 8 8
FOOTNOTES:
a Return to Set Tilt c With Clamping
b Three Function Clamp with Return to Set Tilt
MINI-LEVER CONTROLS
WITH ARMREST – FOUR FUNCTION (S/N A909V01508H →)
KEY:
A: Without Directional Control Switch
B: With Directional Control Switch
QTY
ITEM PART NO. DESCRIPTION A B
1 582001050 Mini-Lever Assembly .................................................................................. 1 ..
1 a 582001052 Mini-Lever Assembly .................................................................................. 1 ..
1 c 582001054 Mini-Lever Assembly .................................................................................. 1 ..
1 b 582001056 Mini-Lever Assembly .................................................................................. 1 ..
1 582001058 Mini-Lever Assembly .................................................................................. .. 1
1 a 582001061 Mini-Lever Assembly .................................................................................. .. 1
1 c 582001063 Mini-Lever Assembly .................................................................................. .. 1
1 b 582001065 Mini-Lever Assembly .................................................................................. .. 1
2 ..... Lever Position 1 ..................................................................................... 1 1
2 580096227 Lever (Single Function) ..................................................................... 1 1
3 ..... Lever Position 2 ..................................................................................... 1 1
3 580096227 Lever (Single Function) ..................................................................... 1 1
3 b 580096229 Lever (With Override) ........................................................................ 1 1
4 ..... Lever Position 3 ..................................................................................... 1 1
4 580096227 Lever (Single Function) ..................................................................... 1 1
5 ..... Lever Position 4 ..................................................................................... 1 1
5 580096227 Lever (Single Function) ..................................................................... 1 1
5 a b 580096228 Lever (Clamping) ............................................................................... 1 1
6 580097446 Armrest (Without Push Buttons Holes) .................................................. 1 1
6 a b c 582003674 Armrest (With Push Buttons) ................................................................. 1 1
7 580097388 Cushion (Armrest) .................................................................................. 1 1
8 580097432 Nut ......................................................................................................... 5 5
9 580093745 Capscrew ............................................................................................... 6 6
10 582005939 Wire Harness ......................................................................................... 1 1
11 a 580095849 Push Button ........................................................................................... 1 1
11 b 580095849 Push Button ........................................................................................... 2 2
12 a 580096147 Cover (Push Button) .............................................................................. 2 2
12 b 580096147 Cover (Push Button) .............................................................................. 1 1
13 580095850 Wire Harness (Forward/Reverse Switch in the MLM) (Push
Buttons) ................................................................................................. 1 1
14 580097449
582005940 Printed Circuit Board .............................................................................. 1 1
15 580097447 Cover (Bottom Armrest) ......................................................................... 1 1
16 582001086 Plug ........................................................................................................ 1 1
17 580097389 Horn Button ............................................................................................ 1 1
18 580096412
582098594 Switch - Directional Control ................................................................... .. 1
19 580096411 Plug (Directional Control Switch) ........................................................... 1 ..
20 580093745 Capscrew ................................................................................................... 8 8
FOOTNOTES:
a With Clamping c With Return to Set Tilt
b With Clamping and Return to Set Tilt
MAST ELECTRICAL
ITEM PART NO. DESCRIPTION QTY
1 580093225 Bracket ................................................................................................................ 1
2 580058270 Capscrew ............................................................................................................ 1
3 580093226 Bracket ................................................................................................................ 1
4 580044862 Insert ................................................................................................................... 1
5 580077709 Sensor (Mast Position) ....................................................................................... 1
6 580047034 Capscrew ............................................................................................................ 2
7 449015112 Locknut ............................................................................................................... 2
8 580072635 Capscrew ............................................................................................................ 1
9 580058190 Nut ...................................................................................................................... 1
NOTES
WIRE HARNESS
ENGINE – CUMMINS QSB 3.3L DIESEL
WIRE HARNESS
RIGHT HAND CHASSIS – CUMMINS QSB 3.3L DIESEL (→ S/N A909V01525H)
WIRE HARNESS
RIGHT HAND CHASSIS – CUMMINS QSB 3.3L DIESEL (→ S/N A909V01525H)
WIRE HARNESS
RIGHT HAND CHASSIS – CUMMINS QSB 3.3L DIESEL (→ S/N A909V01525H)
WIRE HARNESS
RIGHT HAND CHASSIS – CUMMINS QSB 3.3L DIESEL (→ S/N A909V01525H)
WIRE HARNESS
RIGHT HAND CHASSIS – CUMMINS QSB 3.3L DIESEL (→ S/N A909V01525H)
WIRE HARNESS
SEAT JUMPER (→ S/N A909V01525H)
WIRE HARNESS
RIGHT HAND CHASSIS – CUMMINS QSB 3.3L DIESEL (S/N A909V01526H →)
WIRE HARNESS
RIGHT HAND CHASSIS – CUMMINS QSB 3.3L DIESEL (S/N A909V01526H →)
WIRE HARNESS
RIGHT HAND CHASSIS – CUMMINS QSB 3.3L DIESEL (S/N A909V01526H →)
WIRE HARNESS
RIGHT HAND CHASSIS – CUMMINS QSB 3.3L DIESEL (S/N A909V01526H →)
WIRE HARNESS
RIGHT HAND CHASSIS – CUMMINS QSB 3.3L DIESEL (S/N A909V01526H →)
WIRE HARNESS
RIGHT HAND CHASSIS – GM 5.7L LPG
WIRE HARNESS
RIGHT HAND CHASSIS – GM 5.7L LPG
WIRE HARNESS
RIGHT HAND CHASSIS – GM 5.7L LPG
WIRE HARNESS
RIGHT HAND CHASSIS – GM 5.7L LPG
NOTES
WIRE HARNESS
REAR – CUMMINS QSB 3.3L DIESEL
WIRE HARNESS
REAR – GM 5.7L LPG
NOTES
NOTES
WIRE HARNESS
ALTERNATOR-D – CUMMINS QSB 3.3L DIESEL
FOOTNOTES:
a Not Illustrated
WIRE HARNESS
SEALED ALTERNATOR-DS – CUMMINS QSB 3.3L DIESEL
FOOTNOTES:
a Not Illustrated
NOTES
WIRE HARNESS
TRANSMISSION – THREE SPEED
WIRE HARNESS
TRANSMISSION – THREE SPEED
NOTES
WIRE HARNESS
ELECTRONIC CONTROL VALVE – THREE FUNCTION
WIRE HARNESS
ELECTRONIC CONTROL VALVE – FOUR FUNCTION
WIRE HARNESS
LIGHTS WITH OVERHEAD GUARD
NOTES
WIRE HARNESS
JUMPER – HEAD/WORK LIGHTS, 3 STAGE MAST
WIRE HARNESS
BUZZER
NOTES
8 TRANSMISSION
CONTENTS
SECTION 8
TRANSMISSION
DESCRIPTION PAGE
TRANSMISSION MOUNT
ITEM PART NO. DESCRIPTION QTY
1 449001023 Capscrew ............................................................................................................ 1
2 504057795
449022013 Lockwasher ......................................................................................................... 1
3 580063482 Washer ............................................................................................................... 1
4 580063480 Crossmember ..................................................................................................... 1
5 580063478 Housing (Bushing) .............................................................................................. 1
6 502566903 Washer ............................................................................................................... 6
7 502565901 Capscrew ............................................................................................................ 2
8 311323023 Capscrew ............................................................................................................ 8
9 580069314 Bracket (Isolator) ................................................................................................ 1
10 580063481 Pin ....................................................................................................................... 1
11 a 580096451 Transmission Assy (Three Speed) ..................................................................... 1
11 b 582003791 Transmission Assy (Three Speed) ..................................................................... 1
12 580063477 Bushing ............................................................................................................... 1
13 580049879 Washer ............................................................................................................... 4
14 580051384 Nut (Flange) ........................................................................................................ 2
FOOTNOTES:
a → S/N A909V01506G b S/N A909V01507G →
TORQUE CONVERTER
CUMMINS QSB 3.3L DIESEL
TRANSMISSION ASSEMBLY
THREE SPEED – SHEET 1 0F 2
FOOTNOTES:
a → S/N A909V01506G b S/N A909V01507G →
TRANSMISSION ASSEMBLY
THREE SPEED – SHEET 2 OF 2
FOOTNOTES:
a → S/N A909V01506G b S/N A909V01507G →
TRANSMISSION COOLING
WITH EXTERNAL OIL COOLER
FOOTNOTES:
a Not Illustrated b Not used with this application
FOOTNOTES:
a Not Illustrated
CONTROL VALVE
THREE SPEED TRANSMISSION
FOOTNOTES:
a → S/N A909V01506G b S/N A909V01507G →
NOTES
PUMP DRIVE
ITEM PART NO. DESCRIPTION QTY
1 580089184 Drive Gear (Pump) .............................................................................................. 1
2 580080604 Capscrew ............................................................................................................ 1
3 580070516 Lockwasher ......................................................................................................... 1
4 580080603 Support (Pump Drive Bearing) ............................................................................ 1
5 580080605 Pin (Bearing Support) ......................................................................................... 1
6 580080601 Ball Bearing ........................................................................................................ 1
7 580083472 Retaining Ring .................................................................................................... 1
8 580080598 Screw .................................................................................................................. 1
9 580080599 Lockwasher ......................................................................................................... 1
10 580080597 Support (Pump Drive Idler Bearing) .................................................................... 1
11 580080596 Pin (Bearing Support) ......................................................................................... 1
12 580080736 Snap Ring ........................................................................................................... 1
13 580080735 Bearing ............................................................................................................... 1
14 580089183 Idler Gear (Pump Drive) ...................................................................................... 1
NOTES
9 DRIVE AXLE
CONTENTS
SECTION 9
DRIVE AXLE
DESCRIPTION PAGE
KEY:
A: Pneumatic
B: Solid Pneumatic
QTY
ITEM PART NO. DESCRIPTION A B
580081177 Wheel And Tire Assembly (Pneumatic Trelleborg) .................................... 4 ..
580014962 Pneumatic Tire Assembly (Radial) (Radial) ............................................... 4 ..
580097487 Wheel And Tire .......................................................................................... .. 2
1 580050049 Tire (Trelleborg T-900) ........................................................................... 1 ..
1 580015806 Tire (Pneumatic Radial) (Radial) ........................................................... 1 ..
1 580050048 Tire ......................................................................................................... .. 1
2 580078075 Wheel Assy (6.5 x 15) ............................................................................ 1 ..
3 582021051 Wheel ................................................................................................ 1 ..
4 505971515 Wheel Lock Ring ............................................................................... 1 ..
5 580006798 Wheel Side Ring ................................................................................ 1 ..
6 580057316 Wedge Band ...................................................................................... 1 ..
7 580097486 Wheel Assy (8.00 x 15) .......................................................................... .. 1
8 582002195 Wheel ................................................................................................ .. 1
9 580014390 Wheel Side Ring ................................................................................ .. 1
10 580068603 Ring-Tapered Bead Seat ................................................................... .. 1
11 580068606 Wheel Lock Ring ............................................................................... .. 1
a 580014869 Tubeless Bead Seal (Radial) ................................................................. 1 ..
a 580014987 Tubeless Bead Seal Valve (Radial) ....................................................... 1 ..
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Used with Bias Ply Tires b Used with Radial Tires
NOTES
DIFFERENTIAL
ITEM PART NO. DESCRIPTION QTY
580073454 Drive Axle (16.9 Overall Ratio) ........................................................................... 1
580095294 Differential ...................................................................................................... 1
1 580076223
580095290 Differential Carrier ...................................................................................... 1
2 580076224 Washer ....................................................................................................... 2
3 580076225
580095291 Gear , Differential Side ............................................................................... 2
4 580095293 Friction Disk ............................................................................................... 4
5 580076228 Pinion ......................................................................................................... 4
6 580095292 Shaft ........................................................................................................... 2
7 580076230 Bolt ............................................................................................................. 15
8 580069950 Bolt ................................................................................................................. 2
9 580076219 Nut .................................................................................................................. 2
10 580076220 Seal ................................................................................................................ 2
11 580086333 Snap Ring ....................................................................................................... 2
12 580076218 O-Ring ............................................................................................................ 2
13 580076221 Bearing , Tapered Roller ................................................................................ 2
14 580076222 Bolt ................................................................................................................. 2
15 580095289 Gear Set ......................................................................................................... 1
16 580076216 Bearing , Tapered Roller ................................................................................ 1
17 580081758 Kit-Shim .......................................................................................................... 1
18 580076211 Shim (0.1 mm) (0.1 mm) ................................................................................ 1
18 580076212 Shim (0.2 mm) (0.2 mm) ................................................................................ 1
18 580076213 Shim (0.5 mm) (0.5 mm) ................................................................................ 1
18 580076214 Shim (0.15 mm) (0.15 mm) ............................................................................ 1
19 580076208 Spacer ............................................................................................................ 1
20 580069883 Bearing ........................................................................................................... 1
21 580076207 Seal ................................................................................................................ 1
22 580076206 Cover Plate ..................................................................................................... 1
23 580076204 Flange ............................................................................................................ 1
24 580076205 O-Ring ............................................................................................................ 1
25 580076203 Nut .................................................................................................................. 1
NOTES
10 STEERING SYSTEM
CONTENTS
SECTION 10
STEERING SYSTEM
DESCRIPTION PAGE
FOOTNOTES:
a → 1/2011 b 1/2011 →
NOTES
FOOTNOTES:
a Not illustrated c 1/2011 →
b → 1/2011
STEERING LINES
ITEM PART NO. DESCRIPTION QTY
1 580019866 Fitting .................................................................................................................. 2
2 582041056
580047714 Capscrew ............................................................................................................ 7
3 580026621 Nut (Fold Over) ................................................................................................... 7
4 580045558 Clip ...................................................................................................................... 4
5 580092481 Hose Assy ........................................................................................................... 1
6 582010108 Fitting .................................................................................................................. 1
7 582010106 Fitting .................................................................................................................. 1
8 580092482 Hose Assy ........................................................................................................... 1
9 580049814 Clip ...................................................................................................................... 3
STEER AXLE
ITEM PART NO. DESCRIPTION QTY
580087538 Steering Axle ...................................................................................................... 1
1 072387302 Bearing Cup ................................................................................................... 2
2 072387301 Bearing Cone ................................................................................................. 2
3 504224231 Wear Sleeve ................................................................................................... 2
4 504224298 Seal ................................................................................................................ 2
5 580087242
582013199 Spindle (RH) ................................................................................................... 1
6 580093275 Steering Axle (Frame) .................................................................................... 1
7 504224242 Seal ................................................................................................................ 2
8 520045589 Seal ................................................................................................................ 2
9 504225236 O-Ring ............................................................................................................ 2
10 065001000 Bearing Cone ................................................................................................. 2
11 504224222 Shim (0.005 in.) .............................................................................................. 3
12 504224232 Shim (0.007 in.) .............................................................................................. 3
13 504224292 Shim (0.020 in.) .............................................................................................. 2
14 580050203 Shim (0.002 in.) .............................................................................................. 2
15 580007182 Bearing Cap (Assembly) ................................................................................ 2
15 580007183 Bearing Cap ............................................................................................... 1
15 065000900 Bearing Cup ............................................................................................... 1
16 449021006 Washer ........................................................................................................... 2
17 580049010 Capscrew ....................................................................................................... 2
18 015631500 Grease Fitting ................................................................................................. 2
19 931014904 Capscrew ....................................................................................................... 6
20 015915100 Snap Ring ....................................................................................................... 8
21 580086288 Pin .................................................................................................................. 2
22 580086289 Pin .................................................................................................................. 2
23 580091329 Seal ................................................................................................................ 8
24 580086263 Tie Rod Assembly (Assembly) ....................................................................... 1
25 580085583 Bushing ...................................................................................................... 1
26 015631500 Grease Fitting ............................................................................................. 2
27 502565901 Capscrew ....................................................................................................... 8
28 449022041 Lockwasher .................................................................................................... 8
29 580093975 Steering Cylinder Assembly (FP20972 [Page 10-13]).................................. 1
30 580003485 Bushing .......................................................................................................... 2
31 580003484 Shim (0.035 in.) .............................................................................................. AR
32 580003483 Shim (0.065 in.) .............................................................................................. AR
33 580003486 Flange ............................................................................................................ 2
34 580003482 Sealing Ring ................................................................................................... 2
35 580082310 Wheel Hub ...................................................................................................... 2
36 580002014 Wheel Stud ..................................................................................................... 12
37 502175921 Bearing Cup ................................................................................................... 2
38 053239100 Bearing Cup ................................................................................................... 2
39 580003603 Wear Sleeve ................................................................................................... 2
40 015418400 Cotter Pin ....................................................................................................... 2
41 504227283 Cap ................................................................................................................. 2
42 504240211 Wheel Nut (Spindle) ....................................................................................... 2
43 580007181 Washer ........................................................................................................... 2
44 502175920 Bearing Cone ................................................................................................. 2
45 060733800 Bearing Cone ................................................................................................. 2
46 580003602 Seal ................................................................................................................ 2
47 580087241 Spindle (LH) ................................................................................................... 1
STEER AXLE
ITEM PART NO. DESCRIPTION QTY
582013198
48 580001875 Dust Cap ........................................................................................................ 2
49 022784400 Grease Fitting ................................................................................................. 2
501702902 Loctite ............................................................................................................. AR
KEY:
A: 8.25 x 15-14 PR
B: 8.25 R15 Radial
C: 300 x 15/8 Solid Pneumatic
QTY
ITEM PART NO. DESCRIPTION A B C
1 580050049 Tire (Trelleborg T-900) (Trell) ............................................................ 2 .. ..
1 580050048 Tire (Monarch) ................................................................................... .. .. 2
2 580014962 Pneumatic Tire Assembly (Radial) .................................................... .. 2 ..
2 580014869 Tubeless Bead Seal ...................................................................... .. 1 ..
2 580014987 Tubeless Bead Seal Valve ............................................................ .. 1 ..
3 580078076 Wheel Assy ....................................................................................... 2 2 ..
3 580082163 Wheel Assy ....................................................................................... .. .. 2
3 580095040 Wheel Assy ................................................................................... .. .. 1
4 580068606 Wheel Lock Ring ........................................................................... .. .. 1
4 505971515 Wheel Lock Ring ........................................................................... 1 1 ..
5 580014390 Wheel Side Ring ........................................................................... .. .. 1
5 580006798 Wheel Side Ring ........................................................................... 1 1 ..
6 580068603 Ring-Tapered Bead Seat .............................................................. 1 1 1
7 580003941 Wheel Nut .......................................................................................... 12 12 12
NOTES
11 BRAKE SYSTEM
CONTENTS
SECTION 11
BRAKE SYSTEM
DESCRIPTION PAGE
BRAKE PEDAL
SINGLE PEDAL
BRAKE PEDAL
DUAL PEDAL
FOOTNOTES:
a → S/N A909V01500F b S/N A909V01501F →
NOTES
FOOTNOTES:
a Not Illustrated
NOTES
12 HYDRAULIC SYSTEM
CONTENTS
SECTION 12
HYDRAULIC SYSTEM
DESCRIPTION PAGE
HYDRAULIC FILTER
ITEM PART NO. DESCRIPTION QTY
1 580096468 Cap ..................................................................................................................... 1
1 582002950 Cap Assembly (Alternate Part) ........................................................................... 1
1 580096460 O-Ring ............................................................................................................ 1
1 ..... Spring ............................................................................................................. 1
2 ..... Bowl Assembly ................................................................................................... 1
3 580096816 Filter Element ................................................................................................. 1
3 582005255 Filter Element (Alternate Part) ........................................................................ 1
4 a 580049602 Pressure Switch .................................................................................................. 1
580096466 Kit-Seal ............................................................................................................... 1
5 582002951 Kit-O-Ring (Alternate Part) .................................................................................. 1
5 580096854 Kit-Filter Element ................................................................................................ 1
FOOTNOTES:
a With Electronic Monitoring Package
FOOTNOTES:
a Not Illustrated
NOTES
GEAR PUMP
ITEM PART NO. DESCRIPTION QTY
580094450 Gear Pump (Steering) ......................................................................................... 1
1 ..... Gear Housing ................................................................................................. 1
2 580094454 Drive Gear ...................................................................................................... 1
3 580094453 Gear (Driven) .................................................................................................. 1
4 580081576 Flange ............................................................................................................ 1
5 580081577 Cover .............................................................................................................. 1
6 580094452 Side Plate ....................................................................................................... 2
7 ..... Seal Plate ....................................................................................................... 2
8 ..... Back-Up Ring ................................................................................................. 2
9 580012154 Screw ............................................................................................................. 4
10 580054028 Dowel ............................................................................................................. 4
580094451 Gear Set ............................................................................................................. 1
580081579 Kit-Repair ............................................................................................................ 1
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Not Illustrated
NOTES
FOOTNOTES:
a Four Function Only b Three Function Only
TILT SECTION
THREE AND FOUR FUNCTION
FOOTNOTES:
a Four Function Only b Three Function Only
FOOTNOTES:
a Four Function Only b Three Function Only
OUTLET SECTION
THREE AND FOUR FUNCTION
FOOTNOTES:
a 5° Forward/6° Back b 5° Forward/9° Back
TILT CYLINDERS
KEY:
A: 5 Degrees Forward/6 Degrees Back
B: 5 Degrees Forward/10 Degrees Back
QTY
ITEM PART NO. DESCRIPTION A B
580074579 Tilt Cylinder (LH) ........................................................................................ 1 ..
580074580 Tilt Cylinder (LH) ........................................................................................ .. 1
580066856 Tilt Cylinder (RH) ........................................................................................ 1 ..
580066857 Tilt Cylinder (RH) ........................................................................................ .. 1
1 524214602 Rod Wiper .............................................................................................. 1 1
2 580067211 End Plug (Gland) ................................................................................... 1 1
3 580022495 Rod Seal ................................................................................................ 1 1
4 066049400 O-Ring ................................................................................................... 2 2
5 520045452 Back-Up Ring ......................................................................................... 1 1
6 524254202 Piston Rod ............................................................................................. .. 1
6 524254201 Piston Rod ............................................................................................. 1 ..
7 582004792 O-Ring ................................................................................................... 1 1
8 504305709 Piston Seal ............................................................................................. 1 1
9 580067210 Piston ..................................................................................................... 1 1
10 580002761 Wear Ring .............................................................................................. 1 1
11 502637906 Locknut .................................................................................................. 1 1
12 580067904 Tube Wldmt-Cylinder (RH) .................................................................... 1 ..
12 580067905 Tube Wldmt-Cylinder (RH) .................................................................... .. 1
12 580074577 Tube Wldmt-Cylinder (LH) ..................................................................... 1 ..
12 580074578 Tube Wldmt-Cylinder (LH) ..................................................................... .. 1
580067716 Kit-Seal ....................................................................................................... 1 1
TILT HYDRAULICS
ITEM PART NO. DESCRIPTION QTY
1 580019865 Fitting .................................................................................................................. 4
2 580075491 Hose Assy ........................................................................................................... 1
3 580026621 Nut (Fold Over) ................................................................................................... 2
4 580073148 Hose Clamp (Dual Hose) .................................................................................... 2
5 580058269 Capscrew ............................................................................................................ 2
6 580020430 Fitting .................................................................................................................. 6
7 580080018 Fitting .................................................................................................................. 1
8 900011244 Clamp ................................................................................................................. 2
9 580079375 Hose ................................................................................................................... 1
10 580077924 Fitting .................................................................................................................. 1
11 580019810 Fitting .................................................................................................................. 1
12 580075468 Hose Assy ........................................................................................................... 1
13 580020576 Fitting .................................................................................................................. 1
14 582041056
580047714 Capscrew ............................................................................................................ 2
15 582001191 Balance Valve ..................................................................................................... 1
15 582001193 Valve Block ..................................................................................................... 1
15 315976070 Fitting .............................................................................................................. 1
15 052645200 O-Ring ........................................................................................................ 1
15 315976062 Fitting Assembly ............................................................................................. 3
15 580004501 Plug ............................................................................................................ 1
15 056363300 O-Ring ........................................................................................................ 1
15 582002117 Valve .............................................................................................................. 1
16 580075490 Hose Assy ........................................................................................................... 1
17 580075489 Hose ................................................................................................................... 1
18 580075487 Hose Assy ........................................................................................................... 1
19 580075492 Hose Assy ........................................................................................................... 1
NOTES
NOTES
SECTION 13
MAST-TWO STAGE LIMITED FREE-LIFT
DESCRIPTION PAGE
OUTER MAST
W/INTEGRAL SIDESHIFT CARRIAGE
OUTER MAST
W/STANDARD HOOK CARRIAGE
FOOTNOTES:
a Refer to Table
NOTES
INNER MAST
W/INTEGRAL SIDESHIFT CARRIAGE
INNER MAST
W/STANDARD HOOK CARRIAGE
FOOTNOTES:
a Refer to Table
FOOTNOTES:
a Refer to Table
NOTES
FORK POSITIONER
ITEM PART NO. DESCRIPTION QTY
582001701 Kit-Fork Positioner .............................................................................................. 1
1 582001702 Valve .............................................................................................................. 1
2 582001703 Clamp ............................................................................................................. 3
3 582062170
582001704 Cylinder .......................................................................................................... 1
582002985 Kit-Seal ....................................................................................................... 1
4 582062171
582001705 Cylinder .......................................................................................................... 1
582002986 Kit-Seal ....................................................................................................... 1
5 582001706 Bracket ........................................................................................................... 1
6 582001707 Bracket ........................................................................................................... 1
7 580097275 Load Backrest ................................................................................................ 1
8 582001709 Support ........................................................................................................... 1
9 582001710 Bushing .......................................................................................................... 2
10 582001711 Tube ............................................................................................................... 1
11 582001712 Tube ............................................................................................................... 1
12 582001713 Tube ............................................................................................................... 1
13 582001714 Tube ............................................................................................................... 1
14 582001715 Guide .............................................................................................................. 4
15 582001716 Guide .............................................................................................................. 4
16 582010552 Screw ............................................................................................................. 6
17 580037104 Washer ........................................................................................................... 2
18 582001717 Screw ............................................................................................................. 2
19 582001748 Screw ............................................................................................................. 6
20 580040568 Washer ........................................................................................................... 2
21 582000107 Washer ........................................................................................................... 2
22 582000108 Screw ............................................................................................................. 2
23 580085575 Grease Fitting ................................................................................................. 2
24 582001718 Fitting .............................................................................................................. 4
25 582001719 Screw ............................................................................................................. 2
26 582001749 Fitting .............................................................................................................. 2
27 582001750 Fitting .............................................................................................................. 2
28 582001720 Nut .................................................................................................................. 2
29 582001721 Fitting .............................................................................................................. 2
30 582010553
582060939 Hose ............................................................................................................... 1
31 582010554 Hose ............................................................................................................... 1
CARRIAGE
KEY:
A: Standard Carriage (Hook Type)
B: Side-Shift Carriage (Without Fork Positioner)
C: Side-Shift Carriage (With Fork Positioner)
QTY
ITEM PART NO. DESCRIPTION A B C
580096995 Carriage (Standard) ........................................................................... 1 .. ..
582073806
580096996 Carriage (Side-Shift Without Fork Positioner) ................................... .. 1 ..
582000116
580096997 Carriage (Integral Side-Shift with Fork Positioner) ............................ .. .. 1
1 582000104 Sideshift Cylinder .......................................................................... .. 1 1
1 582002987 Kit-Seal ..................................................................................... .. 1 1
2 582001751 Pin ................................................................................................. .. 2 2
3 582001723 Ring ............................................................................................... .. 4 4
4 582000109 Bushing ......................................................................................... .. 4 4
5 580040542 Hook (Lower) ................................................................................. .. 2 2
6 582000107 Washer .......................................................................................... .. 4 4
7 582000108 Screw ............................................................................................ .. 4 4
8 580040543 Grease Fitting ................................................................................ .. 2 2
9 580040544 Pad (Upper) ................................................................................... .. 2 2
10 582033132
582000105 Side-Shift Carriage ........................................................................ .. 1 1
11 582001696 Carriage (Side Plate) ..................................................................... .. 1 1
12 582000373 Carriage ........................................................................................ 1 1 1
13 582007141 Stubshaft ................................................................................... 2 2 2
14 582000062 Bushing (Wear Pad) .......................................................................... 4 4 4
15 582000117 Ring ................................................................................................... 4 4 4
16 582053082
582000063 Roller ................................................................................................. 4 4 4
17 582000081 Screw ................................................................................................ 4 4 4
18 582000119 Nut ..................................................................................................... 4 4 4
19 580037116 Locknut .............................................................................................. 2 2 2
20 580051295
015419800 Cotter Pin .......................................................................................... 4 4 4
21 580037114 Pin ..................................................................................................... 2 2 2
22 580002627 Chain ................................................................................................. AR AR AR
23 580037115 Chain Anchor ..................................................................................... 2 2 2
24 582001680 Pin ..................................................................................................... 2 2 2
HEADER HOSES
ITEM PART NO. DESCRIPTION QTY
1 582000097 Washer ............................................................................................................... 4
2 582073419
582000095 Pulley .................................................................................................................. 4
3 582000096 Pin ....................................................................................................................... 2
4 580037111 Snap Ring ........................................................................................................... 2
5 582010566 Washer ............................................................................................................... 2
6 582000100 Screw .................................................................................................................. 2
7 580040518 Clamp ................................................................................................................. 4
8 582000056 Clamp ................................................................................................................. 12
9 582010568 Hose ................................................................................................................... 4
10 582000370 Fitting (Cap) ........................................................................................................ 4
11 582010569 Hose ................................................................................................................... 4
12 582010567 Fitting .................................................................................................................. 4
13 580037134 Fitting .................................................................................................................. 4
14 582000101 Hose Clamp ........................................................................................................ 8
15 582010552 Screw .................................................................................................................. 4
16 582000069 Fitting .................................................................................................................. 4
NOTES
SECTION 14
MAST-THREE STAGE FULL FREE-LIFT
DESCRIPTION PAGE
OUTER MAST
WITH INTEGRAL SIDE-SHIFT CARRIAGE
OUTER MAST
WITH STANDARD HOOK CARRIAGE
FOOTNOTES:
a Refer to Table
NOTES
INTERMEDIATE MAST
WITH INTEGRAL SIDE-SHIFT CARRIAGE
INTERMEDIATE MAST
WITH STANDARD HOOK CARRIAGE
FOOTNOTES:
a Refer to Table
NOTES
INNER MAST
WITH INTEGRAL SIDE-SHIFT CARRIAGE
INNER MAST
WITH STANDARD HOOK CARRIAGE
FOOTNOTES:
a Refer to Table
FOOTNOTES:
a Refer to Table
FOOTNOTES:
a Refer to Table
NOTES
CARRIAGE
KEY:
A: Standard Carriage (Hook Type)
B: Side-Shift Carriage (Without Fork Positioner)
C: Side-Shift Carriage (With Fork Positioner)
QTY
ITEM PART NO. DESCRIPTION A B C
580097034 Carriage (Standard) ........................................................................... 1 .. ..
580097035 Carriage (Side-Shift) (Without Fork Positioner) ................................. .. 1 ..
582000075
580097036 Carriage (Integral Sideshift with Fork Positioner) .............................. .. .. 1
1 582000104 Sideshift Cylinder .......................................................................... .. 1 1
1 582002987 Kit-Seal ..................................................................................... .. 1 1
2 582001751 Pin ................................................................................................. .. 2 2
3 582001723 Ring ............................................................................................... .. 4 4
4 582000109 Bushing ......................................................................................... .. 4 4
5 580040542 Hook (Lower) ................................................................................. .. 2 2
6 582000107 Washer .......................................................................................... .. 4 4
7 582000108 Screw ............................................................................................ .. 4 4
8 580040543 Grease Fitting ................................................................................ .. 2 2
9 580040544 Pad (Upper) ................................................................................... .. 2 2
10 582033132
582000105 Side-Shift Carriage ........................................................................ .. 1 1
11 582000106 Carriage ........................................................................................ .. 1 1
12 582000076 Carriage ........................................................................................ 1 1 1
13 582007141 Stubshaft ................................................................................... 2 2 2
14 582000062 Bushing (Wear Pad) .......................................................................... 4 4 4
15 582000117 Ring ................................................................................................... 4 4 4
16 582053082
582000063 Roller ................................................................................................. 4 4 4
17 582000081 Screw ................................................................................................ 4 4 4
18 582000119 Nut ..................................................................................................... 4 4 4
19 580051295
015419800 Cotter Pin .......................................................................................... 2 2 2
20 580037114 Pin ..................................................................................................... 1 1 1
21 580002627 Chain ................................................................................................. AR AR AR
HEADER HOSES
ITEM PART NO. DESCRIPTION QTY
1 580040518 Clamp ................................................................................................................. 8
2 582000061 Pulley .................................................................................................................. 4
3 582000055 Pulley .................................................................................................................. 2
3 582107396 Roller .............................................................................................................. 4
4 582000056 Clamp ................................................................................................................. 12
5 582042414 Hose Assy ........................................................................................................... 2
6 582010559 Hose ................................................................................................................... 4
7 582000370 Fitting .................................................................................................................. 4
8 582002359 Hose ................................................................................................................... 2
9 580037134 Fitting (Bulkhead) ................................................................................................ 10
10 582000057 Fitting .................................................................................................................. 2
11 582010573
582010563 Hose ................................................................................................................... 1
12 580040995 Clamp ................................................................................................................. 1
13 582002358 Hose ................................................................................................................... 2
14 582010569 Hose ................................................................................................................... 4
15 582000069 Fitting .................................................................................................................. 4
16 582010560 Hose ................................................................................................................... 2
17 582010572
582010562 Hose ................................................................................................................... 1
18 582000053 Screw .................................................................................................................. 8
FORK POSITIONER
ITEM PART NO. DESCRIPTION QTY
582001701 Kit-Fork Positioner .............................................................................................. 1
1 582001702 Valve .............................................................................................................. 1
2 582001703 Clamp ............................................................................................................. 3
3 582062170
582001704 Cylinder .......................................................................................................... 1
582002985 Kit-Seal ....................................................................................................... 1
4 582062171
582001705 Cylinder .......................................................................................................... 1
582002986 Kit-Seal ....................................................................................................... 1
5 582001706 Bracket ........................................................................................................... 1
6 582001707 Bracket ........................................................................................................... 1
7 580097275 Load Backrest ................................................................................................ 1
8 582001709 Support ........................................................................................................... 1
9 582001710 Bushing .......................................................................................................... 2
10 582001711 Tube ............................................................................................................... 1
11 582001712 Tube ............................................................................................................... 1
12 582001713 Tube ............................................................................................................... 1
13 582001714 Tube ............................................................................................................... 1
14 582001715 Guide .............................................................................................................. 4
15 582001716 Guide .............................................................................................................. 4
16 582010552 Screw ............................................................................................................. 6
17 580037104 Washer ........................................................................................................... 2
18 582001717 Screw ............................................................................................................. 2
19 582001748 Screw ............................................................................................................. 6
20 580040568 Washer ........................................................................................................... 2
21 582000107 Washer ........................................................................................................... 2
22 582000108 Screw ............................................................................................................. 2
23 580085575 Grease Fitting ................................................................................................. 2
24 582001718 Fitting .............................................................................................................. 4
25 582001719 Screw ............................................................................................................. 2
26 582001749 Fitting .............................................................................................................. 2
27 582001750 Fitting .............................................................................................................. 2
28 582001720 Nut .................................................................................................................. 2
29 582001721 Fitting .............................................................................................................. 2
30 582010553
582060939 Hose ............................................................................................................... 2
31 582010554 Hose ............................................................................................................... 1
NOTES
15 OPTIONS
CONTENTS
SECTION 15
OPTIONS
DESCRIPTION PAGE
NOTES
SECTION 16
FIELD CONVERSION KITS
DESCRIPTION PAGE
FOOTNOTES:
a This kit requires software that must be dealer installed.
FOOTNOTES:
a This kit requires software that must be dealer installed. Dealer needs to obtain a new Configuration Data File
(CDF) from Aftermarket Services. The CDF should be ordered from the Software Resources page of HYPASS
Online. See Service Gram LD00018.
FOOTNOTES:
a This kit requires software that must be dealer installed.
FOOTNOTES:
a This kit requires software that must be dealer installed. Dealer needs to obtain a new Configuration Data File
(CDF) from Aftermarket Services. The CDF should be ordered from the Software Resources page of HYPASS
Online. See Service Gram LD00018.
b S/N A909V01508H →
FOOTNOTES:
a This kit requires software that must be dealer installed. Dealer needs to obtain a new Configuration Data File
(CDF) from Aftermarket Services. The CDF should be ordered from the Software Resources page of HYPASS
Online. See Service Gram LD00018.
FOOTNOTES:
a This kit requires software that must be dealer installed. Dealer needs to obtain a new Configuration Data File
(CDF) from Aftermarket Services. The CDF should be ordered from the Software Resources page of HYPASS
Online. See Service Gram LD00018.
NOTES
17 NUMERICAL INDEX
NUMERICAL INDEX
SECTION 17
NUMERICAL INDEX
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
SECTION 18
USER SUPPORT INFORMATION
DESCRIPTION PAGE
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