Professional Documents
Culture Documents
E813 04-2009 90 Hyster XMs
E813 04-2009 90 Hyster XMs
E813 04-2009 90 Hyster XMs
GP/GLP/GDP070-090LJ/MJ; GP/GLP/
GDP100-120MJ
(E813)
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
3 EXHAUST SYSTEM
4 COOLING SYSTEM
5 FUEL SYSTEM
6 ELECTRICAL SYSTEM
7 TRANSMISSION
8 DRIVE AXLE
9 STEERING SYSTEM
10 BRAKE SYSTEM
11 HYDRAULIC SYSTEM
16 OPTIONS
This Parts Manual is divided into 19 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 NUMERICAL INDEX
This Parts Manual is divided into 19 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
MAST LOAD DAMPENING ......................................................................................................................... 15-35
AIR FILTER
GASOLINE AND LPG ................................................................................................................................. 5-6
TIER II - DIESEL ......................................................................................................................................... 5-34
AIR INTAKE AND FILTER SYSTEM
DIESEL TIER II ........................................................................................................................................... 5-30
GASOLINE AND LPG ................................................................................................................................. 5-2
ALTERNATOR
GS, LPS, DS ............................................................................................................................................... 6-22
ALTERNATOR AND MOUNTING ................................................................................................................... 6-24
AMBER STROBE REVERSE LIGHTS
WITHOUT REAR DRIVE LIGHTS (S/N E813V03419B →) ....................................................................... 16-46
ASSEMBLED ENGINE
DIESEL TIER II ........................................................................................................................................... 2-6
GASOLINE 4.3L EPA COMPLIANT - SHEET 1 OF 2 ................................................................................. 2-42
GASOLINE 4.3L EPA COMPLIANT - SHEET 2 0F 2 ................................................................................. 2-46
LPG, 4.3L EPA COMPLIANT - SHEET 1 OF 2 ........................................................................................... 2-36
LPG, 4.3L EPA COMPLIANT - SHEET 2 OF 2 ........................................................................................... 2-40
AUXILIARY TUBE EXTENSION KIT
THREE STAGE FULL FREE-LIFT .............................................................................................................. 15-24
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 15-22
B
BACK-UP ALARM ........................................................................................................................................... 16-30
BAFFLE AND ATTACHING PARTS ................................................................................................................ 4-8
BRAKE ASSEMBLY
1830 MM SHORT WHEEL BASE ............................................................................................................... 10-10
2100 WHEEL BASE .................................................................................................................................... 10-14
BRAKE RELAY ASSEMBLY ........................................................................................................................... 10-8
BRAKE SYSTEM ............................................................................................................................................. 10-2
C
CAB
ATTACHING PARTS - SHEET 1 OF 6 ....................................................................................................... 16-2
ATTACHING PARTS - SHEET 2 OF 6 ....................................................................................................... 16-4
ATTACHING PARTS - SHEET 3 OF 6 ....................................................................................................... 16-6
ATTACHING PARTS - SHEET 4 OF 6 ....................................................................................................... 16-8
ATTACHING PARTS - SHEET 5 OF 6 ....................................................................................................... 16-10
ATTACHING PARTS - SHEET 6 OF 6 ....................................................................................................... 16-12
DOOR ASSEMBLY - LEFT HAND .............................................................................................................. 16-14
DOOR ASSEMBLY - RIGHT HAND ............................................................................................................ 16-16
WIRE HARNESSES .................................................................................................................................... 16-18
CAB WIRE HARNESS
HEADLIGHT AND HANDHELD LIGHT ....................................................................................................... 16-21
WORKLIGHTS AND STROBE LIGHT ........................................................................................................ 16-20
CAMSHAFT AND OIL PAN
GASOLINE AND LPG - 4.3L EPA COMPLIANT ......................................................................................... 2-56
DESCRIPTION PAGE
CARRIAGE
THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-26
TWO STAGE FULL FREE-LIFT .................................................................................................................. 14-18
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 12-14
CLUTCH PACKS
T096 - T098 (→ S/N E813V02052B) .......................................................................................................... 7-18
T118 - SINGLE SPEED (S/N E813V02053B →) ....................................................................................... 7-20
T120 - T121 - TWO SPEED (S/N E813V02053B →) ................................................................................. 7-22
COIL ASSEMBLY ............................................................................................................................................ 2-49
CONTROL VALVE
TRANSMISSION ......................................................................................................................................... 7-24
CONTROL VALVE CONVERSION KITS ........................................................................................................ 17-2
COOLING ........................................................................................................................................................ 4-2
COUNTERWEIGHT ........................................................................................................................................ 1-24
CRANKSHAFT AND PISTONS
DIESEL TIER II ........................................................................................................................................... 2-14
CYLINDER BLOCK
DIESEL TIER II ........................................................................................................................................... 2-8
GASOLINE AND LPG - 4.3L EPA COMPLIANT ......................................................................................... 2-54
CYLINDER HEAD
GASOLINE AND LPG - 4.3L EPA COMPLIANT ......................................................................................... 2-64
CYLINDER HEAD AND INDUCTION MANIFOLD
DIESEL TIER II ........................................................................................................................................... 2-10
D
DIFFERENTIAL ASSEMBLY ........................................................................................................................... 8-5
DIRECTIONAL CONTROL CONVERSION ..................................................................................................... 17-2
DISTRIBUTOR ASSEMBLY
4.3L EPA COMPLIANT ............................................................................................................................... 6-21
DRIP SHIELD
GASOLINE AND LPG - 4.3L EPA COMPLIANT ......................................................................................... 2-70
DRIVE AXLE ................................................................................................................................................... 8-2
DRIVE TIRES AND WHEELS
DUAL ........................................................................................................................................................... 16-28
SINGLE - GP/GLP/GDP 100-120MJ ........................................................................................................... 8-8
DRIVE WHEELS AND TIRES
SINGLE - GP/GLP/GDP 070-090LJ/ML ...................................................................................................... 8-6
DUAL MIRRORS
WITHOUT CAB ........................................................................................................................................... 16-36
DUAL WHEEL CONVERSION ........................................................................................................................ 17-2
E
ELECTRICAL SYSTEM
ALTERNATOR AND BATTERY - GASOLINE AND LPG ............................................................................ 6-10
ALTERNATOR AND BATTERY - GASOLINE AND LPG SAFETY (GS AND LPS) .................................... 6-12
COWL .......................................................................................................................................................... 6-2
DIESEL TIER II ........................................................................................................................................... 6-14
ENGINE COMPARTMENT - GASOLINE AND LPG ................................................................................... 6-8
TYPE DS ..................................................................................................................................................... 6-18
DESCRIPTION PAGE
ENGINE BELT DRIVE AND ALTERNATOR MOUNTING
4.3L EPA COMPLIANT ............................................................................................................................... 2-52
ENGINE FUEL SYSTEM
LPG - 4.3L EPA COMPLIANT ..................................................................................................................... 5-22
ENGINE MOUNTING
DIESEL TIER II ........................................................................................................................................... 2-4
GASOLINE AND LPG - 4.3L EPA COMPLIANT ......................................................................................... 2-34
EXHAUST
DIESEL TIER II ........................................................................................................................................... 3-4
GASOLINE AND LPG ................................................................................................................................. 3-2
EXHAUST MANIFOLD
DIESEL TIER II ........................................................................................................................................... 2-22
GASOLINE AND LPG - 4.3L EPA COMPLIANT ......................................................................................... 2-50
EXHAUST WRAPS
PAPER INDUSTRY OPTION ...................................................................................................................... 3-6
F
FAN DRIVE ASSEMBLY ................................................................................................................................. 4-6
FENDER EXTENSIONS .................................................................................................................................. 16-34
FLOOR PLATES AND COVERS ..................................................................................................................... 1-10
FLYWHEEL AND TORQUE CONVERTER ..................................................................................................... 7-16
FOOT DIRECTIONAL CONTROL PEDAL ...................................................................................................... 5-54
FOOT DIRECTIONAL CONTROL PEDAL AND BRACKET ASSEMBLY ....................................................... 5-52
FORKS
POLISHED FULL BOTTOM TAPER - CLASS III AND IV ........................................................................... 1-43
STANDARD TAPER - CLASS III ................................................................................................................. 1-40
STANDARD TAPER - CLASS IV ................................................................................................................ 1-42
FREE-LIFT
THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-18
FREE-LIFT CYLINDERS
THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-22
TWO STAGE FULL FREE-LIFT .................................................................................................................. 14-14
FRONT HEADLIGHTS
WITHOUT CAB ........................................................................................................................................... 16-38
FUEL FILTER AND ATTACHING PARTS
DIESEL TIER II ........................................................................................................................................... 5-36
FUEL INJECTION PUMP
DIESEL TIER II ........................................................................................................................................... 2-28
WITH BLEED BACK SYSTEM .................................................................................................................... 2-30
FUEL PUMP AND WATER SEPERATOR
DIESEL TIER II ........................................................................................................................................... 5-38
FUEL SENDER AND ATTACHING PARTS
DIESEL TIER II ........................................................................................................................................... 5-40
FUEL SUPPLY SYSTEM
DIESEL TIER II ........................................................................................................................................... 5-12
GASOLINE .................................................................................................................................................. 5-8
LPG ............................................................................................................................................................. 5-10
DESCRIPTION PAGE
FULL SUSPENSION SEAT
S/N E813V03851C → ................................................................................................................................ 1-22
SHEET 1 OF 2 (→ S/N E813V03850C) ..................................................................................................... 1-16
SHEET 2 OF 2 (→ S/N E813V03850C) ..................................................................................................... 1-20
G
GENERAL TRUCK .......................................................................................................................................... 1-2
H
HEADER HOSE
THREE STAGE FULL FREE-LIFT .............................................................................................................. 15-32
TWO STAGE FULL FREE-LIFT .................................................................................................................. 15-28
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 15-26
HEADER HOSE CONVERSION KITS
HEATER INSTALLATION
DIESEL TIER II ........................................................................................................................................... 16-26
GASOLINE .................................................................................................................................................. 16-22
LPG ............................................................................................................................................................. 16-24
HIGH AND LOW VALVE ................................................................................................................................. 7-27
HOOD AND COVERS ..................................................................................................................................... 1-6
HYDRAULIC CONTROL LINES
FOUR FUNCTION ....................................................................................................................................... 11-8
THREE FUNCTION ..................................................................................................................................... 11-6
HYDRAULIC CONTROL VALVE
THREE AND FOUR FUNCTION ................................................................................................................. 11-16
HYDRAULIC CONTROL VALVE ATTACHING PARTS
FOUR FUNCTION - WITH DETENTED LEVERS ....................................................................................... 11-14
THREE FUNCTION (TWO LEVERS WITHOUT DETENT) - THREE FUNCTION (THREE LEVERS WITH
AND WITHOUT DETENT) .......................................................................................................................... 11-10
HYDRAULIC FILTER HOUSING ..................................................................................................................... 11-20
HYDRAULIC PUMP ........................................................................................................................................ 11-22
HYDRAULIC SYSTEM .................................................................................................................................... 11-2
I
INNER MAST
THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-8
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 12-4
INNER MAST AND FREE-LIFT
TWO STAGE FULL FREE-LIFT .................................................................................................................. 14-6
INTAKE MANIFOLD AND FUEL RAIL
GASOLINE - 4.3L EPA COMPLIANT .......................................................................................................... 2-66
INTEGRAL SIDE-SHIFT ASSEMBLY
TWO AND THREE STAGE FULL FREE-LIFT - 48 AND 60-INCH (GP/GLP/GDP70LJ, GP/GLP/GDP80LJ,
GP/GLP/GDP90LJ) ..................................................................................................................................... 15-10
TWO AND THREE STAGE FULL FREE-LIFT - 54 AND 60-INCH ............................................................. 15-16
TWO STAGE LIMITED FREE-LIFT - 48 AND 60-INCH (GP/GLP/GDP70LJ, GP/GLP/GDP80LJ, GP/GLP/
GDP90LJ) .................................................................................................................................................... 15-2
TWO STAGE LIMITED FREE-LIFT - 54 AND 60-INCH (GP/GLP/GDP100MJ, GP/GLP/GDP110MJ, GP/
GLP/GDP120MJ) ........................................................................................................................................ 15-6
DESCRIPTION PAGE
INTEGRAL SIDE-SHIFT CARRIAGE
TWO AND THREE STAGE FULL FREE-LIFT - 48-INCH (GP/GLP/GDP70LJ, GP/GLP/GDP80LJ, GP/
GLP/GDP90LJ) ........................................................................................................................................... 15-12
TWO AND THREE STAGE FULL FREE-LIFT - 60-INCH (GP/GLP/GDP70LJ, GP/GLP/GDP80LJ, GP/
GLP/GDP90LJ) ........................................................................................................................................... 15-14
TWO AND THREE STAGE FULL FREE-LIFT - 54 AND 60-INCH ............................................................. 15-18
TWO STAGE LIMITED FREE-LIFT - 48 AND 60-INCH (GP/GLP/GDP70LJ, GP/GLP/GDP80LJ, GP/GLP/
GDP90LJ) .................................................................................................................................................... 15-4
TWO STAGE LIMITED FREE-LIFT - 54 AND 60-INCH (GP/GLP/GDP100MJ, GP/GLP/GDP110MJ, GP/
GLP/GDP120MJ) ........................................................................................................................................ 15-8
INTERMEDIATE MAST
THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-6
INTRUMENT PANEL ....................................................................................................................................... 6-6
L
LABELS AND DECALS ................................................................................................................................... 1-34
LIFTING EYES ................................................................................................................................................ 16-48
LIGHTS, BACK-UP AND BRAKE .................................................................................................................... 16-50
LIGHTS, LED BACK-UP AND BRAKE
6/2004 → .................................................................................................................................................... 16-52
LOAD BACKREST .......................................................................................................................................... 1-38
LPG REGULATING SYSTEM
4.3L EPA COMPLIANT ENGINE ................................................................................................................ 5-26
LPG TANK BRACKET
FIXED .......................................................................................................................................................... 5-14
SWING OUT ................................................................................................................................................ 5-16
SWING OUT/DROP DOWN ........................................................................................................................ 5-18
M
MAIN LIFT
THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-10
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 12-6
MAIN LIFT CYLINDERS
THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-14
TWO STAGE FULL FREE-LIFT .................................................................................................................. 14-10
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 12-10
MANIFOLD VALVE ......................................................................................................................................... 7-26
MAST INSTALLATION .................................................................................................................................... 11-24
MASTER CYLINDER AND BOOSTER ........................................................................................................... 10-6
N
NON-SUSPENSION SEAT
→ S/N E813V03850C ................................................................................................................................ 1-12
S/N E813V03851C → ................................................................................................................................ 1-14
O
OIL COOLER
DIESEL TIER II ........................................................................................................................................... 2-26
OIL FILTER
DIESEL TIER II ........................................................................................................................................... 2-24
DESCRIPTION PAGE
OIL PAN AND PUMP
DIESEL TIER II ........................................................................................................................................... 2-16
OIL PUMP
GASOLINE AND LPG - 4.3L EPA COMPLIANT ......................................................................................... 2-68
OPERATOR MODULE .................................................................................................................................... 1-4
OUTER MAST
THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-2
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 12-2
OUTER MAST AND MAIN LIFT
TWO STAGE FULL FREE-LIFT .................................................................................................................. 14-2
OVERHEAD GUARD ...................................................................................................................................... 1-28
P
PARK BRAKE .................................................................................................................................................. 10-18
PLUGS
WITHOUT BACK-UP AND BRAKE LIGHTS ............................................................................................... 16-56
Q
QUICK DISCONNECT FITTINGS ................................................................................................................... 15-20
R
REAR ACCESS SCREEN ............................................................................................................................... 1-26
REAR DRIVE LIGHT
WITHOUT CAB ........................................................................................................................................... 16-40
REAR DRIVE LIGHTS
WITH AMBER STROBE - WITHOUT CAB (S/N E813V03419B →) .......................................................... 16-42
ROTARY EXHAUSTER
DIESEL TIER II ........................................................................................................................................... 2-32
S
SHIFT LEVER ................................................................................................................................................. 9-6
SOUND REDUCTION
GASOLINE AND LPG WITH CAB AND ALL DIESEL ................................................................................. 1-30
STARTER
DIESEL TIER II ........................................................................................................................................... 6-28
STARTER MOTOR
GASOLINE AND LPG - GM 4.3L ................................................................................................................ 6-26
STEER AXLE .................................................................................................................................................. 9-8
STEER COLUMN ............................................................................................................................................ 9-4
STEER CYLINDER ......................................................................................................................................... 9-12
STEER PUMP ................................................................................................................................................. 9-14
STEER TIRES AND WHEELS ........................................................................................................................ 9-16
STEERING SYSTEM ...................................................................................................................................... 9-2
STROBE LIGHT
AMBER - WITHOUT CAB (→ S/N E813V03418B) .................................................................................... 16-44
T
THROTTLE ARM ASSEMBLY ........................................................................................................................ 5-50
THROTTLE BODY AND LPG MIXER
4.3L EPA COMPLIANT ENGINE ................................................................................................................ 5-24
DESCRIPTION PAGE
THROTTLE BODY ASSEMBLY
GASOLINE - 4.3L EPA COMPLIANT ENGINE ........................................................................................... 5-28
THROTTLE LINKAGE
DIESEL TIER II ........................................................................................................................................... 5-48
GASOLINE AND LPG - FORWARD/REVERSE LEVER ............................................................................ 5-44
GASOLINE AND LPG - FOOT DIRECTIONAL CONTROL PEDAL ........................................................... 5-46
TILT CYLINDERS ............................................................................................................................................ 11-26
TIMING GEAR
DIESEL TIER II ........................................................................................................................................... 2-20
TRANSMISSION
T086 - T089 - SHEET 1 OF 2 (→ S/N E813V02052B) .............................................................................. 7-2
T086 - T089 - SHEET 2 OF 2 (→ S/N E813V02052B) .............................................................................. 7-6
T118 - T121 - SHEET 1 OF 2 (S/N E813V02053B →) .............................................................................. 7-10
T118 - T121 - SHEET 2 OF 2 (S/N E813V02053B →) .............................................................................. 7-12
TRANSMISSION LINES .................................................................................................................................. 7-28
TRANSMISSION MOUNT ............................................................................................................................... 7-30
U
UNDERCARRIAGE PAN ................................................................................................................................. 1-32
V
VALVE COVER AND INLET MANIFOLD
GASOLINE AND LPG - 4.3L EPA COMPLIANT ......................................................................................... 2-60
VALVE COVER AND ROCKER ARM SHAFT
DIESEL TIER II ........................................................................................................................................... 2-12
W
WATER PUMP AND OUTLET
DIESEL TIER II ........................................................................................................................................... 2-18
WATER SEPARATOR
DIESEL TIER II ........................................................................................................................................... 5-42
WIDE TIRE CONVERSION ............................................................................................................................. 17-2
DESCRIPTION PAGE
WIRE HARNESS
ALTERNATOR TO CIRCUIT BREAKER - FUSED ..................................................................................... 6-62
BACK-UP ALARM ....................................................................................................................................... 16-32
BRAKE PRESSURE SWITCH (S/N E813V02626C →) ............................................................................. 6-66
BRAKE PRESSURE SWITCH (→ S/N E813V02625C) ............................................................................. 6-67
DIESEL ENGINE (→ S/N E813A01842C) ................................................................................................. 6-30
DIESEL ENGINE (S/N E813A01843C →) ................................................................................................. 6-32
ENGINE, GASOLINE GM 4.3L - SHEET 1 0F 2 ......................................................................................... 6-36
ENGINE, GASOLINE GM 4.3L - SHEET 2 OF 2 ........................................................................................ 6-38
ENGINE, LPG, GM 4.3L - SHEET 1 0F 2 ................................................................................................... 6-40
ENGINE, LPG, GM 4.3L - SHEET 2 OF 2 .................................................................................................. 6-42
FUEL INJECTOR - GASOLINE GM 4.3L .................................................................................................... 6-34
INTERFACE ................................................................................................................................................ 6-64
LPG REGULATOR - GM 4.3L ..................................................................................................................... 6-44
MODULE - SHEET 1 OF 2 (→ 3/2004) ...................................................................................................... 6-46
MODULE - SHEET 2 OF 2 (→ 3/2004) ...................................................................................................... 6-50
MODULE - POWERSHIFT TRANSMISSION (3/2004 →) ......................................................................... 6-54
POWERSHIFT TRANSMISSION CONTROL (→ S/N E813V02625C) ...................................................... 6-68
POWERSHIFT TRANSMISSION CONTROL (S/N E813V02626C →) ...................................................... 6-70
POWERSHIFT TRANSMISSION CONTROL (S/N E813V03851C →) ...................................................... 6-74
PRESSURE SWITCH - LED BRAKE LIGHTS ............................................................................................ 16-54
SEALED ALTERNATOR ............................................................................................................................. 6-60
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.
1. Determine the function and application of the part 9. Quantities shown are for one assembly. The
required. Turn to the Sections Page. Choose the quantities of the subpart BEARING CAP are
general area of reference most likely to include the indicated as two and two. This means two per
part. CASE assembly.
2. Turn to the section you chose. Use the Section 10. Serial number breaks identify the most current
Table of Contents to determine the assembly parts information and are shown as follows:
which would normally contain the part required. → S/N A810N2639
Then locate the part on the assembly breakdown Indicates last serial number affected.
page. S/N A810N2640 →
Indicates the first serial number affected.
WHEN THE PART NUMBER IS NOT KNOWN S/N A810N1553 ↔ S/N A810N3291
AND THE NEXT HIGHER ASSEMBLY IS Indicates a range of serial numbers affected.
KNOWN:
ECN numbers for pending serial numbers are
3. Determine the assembly the required part is used shown to allow for the inclusion of the most current
on. Turn to the Table of Contents (Page i). parts information and are identified as follows:
→ S/N Pending Per ECN 63243
4. Locate the assembly the required part is used on
Indicates a pending serial number for last unit
and turn to the page indicated for that assembly.
affected.
Then locate the part on the assembly breakdown
S/N Pending Per ECN 63243 →
page.
Indicates a pending serial number for first unit
WHEN THE PART NUMBER IS KNOWN: affected.
5. Use the Numerical Index (Page 18-1) to find the Date breaks are used to indicate when a change
part number. Turn to the page listed and locate the occurred but a subsequent serial number break
part as indicated by the item number. was not recorded. This is an arbitrary date usually
based on the ECN release and are identified as
GENERAL: follows:
→ D/B 3/00
The assembly breakdowns include part numbers, Indicates that a change occurred sometime
descriptions, quantities required, keys and within that month for the item affected.
footnotes to help in selecting correct parts. D/B 3/00 →
Indicates that a change occurred sometime
6. Five periods in the PART NO. column (. . . . .)
within that month for the item affected.
indicate that the part is either Not Serviced
D/B 3/00 ↔ D/B 4/00
Separately or there is a reference to another figure.
Indicates a range of production dates of the item
A figure reference is denoted by a pointing hand
affected.
followed by a parts page number in the
DESCRIPTION column (F7A56) Contact your local dealer for Yale lift trucks for
serial number information for items with a ECN or
7. Keys are used to show two or more similar
a date break.
assemblies, RH and LH assembly parts, etc.
Select the appropriate key, "A", "B", "C", "D", or "E" ORDERING PARTS:
and the corresponding quantity column to find the
required parts. Two periods in the QTY column (..) When ordering replacement parts, give the unit serial
indicate that the part is not used for that assembly. number, part number, name of part and quantity
required.
8. Indented descriptions under the DESCRIPTION
column are used to indicate assemblies and For any further information on parts, service, or
subparts of assemblies. In the example on the ordering, consult your local dealer for Yale lift trucks.
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.
NOTES
1 GENERAL TRUCK
CONTENTS
SECTION 1
GENERAL TRUCK
DESCRIPTION PAGE
GENERAL TRUCK
ITEM PART NO. DESCRIPTION QTY
1 ..... Forks (Standard Taper, Class III) (FP14241 [Page 1-40])................................. 1
1 ..... Forks (Standard Taper, Class IV) (FP14242 [Page 1-42])................................ 1
1 ..... Forks (Polished Full Tapered, Class III And IV) (FP14243 [Page 1-43])........... 1
2 ..... Load Backrest (FP14240 [Page 1-38]).............................................................. 1
3 ..... Mast-Two Stage Limited Free-Lift ....................................................................... 1
3 ..... Mast-Two Stage Full Free-Lift ............................................................................ 1
3 ..... Mast-Three Stage Full Free-Lift .......................................................................... 1
4 ..... Seats (FP14231 [Page 1-12], FP14232 [Page 1-16], FP14233 [Page 1-
20])....................................................................................................................... 1
5 ..... Overhead Guard (FP14236 [Page 1-28]).......................................................... 1
6 ..... Floor Plates, Hood, And Covers (FP14229 [Page 1-6], FP14230 [Page 1-
10])....................................................................................................................... 1
7 ..... Counterweight (FP14234 [Page 1-24]).............................................................. 1
8 ..... Steering System (FP14328 [Page 9-2])............................................................. 1
9 ..... Drive System (FP14320 [Page 8-2]).................................................................. 1
10 ..... Electrical Systems (FP14286 [Page 6-6], FP14765 [Page 6-12],
FP14767 [Page 6-18], FP14933 [Page 6-21])................................................... 1
10 ..... Engine And Fuel Assemblies (FP14466 [Page 2-4], FP14481 [Page 2-
34], FP14268 [Page 5-8], FP14269 [Page 5-10], FP14951 [Page 5-
22])....................................................................................................................... 1
OPERATOR MODULE
ITEM PART NO. DESCRIPTION QTY
1 524145053 Operator Module (1830 mm Short Wheel Base) ................................................ 1
1 524145055 Operator Module (2100 mm Long Wheel Base) ................................................. 1
2 580007036 Snubber .............................................................................................................. 4
3 580007035 Rubber Mount ..................................................................................................... 4
4 505966562 Washer ............................................................................................................... 6
5 504233271 Washer ............................................................................................................... 6
6 931015915 Capscrew ............................................................................................................ 2
7 449015115 Locknut ............................................................................................................... 2
8 580013487 Trim ..................................................................................................................... 1
9 449022017 Lockwasher ......................................................................................................... 2
10 931015914 Capscrew ............................................................................................................ 2
11 524141538 Bracket ................................................................................................................ 1
12 504230231 Screw .................................................................................................................. 3
13 580010741 Plug ..................................................................................................................... 2
14 580010743 Plug ..................................................................................................................... 8
15 580012678 Trim Seal ............................................................................................................ AR
16 504323759 Stud (Optional) .................................................................................................... 2
16 501702903 Loctite ................................................................................................................. AR
17 909882405 Nut (Optional) ..................................................................................................... 2
18 580016557 Latch (Rotary) ..................................................................................................... 1
19 203142800 Capscrew ............................................................................................................ 2
20 015026000 Lockwasher ......................................................................................................... 2
21 016103500 Washer ............................................................................................................... 2
22 580032781 Capscrew ............................................................................................................ 1
23 016104000 Washer ............................................................................................................... 2
24 014970900 Nut ...................................................................................................................... 2
25 015026400 Lockwasher ......................................................................................................... 1
FOOTNOTES:
a → S/N E813V03850C b S/N E813V03821C →
NOTES
NON-SUSPENSION SEAT
(→ S/N E813V03850C)
NON-SUSPENSION SEAT
(S/N E813V03851C →)
NOTES
FOOTNOTES:
a Not Illustrated
COUNTERWEIGHT
ITEM PART NO. DESCRIPTION QTY
1 504294725 Counterweight (GP070 LJ) ................................................................................. 1
1 504294726 Counterweight (GP 080 LJ) ................................................................................ 1
1 504294727 Counterweight (GP 090 LJ) ................................................................................ 1
1 504294728 Counterweight (GP 100 MJ) ............................................................................... 1
1 504294729 Counterweight (GP 110 MJ) ............................................................................... 1
1 504294730 Counterweight (GP 120 MJ) ............................................................................... 1
2 504294746 Tow Pin ............................................................................................................... 1
3 580010394 Seal (GP 070 LJ, 080 LJ, 090 LJ) ....................................................................... 2
3 580010392 Seal (GP 100 MJ, 110 MJ, 120 MJ) .................................................................... 2
4 925776402 Cap ..................................................................................................................... 2
5 449001409 Capscrew ............................................................................................................ 2
6 955400911 Washer ............................................................................................................... 2
7 580017374 Washer ............................................................................................................... 1
8 505970557 Shim (0.109 in.) .................................................................................................. 4
8 580000884 Shim (0.059 in.) .................................................................................................. AR
9 504226242 Washer ............................................................................................................... 4
10 449022016 Lockwasher ......................................................................................................... 4
11 449015014 Nut ...................................................................................................................... 4
12 504240715 Cover .................................................................................................................. 1
13 449001023 Capscrew ............................................................................................................ 3
OVERHEAD GUARD
ITEM PART NO. DESCRIPTION QTY
1 a 524166186 Overhead Guard (OAH 55.3 in.) ......................................................................... 1
1 b 504307760 Overhead Guard (OAH 55.3 in.) ......................................................................... 1
1 a 524166189 Overhead Guard (OAH 58.5 in.) ......................................................................... 1
1 b 504314715 Overhead Guard (OAH 58.5 in.) ......................................................................... 1
2 580007037 Handle Grip ......................................................................................................... 1
3 504230231 Screw .................................................................................................................. 2
4 931015902 Capscrew ............................................................................................................ 4
5 504233271 Washer ............................................................................................................... 6
6 449022017 Lockwasher ......................................................................................................... 6
7 501725901 Capscrew ............................................................................................................ 2
8 504241783 Plug ..................................................................................................................... 6
9 504241782 Plug ..................................................................................................................... 14
10 504241784 Plug ..................................................................................................................... 4
11 580012485 Seal ..................................................................................................................... 1
12 505972576 Plug ..................................................................................................................... 2
13 258979300 Plug ..................................................................................................................... 8
FOOTNOTES:
a Gasoline And Diesel b LPG
SOUND REDUCTION
GASOLINE AND LPG WITH CAB AND ALL DIESEL
UNDERCARRIAGE PAN
KEY:
A: 1830 mm Short Wheel Base
B: 2100 mm Long Wheel Base
QTY
ITEM PART NO. DESCRIPTION A B
580011017 Undercarriage (Assembly) ......................................................................... 1 ..
580011018 Undercarriage (Assembly) ......................................................................... .. 1
1 580013496 Undercarriage ........................................................................................ 1 ..
1 580013497 Undercarriage ........................................................................................ .. 1
2 580011026 Bracket Wldmt ....................................................................................... 4 6
3 580011028 Capscrew ............................................................................................... 4 6
4 580011025 Bumper .................................................................................................. 3 3
5 580011024 Screw ..................................................................................................... 1 1
6 449021002 Washer .................................................................................................. 1 1
7 449015112 Locknut .................................................................................................. 1 1
8 580011023 Rivet ....................................................................................................... 8 8
9 580011021 Insulator ................................................................................................. 1 ..
9 580011022 Insulator ................................................................................................. .. 1
10 580013498 Washer .................................................................................................. 8 8
11 580011030 Edge Protector (250 mm) ...................................................................... 2 2
12 580011031 Edge Protector (420 mm) ...................................................................... 4 4
13 449021003 Washer .................................................................................................. 4 6
14 449022018 Washer .................................................................................................. 4 6
FOOTNOTES:
a See Your Local Yale Dealer
NOTES
LOAD BACKREST
KEY:
A: 1830 mm Short Wheel Base
B: 2100 mm Long Wheel Base
QTY
ITEM PART NO. DESCRIPTION A B
1 504314701 Load Backrest (48 in.) ................................................................................ 1 ..
1 504314705 Load Backrest (48 in.) ................................................................................ .. 1
1 504314703 Load Backrest (60 in.) ................................................................................ 1 ..
1 504314707 Load Backrest (60 in.) ................................................................................ .. 1
2 580013508 Capscrew ................................................................................................... 4 4
3 061278200 Washer ....................................................................................................... 4 4
3 504233271 Washer (Optional) ...................................................................................... 4 4
4 580033885 Nut .............................................................................................................. 4 4
5 449022017 Lockwasher ................................................................................................ 4 4
KEY:
A: GDP, GP/GLP 070 LJ
B: GDP, GP/GLP 080 LJ
C: GDP, GP/GLP 090 LJ
QTY
ITEM PART NO. DESCRIPTION A B C
1 a 518688603 Fork (48 in.) ....................................................................................... 2 2 2
1 b 518688604 Fork (54 in.) ....................................................................................... 2 2 ..
1 a 518688605 Fork (60 in.) ....................................................................................... 2 .. ..
1 b 518717605 Fork (60 in.) ....................................................................................... .. 2 2
1 a 518688607 Fork (72 in.) ....................................................................................... 2 .. ..
1 b 518717607 Fork (72 in.) ....................................................................................... .. 2 2
2 580035001 Pin ................................................................................................. 1 1 1
3 580034999 Knob .............................................................................................. 1 1 1
4 580016727 Washer .......................................................................................... 1 1 1
5 580026751 Spring ............................................................................................ 1 1 1
6 580035011 Pin ................................................................................................. 1 1 1
7 580016736 Wedge Band ................................................................................. 1 1 1
580035017 Kit-Latch ........................................................................................ 1 1 1
FOOTNOTES:
a (50 mm x 125 mm, 2 in. x 5 in.)
b (50 mm x 150 mm, 2 in. x 6 in.)
NOTE: Other fork dimensions are available upon request. Contact your Yale truck dealer.
KEY:
A: GDP, GP/GLP 070 MJ
B: GDP, GP/GLP 080 MJ
C: GDP, GP/GLP 090 MJ
QTY
ITEM PART NO. DESCRIPTION A B C
1 a 518718603 Fork (48 in.) ....................................................................................... 2 .. ..
1 a 518718604 Fork (54 in.) ....................................................................................... 2 2 ..
1 a 518718605 Fork (60 in.) ....................................................................................... 2 2 ..
1 b 505849503 Fork (48 in.) ....................................................................................... .. .. 2
1 b 505849504 Fork (54 in.) ....................................................................................... .. 2 2
1 b 505849507 Fork (72 in.) ....................................................................................... .. .. 2
2 580035001 Pin ................................................................................................. 1 1 1
3 580034999 Knob .............................................................................................. 1 1 1
4 580026753 Spring ............................................................................................ 1 1 1
5 580035018 Pin ................................................................................................. 1 1 1
580035019 Kit-Latch (Class IV) ....................................................................... 1 1 1
FOOTNOTES:
a (50mm x 150 mm, 2 in. x 6 in.) b (60 mm x 150 mm, 2.36 in. x 6 in.)
KEY:
A: GDP, GP/GLP 070, 080, 090 LJ
B: GDP, GP/GLP 100, 110, 120 MJ
QTY
ITEM PART NO. DESCRIPTION A B
1 524139139 Fork (47.5 in.) ............................................................................................. 2 ..
1 524139140 Fork (54 in.) ................................................................................................ 2 ..
1 524139141 Fork (47.5 in.) ............................................................................................. .. 2
1 524139142 Fork (54 in.) ................................................................................................ .. 2
2 580035001 Pin .......................................................................................................... 1 1
3 580034999 Knob ...................................................................................................... 1 1
4 580016727 Washer .................................................................................................. 1 ..
5 580026751 Spring .................................................................................................... 1 ..
5 580026753 Spring .................................................................................................... .. 1
6 580035011 Pin .......................................................................................................... 1 ..
6 580035018 Pin .......................................................................................................... .. 1
7 580016736 Wedge Band .......................................................................................... 1 ..
580035017 Kit-Latch ................................................................................................. 2 ..
580035019 Kit-Latch (Class IV) ................................................................................ .. 2
NOTES
2 ENGINE ASSEMBLY
CONTENTS
SECTION 2
ENGINE ASSEMBLY
DESCRIPTION PAGE
ASSEMBLED ENGINE
DIESEL TIER II ........................................................................................................................................... 2-6
GASOLINE 4.3L EPA COMPLIANT - SHEET 1 OF 2 ................................................................................. 2-42
GASOLINE 4.3L EPA COMPLIANT - SHEET 2 0F 2 ................................................................................. 2-46
LPG, 4.3L EPA COMPLIANT - SHEET 1 OF 2 ........................................................................................... 2-36
LPG, 4.3L EPA COMPLIANT - SHEET 2 OF 2 ........................................................................................... 2-40
CAMSHAFT AND OIL PAN
GASOLINE AND LPG - 4.3L EPA COMPLIANT ......................................................................................... 2-56
COIL ASSEMBLY ............................................................................................................................................ 2-49
CRANKSHAFT AND PISTONS
DIESEL TIER II ........................................................................................................................................... 2-14
CYLINDER BLOCK
DIESEL TIER II ........................................................................................................................................... 2-8
GASOLINE AND LPG - 4.3L EPA COMPLIANT ......................................................................................... 2-54
CYLINDER HEAD
GASOLINE AND LPG - 4.3L EPA COMPLIANT ......................................................................................... 2-64
CYLINDER HEAD AND INDUCTION MANIFOLD
DIESEL TIER II ........................................................................................................................................... 2-10
DRIP SHIELD
GASOLINE AND LPG - 4.3L EPA COMPLIANT ......................................................................................... 2-70
ENGINE BELT DRIVE AND ALTERNATOR MOUNTING
4.3L EPA COMPLIANT ............................................................................................................................... 2-52
ENGINE MOUNTING
DIESEL TIER II ........................................................................................................................................... 2-4
GASOLINE AND LPG - 4.3L EPA COMPLIANT ......................................................................................... 2-34
EXHAUST MANIFOLD
DIESEL TIER II ........................................................................................................................................... 2-22
GASOLINE AND LPG - 4.3L EPA COMPLIANT ......................................................................................... 2-50
FUEL INJECTION PUMP
DIESEL TIER II ........................................................................................................................................... 2-28
WITH BLEED BACK SYSTEM .................................................................................................................... 2-30
INTAKE MANIFOLD AND FUEL RAIL
GASOLINE - 4.3L EPA COMPLIANT .......................................................................................................... 2-66
OIL COOLER
DIESEL TIER II ........................................................................................................................................... 2-26
OIL FILTER
DIESEL TIER II ........................................................................................................................................... 2-24
OIL PAN AND PUMP
DIESEL TIER II ........................................................................................................................................... 2-16
OIL PUMP
GASOLINE AND LPG - 4.3L EPA COMPLIANT ......................................................................................... 2-68
ROTARY EXHAUSTER
DIESEL TIER II ........................................................................................................................................... 2-32
TIMING GEAR
DIESEL TIER II ........................................................................................................................................... 2-20
VALVE COVER AND INLET MANIFOLD
GASOLINE AND LPG - 4.3L EPA COMPLIANT ......................................................................................... 2-60
VALVE COVER AND ROCKER ARM SHAFT
DIESEL TIER II ........................................................................................................................................... 2-12
SECTION 2
ENGINE ASSEMBLY
DESCRIPTION PAGE
NOTES
ENGINE MOUNTING
DIESEL TIER II
ASSEMBLED ENGINE
DIESEL TIER II
FOOTNOTES:
a → S/N E813V01907B c S/N E813V01908B ↔ S/N E813V03064C
b → S/N E813V03064C d S/N E813V03065C →
CYLINDER BLOCK
DIESEL TIER II
FOOTNOTES:
a Seal is included in Housing c S/N E813V01908B ↔ S/N E813V03064C
b → S/N E813V01907B d S/N E813V03065C →
FOOTNOTES:
a → S/N E813V01907B c S/N E813V03065C →
b S/N E813V01908B ↔ S/N E813V03064C
FOOTNOTES:
a → S/N E813V01907B c S/N E813V03065C →
b S/N E813V01908B ↔ S/N E813V03064C
FOOTNOTES:
a → S/N E813V01907B c S/N E813V03065C →
b S/N E813V01908B ↔ S/N E813V03064C
FOOTNOTES:
a → 5/2007 d S/N E813V03065C →
b → S/N E813V01907B e 5/2007 →
c S/N E813V01908B ↔ S/N E813V03064C
FOOTNOTES:
a → S/N E813V01907B c S/N E813V03065C →
b S/N E813V01908B ↔ S/N E813V03064C
TIMING GEAR
DIESEL TIER II
FOOTNOTES:
a → S/N E813V01907B c S/N E813V03065C →
b S/N E813V01907B ↔ S/N E813V03064C
FOOTNOTES:
a → S/N E813V01907B c S/N E813V03065C →
b S/N E813V01908B ↔ S/N E813V03064C
NOTES
OIL FILTER
DIESEL TIER II
FOOTNOTES:
a → S/N E813V01907B c S/N E813V03065C →
b S/N E813V01908B ↔ S/N E813V03064C
FOOTNOTES:
a → S/N E813V01907B c S/N E813V03065C →
b S/N E813V01908B ↔ S/N E813V03064C
FOOTNOTES:
a Must identify the serial number of the engine from
which the injection pump was removed
FOOTNOTES:
a Includes Kits 524221347 and 580054531 d → S/N E813V03064C
b Must identify the serial number of the engine from e S/N E813V03065C →
which the injection pump was removed
c Not Illustrated
ROTARY EXHAUSTER
DIESEL TIER II
FOOTNOTES:
a → S/N E813V01907B c S/N E813V03065C →
b S/N E813V01908B ↔ S/N E813V03064C
ENGINE MOUNTING
GASOLINE AND LPG – 4.3L EPA COMPLIANT
ASSEMBLED ENGINE
LPG, 4.3L EPA COMPLIANT – SHEET 1 OF 2
FOOTNOTES:
a → S/N E813V02151B
b S/N E813V02152B →
NOTES
ASSEMBLED ENGINE
LPG, 4.3L EPA COMPLIANT – SHEET 2 OF 2
FOOTNOTES:
a → S/N E813V02151B b S/N E813V02152B →
ASSEMBLED ENGINE
GASOLINE 4.3L EPA COMPLIANT – SHEET 1 OF 2
ASSEMBLED ENGINE
GASOLINE 4.3L EPA COMPLIANT – SHEET 1 OF 2
FOOTNOTES:
a → S/N E813V02151B b S/N E813V02152B →
NOTES
ASSEMBLED ENGINE
GASOLINE 4.3L EPA COMPLIANT – SHEET 2 0F 2
FOOTNOTES:
a → S/N E813V02151B b S/N E813V02152B →
FOOTNOTES:
a → S/N E813V02151B b S/N E813V02152B →
NOTES
CYLINDER BLOCK
GASOLINE AND LPG – 4.3L EPA COMPLIANT
FOOTNOTES:
a → S/N E813V02151B b S/N E813V02152B →
FOOTNOTES:
a GM Identification Number on Left Side of Rear c S/N E813V02152B →
Transmission Housing is 8 Digits
b → S/N E813V02151B
NOTES
FOOTNOTES:
a Quanity is listed for both heads c S/N E813V02152B →
b → S/N E813V02151B
NOTES
CYLINDER HEAD
GASOLINE AND LPG – 4.3L EPA COMPLIANT
FOOTNOTES:
a → S/N E813V02151B b S/N E813V02152B →
FOOTNOTES:
a → S/N E813V02151B b S/N E813V02152B →
OIL PUMP
GASOLINE AND LPG – 4.3L EPA COMPLIANT
FOOTNOTES:
a → S/N E813V02151B b S/N E813V02152B →
NOTES
3 EXHAUST SYSTEM
CONTENTS
SECTION 3
EXHAUST SYSTEM
DESCRIPTION PAGE
EXHAUST
DIESEL TIER II ........................................................................................................................................... 3-4
GASOLINE AND LPG ................................................................................................................................. 3-2
EXHAUST WRAPS
PAPER INDUSTRY OPTION ...................................................................................................................... 3-6
EXHAUST
GASOLINE AND LPG
FOOTNOTES:
a Counterweight d U.L. Safety
b EPA Compliant e U.L. Safety - Counterweight
c Overhead
EXHAUST
DIESEL TIER II
FOOTNOTES:
a Counterweight b Overhead
EXHAUST WRAPS
PAPER INDUSTRY OPTION
NOTES
4 COOLING SYSTEM
CONTENTS
SECTION 4
COOLING SYSTEM
DESCRIPTION PAGE
COOLING
ITEM PART NO. DESCRIPTION QTY
1 580002881 Radiator Cap (Radiator) ...................................................................................... 1
2 900011286 Clamp ................................................................................................................. 1
3 580013798 Hose ................................................................................................................... 1
4 580002884 Reservoir ............................................................................................................ 1
5 505972579 Outlet .................................................................................................................. 1
5 580002394 Hose ............................................................................................................... 1
5 900001230 Outlet (Reservoir) ........................................................................................... 1
5 900001231 Cap ................................................................................................................. 1
5 900003260 Bushing .......................................................................................................... 1
6 580002886 Strap ................................................................................................................... 1
7 580042918 Bracket ................................................................................................................ 1
8 504230231 Screw .................................................................................................................. 4
9 580002887 Drain Valve (Drain) ............................................................................................. 1
10 505966595 Clamp ................................................................................................................. 1
11 580039904 Hose Clamp ........................................................................................................ 1
12 580046106 Hose Clamp (Gasoline and LPG) ....................................................................... 1
13 930101906 Capscrew ............................................................................................................ 4
14 016103200 Washer ............................................................................................................... 4
15 449022019 Lockwasher ......................................................................................................... 4
16 580002234 Shroud (Upper) ................................................................................................... 1
17 580002235 Shroud (Lower) ................................................................................................... 1
18 580002236 Shroud (Door) ..................................................................................................... 1
19 580013509 Washer ............................................................................................................... 2
20 580013510 Spring ................................................................................................................. 2
21 580013511 Receptacle .......................................................................................................... 2
22 580013512 Retainer .............................................................................................................. 2
23 580013513 Stud .................................................................................................................... 2
24 016103500 Washer ............................................................................................................... 4
25 580013800 Rivet .................................................................................................................... 2
26 449022018 Washer ............................................................................................................... 1
27 580013375 Clamp ................................................................................................................. 3
28 580008327 Clamp ................................................................................................................. 1
29 449001412 Capscrew ............................................................................................................ 1
30 449015002 Nut ...................................................................................................................... 1
31 449021003 Washer ............................................................................................................... 2
32 449022017 Lockwasher ......................................................................................................... 6
33 580014829 Washer ............................................................................................................... 4
33 bc 580014829 Washer ............................................................................................................... 6
34 449022016 Lockwasher ......................................................................................................... 4
34 a 449022016 Lockwasher ......................................................................................................... 6
34 c 449022016 Lockwasher ......................................................................................................... 6
35 449001014 Screw .................................................................................................................. 4
35 c 449001014 Screw .................................................................................................................. 6
36 580008988 Nut ...................................................................................................................... 4
36 a 580008988 Nut ...................................................................................................................... 1
37 449001004 Capscrew ............................................................................................................ 6
37 a 449001004 Capscrew ............................................................................................................ 4
38 a 580014292 Screen (Rear Access) (FP14235 [Page 1-26]).................................................. 1
39 a 580004721 Mount .................................................................................................................. 2
40 449021010 Washer ............................................................................................................... 6
41 a 449021010 Washer ............................................................................................................... 4
COOLING
ITEM PART NO. DESCRIPTION QTY
42 a 580004761 Washer ............................................................................................................... 2
43 a 449001059 Capscrew ............................................................................................................ 2
44 900011233 Clamp ................................................................................................................. 1
45 449021006 Washer ............................................................................................................... 1
46 449022013 Lockwasher ......................................................................................................... 1
47 449015044 Nut ...................................................................................................................... 1
48 580039904 Hose Clamp ........................................................................................................ 1
49 580046106 Hose Clamp ........................................................................................................ 1
50 580002232 Radiator .............................................................................................................. 1
51 580041923 Radiator Hose (Gasoline and LPG) (Upper) ....................................................... 1
52 580002248 Radiator Hose (Gasoline and LPG) (Lower) ....................................................... 1
53 580039230 Radiator Hose (Diesel Lower) ............................................................................. 1
54 580039232 Radiator Hose (Diesel) (Upper) .......................................................................... 1
55 505972504 Nut ...................................................................................................................... 4
56 580046107 Hose Clamp (Diesel) ........................................................................................... 2
57 580002262 Adapter (Diesel) .................................................................................................. 1
57 580002261 Adapter (Gasoline and LPG) .............................................................................. 1
58 580006966 Capscrew (Diesel) .............................................................................................. 4
59 580006965 Lockwasher (Diesel) ........................................................................................... 4
60 580002256 Drive Shaft (Gasoline and LPG) (FP13780 [Page 4-6]).................................... 1
60 580002257 Drive Shaft (Diesel) (FP13780 [Page 4-6])........................................................ 1
61 580049863 Nut ...................................................................................................................... 6
62 580008988 Nut ...................................................................................................................... 6
63 580011963 Screen ................................................................................................................ 1
64 580011960 Plate (Screen Mounting) ..................................................................................... 1
FOOTNOTES:
a 2100 Wheel Base c With Standard Counterweight Exhaust
b With Overhead Exhaust or UL Safety
NOTES
NOTES
5 FUEL SYSTEM
CONTENTS
SECTION 5
FUEL SYSTEM
DESCRIPTION PAGE
AIR FILTER
GASOLINE AND LPG ................................................................................................................................. 5-6
TIER II - DIESEL ......................................................................................................................................... 5-34
AIR INTAKE AND FILTER SYSTEM
DIESEL TIER II ........................................................................................................................................... 5-30
GASOLINE AND LPG ................................................................................................................................. 5-2
ENGINE FUEL SYSTEM
LPG - 4.3L EPA COMPLIANT ..................................................................................................................... 5-22
FOOT DIRECTIONAL CONTROL PEDAL ...................................................................................................... 5-54
FOOT DIRECTIONAL CONTROL PEDAL AND BRACKET ASSEMBLY ....................................................... 5-52
FUEL FILTER AND ATTACHING PARTS
DIESEL TIER II ........................................................................................................................................... 5-36
FUEL PUMP AND WATER SEPERATOR
DIESEL TIER II ........................................................................................................................................... 5-38
FUEL SENDER AND ATTACHING PARTS
DIESEL TIER II ........................................................................................................................................... 5-40
FUEL SUPPLY SYSTEM
DIESEL TIER II ........................................................................................................................................... 5-12
GASOLINE .................................................................................................................................................. 5-8
LPG ............................................................................................................................................................. 5-10
LPG REGULATING SYSTEM
4.3L EPA COMPLIANT ENGINE ................................................................................................................ 5-26
LPG TANK BRACKET
FIXED .......................................................................................................................................................... 5-14
SWING OUT ................................................................................................................................................ 5-16
SWING OUT/DROP DOWN ........................................................................................................................ 5-18
THROTTLE ARM ASSEMBLY ........................................................................................................................ 5-50
THROTTLE BODY AND LPG MIXER
4.3L EPA COMPLIANT ENGINE ................................................................................................................ 5-24
THROTTLE BODY ASSEMBLY
GASOLINE - 4.3L EPA COMPLIANT ENGINE ........................................................................................... 5-28
THROTTLE LINKAGE
DIESEL TIER II ........................................................................................................................................... 5-48
GASOLINE AND LPG - FORWARD/REVERSE LEVER ............................................................................ 5-44
GASOLINE AND LPG - FOOT DIRECTIONAL CONTROL PEDAL ........................................................... 5-46
WATER SEPARATOR
DIESEL TIER II ........................................................................................................................................... 5-42
NOTES
AIR FILTER
GASOLINE AND LPG
FOOTNOTES:
a → S/N E813V02595C b S/N E813V02596C →
FOOTNOTES:
a Contact your authorized dealer for service parts
FOOTNOTES:
a Contact Your Authorized Yale Dealer for Service
Parts
NOTES
FOOTNOTES:
a Adapter to Manifold
NOTES
AIR FILTER
TIER II – DIESEL
NOTES
WATER SEPARATOR
DIESEL TIER II
THROTTLE LINKAGE
GASOLINE AND LPG – FORWARD/REVERSE LEVER
THROTTLE LINKAGE
GASOLINE AND LPG – FOOT DIRECTIONAL CONTROL PEDAL
THROTTLE LINKAGE
DIESEL TIER II
KEY:
A: Forward/Reverse Lever
B: Monotrol Pedal
QTY
ITEM PART NO. DESCRIPTION A B
1 924473400 Pedal .......................................................................................................... 1 ..
2 449001412 Capscrew ................................................................................................... 2 ..
3 449022018 Washer ....................................................................................................... 2 ..
4 580012499 Throttle Arm (FP14280 [Page 5-50])......................................................... 1 ..
5 449001302 Capscrew ................................................................................................... 2 2
6 449015044 Nut .............................................................................................................. 2 1
7 449022013 Lockwasher ................................................................................................ 2 1
8 580012980 Cover .......................................................................................................... 1 ..
9 524139210 Foot Directional Control Pedal (FP14281 [Page 5-52])............................ .. 1
10 524159812 Cover Plate (With Cab) .............................................................................. .. 1
10 504316774 Cover Plate (Without Cab) ......................................................................... .. 1
11 504230231 Screw ......................................................................................................... .. 3
12 580040474 Bracket ....................................................................................................... 1 1
13 580046165 Throttle Cable ............................................................................................. .. 1
13 580046166 Throttle Cable ............................................................................................. 1 ..
14 520082888 Pin .............................................................................................................. 2 2
15 449025027 Cotter Pin ................................................................................................... 2 2
16 449021003 Washer ....................................................................................................... 3 3
17 580039438 Capscrew ................................................................................................... 2 2
18 580042917 Drip Shield .................................................................................................. 2 2
19 580047919 Nut .............................................................................................................. 2 2
20 930101905 Capscrew ................................................................................................... .. 4
21 940004903 Washer ....................................................................................................... .. 4
22 449022019 Lockwasher ................................................................................................ .. 4
23 937100903 Nut .............................................................................................................. .. 4
24 524159827 Brush Seal .................................................................................................. .. 1
NOTES
6 ELECTRICAL SYSTEM
CONTENTS
SECTION 6
ELECTRICAL SYSTEM
DESCRIPTION PAGE
ALTERNATOR
GS, LPS, DS ............................................................................................................................................... 6-22
ALTERNATOR AND MOUNTING ................................................................................................................... 6-24
DISTRIBUTOR ASSEMBLY
4.3L EPA COMPLIANT ............................................................................................................................... 6-21
ELECTRICAL SYSTEM
ALTERNATOR AND BATTERY - GASOLINE AND LPG ............................................................................ 6-10
ALTERNATOR AND BATTERY - GASOLINE AND LPG SAFETY (GS AND LPS) .................................... 6-12
COWL .......................................................................................................................................................... 6-2
DIESEL TIER II ........................................................................................................................................... 6-14
ENGINE COMPARTMENT - GASOLINE AND LPG ................................................................................... 6-8
TYPE DS ..................................................................................................................................................... 6-18
INTRUMENT PANEL ....................................................................................................................................... 6-6
STARTER
DIESEL TIER II ........................................................................................................................................... 6-28
STARTER MOTOR
GASOLINE AND LPG - GM 4.3L ................................................................................................................ 6-26
WIRE HARNESS
ALTERNATOR TO CIRCUIT BREAKER - FUSED ..................................................................................... 6-62
BRAKE PRESSURE SWITCH (S/N E813V02626C →) ............................................................................. 6-66
BRAKE PRESSURE SWITCH (→ S/N E813V02625C) ............................................................................. 6-67
DIESEL ENGINE (→ S/N E813A01842C) ................................................................................................. 6-30
DIESEL ENGINE (S/N E813A01843C →) ................................................................................................. 6-32
ENGINE, GASOLINE GM 4.3L - SHEET 1 0F 2 ......................................................................................... 6-36
ENGINE, GASOLINE GM 4.3L - SHEET 2 OF 2 ........................................................................................ 6-38
ENGINE, LPG, GM 4.3L - SHEET 1 0F 2 ................................................................................................... 6-40
ENGINE, LPG, GM 4.3L - SHEET 2 OF 2 .................................................................................................. 6-42
FUEL INJECTOR - GASOLINE GM 4.3L .................................................................................................... 6-34
INTERFACE ................................................................................................................................................ 6-64
LPG REGULATOR - GM 4.3L ..................................................................................................................... 6-44
MODULE - SHEET 1 OF 2 (→ 3/2004) ...................................................................................................... 6-46
MODULE - SHEET 2 OF 2 (→ 3/2004) ...................................................................................................... 6-50
MODULE - POWERSHIFT TRANSMISSION (3/2004 →) ......................................................................... 6-54
POWERSHIFT TRANSMISSION CONTROL (→ S/N E813V02625C) ...................................................... 6-68
POWERSHIFT TRANSMISSION CONTROL (S/N E813V02626C →) ...................................................... 6-70
POWERSHIFT TRANSMISSION CONTROL (S/N E813V03851C →) ...................................................... 6-74
SEALED ALTERNATOR ............................................................................................................................. 6-60
ELECTRICAL SYSTEM
COWL
KEY:
A: Single And Two Speed Transmission (With Speed Control)
B: Single Speed Transmission (Without Speed Control)
QTY
ITEM PART NO. DESCRIPTION A B
1 580039498 Controller .................................................................................................... 1 ..
2 449021001 Washer ....................................................................................................... 10 10
3 449015014 Nut .............................................................................................................. 7 7
4 580006531 Switch (Park Brake) (Brake) ....................................................................... 2 2
5 580006530 Spacer ........................................................................................................ 2 2
6 502632902 Screw ......................................................................................................... 4 4
7 504069724 Clamp ......................................................................................................... .. 4
8 930102904 Capscrew ................................................................................................... 4 4
9 449021002 Washer ....................................................................................................... 8 8
10 449022021 Washer ....................................................................................................... 8 8
11 580025188 Sender (Coolant Level) .............................................................................. 1 1
11 580006584 Sender (Low Coolant) ................................................................................ 1 1
12 580008371 Clamp ......................................................................................................... 9 9
13 504230231 Screw ......................................................................................................... 11 11
14 580011098 Screw ......................................................................................................... 2 ..
15 937100904 Nut .............................................................................................................. 4 4
16 580006371 Switch (First Gear) (Transmission Control) ................................................ 1 ..
17 900015239 Clamp ......................................................................................................... 1 1
18 580009292 Clamp ......................................................................................................... 2 2
19 504069724 Clamp ......................................................................................................... 4 ..
20 505972571 Wire ............................................................................................................ 1 1
21 580003615 Nut .............................................................................................................. 2 ..
22 449001014 Screw ......................................................................................................... 7 7
23 940600908 Washer ....................................................................................................... 4 4
24 504226242 Washer ....................................................................................................... 1 1
25 518793603 Strap ........................................................................................................... 1 1
26 d 580038957 Wire Harness (Powershift Transmission Control) (FP15225 [Page 6-
68]).............................................................................................................. 1 1
26 e 580052875 Wire Harness (Powershift Transmission Control) (FP15270 [Page 6-
70]).............................................................................................................. 1 1
27 312850034 Strap Clamp ............................................................................................... 4 4
28 449022016 Lockwasher ................................................................................................ 4 4
29 504231226 Clamp ......................................................................................................... 1 1
30 ..... Instrument Panel (FP14286 [Page 6-6])................................................... 1 1
30 580011639 Lubricant .................................................................................................... AR AR
31 580011066 Strap ........................................................................................................... 2 2
32 a 501884905 Fitting (Pipe Plug) ....................................................................................... 1 1
33 ab 580003440 Pressure Switch ......................................................................................... 1 1
34 b 505973588 Switch (Restriction) .................................................................................... 1 1
34 c 580046971 Indicator (Restriction) ................................................................................. 1 1
35 bc 500132901 Fitting ......................................................................................................... 1 1
36 580009159 Wire Harness (LPG Switch) ....................................................................... 1 1
37 580052625 Wire Harness (Powershift Transmission Module) (G, LPG, D) (FP14982
[Page 6-54])................................................................................................ 1 1
ELECTRICAL SYSTEM
COWL
KEY:
A: Single And Two Speed Transmission (With Speed Control)
B: Single Speed Transmission (Without Speed Control)
QTY
ITEM PART NO. DESCRIPTION A B
37 580052624 Wire Harness (Powershift Transmission Module) (GS, LPS, DS)
(FP14982 [Page 6-54]).............................................................................. 1 1
38 580039661 Horn ........................................................................................................... 1 1
39 524145234 Bracket (Fuse Box) .................................................................................... 1 1
40 504240838 Ignition Switch ............................................................................................ 1 1
40 504240712 Key ......................................................................................................... 1 1
41 524157501 Label (Fuse Panel Relays) ......................................................................... 1 1
42 504241782 Plug ............................................................................................................ 4 4
43 505972534 Cover .......................................................................................................... 1 1
44 505972520 Cover (Cover) ............................................................................................. 1 1
45 580006583 Label (Fuse Panel) ..................................................................................... 1 1
46 449001013 Capscrew ................................................................................................... 2 2
47 580013716 Screw ......................................................................................................... 4 4
48 580063250 Module (Operator Presence) ...................................................................... 1 1
49 580011098 Screw ......................................................................................................... 2 2
50 580003615 Nut .............................................................................................................. 2 2
580068393 Shield (GS, LPS, DS, Not illustrated) ......................................................... 1 1
FOOTNOTES:
a LPG d → S/N E813V02625C
b Premium e S/N E813V02626C →
c Standard Diesel
NOTES
INTRUMENT PANEL
KEY:
A: Standard
B: Premium
QTY
ITEM PART NO. DESCRIPTION A B
524153718 Instrument Cluster (Gas and Diesel) .......................................................... 1 ..
524153719 Instrument Cluster (LPG) ........................................................................... 1 ..
524153716 Instrument Cluster (Gas and Diesel) .......................................................... .. 1
524153717 Instrument Cluster (LPG) ........................................................................... .. 1
1 580047694 Lens ....................................................................................................... 1 ..
1 580047697 Lens ....................................................................................................... .. 1
2 580039596 Bulb ........................................................................................................ 2 4
580068115 Buzzer (Not Illustrated) .......................................................................... 1 1
ELECTRICAL SYSTEM
ENGINE COMPARTMENT – GASOLINE AND LPG
ELECTRICAL SYSTEM
ALTERNATOR AND BATTERY – GASOLINE AND LPG
ELECTRICAL SYSTEM
ALTERNATOR AND BATTERY – GASOLINE AND LPG SAFETY (GS AND LPS)
FOOTNOTES:
a → 3/2004 b 3/2004 →
ELECTRICAL SYSTEM
DIESEL TIER II
ELECTRICAL SYSTEM
DIESEL TIER II
FOOTNOTES:
a Not Illustrated c 9/2004 →
b → S/N E813V03064C d S/N E813V03065C →
NOTES
ELECTRICAL SYSTEM
TYPE DS
ELECTRICAL SYSTEM
TYPE DS
ALTERNATOR
GS, LPS, DS
NOTES
STARTER
DIESEL TIER II
WIRE HARNESS
DIESEL ENGINE (→ S/N E813A01842C)
WIRE HARNESS
DIESEL ENGINE (S/N E813A01843C →)
WIRE HARNESS
ENGINE, GASOLINE GM 4.3L – SHEET 1 0F 2
WIRE HARNESS
ENGINE, GASOLINE GM 4.3L – SHEET 2 OF 2
WIRE HARNESS
ENGINE, LPG, GM 4.3L – SHEET 1 0F 2
WIRE HARNESS
ENGINE, LPG, GM 4.3L – SHEET 2 OF 2
WIRE HARNESS
LPG REGULATOR – GM 4.3L
WIRE HARNESS
MODULE – SHEET 1 OF 2 (→ 3/2004)
WIRE HARNESS
MODULE – SHEET 1 OF 2 (→ 3/2004)
WIRE HARNESS
MODULE – SHEET 1 OF 2 (→ 3/2004)
WIRE HARNESS
MODULE – SHEET 2 OF 2 (→ 3/2004)
WIRE HARNESS
MODULE – SHEET 2 OF 2 (→ 3/2004)
NOTES
WIRE HARNESS
MODULE – POWERSHIFT TRANSMISSION (3/2004 →)
WIRE HARNESS
MODULE – POWERSHIFT TRANSMISSION (3/2004 →)
WIRE HARNESS
MODULE – POWERSHIFT TRANSMISSION (3/2004 →)
WIRE HARNESS
MODULE – POWERSHIFT TRANSMISSION (3/2004 →)
NOTES
WIRE HARNESS
SEALED ALTERNATOR
NOTES
WIRE HARNESS
INTERFACE
NOTES
WIRE HARNESS
POWERSHIFT TRANSMISSION CONTROL (S/N E813V02626C →)
WIRE HARNESS
POWERSHIFT TRANSMISSION CONTROL (S/N E813V02626C →)
NOTES
WIRE HARNESS
POWERSHIFT TRANSMISSION CONTROL (S/N E813V03851C →)
WIRE HARNESS
POWERSHIFT TRANSMISSION CONTROL (S/N E813V03851C →)
7 TRANSMISSION
CONTENTS
SECTION 7
TRANSMISSION
DESCRIPTION PAGE
CLUTCH PACKS
T096 - T098 (→ S/N E813V02052B) .......................................................................................................... 7-18
T118 - SINGLE SPEED (S/N E813V02053B →) ....................................................................................... 7-20
T120 - T121 - TWO SPEED (S/N E813V02053B →) ................................................................................. 7-22
CONTROL VALVE
TRANSMISSION ......................................................................................................................................... 7-24
FLYWHEEL AND TORQUE CONVERTER ..................................................................................................... 7-16
HIGH AND LOW VALVE ................................................................................................................................. 7-27
MANIFOLD VALVE ......................................................................................................................................... 7-26
TRANSMISSION
T086 - T089 - SHEET 1 OF 2 (→ S/N E813V02052B) .............................................................................. 7-2
T086 - T089 - SHEET 2 OF 2 (→ S/N E813V02052B) .............................................................................. 7-6
T118 - T121 - SHEET 1 OF 2 (S/N E813V02053B →) .............................................................................. 7-10
T118 - T121 - SHEET 2 OF 2 (S/N E813V02053B →) .............................................................................. 7-12
TRANSMISSION LINES .................................................................................................................................. 7-28
TRANSMISSION MOUNT ............................................................................................................................... 7-30
TRANSMISSION
T086 - T089 – SHEET 1 OF 2 (→ S/N E813V02052B)
KEY:
A: Single Speed
B: Two Speed
QTY
ITEM PART NO. DESCRIPTION A B
580020550 Transmission Assy (T086) (Short Wheel Base) (T86, 1830 mm Short
Wheel Base) ............................................................................................... 1 ..
580020552 Transmission Assy (T088) (Short Wheel Base) (T88, 1830 mm Short
Wheel Base) ............................................................................................... .. 1
580020553 Transmission Assy (T089) (Long Wheel Base) (T89, 2100 mm Long Wheel
Base) .......................................................................................................... .. 1
1 500195904 Bearing .................................................................................................. 2 3
2 580009235 Thrust Washer ....................................................................................... 2 3
3 580007317 Needle Bearing ...................................................................................... 4 6
4 580007316 Thrust Washer ....................................................................................... 6 9
5 580007318 Needle Bearing ...................................................................................... 6 9
6 580009242 Gear (Clutch Output) ............................................................................. .. 1
7 580009241 Gear (Clutch Output) ............................................................................. .. 1
8 580012280 O-Ring ................................................................................................... 2 3
9 580013506 Gear (Clutch Output) ............................................................................. .. 1
10 580013507 Converter Housing ................................................................................. .. 1
10 580009226 Converter Housing ................................................................................. 1 ..
11 580009215 Dipstick Tube (Dipstick) ......................................................................... 1 1
12 580009216 Dipstick .................................................................................................. 1 1
13 500195904 Bearing .................................................................................................. 2 3
14 580020547 Clutch Pack (Directional) ....................................................................... 1 2
15 580004528 Snap Ring .............................................................................................. 2 3
16 580020546 Clutch Pack (Input) ................................................................................ 1 1
17 580007800 Sealing Ring .......................................................................................... 5 7
18 520045522 Dowel (Single Speed) ............................................................................ 4 4
19 449022013 Lockwasher ............................................................................................ 16 16
20 449001006 Capscrew ............................................................................................... 4 4
21 449001302 Capscrew ............................................................................................... 10 10
22 580009211 Spool ...................................................................................................... 1 1
23 580009212 Snap Ring .............................................................................................. 1 1
24 580009213 Spring .................................................................................................... 1 1
25 505967551 Fitting ..................................................................................................... 1 1
25 052645300 O-Ring ............................................................................................... 1 1
26 505967573 Switch (Oil Temperature Warning) (Transmission) ................................ 1 1
27 580007359 Screen ................................................................................................... 1 1
28 580009214 Spring (Screen) ...................................................................................... 1 1
29 810646400 Fitting ..................................................................................................... 1 1
29 052645800 O-Ring ............................................................................................... 1 1
30 580007362 Charge Pump ......................................................................................... 1 1
30 580007364 O-Ring ............................................................................................... 1 1
30 580007363 Bushing ............................................................................................. 1 1
31 580007365 Washer .................................................................................................. 1 1
32 449001138 Capscrew ............................................................................................... 1 1
33 580025916 Seal (Double Lip) ................................................................................... 1 1
34 580009217 Cover Plate ............................................................................................ 2 2
TRANSMISSION
T086 - T089 – SHEET 1 OF 2 (→ S/N E813V02052B)
KEY:
A: Single Speed
B: Two Speed
QTY
ITEM PART NO. DESCRIPTION A B
35 449001418 Capscrew ............................................................................................... 2 2
36 580014184 Fitting ..................................................................................................... 2 2
36 052645300 O-Ring ............................................................................................... 1 1
37 500179904 Nut ......................................................................................................... 2 2
38 056943000 Fitting ..................................................................................................... 1 1
38 052645400 O-Ring ............................................................................................... 1 1
39 580009236 Gear (Output) ......................................................................................... 2 ..
NOTES
TRANSMISSION
T086 - T089 – SHEET 2 OF 2 (→ S/N E813V02052B)
KEY:
A: Single Speed
B: Two Speed
QTY
ITEM PART NO. DESCRIPTION A B
580020550 Transmission Assy (T086) (Short Wheel Base) (T86, 1830 mm Short
Wheel Base) ............................................................................................... 1 ..
580020552 Transmission Assy (T088) (Short Wheel Base) (T88, 1830 mm Short
Wheel Base) ............................................................................................... .. 1
580020553 Transmission Assy (T089) (Long Wheel Base) (T89, 2100 mm Long Wheel
Base) .......................................................................................................... .. 1
1 580009218 Transmission Housing ........................................................................... 1 ..
1 580009238 Transmission Housing ........................................................................... .. 1
2 504226268 Dowel ................................................................................................ 4 4
3 580009223 Bearing Cap ........................................................................................... 2 2
4 502566903 Washer .................................................................................................. 4 4
5 931017917 Capscrew ............................................................................................... 4 4
6 580009247 Gasket ................................................................................................... .. 1
7 580009210 Gasket (Cover) ...................................................................................... 1 1
8 580014185 Screw ..................................................................................................... 1 1
9 580009854 Nut ......................................................................................................... 1 1
10 580012294 Gasket (Control Valve) .......................................................................... 1 1
11 580009243 Valve ...................................................................................................... .. 1
12 504226235 Lockplate ............................................................................................... 2 2
13 449022016 Lockwasher ............................................................................................ 2 2
14 449001415 Capscrew ............................................................................................... 2 2
15 015630100 Breather ................................................................................................. 1 1
16 580009197 Shim (0.020 in.) ..................................................................................... AR AR
17 580009198 Shim (0.007 in.) ..................................................................................... AR AR
18 580007836 Carrier .................................................................................................... 1 1
19 502566902 Washer .................................................................................................. 10 10
20 056226300 Bearing Cup ........................................................................................... 2 2
21 502515904 Bearing Cone ......................................................................................... 2 2
22 580009196 Spacer ................................................................................................... 1 1
23 580009200 Seal ........................................................................................................ 1 1
24 580009203 Shim (0.014 in.) ..................................................................................... AR AR
25 580009208 Shim (0.025 in.) ..................................................................................... AR AR
26 580006716 Gear and Pinion (1830 mm Short Wheel Base) .................................... 1 1
26 580006715 Gear and Pinion (2100 mm Long Wheel Base) ..................................... 1 1
27 580009195 Bearing .................................................................................................. 1 1
28 580009194 Snap Ring .............................................................................................. 1 1
29 931015915 Capscrew ............................................................................................... 10 10
30 580016558 Differential .............................................................................................. 1 1
31 501873914 Bearing Cone ......................................................................................... 2 2
32 056227700 Bearing Cup ........................................................................................... 2 2
33 580009193 Nut ......................................................................................................... 2 2
34 580044374 Sensor ................................................................................................... .. 1
35 505967598 Magnet ................................................................................................... 1 1
36 580009248 Tube Assy .............................................................................................. .. 1
37 580012758 Valve ...................................................................................................... 1 1
TRANSMISSION
T086 - T089 – SHEET 2 OF 2 (→ S/N E813V02052B)
KEY:
A: Single Speed
B: Two Speed
QTY
ITEM PART NO. DESCRIPTION A B
38 580007144 Transmission Filter ................................................................................ 1 1
39 520052872 Gasket ................................................................................................... 1 1
40 580011163 Valve ...................................................................................................... 1 1
41 505971550 Tube Assy .............................................................................................. 1 1
42 580000082 Strap ...................................................................................................... 1 1
43 449021001 Washer .................................................................................................. 1 1
44 449001073 Capscrew ............................................................................................... 4 4
45 449001072 Capscrew ............................................................................................... 3 3
46 449001028 Capscrew ............................................................................................... 1 1
47 449001050 Capscrew ............................................................................................... .. 4
48 580007834 Gear (Output) ......................................................................................... .. 1
48 580007835 Gear (Output) ......................................................................................... 1 ..
49 501967902 Fitting ..................................................................................................... 1 1
49 052645500 O-Ring ............................................................................................... 1 1
50 500390901 Fitting ..................................................................................................... .. 1
50 052645500 O-Ring ............................................................................................... .. 1
51 315976070 Fitting ..................................................................................................... 1 3
51 052645200 O-Ring ............................................................................................... 1 1
52 052643200 Connector .............................................................................................. .. 1
52 052645200 O-Ring ............................................................................................... .. 1
53 052642200 Fitting ..................................................................................................... .. 1
53 052645200 O-Ring ............................................................................................... .. 1
54 449022018 Washer .................................................................................................. .. 1
55 580012838 Capscrew ............................................................................................... 18 18
56 061278200 Washer .................................................................................................. 18 18
57 520045493 Nut ......................................................................................................... 18 18
58 500002903 Adapter .................................................................................................. 2 ..
58 052645100 O-Ring ............................................................................................... 1 ..
58 134023101 Fitting ..................................................................................................... .. 3
58 052645100 O-Ring ............................................................................................... .. 1
59 500179904 Nut ......................................................................................................... 2 3
60 580009201 Washer .................................................................................................. 1 1
61 580009202 Nut ......................................................................................................... 1 1
62 580009204 Shim (0.381 in.) ..................................................................................... AR AR
63 580009205 Shim (0.016 in.) ..................................................................................... AR AR
64 580009206 Shim (0.020 in.) ..................................................................................... AR AR
65 580009207 Shim (0.022 in.) ..................................................................................... AR AR
66 580009199 Shim (0.005 in.) ..................................................................................... AR AR
67 520042831 Adhesive ................................................................................................ AR AR
68 449001412 Capscrew ............................................................................................... .. 1
NOTES
TRANSMISSION
T118 - T121 – SHEET 1 OF 2 (S/N E813V02053B →)
KEY:
A: Single Speed
B: Two Speed
QTY
ITEM PART NO. DESCRIPTION A B
580048212 Transmission Assy (T118) (Short Wheel Base) ......................................... 1 ..
580048214 Transmission Assy (T120) (Short Wheel Base) ......................................... .. 1
580048215 Transmission Assy (T121) (Long Wheel Base) .......................................... .. 1
1 056943000 Fitting ..................................................................................................... 1 1
1 052645400 O-Ring ............................................................................................... 1 1
2 449001006 Capscrew ............................................................................................... 4 4
3 449022013 Lockwasher ............................................................................................ 16 16
4 580009217 Cover Plate ............................................................................................ 2 2
5 449001418 Capscrew ............................................................................................... 2 2
6 580009216 Dipstick .................................................................................................. 1 1
7 500179904 Nut ......................................................................................................... 2 2
8 580014184 Fitting ..................................................................................................... 2 2
8 052645300 O-Ring ............................................................................................... 1 1
9 580009215 Dipstick Tube (Dipstick) ......................................................................... 1 1
10 580009211 Spool (Relief) ......................................................................................... 1 1
11 580009212 Snap Ring .............................................................................................. 1 1
12 580009213 Spring (Relief) ........................................................................................ 1 1
13 505967551 Fitting ..................................................................................................... 1 1
13 052645300 O-Ring ............................................................................................... 1 1
14 520045522 Dowel ..................................................................................................... 4 4
15 449001302 Capscrew ............................................................................................... 10 10
16 505967573 Switch (Oil Temperature Warning) ........................................................ 1 1
17 580009226 Converter Housing ................................................................................. 1 ..
17 580013507 Converter Housing ................................................................................. .. 1
18 580007365 Washer .................................................................................................. 4 4
19 449001138 Capscrew ............................................................................................... 4 4
20 580007362 Charge Pump ......................................................................................... 1 1
20 580007364 O-Ring ............................................................................................... 1 1
20 580007363 Bushing ............................................................................................. 1 1
21 580025916 Seal (Double Lip) ................................................................................... 1 1
22 810646400 Fitting ..................................................................................................... 1 1
22 052645800 O-Ring ............................................................................................... 1 1
23 580009214 Spring .................................................................................................... 1 1
24 580007359 Screen ................................................................................................... 1 1
25 580038901 Clutch Pack (FP14359 [Page 7-20])..................................................... 1 ..
25 580039086 Clutch Pack (FP14360 [Page 7-22])..................................................... .. 1
26 580038902 Clutch Pack (FP14359 [Page 7-20])..................................................... 1 ..
26 580039087 Clutch Pack (FP14360 [Page 7-22])..................................................... .. 1
27 580039088 Clutch Pack (FP14360 [Page 7-22])..................................................... .. 1
28 580048182 Washer (Stepped) .................................................................................. 2 3
29 580048181 Ball Bearing ........................................................................................... 2 3
TRANSMISSION
T118 - T121 – SHEET 2 OF 2 (S/N E813V02053B →)
KEY:
A: Single Speed
B: Two Speed
QTY
ITEM PART NO. DESCRIPTION A B
580048212 Transmission Assy (T118) (Short Wheel Base) ......................................... 1 ..
580048214 Transmission Assy (T120) (Short Wheel Base) ......................................... .. 1
580048215 Transmission Assy (T121) (Long Wheel Base) .......................................... .. 1
1 505971550 Tube Assy .............................................................................................. 1 1
2 580011163 Valve (FP14312 [Page 7-26])............................................................... 1 1
3 520052872 Gasket ................................................................................................... 1 1
4 449001050 Capscrew ............................................................................................... .. 4
5 449021001 Washer .................................................................................................. 1 4
6 580012758 Valve (FP14311 [Page 7-24])............................................................... 1 1
7 580009243 Valve (Hi and Low) (FP14313 [Page 7-27]).......................................... .. 1
8 580009247 Gasket ................................................................................................... .. 1
9 580009248 Tube Assy .............................................................................................. .. 1
10 015630100 Breather ................................................................................................. 1 1
11 052642200 Fitting ..................................................................................................... .. 1
11 052645200 O-Ring ............................................................................................... .. 1
12 580006715 Gear and Pinion (2100 mm Short Wheel Base) .................................... 1 1
12 580006716 Gear and Pinion (1830 mm Long Wheel Base) ..................................... 1 1
13 520045493 Nut ......................................................................................................... 18 18
14 061278200 Washer .................................................................................................. 18 18
15 580012838 Capscrew ............................................................................................... 18 18
16 580009218 Transmission Housing ........................................................................... 1 ..
16 580009238 Transmission Housing ........................................................................... .. 1
16 504226268 Dowel ................................................................................................ 4 4
16 ..... Bearing Cap ...................................................................................... 2 2
16 931017917 Capscrew .......................................................................................... 4 4
16 502566903 Washer .............................................................................................. 4 4
17 580016558 Differential (FP14321 [Page 8-5])......................................................... 1 1
18 501873914 Bearing Cone ......................................................................................... 2 2
19 056227700 Bearing Cup ........................................................................................... 2 2
20 580009193 Nut ......................................................................................................... 2 2
21 449022016 Lockwasher ............................................................................................ 2 2
22 504226235 Lockplate ............................................................................................... 2 2
23 449001415 Capscrew ............................................................................................... 2 2
24 580009199 Shim (0.005 in.) ..................................................................................... AR AR
24 580009198 Shim (0.007 in.) ..................................................................................... AR AR
24 580009197 Shim (0.020 in.) ..................................................................................... AR AR
25 580007836 Carrier .................................................................................................... 1 1
26 315976070 Fitting ..................................................................................................... 1 3
26 052645200 O-Ring ............................................................................................... 1 1
27 501967902 Fitting ..................................................................................................... 1 1
27 052645500 O-Ring ............................................................................................... 1 1
28 502566902 Washer .................................................................................................. 10 10
29 931015915 Capscrew ............................................................................................... 10 10
30 580009200 Seal ........................................................................................................ 1 1
31 580009196 Spacer ................................................................................................... 1 1
TRANSMISSION
T118 - T121 – SHEET 2 OF 2 (S/N E813V02053B →)
KEY:
A: Single Speed
B: Two Speed
QTY
ITEM PART NO. DESCRIPTION A B
32 580009203 Shim (0.014 in.) ..................................................................................... AR AR
32 580009204 Shim (0.381 in.) ..................................................................................... AR AR
32 580009205 Shim (0.016 in.) ..................................................................................... AR AR
32 580009206 Shim (0.020 in.) ..................................................................................... AR AR
32 580009207 Shim (0.022 in.) ..................................................................................... AR AR
32 580009208 Shim (0.025 in.) ..................................................................................... AR AR
33 500179904 Nut ......................................................................................................... 4 5
34 500002903 Adapter .................................................................................................. 2 ..
34 052645100 O-Ring ............................................................................................... 1 ..
34 134023101 Fitting ..................................................................................................... .. 3
34 052645100 O-Ring ............................................................................................... .. 1
35 056226300 Bearing Cup ........................................................................................... 2 2
36 502515904 Bearing Cone ......................................................................................... 2 2
37 580007835 Gear (Output) ......................................................................................... 1 ..
37 580007834 Gear (Output) ......................................................................................... .. 1
38 580009201 Washer .................................................................................................. 1 1
39 580009202 Nut ......................................................................................................... 1 1
40 580009195 Bearing .................................................................................................. 1 1
41 580009194 Snap Ring .............................................................................................. 1 1
42 505967598 Magnet ................................................................................................... 1 1
43 520042831 Adhesive ................................................................................................ AR AR
44 580009210 Gasket (Cover) ...................................................................................... 1 1
45 580044374 Sensor ................................................................................................... .. 1
46 449022018 Washer .................................................................................................. .. 1
47 449001412 Capscrew ............................................................................................... .. 1
48 580014185 Screw ..................................................................................................... 1 1
49 580009854 Nut ......................................................................................................... 1 1
50 500390901 Fitting ..................................................................................................... .. 1
50 052645500 O-Ring ............................................................................................... .. 1
51 052643200 Connector .............................................................................................. .. 1
51 052645200 O-Ring ............................................................................................... .. 1
52 580012294 Gasket (Control Valve) .......................................................................... 1 1
53 580000082 Strap ...................................................................................................... 2 2
54 449001072 Capscrew ............................................................................................... 3 3
55 449001028 Capscrew ............................................................................................... 1 1
56 580007144 Transmission Filter ................................................................................ 1 1
57 449001073 Capscrew ............................................................................................... 4 4
58 449021001 Washer .................................................................................................. 1 1
59 504070790 Strap Clamp ........................................................................................... 2 2
NOTES
CLUTCH PACKS
T096 - T098 (→ S/N E813V02052B)
KEY:
A: Input
B: Directional
QTY
ITEM PART NO. DESCRIPTION A B
580020546 Clutch Pack (Long Shaft) ........................................................................... 1 ..
580020547 Clutch Pack (Short Shaft) ........................................................................... .. 1
1 580009228 Shaft ...................................................................................................... 1 ..
1 580009232 Shaft ...................................................................................................... .. 1
2 505971555 Seal ........................................................................................................ 1 1
3 580035104 Piston ..................................................................................................... 1 1
4 580001161 O-Ring ................................................................................................... 1 1
5 580001163 Spring .................................................................................................... 1 1
6 580001167 Guide ..................................................................................................... 1 1
7 580001169 Snap Ring .............................................................................................. 1 1
8 580032798 Washer .................................................................................................. 1 1
9 580034918 Spring .................................................................................................... 1 1
10 580020036 Separator Plate (Separator) ................................................................... 8 8
11 580019516 Friction Disk (Friction) ............................................................................ 8 8
12 580001691 Pressure Plate (0.248-0.252 in.) ............................................................ 1 1
12 580020040 Pressure Plate (Shimming) (0.272-0.276 in.) (Optional) ........................ 1 1
12 580046697 Pressure Plate (Shimming, Stepped) (0.201-0.205 in.) (Optional) ........ 1 1
12 580020041 Pressure Plate (Shimming, Stepped) (0.220-0.224 in.) (Optional) ........ 1 1
13 505971572 Snap Ring .............................................................................................. 1 1
CLUTCH PACKS
T118 – SINGLE SPEED (S/N E813V02053B →)
KEY:
A: Input Clutch, Reverse (Long Shaft)
B: Counter Clutch, Forward (Short Shaft)
QTY
ITEM PART NO. DESCRIPTION A B
580038901 Clutch Pack ................................................................................................ 1 ..
580038902 Clutch Pack ................................................................................................ .. 1
1 580048168 Ball Bearing ........................................................................................... 1 1
2 ..... Seal Ring ............................................................................................... 3 2
3 ..... Shaft Assembly ...................................................................................... 1 1
4 ..... Seal Ring ............................................................................................... 1 1
5 580048161 Piston ..................................................................................................... 1 1
6 ..... Seal Ring ............................................................................................... 1 1
7 580048162 Spring .................................................................................................... 1 1
8 580040782 Spring Guide .......................................................................................... 1 1
9 580040783 Snap Ring .............................................................................................. 1 1
10 580048171 Snap Ring .............................................................................................. 2 2
11 580048182 Washer (Stepped) .................................................................................. 1 1
12 ..... Thrust Washer ....................................................................................... 2 2
13 ..... Thrust Bearing (Needle) ........................................................................ 2 2
14 580048174 Needle Bearing ...................................................................................... 1 1
15 580048173 Needle Bearing ...................................................................................... 1 1
16 ..... Plate (Conical) ....................................................................................... 1 1
17 ..... Plate (Friction) ....................................................................................... 8 8
18 ..... Plate (Separator) ................................................................................... 7 7
19 580042529 Pressure Plate (5.8 mm) ........................................................................ 1 1
20 580040787 Snap Ring .............................................................................................. 1 1
21 ..... Seal (D Ring) ......................................................................................... 1 1
22 580048163 Gear (Clutch Output) ............................................................................. 1 1
23 580053110 Kit-Clutch Pack Plates (Clutch Pack Plates) .............................................. 1 1
23 580053111 Kit-Clutch Pack Seals (Clutch Pack Seals) ................................................ 1 1
23 580053112 Kit-Clutch Pack Plates/Seals (Clutch Pack Plates And Seals) .................. 1 1
23 580053113 Kit-Clutch Pack (Needle Thrust Bearings) ................................................. 1 1
CLUTCH PACKS
T120 - T121 – TWO SPEED (S/N E813V02053B →)
KEY:
A: Input Clutch, Reverse (Long Shaft)
B: Counter Clutch, Forward (Short Shaft, Low Speed)
C: Counter Clutch, Forward (Short Shaft, High Speed)
QTY
ITEM PART NO. DESCRIPTION A B C
580039086 Clutch Pack ....................................................................................... 1 .. ..
580039087 Clutch Pack ....................................................................................... .. 1 ..
580039088 Clutch Pack ....................................................................................... .. .. 1
1 580048168 Ball Bearing ................................................................................... 1 1 1
2 ..... Seal Ring ....................................................................................... 3 2 2
3 ..... Shaft Assembly ............................................................................. 1 1 1
4 ..... Seal Ring ....................................................................................... 1 1 1
5 580048161 Piston ............................................................................................ 1 1 1
6 ..... Seal Ring ....................................................................................... 1 1 1
7 580048162 Spring ............................................................................................ 1 1 1
8 580040782 Spring Guide ................................................................................. 1 1 1
9 580040783 Snap Ring ..................................................................................... 1 1 1
10 580048171 Snap Ring ..................................................................................... 2 2 2
11 580048182 Washer (Stepped) ......................................................................... 1 1 1
12 ..... Thrust Washer ............................................................................... 2 2 2
13 ..... Thrust Bearing (Needle) ................................................................ 2 2 2
14 580048174 Needle Bearing ............................................................................. 1 1 1
15 580048173 Needle Bearing ............................................................................. 1 1 1
16 ..... Plate (Conical) ............................................................................... 1 1 1
17 ..... Plate (Friction) ............................................................................... 8 8 8
18 ..... Plate (Separator) ........................................................................... 7 7 7
19 580042529 Pressure Plate (5.8 mm) ............................................................... 1 1 1
20 580040787 Snap Ring ..................................................................................... 1 1 1
21 ..... Seal (D Ring) ................................................................................. 1 1 1
22 580048164 Gear (Clutch Output) ..................................................................... 1 .. ..
22 580048165 Gear (Clutch Output) ..................................................................... .. 1 ..
22 580048166 Gear (Clutch Output) ..................................................................... .. .. 1
23 580053110 Kit-Clutch Pack Plates (Clutch Pack Plates) ..................................... 1 1 1
23 580053111 Kit-Clutch Pack Seals (Clutch Pack Seals) ....................................... 1 1 1
23 580053112 Kit-Clutch Pack Plates/Seals (Clutch Pack Plates And Seals) .......... 1 1 1
23 580053113 Kit-Clutch Pack (Needle Thrust Bearings) ......................................... 1 1 1
CONTROL VALVE
TRANSMISSION
FOOTNOTES:
a Services One Solenoid Valve
TRANSMISSION LINES
ITEM PART NO. DESCRIPTION QTY
1 013381000 Fitting .................................................................................................................. 1
2 580006886 Hose Assy ........................................................................................................... 1
3 580008603 Hose Assy ........................................................................................................... 1
4 580012987 Nut ...................................................................................................................... 2
5 580010483 Clamp ................................................................................................................. 2
6 449021001 Washer ............................................................................................................... 2
7 449022016 Lockwasher ......................................................................................................... 2
8 449001343 Capscrew ............................................................................................................ 2
9 013380600 Fitting .................................................................................................................. 1
KEY:
A: Single Speed
B: Two Speed
QTY
ITEM PART NO. DESCRIPTION A B
580020550 Transmission Assy (T086) (Short Wheel Base) (T86, 1830 mm Short
Wheel Base) ............................................................................................... 1 ..
580020552 Transmission Assy (T088) (Short Wheel Base) (T88, 1830 mm Short
Wheel Base) ............................................................................................... .. 1
580020553 Transmission Assy (T089) (Long Wheel Base) (T89, 2100 mm Long Wheel
Base) .......................................................................................................... .. 1
1 449001049 Capscrew ................................................................................................... 15 15
2 449022017 Lockwasher ................................................................................................ 15 15
3 449001069 Capscrew ................................................................................................... 11 11
4 449022013 Lockwasher ................................................................................................ 11 11
5 580009192 Cover (Starter, Diesel) ............................................................................... 1 1
5 580012248 Cover (Starter, Gas, LPG, Dual Fuel) ........................................................ 1 1
6 520042831 Adhesive .................................................................................................... AR AR
8 DRIVE AXLE
CONTENTS
SECTION 8
DRIVE AXLE
DESCRIPTION PAGE
DRIVE AXLE
KEY:
A: GP/GLP/GDP 070-90LJ/MJ
B: GP/GLP/GDP 100-120MJ
QTY
ITEM PART NO. DESCRIPTION A B
580037291 Drive Axle ................................................................................................... 1 ..
580040434 Drive Axle ................................................................................................... .. 1
1 580002016 Differential Housing ............................................................................... 1 1
2 580036615 Spindle ................................................................................................... 2 2
3 580014158 O-Ring ................................................................................................... 2 2
4 931018909 Capscrew ............................................................................................... 20 20
5 955400910 Lockwasher ............................................................................................ 20 20
6 580036664 Hanger (LH) ........................................................................................... 1 1
7 580036612 Hanger (RH) .......................................................................................... 1 1
8 580002080 Bushing .................................................................................................. 2 2
9 580006490 Brake Assembly (LH) (FP14338 [Page 10-10], FP14339 [Page 10-
14]).......................................................................................................... 1 ..
9 580040443 Brake Assembly (LH) (FP14338 [Page 10-10], FP14339 [Page 10-
14]).......................................................................................................... .. 1
10 580006493 Brake Assembly (RH) (FP14338 [Page 10-10], FP14339 [Page 10-
14]).......................................................................................................... 1 ..
10 580040444 Brake Assembly (RH) (FP14338 [Page 10-10], FP14339 [Page 10-
14]).......................................................................................................... .. 1
11 580040445 Hub ........................................................................................................ 1 1
11 580040409 Wheel Hub ......................................................................................... 1 1
12 054082600 Bearing Cup ...................................................................................... 1 1
13 580004040 Bearing Cup ...................................................................................... 1 1
14 504314781 Seal ................................................................................................... 1 1
15 504314782 Seal ................................................................................................... 1 1
16 580002079 Bearing Cone .................................................................................... 1 1
17 580002013 Wheel Stud ........................................................................................ 6 6
18 065862400 Bearing Cone ......................................................................................... 2 2
19 580002075 Locknut .................................................................................................. 2 2
20 580002077 Lockwasher ............................................................................................ 2 2
21 580002076 Locknut .................................................................................................. 2 2
22 580001979 Axle Shaft .............................................................................................. 2 2
23 520042831 Adhesive ................................................................................................ AR AR
24 931017904 Capscrew ............................................................................................... 20 20
25 580017291 Brake Drum ............................................................................................ 2 ..
25 580019593 Brake Drum ............................................................................................ .. 2
26 580002081 Bolt (Special) ......................................................................................... 16 16
27 520045503 Dowel ..................................................................................................... 4 4
28 505970537 Fitting ..................................................................................................... 1 1
29 014932700 Fitting ..................................................................................................... 1 1
30 520045510 Pin .............................................................................................................. 4 4
31 504226218 Lubricant .................................................................................................... AR AR
32 449001026 Capscrew ................................................................................................... 8 8
33 955400910 Lockwasher ................................................................................................ 8 8
34 449015018 Nut .............................................................................................................. 8 8
35 580014159 Shim (0.04 in.) ............................................................................................ AR AR
36 449022016 Lockwasher ................................................................................................ 2 2
DRIVE AXLE
KEY:
A: GP/GLP/GDP 070-90LJ/MJ
B: GP/GLP/GDP 100-120MJ
QTY
ITEM PART NO. DESCRIPTION A B
37 449001091 Capscrew ................................................................................................... 2 2
38 580001926 Adapter (Dual Wheel) (2100 mm Long Wheel Base) ................................. .. 1
38 580001925 Adapter (Dual Wheel) (1830 mm Short Wheel Base) ................................ 1 ..
39 580003941 Wheel Nut .................................................................................................. 12 12
39 580003941 Wheel Nut (Dual Wheel) ............................................................................ 24 24
39 580001931 Wheel Nut (Optional) .................................................................................. 12 12
39 580001931 Wheel Nut (Dual Wheel) (Optional) ............................................................ 24 24
40 449022041 Lockwasher ................................................................................................ 20 20
FOOTNOTES:
a Standard Tread b Wide Tread
FOOTNOTES:
a Standard Tread b Wide Tread
NOTES
9 STEERING SYSTEM
CONTENTS
SECTION 9
STEERING SYSTEM
DESCRIPTION PAGE
STEERING SYSTEM
ITEM PART NO. DESCRIPTION QTY
1 052643300 Fitting .................................................................................................................. 1
1 052645300 O-Ring ............................................................................................................ 1
2 580043718 Hose and Tube Assy .......................................................................................... 1
3 504226242 Washer ............................................................................................................... 6
4 580012090 Clamp ................................................................................................................. 1
5 580012987 Nut ...................................................................................................................... 5
6 449021001 Washer ............................................................................................................... 7
7 449022016 Lockwasher ......................................................................................................... 6
8 580012070 Pad ..................................................................................................................... 4
9 580006876 Hose Assy ........................................................................................................... 3
10 580006873 Hose Assy (Short Wheel Base) .......................................................................... 2
10 580006874 Hose Assy (Long Wheel Base) ........................................................................... 2
11 903259104 Strap Clamp ........................................................................................................ AR
12 449001072 Capscrew ............................................................................................................ 1
13 580045322 Plate .................................................................................................................... 1
14 580006877 Hose Assy ........................................................................................................... 1
15 504226242 Washer ............................................................................................................... 6
16 520037834 Clamp ................................................................................................................. 4
17 520045882 Sleeve ................................................................................................................. 1
18 449015014 Nut ...................................................................................................................... 3
19 449001343 Capscrew ............................................................................................................ 6
20 060371700 Fitting .................................................................................................................. 1
21 013405600 Nut ...................................................................................................................... 1
22 052642200 Fitting .................................................................................................................. 2
22 052645200 O-Ring ............................................................................................................ 1
23 520037856 Pin ....................................................................................................................... 1
24 449021003 Washer ............................................................................................................... 1
25 965801904 Cotter Pin ............................................................................................................ 1
STEER COLUMN
ITEM PART NO. DESCRIPTION QTY
1 580006573 Bracket Wldmt .................................................................................................... 1
2 449001302 Capscrew ............................................................................................................ 4
3 449022013 Lockwasher ......................................................................................................... 4
4 449015044 Nut ...................................................................................................................... 4
5 505977597 Bracket ................................................................................................................ 1
6 520037801 Spring ................................................................................................................. 1
7 505977562 Shaft ................................................................................................................... 1
8 505977538 Plate .................................................................................................................... 2
9 449001014 Screw .................................................................................................................. 4
10 449022016 Lockwasher ......................................................................................................... 4
11 580022964 Capscrew ............................................................................................................ 1
12 449015098 Nut ...................................................................................................................... 1
13 518796642 Latch (Gear) ........................................................................................................ 1
14 505977589 Pin ....................................................................................................................... 1
15 015416200 Cotter Pin ............................................................................................................ 1
16 505977566 Handle Grip (Latch) ............................................................................................ 1
17 504235265 Capscrew ............................................................................................................ 2
18 505977509 Rod ..................................................................................................................... 1
19 504574273 Spring ................................................................................................................. 1
20 449021002 Washer ............................................................................................................... 1
21 580008931 Steering Pump .................................................................................................... 1
22 059719100 Capscrew ............................................................................................................ 4
23 015026400 Lockwasher ......................................................................................................... 4
24 016104000 Washer ............................................................................................................... 4
25 518802659 Steering Column ................................................................................................. 1
25 518794682 Nut .................................................................................................................. 1
25 580008094 Kit-Terminal (Contact Rivets) ......................................................................... 1
26 580030014 Screw .................................................................................................................. 6
27 504227269 Steering Wheel ................................................................................................... 1
28 504503703 Cover (Upper) ..................................................................................................... 1
29 504504703 Cover (Lower) ..................................................................................................... 1
30 580014160 Plug (Without Turn Signals) ................................................................................ 1
31 520045057 Plug ..................................................................................................................... 2
32 a 504260795 Horn Button ......................................................................................................... 1
33 580035444 Washer ............................................................................................................... 4
34 312850046 Strap Clamp (Strap) ............................................................................................ 1
35 504238241 Wheelspinner ...................................................................................................... 1
FOOTNOTES:
a Service with Horn Replacement Kit 524276063
SHIFT LEVER
ITEM PART NO. DESCRIPTION QTY
520038825 Lever Assembly .................................................................................................. 1
1 504574276 Base ............................................................................................................... 1
2 504574277 Link ................................................................................................................. 1
3 505977569 Crank .............................................................................................................. 1
3 580049408 Crank .......................................................................................................... 1
3 580049409 Pin .............................................................................................................. 1
4 505977542 Crank .............................................................................................................. 1
4 580049410 Crank .......................................................................................................... 1
4 580049409 Pin .............................................................................................................. 1
5 505977598 Lever .............................................................................................................. 1
6 505977590 Screw ............................................................................................................. 2
7 449015112 Locknut ........................................................................................................... 2
8 580022130 Spring ............................................................................................................. 2
9 505977516 Bolt ................................................................................................................. 2
10 449015002 Nut .................................................................................................................. 2
11 505977500 Spring Washer ................................................................................................ 4
12 505977550 Plate .................................................................................................................... 1
13 504307785 Switch ................................................................................................................. 2
14 502700903 Screw .................................................................................................................. 4
15 504226282 Washer ............................................................................................................... 4
16 032643500 Nut ...................................................................................................................... 4
17 449001412 Capscrew ............................................................................................................ 4
18 449021003 Washer ............................................................................................................... 4
19 449022018 Washer ............................................................................................................... 4
20 520045057 Plug (Monotrol) ................................................................................................... 1
21 505977573 Bracket (Label) ................................................................................................... 1
STEER AXLE
ITEM PART NO. DESCRIPTION QTY
580021863 Steering Axle ...................................................................................................... 1
1 580002031 Steering Axle (Steer Axle) .............................................................................. 1
2 580002502 Spindle (RH) ................................................................................................... 1
3 502565906 Capscrew ....................................................................................................... 8
4 449022041 Lockwasher .................................................................................................... 8
5 580001869 Steering Cylinder (FP14332 [Page 9-12])..................................................... 1
6 015631500 Grease Fitting ................................................................................................. 12
7 580008277 Seal ................................................................................................................ 8
8 015918200 Snap Ring ....................................................................................................... 8
9 a 580021864 Tie Rod ........................................................................................................... 2
9 b 580052283 Tie Rod ........................................................................................................... 2
9 a 580009716 Bearing ....................................................................................................... 1
9 b 580052264 Spherical Roller Bearing ............................................................................ 2
10 a 580043736 Pin .................................................................................................................. 2
10 b 580052360 Pin .................................................................................................................. 2
11 931014904 Capscrew ....................................................................................................... 6
11 502566904 Washer ........................................................................................................... 4
12 580009734 Bearing Cap ................................................................................................... 2
12 580009733 Bearing Cap ............................................................................................... 1
13 504225236 O-Ring ............................................................................................................ 2
14 580009746 Shim (0.020 in.) .............................................................................................. 2
15 580009745 Shim (0.007 in.) .............................................................................................. 2
16 580009744 Shim (0.005 in.) .............................................................................................. 2
17 065001000 Bearing Cone ................................................................................................. 2
17 065000900 Bearing Cup ................................................................................................... 1
18 520045589 Seal ................................................................................................................ 2
19 504224242 Seal ................................................................................................................ 2
20 580001880 Spindle (LH) ................................................................................................... 1
21 504224218 Seal ................................................................................................................ 2
22 520049820 Bearing Cone ................................................................................................. 2
23 580001876 Hub ................................................................................................................. 2
23 580001877 Wheel Hub ................................................................................................. 1
24 504224217 Wear Sleeve ............................................................................................... 1
25 580002014 Wheel Stud (Wheel) ................................................................................... 5
26 053236500 Bearing Cup ............................................................................................... 1
27 580014161 Bearing Cup ............................................................................................... 1
28 580014163 Bearing Cone ................................................................................................. 2
29 015418500 Cotter Pin ....................................................................................................... 2
30 504227283 Cap ................................................................................................................. 2
31 520044815 Nut (Spindle) .................................................................................................. 2
32 580001878 Lockwasher .................................................................................................... 2
33 580003941 Wheel Nut ....................................................................................................... 10
33 580001931 Wheel Nut (Optional) ...................................................................................... 10
34 504224231 Wear Sleeve ................................................................................................... 2
35 a 580043737 Pin .................................................................................................................. 2
35 b 580052361 Pin .................................................................................................................. 2
36 504224298 Seal ................................................................................................................ 2
37 072387301 Bearing Cone ................................................................................................. 2
38 072387302 Bearing Cup ................................................................................................... 2
39 520039889 Sealant ........................................................................................................... AR
40 580001875 Dust Cap ........................................................................................................ 2
STEER AXLE
ITEM PART NO. DESCRIPTION QTY
41 909882405 Nut .................................................................................................................. 4
42 449021010 Washer ........................................................................................................... 8
43 502565903 Capscrew ....................................................................................................... 4
44 504224240 Rubber Mount ................................................................................................. 2
45 504224214 Plate ............................................................................................................... 2
46 580002046 Rubber Mount (Optional, Extra Capacity) ...................................................... 2
47 580050204 Shim (0.002 in.) .............................................................................................. AR
FOOTNOTES:
a → S/N E813V02062B b S/N E813V02063B →
NOTES
STEER CYLINDER
ITEM PART NO. DESCRIPTION QTY
580001869 Steering Cylinder (Group No. 8602499) ............................................................. 1
1 580001872 Cylinder Rod ................................................................................................... 1
2 500167917 Back-Up Ring ................................................................................................. 2
3 580006367 O-Ring ............................................................................................................ 2
4 580001874 End Cap ......................................................................................................... 2
5 504225226 Rod Wiper ...................................................................................................... 2
6 504804790 Seal ................................................................................................................ 2
7 580001871 Tube Wldmt-Cylinder ...................................................................................... 1
8 504305713 Seal ................................................................................................................ 1
580026954 Kit-Seal ............................................................................................................... 1
STEER PUMP
ITEM PART NO. DESCRIPTION QTY
580008931 Steering Pump .................................................................................................... 1
1 ..... Seal Ring ........................................................................................................ 1
2 ..... Housing .......................................................................................................... 1
2 ..... Spool and Sleeve ........................................................................................... 1
3 504226283 Ball ................................................................................................................. 1
4 580008004 Stop ................................................................................................................ 1
5 580000189 Seal ................................................................................................................ 1
6 012828600 O-Ring ............................................................................................................ 4
6 580000361 O-Ring (Optional Replacement) ..................................................................... 4
7 504226233 Bearing Set ..................................................................................................... 1
8 504226256 Ring ................................................................................................................ 1
9 504226253 Pin .................................................................................................................. 1
10 518793630 Spring ............................................................................................................. 1
11 518793644 Shaft ............................................................................................................... 1
12 580008000 Ball ................................................................................................................. 1
13 ..... O-Ring ............................................................................................................ 1
14 ..... Plate ............................................................................................................... 1
15 ..... Gear Set ......................................................................................................... 1
16 580008005 O-Ring ............................................................................................................ 2
17 ..... Cover .............................................................................................................. 1
18 ..... Washer ........................................................................................................... 3
19 580008003 Spring ............................................................................................................. 1
20 580007188 Screw ............................................................................................................. 1
21 504225299 Capscrew ....................................................................................................... 1
22 580008001 Fitting (Male) .................................................................................................. 4
23 580008002 Screw ............................................................................................................. 1
580007999 Kit-Seal ............................................................................................................... 1
KEY:
A: 7.00 x 12 Solid
B: 7.00 x 12 12 Ply
C: 7.00 R12 Radial
QTY
ITEM PART NO. DESCRIPTION A B C
1 505970525 Solid Pneumatic Tire (Standard Hardness) ....................................... 2 .. ..
2 505970565 Tire Flap ............................................................................................ .. 2 ..
2 505969503 Tire Flap (With Flap) ..................................................................... .. 1 ..
2 505969564 Tire Flap ........................................................................................ .. 1 ..
2 904575103 Tire (Optional) ................................................................................... .. 2 ..
2 917071306 Tire (Optional) ................................................................................... .. 2 ..
3 505973521 Pneumatic Tire (Michelin XMZ) ......................................................... .. .. 2
3 505973583 Pneumatic Tire .............................................................................. .. .. 1
3 505973564 Tube .............................................................................................. .. .. 1
3 520044952 Washer (Valve Stem) (Not Illustrated) .......................................... .. .. 1
3 580014954 Pneumatic Tire (Michelin XZM) (Tubeless) ....................................... .. .. 2
3 580014862 Tubeless Bead Seal (Not Illustrated) ............................................ .. .. 1
3 580014987 Tubeless Bead Seal Valve (Not Illustrated) .................................. .. .. 1
3 505973583 Pneumatic Tire .............................................................................. .. .. 1
4 580001929 Wheel (Outer) ................................................................................ 1 1 ..
4 505971656 Label (Warning) (Not Illustrated) ............................................... 1 1 ..
5 580033449 Wheel Stud (Press Fitted) ......................................................... 5 5 ..
6 505969526 Wheel Nut ..................................................................................... 5 5 ..
6 015418300 Cotter Pin ...................................................................................... 5 5 ..
7 580001930 Wheel Assy (Inner) ........................................................................ 2 2 ..
7 505971656 Label (Warning) ........................................................................ 1 1 ..
8 580001927 Rim (5.00 x 12) .................................................................................. .. .. 2
9 580001928 Wheel ............................................................................................ .. .. 1
10 505971531 Shoulder Ring ............................................................................... .. .. 1
11 505970551 Wheel Side Ring ........................................................................... .. .. 1
12 505970589 Wheel Lock Ring ........................................................................... .. .. 1
13 580003941 Wheel Nut .......................................................................................... 10 10 ..
KEY:
A: 7.00 x 12 Solid
B: 7.00 x 12 12 Ply
C: 7.00 R12 Radial
QTY
ITEM PART NO. DESCRIPTION A B C
13 580001931 Wheel Nut (Optional) ......................................................................... 10 10 ..
NOTES
10 BRAKE SYSTEM
CONTENTS
SECTION 10
BRAKE SYSTEM
DESCRIPTION PAGE
BRAKE ASSEMBLY
1830 MM SHORT WHEEL BASE ............................................................................................................... 10-10
2100 WHEEL BASE .................................................................................................................................... 10-14
BRAKE RELAY ASSEMBLY ........................................................................................................................... 10-8
BRAKE SYSTEM ............................................................................................................................................. 10-2
MASTER CYLINDER AND BOOSTER ........................................................................................................... 10-6
PARK BRAKE .................................................................................................................................................. 10-18
BRAKE SYSTEM
ITEM PART NO. DESCRIPTION QTY
1 580049460 Bracket ................................................................................................................ 1
2 580021079 Pedal ................................................................................................................... 1
3 505972578 Bushing ............................................................................................................... 2
4 449001302 Capscrew ............................................................................................................ 3
5 449022013 Lockwasher ......................................................................................................... 8
6 449015044 Nut ...................................................................................................................... 9
7 580008913 Master Cylinder (FP14337 [Page 10-6])............................................................ 1
8 580014156 Pin ....................................................................................................................... 3
9 449022016 Lockwasher ......................................................................................................... 4
10 449015014 Nut ...................................................................................................................... 4
11 449021006 Washer ............................................................................................................... 6
12 449001015 Capscrew ............................................................................................................ 3
13 520045050 Rod End .............................................................................................................. 1
14 505972564 Rod End .............................................................................................................. 1
15 580009150 Link ..................................................................................................................... 1
16 014972700 Nut ...................................................................................................................... 1
17 061427100 Nut ...................................................................................................................... 1
18 580056294 Crank (Inching) ................................................................................................... 1
19 505972500 Spacer ................................................................................................................ 1
20 505972502 Washer ............................................................................................................... 1
21 449001072 Capscrew ............................................................................................................ 1
22 580008916 Link ..................................................................................................................... 2
23 504323796 Spring ................................................................................................................. 2
24 505974532 Spring Washer .................................................................................................... 1
25 580009149 Plate .................................................................................................................... 1
26 449001010 Capscrew ............................................................................................................ 1
27 900001201 Pad (Pedal) ......................................................................................................... 1
28 580019391 Block ................................................................................................................... 1
29 449001386 Capscrew ............................................................................................................ 1
30 502398901 Washer ............................................................................................................... 2
31 449015002 Nut ...................................................................................................................... 1
32 a 580009100 Tube Assy (LH) ................................................................................................... 1
32 b 580009102 Tube Assy (LH) ................................................................................................... 1
33 a 580009101 Tube Assy (RH) .................................................................................................. 1
33 b 580009103 Tube Assy (RH) .................................................................................................. 1
34 580009099 Hose Assy ........................................................................................................... 1
35 504237211 Pin ....................................................................................................................... 3
36 580000868 Lockring .............................................................................................................. 5
37 449007052 Screw .................................................................................................................. 1
38 504574259 Nut ...................................................................................................................... 1
39 055162500 Fitting .................................................................................................................. 1
40 500595901 Fitting (Monotrol Pedal) ...................................................................................... 1
41 505972532 Pressure Switch (Monotrol Pedal) ...................................................................... 1
41 580046387 Pressure Switch .................................................................................................. 1
42 580006019 Fitting .................................................................................................................. 1
43 501884905 Fitting (Pipe Plug) ............................................................................................... 2
44 580014157 Collar .................................................................................................................. 1
45 449022018 Washer ............................................................................................................... 1
46 016104000 Washer ............................................................................................................... 6
47 504323795 Hose (LPG) ......................................................................................................... 1
47 504323797 Hose (Diesel) ...................................................................................................... 1
BRAKE SYSTEM
ITEM PART NO. DESCRIPTION QTY
48 502056906 Clamp ................................................................................................................. 2
49 504070790 Strap Clamp (LPG) ............................................................................................. 1
49 504070790 Strap Clamp (Diesel) .......................................................................................... 4
50 580012331 Washer ............................................................................................................... 1
51 504226242 Washer ............................................................................................................... 4
52 502080902 Fitting .................................................................................................................. 1
53 580026401 Filter .................................................................................................................... 1
54 580015022 Hose ................................................................................................................... 1
55 900011244 Clamp ................................................................................................................. 2
56 505972532 Pressure Switch (Forward And Reverse Lever) ................................................. 1
56 505972532 Pressure Switch (Foot Directional Control Pedal) .............................................. 2
..... Brake Relay Assembly (Foot Directional Control Pedal) (FP15192 [Page 10-
8])......................................................................................................................... 1
FOOTNOTES:
a 1830 mm Short Wheel Base b 2100 Wheel Base
NOTES
FOOTNOTES:
a S/N E813V03850C →
NOTES
BRAKE ASSEMBLY
1830 MM SHORT WHEEL BASE
KEY:
A: Left Hand
B: Right Hand
QTY
ITEM PART NO. DESCRIPTION A B
580006490 Brake Assembly (With Park Brake Cable) ................................................. 1 ..
580006493 Brake Assembly (With Park Brake Cable) ................................................. .. 1
580011222 Brake Assembly (LH) (Without Park Brake Cable) ................................ 1 ..
580011223 Brake Assembly (RH) (Without Park Brake Cable) ............................... .. 1
1 580011219 Backplate ........................................................................................... 1 ..
1 580011220 Backplate ........................................................................................... .. 1
2 908630400 Wheel Cylinder .................................................................................. 1 1
2 580011200 Kit-Repair Wheel Cylinder ............................................................. 1 1
2 ..... Piston and Cup ........................................................................................... 2 2
2 ..... Boot ............................................................................................................ 2 2
3 580011203 Kit-Brake Shoe .................................................................................. 1 ..
3 580011206 Kit-Brake Shoe .................................................................................. .. 1
3 ..... Shoe and Lining ............................................................................ 1 1
3 ..... Shoe Lining and Pin Assembly ..................................................... 1 1
4 900955806 Adjuster ............................................................................................. 1 ..
4 900955807 Adjuster ............................................................................................. .. 1
5 900955811 Lever ................................................................................................. 1 ..
5 900955812 Lever ................................................................................................. .. 1
6 900955813 Spring ................................................................................................ 1 ..
6 900955814 Spring ................................................................................................ .. 1
7 900955830 Kit-Cable ............................................................................................ 1 1
8 900955825 Parking Brake Lever .......................................................................... 1 ..
8 900955826 Parking Brake Lever .......................................................................... .. 1
9 900955815 Strut ................................................................................................... 1 ..
9 900955816 Strut ................................................................................................... .. 1
10 901428819 Spring ................................................................................................ 1 1
11 901836818 Spring ................................................................................................ 1 1
12 900955827 Spring ................................................................................................ 1 1
13 900488804 Spring ................................................................................................ 1 1
14 900955821 Pin (Shoe Hold Down) ....................................................................... 2 2
15 900750841 Cup (Shoe Hold Down) ..................................................................... 4 4
16 900955822 Spring (Shoe Hold Down) .................................................................. 2 2
17 900955809 Wear Plate ......................................................................................... 1 1
18 900488824 Retainer ............................................................................................. 2 2
19 900488823 Washer .............................................................................................. 2 2
20 900488827 Cover ................................................................................................. 1 1
21 900955823 Bolt .................................................................................................... 4 4
22 ..... Sheave .............................................................................................. 1 1
23 ..... Washer .............................................................................................. 1 1
24 ..... Nut ..................................................................................................... 1 1
25 ..... Pin ..................................................................................................... 1 1
26 900488826 Snap Ring .............................................................................................. 1 1
27 580011224 Parking Brake Cable (LH) (FP14340 [Page 10-18])............................. 1 ..
27 580011225 Parking Brake Cable (RH) (FP14340 [Page 10-18])............................ .. 1
28 908621405 Bleeder Screw ....................................................................................... 1 1
BRAKE ASSEMBLY
1830 MM SHORT WHEEL BASE
KEY:
A: Left Hand
B: Right Hand
QTY
ITEM PART NO. DESCRIPTION A B
29 900488835 Cap ........................................................................................................ 1 1
580011997 Kit-Sheave ............................................................................................. 1 1
580011995 Kit-Park Brake (LH) ................................................................................ 1 ..
580011996 Kit-Park Brake (RH) ............................................................................... .. 1
901836870 Kit-Spring ............................................................................................... 1 1
909377300 Kit-Hold Down ........................................................................................ 2 2
NOTES
BRAKE ASSEMBLY
2100 WHEEL BASE
KEY:
A: Left Hand
B: Right Hand
QTY
ITEM PART NO. DESCRIPTION A B
580040443 Brake Assembly (With Park Brake Cable) ................................................. 1 ..
580040444 Brake Assembly (With Park Brake Cable) ................................................. .. 1
580041363 Brake Assembly (Without Park Brake Cable) ........................................ 1 ..
580041364 Brake Assembly (Without Park Brake Cable) ........................................ .. 1
1 580011421 Backplate ........................................................................................... 1 ..
1 580011422 Backplate ........................................................................................... .. 1
2 580011423 Wheel Cylinder .................................................................................. 1 1
2 580011208 Kit-Repair Wheel Cylinder ............................................................. 1 1
2 ..... Piston And Cup .......................................................................................... 2 2
2 ..... Boot ............................................................................................................ 2 2
2 ..... Spring ......................................................................................................... 1 1
3 580039188 Kit-Brake Shoe .................................................................................. 1 ..
3 580039189 Kit-Brake Shoe .................................................................................. .. 1
3 ..... Shoe and Lining Assembly ............................................................ 1 ..
3 ..... Shoe and Lining Assembly ............................................................ .. 1
4 524138928 Adjuster ............................................................................................. 1 ..
4 524138929 Adjuster ............................................................................................. .. 1
5 524138930 Lever ................................................................................................. 1 ..
5 524138931 Lever ................................................................................................. .. 1
6 580011432 Spring ................................................................................................ 1 ..
6 580011433 Spring ................................................................................................ .. 1
7 580011434 Link .................................................................................................... 1 ..
7 580011435 Link .................................................................................................... .. 1
8 580011436 Spring ................................................................................................ 1 1
9 580011437 Parking Brake Lever (Parking) .......................................................... 1 ..
9 580011438 Parking Brake Lever (Parking) .......................................................... .. 1
10 580011439 Strut ................................................................................................... 1 ..
10 580011440 Strut ................................................................................................... .. 1
11 580011441 Spring ................................................................................................ 1 1
11 580032504 Spring (White) ................................................................................... 1 1
12 524138932 Spring ................................................................................................ 1 1
13 900955821 Pin (Shoe Hold Down) ....................................................................... 2 2
14 580011443 Cup (Shoe Hold Down) ..................................................................... 4 4
15 580011444 Spring (Shoe Hold Down) .................................................................. 2 2
16 580011445 Lever ................................................................................................. 1 1
17 900750815 Washer .............................................................................................. 1 1
18 900750816 Cotter Pin .......................................................................................... 1 1
19 580011446 Dust Shield ........................................................................................ 1 1
20 900750848 Cover ................................................................................................. 1 1
21 580011447 Bolt .................................................................................................... 4 ..
22 580011448 Bolt .................................................................................................... 2 2
23 900488824 Retainer ............................................................................................. 2 2
24 900488823 Washer .............................................................................................. 2 2
25 900488826 Snap Ring .............................................................................................. 1 1
26 580011489 Parking Brake Cable (FP14340 [Page 10-18])..................................... 1 ..
BRAKE ASSEMBLY
2100 WHEEL BASE
KEY:
A: Left Hand
B: Right Hand
QTY
ITEM PART NO. DESCRIPTION A B
26 580011490 Parking Brake Cable (FP14340 [Page 10-18])..................................... .. 1
27 900488834 Bleeder Screw ....................................................................................... 1 1
28 900488835 Cap ........................................................................................................ 1 1
NOTES
PARK BRAKE
ITEM PART NO. DESCRIPTION QTY
1 580013352 Parking Brake Lever ........................................................................................... 1
2 449001014 Screw .................................................................................................................. 5
3 580012660 Nut (Flanged) ...................................................................................................... 5
4 504226242 Washer ............................................................................................................... 4
5 504236269 Clamp ................................................................................................................. 1
6 501921909 Clamp ................................................................................................................. 2
7 a 580011224 Parking Brake Cable (LH) (1850 Wheel Base) ................................................... 2
7 a 580011225 Parking Brake Cable (RH) (1850 Wheel Base) .................................................. 2
7 a 580011489 Parking Brake Cable (LH) (2100 mm Long Wheel Base) ................................... 2
7 a 580011490 Parking Brake Cable (RH) (2100 mm Long Wheel Base) .................................. 2
FOOTNOTES:
a Cables Are Included With Service Brake
Assemblies
NOTES
11 HYDRAULIC SYSTEM
CONTENTS
SECTION 11
HYDRAULIC SYSTEM
DESCRIPTION PAGE
HYDRAULIC SYSTEM
ITEM PART NO. DESCRIPTION QTY
1 580013459 Hydraulic Pump (1830 mm Short Wheel Base) (FP14354 [Page 11-22])......... 1
1 580013460 Hydraulic Pump (2100 mm Long Wheel Base) (FP14354 [Page 11-22]).......... 1
2 500002907 Fitting .................................................................................................................. 1
2 052645500 O-Ring ............................................................................................................ 1
3 580009073 Isolator ................................................................................................................ 2
4 580006930 Hose ................................................................................................................... 4
5 580011016 Plate .................................................................................................................... 1
6 502566902 Washer ............................................................................................................... 4
7 909882405 Nut ...................................................................................................................... 4
8 580009037 Hydraulic Filter .................................................................................................... 1
9 580014082 Fitting .................................................................................................................. 1
10 580009062 Hose (Suction) .................................................................................................... 1
11 580045693 Fitting .................................................................................................................. 1
11 052645500 O-Ring ............................................................................................................ 1
12 580042755 Tube Assy ........................................................................................................... 1
13 449001343 Capscrew ............................................................................................................ 6
14 580006753 Hydraulic Filter .................................................................................................... 1
15 580012151 Hydraulic Filter .................................................................................................... 1
16 514214804 O-Ring ................................................................................................................ 6
17 449001013 Capscrew ............................................................................................................ 6
18 502169905 Fitting .................................................................................................................. 1
19 504226242 Washer ............................................................................................................... 9
20 449022016 Lockwasher ......................................................................................................... 9
21 580014081 Clamp ................................................................................................................. 1
22 449015014 Nut ...................................................................................................................... 4
23 449021001 Washer ............................................................................................................... 6
24 580014232 Plug (Magnetic) (Magnetic Drain Plug) ............................................................... 1
25 023081400 Fitting .................................................................................................................. 1
26 580010791 Tube Assy ........................................................................................................... 1
27 580029082 Hose Assy ........................................................................................................... 1
28 580006832 Seal ..................................................................................................................... 1
28 580016733 Adhesive ............................................................................................................. 1
29 580002923 Filter Head (Filter) ............................................................................................... 1
30 580012106 Dipstick ............................................................................................................... 1
31 052645700 O-Ring ................................................................................................................ 1
32 518794681 Breather (40 Micron) ........................................................................................... 1
32 520036890 Breather (10 Micron) (Optional) .......................................................................... 1
33 06417010J Fitting .................................................................................................................. 1
34 502600902 Fitting .................................................................................................................. 1
35 580007557 Clamp ................................................................................................................. 2
36 580007995 Fitting .................................................................................................................. 1
36 052645700 O-Ring ............................................................................................................ 1
37 316441036 Fitting .................................................................................................................. 1
37 052645700 O-Ring ............................................................................................................ 1
38 062159700 Clamp ................................................................................................................. 4
39 502056904 Clamp (Hose) ...................................................................................................... 2
40 580012987 Nut ...................................................................................................................... 6
41 580009024 Clamp ................................................................................................................. 2
42 580014080 Clamp ................................................................................................................. 1
43 520049839 Hose ................................................................................................................... 1
44 580024298 Hose ................................................................................................................... 1
HYDRAULIC SYSTEM
ITEM PART NO. DESCRIPTION QTY
44 580015814 Hose (Optional) ................................................................................................... 1
44 504231226 Clamp ................................................................................................................. 1
45 580001406 O-Ring ................................................................................................................ 1
46 506395533 Fitting (Two Stage Full Free-Lift) ........................................................................ 1
46 013393300 Fitting (Two Stage Limited Free-Lift and Three Stage Full Free-Lift Masts) ....... 1
47 580028819 Hose ................................................................................................................... 1
48 903259104 Strap Clamp ........................................................................................................ 1
49 580051731 O-Ring ................................................................................................................ 1
NOTES
NOTES
NOTES
HYDRAULIC PUMP
KEY:
A: 2100 mm Long Wheel Base
B: 1830/1880 mm Short Wheel Base
QTY
ITEM PART NO. DESCRIPTION A B
580013460 Hydraulic Pump .......................................................................................... 1 ..
580013459 Hydraulic Pump .......................................................................................... .. 1
1 580014230 Gear Set ................................................................................................ 1 ..
1 580014229 Gear Set ................................................................................................ .. 1
2 580012842 Cover (Port End) .................................................................................... 1 1
3 580003118 Bushing ............................................................................................. 2 2
4 580012843 Cover (Shaft End) .................................................................................. 1 1
5 580003118 Bushing ............................................................................................. 2 2
6 580012844 Housing .................................................................................................. 1 ..
6 580014244 Housing .................................................................................................. .. 1
7 580012846 Capscrew ............................................................................................... 4 4
8 580012847 Stud ....................................................................................................... 4 4
9 580003129 Dowel ..................................................................................................... 4 4
10 580003125 Washer .................................................................................................. 4 4
11 ..... Bearing .................................................................................................. 1 1
12 501975904 Snap Ring .............................................................................................. 1 1
13 ..... Snap Ring .............................................................................................. 1 1
14 580014096 Seal ........................................................................................................ 1 1
15 ..... Plate ....................................................................................................... 2 2
16 580003143 Seal ........................................................................................................ 2 2
17 580003144 Seal ........................................................................................................ 2 2
18 580003130 Seal ........................................................................................................ 2 2
580012812 Kit-Seal ....................................................................................................... 1 1
580014231 Kit-Seal ....................................................................................................... 1 1
580014243 Kit-Pump Thrust Plate ................................................................................ 1 1
MAST INSTALLATION
ITEM PART NO. DESCRIPTION QTY
1 ab 580002226 Tilt Cylinder (FP14356 [Page 11-26])................................................................ 2
1 c 580002228 Tilt Cylinder (FP14356 [Page 11-26])................................................................ 2
2 bc 520045696 Rod End .............................................................................................................. 2
2 a 580040974 Rod End .............................................................................................................. 2
3 520045464 Bushing ............................................................................................................... 4
4 580039203 Pin ....................................................................................................................... 4
5 055485000 Capscrew ............................................................................................................ 2
6 015026600 Washer ............................................................................................................... 2
7 520045462 Anchor ................................................................................................................ 4
8 449015029 Nut ...................................................................................................................... 2
9 449022017 Lockwasher ......................................................................................................... 4
10 449001048 Capscrew ............................................................................................................ 2
11 449001003 Capscrew ............................................................................................................ 2
12 015627900 Grease Fitting ..................................................................................................... 4
13 502139901 Grease Fitting ..................................................................................................... 2
14 580076742 Capscrew ............................................................................................................ 4
15 580019523 Bushing ............................................................................................................... 2
16 580012350 Snap Ring ........................................................................................................... 4
17 580019520 Pin ....................................................................................................................... 2
18 580027220 Washer ............................................................................................................... 2
FOOTNOTES:
a 12°Forward/6°Back c 6°Forward/6°Back
b 6°Forward/12°Back
FOOTNOTES:
a 6° Forward/12° Back, 12° Forward/6° Back b 6° Forward/6° Back
SECTION 12
MAST-TWO STAGE LIMITED FREE-LIFT
DESCRIPTION PAGE
CARRIAGE
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 12-14
INNER MAST
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 12-4
MAIN LIFT
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 12-6
MAIN LIFT CYLINDERS
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 12-10
OUTER MAST
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 12-2
OUTER MAST
TWO STAGE LIMITED FREE-LIFT
70-90LJ
100-120MJ
FOOTNOTES:
a Refer to Table
INNER MAST
TWO STAGE LIMITED FREE-LIFT
70-90LJ
100-120MJ
FOOTNOTES:
a Refer to Table
MAIN LIFT
TWO STAGE LIMITED FREE-LIFT
70-90LJ
100-120MJ
KEY:
A: 70-90LJ
B: 100-120MJ
QTY
ITEM PART NO. DESCRIPTION A B
1 ..... Main Cylinder ......................................................................................... 2 2
2 502978505 Hyd Velocity Fuse .................................................................................. 2 ..
2 502978506 Hyd Velocity Fuse .................................................................................. .. 2
3 030252011 Fitting ..................................................................................................... 2 2
3 052645200 O-Ring ............................................................................................... 1 1
4 500227908 Snap Ring .............................................................................................. 2 2
5 520045188 Washer .................................................................................................. 2 2
6 504232202 Shim ....................................................................................................... 4 4
7 518795660 Shim ....................................................................................................... 2 2
8 580007862 Bracket (RH) .......................................................................................... 1 1
9 449022013 Lockwasher ............................................................................................ 2 2
10 932202903 Capscrew ............................................................................................... 2 2
11 504407299 Bracket Wldmt ....................................................................................... 2 2
12 580012383 Hose Clamp ........................................................................................... 4 4
13 504230271 Nut ......................................................................................................... 14 14
14 449001302 Capscrew ............................................................................................... 4 4
15 504071785 Washer .................................................................................................. 4 4
16 580007860 Bracket (LH) ........................................................................................... 1 1
17 a. . . . . Chain ..................................................................................................... 2 2
18 580007839 Housing .................................................................................................. 1 1
MAIN LIFT
TWO STAGE LIMITED FREE-LIFT
KEY:
A: 70-90LJ
B: 100-120MJ
QTY
ITEM PART NO. DESCRIPTION A B
19 052643300 Fitting ..................................................................................................... 1 1
19 052645300 O-Ring ............................................................................................... 1 1
20 052642300 Fitting ..................................................................................................... 1 1
20 052645300 O-Ring ............................................................................................... 1 1
21 520045170 Lowering Control Valve .......................................................................... 2 ..
21 520045180 Lowering Control Valve .......................................................................... .. 2
21 052645600 O-Ring ............................................................................................... 1 1
22 080437000 Plug ........................................................................................................ 1 1
22 052645500 O-Ring ............................................................................................... 1 1
23 449001227 Capscrew ............................................................................................... 6 6
24 580007870 Hose Assy .............................................................................................. 1 1
25 580007871 Hose Assy .............................................................................................. 1 1
26 514835800 Fitting ..................................................................................................... 1 1
27 a. . . . . Hose Assy (LH) ...................................................................................... 1 1
28 580007557 Clamp .................................................................................................... 4 4
29 a. . . . . Hose Assy (RH) ..................................................................................... 1 1
30 505970524 Hose Clamp ........................................................................................... 4 ..
30 504058787 Hose Clamp ........................................................................................... .. 4
31 520045163 Wheel Nut .............................................................................................. 1 1
32 520045361 Chain Anchor ......................................................................................... 1 ..
32 520045362 Chain Anchor ......................................................................................... .. 1
33 520045183 Pin .......................................................................................................... 1 ..
33 520045195 Pin .......................................................................................................... .. 1
34 015417900 Cotter Pin ............................................................................................... 2 2
35 580012383 Hose Clamp ........................................................................................... 4 4
FOOTNOTES:
a Refer to Table
NOTES
100-120MJ
KEY:
A: 70-90LJ
B: 100-120MJ
QTY
ITEM PART NO. DESCRIPTION A B
a. . . . . Cylinder Assy ............................................................................................. 2 2
1 a. . . . . Tube Wldmt-Cylinder ............................................................................. 1 1
2 a. . . . . Cylinder Rod .......................................................................................... 1 1
3 580006894 Gland ..................................................................................................... 1 ..
3 b 580006895 Gland ..................................................................................................... 1 ..
3 580006895 Gland ..................................................................................................... .. 1
3 c 580006896 Gland ..................................................................................................... .. 1
4 520045162 Wear Ring .............................................................................................. 1 ..
4 b 504232291 Wear Ring .............................................................................................. 1 ..
4 504232291 Wear Ring .............................................................................................. .. 1
4 c 520045160 Wear Ring .............................................................................................. .. 1
5 502978505 Hyd Velocity Fuse .................................................................................. 1 ..
5 502978506 Hyd Velocity Fuse .................................................................................. .. 1
FOOTNOTES:
a Refer to Table c Used only on Cylinder 580007119
b Used only on Cylinder 580007112
NOTES
CARRIAGE
TWO STAGE LIMITED FREE-LIFT
KEY:
A: GP/GLP/GDP70-90LJ
B: GP/GLP/GDP100-120MJ
QTY
ITEM PART NO. DESCRIPTION A B
580006481 Carriage (48 in.) ......................................................................................... 1 ..
580006483 Carriage (60 in.) ......................................................................................... 1 ..
580006486 Carriage (60 in.) ......................................................................................... .. 1
1 580006412 Carriage Wldmt (48 in.) .......................................................................... 1 ..
1 580006414 Carriage Wldmt (60 in.) .......................................................................... 1 ..
1 580006417 Carriage Wldmt (60 in.) .......................................................................... .. 1
2 580026922 Stubshaft ........................................................................................... 6 6
3 a 580012185 Bracket ................................................................................................... .. 2
4 a 580012184 Side Roller ............................................................................................. .. 2
5 a 580012183 Pin .......................................................................................................... .. 2
6 a 449022017 Lockwasher ............................................................................................ .. 4
7 a 449001058 Capscrew ............................................................................................... .. 4
8 580009893 Chain Anchor ......................................................................................... 2 ..
8 580009922 Chain Anchor ......................................................................................... .. 2
9 520045183 Pin (Anchor) ........................................................................................... 2 ..
9 520045195 Pin (Anchor) ........................................................................................... .. 2
10 015417900 Cotter Pin ............................................................................................... 2 2
11 520045163 Wheel Nut .............................................................................................. 4 4
12 580012093 Snap Ring .............................................................................................. 6 6
13 580011609 Spacer ................................................................................................... 2 2
14 580010268 Shim (0.020 in.) ..................................................................................... AR AR
15 b 580031672 Load Roller (100.91 mm) ("A") ............................................................... 6 6
15 b 580031673 Load Roller (101.67 mm ) ("B") (0,26 mm) ............................................ 6 6
15 b 580031674 Load Roller (102.43 mm) ("C") (1,52 mm) ............................................. 6 6
16 a 015627900 Grease Fitting ........................................................................................ .. 2
17 a 520045150 Roll Pin .................................................................................................. .. 2
18 a 520045395 Shim (0.062 in.) ..................................................................................... .. AR
19 a 520045159 Shim (0.030 in.) ..................................................................................... .. AR
FOOTNOTES:
a Attachment Carriage (GP/GDP070, 080, 090LJ) b Letter Located on Inside Surface of Load Roller
NOTES
SECTION 13
MAST-THREE STAGE FULL FREE-LIFT
DESCRIPTION PAGE
CARRIAGE
THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-26
FREE-LIFT
THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-18
FREE-LIFT CYLINDERS
THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-22
INNER MAST
THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-8
INTERMEDIATE MAST
THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-6
MAIN LIFT
THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-10
MAIN LIFT CYLINDERS
THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-14
OUTER MAST
THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-2
OUTER MAST
THREE STAGE FULL FREE-LIFT
70-90LJ
100-120MJ
KEY:
A: 70-90LJ
B: 100-120MJ
QTY
ITEM PART NO. DESCRIPTION A B
a. . . . . Mast Assy ................................................................................................... 1 1
1 a. . . . . Outer Mast ............................................................................................. 1 1
2 580026922 Stubshaft ........................................................................................... 2 2
3 580010279 Load Roller (124.31 mm) ....................................................................... 2 2
4 520045153 Shim (0.020 in.) ..................................................................................... 12 12
5 580012093 Snap Ring .............................................................................................. 2 2
6 520045157 Shim (0.020 in.) ..................................................................................... AR AR
7 520045156 Shim (0.007 in.) ..................................................................................... AR AR
8 520045151 Wear Strip .............................................................................................. 2 2
9 012824300 O-Ring ................................................................................................... 4 4
10 520045361 Chain Anchor ......................................................................................... 2 ..
10 520045362 Chain Anchor ......................................................................................... .. 2
11 520045183 Pin (Anchor) ........................................................................................... 2 ..
11 520045195 Pin (Anchor) ........................................................................................... .. 2
12 015417900 Cotter Pin ............................................................................................... 2 2
13 520045163 Wheel Nut .............................................................................................. 4 4
14 a. . . . . Chain (Main) .......................................................................................... 2 2
FOOTNOTES:
a Refer to Table
NOTES
INTERMEDIATE MAST
THREE STAGE FULL FREE-LIFT
70-90LJ
100-120MJ
FOOTNOTES:
a Refer to Table
INNER MAST
THREE STAGE FULL FREE-LIFT
70-90LJ
100-120MJ
KEY:
A: 70-90LJ
B: 100-120MJ
QTY
ITEM PART NO. DESCRIPTION A B
a. . . . . Mast Assy ................................................................................................... 1 1
1 a. . . . . Inner Mast .............................................................................................. 1 1
2 580026922 Stubshaft ........................................................................................... 2 2
3 580031673 Load Roller (101.67 mm ) ...................................................................... 2 2
4 520045153 Shim (0.020 in.) ..................................................................................... 12 12
5 580012093 Snap Ring .............................................................................................. 2 2
6 580009893 Chain Anchor ......................................................................................... 2 ..
6 580009922 Chain Anchor ......................................................................................... .. 2
7 520045183 Pin (Anchor) ........................................................................................... 2 ..
7 520045195 Pin (Anchor) ........................................................................................... .. 2
8 015417900 Cotter Pin ............................................................................................... 2 2
9 520045163 Wheel Nut .............................................................................................. 4 4
10 015418300 Cotter Pin ............................................................................................... 2 2
FOOTNOTES:
a Refer to Table
MAIN LIFT
THREE STAGE FULL FREE-LIFT
70-90LJ
100-120MJ
KEY:
A: H70-90XM
B: H100-120XM
QTY
ITEM PART NO. DESCRIPTION A B
1 ..... Main Cylinder ......................................................................................... 2 2
2 502978505 Hyd Velocity Fuse .................................................................................. 2 ..
2 502978506 Hyd Velocity Fuse .................................................................................. .. 2
3 030252011 Fitting ..................................................................................................... 2 2
3 052645200 O-Ring ............................................................................................... 1 1
4 500227908 Snap Ring .............................................................................................. 2 2
5 518795660 Shim ....................................................................................................... AR AR
6 504232202 Shim ....................................................................................................... AR AR
7 520045188 Washer .................................................................................................. 1 1
8 580007863 Bracket (RH) .......................................................................................... 1 1
9 449022013 Lockwasher ............................................................................................ 2 2
10 932202903 Capscrew ............................................................................................... 2 2
11 580026923 Bracket (RH) .......................................................................................... 1 1
11 580026924 Bracket (LH) ........................................................................................... 1 1
12 580007853 Clamp .................................................................................................... 2 ..
12 580007854 Clamp .................................................................................................... .. 2
13 449015014 Nut ......................................................................................................... 4 4
14 449001015 Capscrew ............................................................................................... 4 4
15 909882404 Nut ......................................................................................................... 4 4
16 580007861 Bracket (LH) ........................................................................................... 1 1
17 580007839 Housing (Control Valve) ......................................................................... 1 1
18 052642300 Fitting ..................................................................................................... 1 1
18 052645300 O-Ring ............................................................................................... 1 1
MAIN LIFT
THREE STAGE FULL FREE-LIFT
KEY:
A: H70-90XM
B: H100-120XM
QTY
ITEM PART NO. DESCRIPTION A B
19 052643500 Connector .............................................................................................. 1 1
19 052645500 O-Ring ............................................................................................... 1 1
20 052643300 Fitting ..................................................................................................... 1 1
20 052645300 O-Ring ............................................................................................... 1 1
21 520045170 Lowering Control Valve .......................................................................... 1 ..
21 520045180 Lowering Control Valve .......................................................................... .. 1
22 504230271 Nut ......................................................................................................... 6 6
23 449001227 Capscrew ............................................................................................... 2 2
24 580007870 Hose Assy .............................................................................................. 1 1
25 580007871 Hose Assy .............................................................................................. 1 1
26 580007557 Clamp .................................................................................................... 4 4
27 a. . . . . Hose Assy (LH) ...................................................................................... 1 1
28 a. . . . . Hose Assy (RH) ..................................................................................... 1 1
29 504071785 Washer .................................................................................................. 4 4
30 580012383 Hose Clamp ........................................................................................... 4 4
31 505970524 Hose Clamp ........................................................................................... 4 ..
31 504058787 Hose Clamp ........................................................................................... .. 4
32 514835800 Fitting ..................................................................................................... 1 1
FOOTNOTES:
a Refer to Table
NOTES
100-120MJ
KEY:
A: 70-90LJ
B: 100-120MJ
QTY
ITEM PART NO. DESCRIPTION A B
a. . . . . Cylinder Assy ............................................................................................. 2 2
1 a. . . . . Tube Wldmt-Cylinder ............................................................................. 1 1
2 a. . . . . Cylinder Rod .......................................................................................... 1 1
3 580006894 Gland ..................................................................................................... 1 ..
3 580006896 Gland ..................................................................................................... .. 1
4 520045162 Wear Ring .............................................................................................. 1 ..
4 520045160 Wear Ring .............................................................................................. .. 1
5 580022511 Rod Wiper (Rod) .................................................................................... 1 ..
5 580022513 Rod Wiper (Rod) .................................................................................... .. 1
6 504232292 Rod Seal ................................................................................................ 1 ..
6 504232205 Rod Seal ................................................................................................ .. 1
7 504232217 Back-Up Ring ......................................................................................... 1 ..
7 504232277 Back-Up Ring ......................................................................................... .. 1
FOOTNOTES:
a Refer to Table
NOTES
FREE-LIFT
THREE STAGE FULL FREE-LIFT
70-90LJ
100-120MJ
FREE-LIFT
THREE STAGE FULL FREE-LIFT
FOOTNOTES:
a 100-120MJ c Refer to Table
b 70-90LJ
NOTES
FREE-LIFT CYLINDERS
THREE STAGE FULL FREE-LIFT
70-90LJ
100-120MJ
KEY:
A: 70-90LJ
B: 100-120MJ
QTY
ITEM PART NO. DESCRIPTION A B
a. . . . . Cylinder Assy ............................................................................................. 1 1
1 a. . . . . Tube Wldmt-Cylinder ............................................................................. 1 1
2 a. . . . . Cylinder Rod .......................................................................................... 1 1
3 520585600 Gland ..................................................................................................... 1 ..
3 580046965 Gland ..................................................................................................... .. 1
4 501753904 Screw ..................................................................................................... 1 1
5 504235239 Check Valve ........................................................................................... 1 1
6 504148200 Washer .................................................................................................. 1 1
6 504233257 Washer (Optional) .................................................................................. 1 1
7 501850904 Snap Ring .............................................................................................. 1 1
8 580054715 Rod Wiper .............................................................................................. 1 1
9 520045326 Rod Seal ................................................................................................ 1 1
10 502011923 Back-Up Ring ......................................................................................... 1 ..
FREE-LIFT CYLINDERS
THREE STAGE FULL FREE-LIFT
KEY:
A: 70-90LJ
B: 100-120MJ
QTY
ITEM PART NO. DESCRIPTION A B
10 502011915 Back-Up Ring ......................................................................................... .. 1
11 015492400 O-Ring ................................................................................................... 1 ..
11 066415900 O-Ring ................................................................................................... .. 1
12 520045324 Wear Ring .............................................................................................. 1 ..
12 580041728 Wear Ring .............................................................................................. .. 1
13 520045327 Rod Seal ................................................................................................ 1 ..
13 580046967 Rod Seal ................................................................................................ .. 1
14 520045331 Back-Up Ring ......................................................................................... 1 ..
14 580041729 Back-Up Ring ......................................................................................... .. 1
15 504232230 O-Ring ................................................................................................... 1 ..
15 580011167 O-Ring ................................................................................................... .. 1
16 502687901 Sealing Ring .......................................................................................... 1 1
17 504287721 Hyd Velocity Fuse .................................................................................. 1 ..
17 504287722 Hyd Velocity Fuse .................................................................................. .. 1
505136072 Kit-Seal ....................................................................................................... 1 ..
524169325 Kit-Seal ....................................................................................................... .. 1
FOOTNOTES:
a Refer to Table
NOTES
CARRIAGE
THREE STAGE FULL FREE-LIFT
KEY:
A: GLP/GDP070LJ, GLP/GDP080LJ, GLP/GDP090LJ
B: GLP/GDP100MJ, GLP/GDP110MJ, GLP/GDP120MJ
C: GLP/GDP100MJ Only
QTY
ITEM PART NO. DESCRIPTION A B C
580007023 Carriage (48 in.) ................................................................................ 1 .. ..
580094425 Carriage (48 in.) (Alternate Part) ....................................................... 1 .. ..
580007025 Carriage (60 in.) ................................................................................ 1 .. ..
580094463 Carriage (60 in.) (Alternate Part) ....................................................... 1 .. ..
580007027 Carriage (54 in.) ................................................................................ .. 1 ..
b 580012000 Carriage (54 in.) ................................................................................ .. .. 1
580007028 Carriage (60 in.) ................................................................................ .. 1 ..
1 580007011 Carriage Wldmt (48 in.) ................................................................. 1 .. ..
1 580094426 Carriage Wldmt (48 in.) (Alternate Part) ........................................ 1 .. ..
1 580007013 Carriage Wldmt (60 in.) ................................................................. 1 .. ..
1 580094464 Carriage Wldmt (60 in.) (Alternate Part) ........................................ 1 .. ..
1 580007021 Carriage Wldmt (54 in.) ................................................................. .. 1 ..
1 b 580012221 Carriage Wldmt (54 in.) ................................................................. .. .. 1
1 580007022 Carriage Wldmt (60 in.) ................................................................. .. 1 ..
2 580026922 Stubshaft ................................................................................... 6 6 6
3 ab 580012185 Bracket .......................................................................................... .. .. 2
4 ab 580012184 Side Roller ..................................................................................... .. .. 2
5 ab 580012183 Pin ................................................................................................. .. .. 2
6 ab 449022017 Lockwasher ................................................................................... .. .. 4
7 ab 449001058 Capscrew ...................................................................................... .. .. 4
8 520045178 Bracket Wldmt (LH) ....................................................................... 1 1 1
9 520045177 Bracket Wldmt (RH) ...................................................................... 1 1 1
10 580007124 Chain Anchor ................................................................................ 2 .. ..
10 580017492 Chain Anchor ................................................................................ .. 2 2
11 580007125 Pin (Anchor) .................................................................................. 2 .. ..
11 520045195 Pin (Anchor) .................................................................................. .. 2 ..
12 015417900 Cotter Pin ...................................................................................... 2 2 2
13 580012093 Snap Ring ..................................................................................... 6 6 6
14 580011609 Spacer ........................................................................................... 2 2 2
15 520045153 Shim (0.020 in.) ............................................................................. AR AR AR
16 580031673 Load Roller (101.67 mm ) ............................................................. 6 6 6
17 520045171 Spacer ........................................................................................... 4 4 4
18 062144100 Capscrew ...................................................................................... 4 4 4
19 015026200 Lockwasher ................................................................................... 4 4 4
20 580014169 Plate .............................................................................................. 1 .. ..
21 580014174 Spacer ........................................................................................... 1 .. ..
22 449001038 Capscrew ...................................................................................... 1 .. ..
23 520045182 Pin ................................................................................................. .. 2 ..
24 500227907 Snap Ring ..................................................................................... .. 2 ..
25 a 520045150 Roll Pin .......................................................................................... .. .. 2
26 a 015627900 Grease Fitting ................................................................................ .. .. 2
27 a 520045395 Shim (0.062 in.) ............................................................................. .. .. AR
28 a 520045159 Shim (0.030 in.) ............................................................................. .. .. AR
FOOTNOTES:
a 1372 mm b Side Roller
SECTION 14
MAST-TWO STAGE FULL FREE-LIFT
DESCRIPTION PAGE
CARRIAGE
TWO STAGE FULL FREE-LIFT .................................................................................................................. 14-18
FREE-LIFT CYLINDERS
TWO STAGE FULL FREE-LIFT .................................................................................................................. 14-14
INNER MAST AND FREE-LIFT
TWO STAGE FULL FREE-LIFT .................................................................................................................. 14-6
MAIN LIFT CYLINDERS
TWO STAGE FULL FREE-LIFT .................................................................................................................. 14-10
OUTER MAST AND MAIN LIFT
TWO STAGE FULL FREE-LIFT .................................................................................................................. 14-2
100-120MJ
FOOTNOTES:
a Refer to Table
NOTES
100-120MJ
FOOTNOTES:
a Refer to Table
NOTES
KEY:
A: 70-90LJ
B: 100-120MJ
QTY
ITEM PART NO. DESCRIPTION A B
a. . . . . Cylinder Assy ............................................................................................. 1 1
1 a. . . . . Tube Wldmt-Cylinder ............................................................................. 1 1
2 a. . . . . Cylinder Rod .......................................................................................... 1 1
3 520045349 Gland ..................................................................................................... 1 ..
3 520045350 Gland ..................................................................................................... .. 1
4 504450753 Rod Wiper .............................................................................................. 1 ..
4 520045346 Rod Wiper .............................................................................................. .. 1
5 520045347 Rod Seal ................................................................................................ 1 ..
5 520045348 Rod Seal ................................................................................................ .. 1
5 580022494 Rod Seal (Alternate Part) ....................................................................... .. 1
6 504232252 O-Ring ................................................................................................... 1 1
7 502011911 Back-Up Ring ......................................................................................... 1 1
8 504017208 Wear Ring .............................................................................................. 1 1
9 502895204 Piston Ring ............................................................................................ 1 1
10 502978507 Hyd Velocity Fuse (RH) ......................................................................... 1 ..
10 502978505 Hyd Velocity Fuse (RH) ......................................................................... .. 1
11 502687901 Sealing Ring .......................................................................................... 1 1
12 501753914 Screw ..................................................................................................... 1 1
13 580016816 Piston (RH) ............................................................................................ 1 1
13 580016817 Piston (LH) ............................................................................................. 1 1
14 501702903 Loctite .................................................................................................... AR AR
15 507454554 Sleeve (Alternate Part) .......................................................................... .. 1
504287713 Kit-Seal ....................................................................................................... 1 ..
504287718 Kit-Seal ....................................................................................................... .. 1
507456511 Kit-Seal (Alternate Part) ............................................................................. .. 1
FOOTNOTES:
a Refer to Table
NOTES
FREE-LIFT CYLINDERS
TWO STAGE FULL FREE-LIFT
70-90LJ
100-120MJ
KEY:
A: 70-90LJ
B: 100-120MJ
QTY
ITEM PART NO. DESCRIPTION A B
a. . . . . Cylinder Assy ............................................................................................. 1 1
1 a. . . . . Tube Wldmt-Cylinder ............................................................................. 1 1
2 a. . . . . Cylinder Rod .......................................................................................... 1 1
3 520585600 Gland ..................................................................................................... 1 ..
3 580046965 Gland ..................................................................................................... .. 1
4 501753904 Screw ..................................................................................................... 1 1
5 504235239 Check Valve ........................................................................................... 1 1
6 504148200 Washer .................................................................................................. 1 1
6 504233257 Washer (Optional) .................................................................................. 1 1
7 501850904 Snap Ring .............................................................................................. 1 1
8 580054715 Rod Wiper .............................................................................................. 1 1
9 520045326 Rod Seal ................................................................................................ 1 1
10 502011923 Back-Up Ring ......................................................................................... 1 ..
FREE-LIFT CYLINDERS
TWO STAGE FULL FREE-LIFT
KEY:
A: 70-90LJ
B: 100-120MJ
QTY
ITEM PART NO. DESCRIPTION A B
10 502011915 Back-Up Ring ......................................................................................... .. 1
11 015492400 O-Ring ................................................................................................... 1 ..
11 066415900 O-Ring ................................................................................................... .. 1
12 520045324 Wear Ring .............................................................................................. 1 ..
12 580041728 Wear Ring .............................................................................................. .. 1
13 520045327 Rod Seal ................................................................................................ 1 ..
13 580046967 Rod Seal ................................................................................................ .. 1
14 520045331 Back-Up Ring ......................................................................................... 1 ..
14 580041729 Back-Up Ring ......................................................................................... .. 1
15 504232230 O-Ring ................................................................................................... 1 1
16 502687901 Sealing Ring .......................................................................................... 1 1
17 502981505 Hyd Velocity Fuse .................................................................................. 1 ..
17 502981504 Hyd Velocity Fuse .................................................................................. .. 1
505136072 Kit-Seal ....................................................................................................... 1 ..
524169325 Kit-Seal ....................................................................................................... .. 1
FOOTNOTES:
a Refer to Table
NOTES
CARRIAGE
TWO STAGE FULL FREE-LIFT
KEY:
A: GLP/GDP070LJ, GLP/GDP080LJ, GLP/GDP090LJ
B: GLP/GDP100MJ, GLP/GDP110MJ, GLP/GDP120MJ
C: GLP/GDP110MJ (Attachment Carriage)
QTY
ITEM PART NO. DESCRIPTION A B C
580014049 Carriage (48 in.) ................................................................................ 1 .. ..
580094389 Carriage (48 in.) (Alternate Part) ....................................................... 1 .. ..
580014058 Carriage (54 in.) ................................................................................ .. 1 ..
580014056 Carriage (54 in.) ................................................................................ .. .. 1
1 580014214 Carriage Wldmt (48 in.) ................................................................. 1 .. ..
1 580094390 Carriage Wldmt (48 in.) (Alternate Part) ........................................ 1 .. ..
1 580012565 Carriage Wldmt (54 in.) ................................................................. .. 1 ..
1 580014225 Carriage Wldmt (54 in.) ................................................................. .. .. 1
2 580026922 Stubshaft ................................................................................... 6 6 ..
3 580012185 Bracket .......................................................................................... .. .. 2
4 580012184 Side Roller ..................................................................................... .. .. 2
5 580012183 Pin ................................................................................................. .. .. 2
6 449022017 Lockwasher ................................................................................... .. .. 4
7 449001058 Capscrew ...................................................................................... .. .. 4
8 520045178 Bracket Wldmt (LH) ....................................................................... 1 1 ..
9 520045177 Bracket Wldmt (RH) ...................................................................... 1 1 ..
10 580007124 Chain Anchor ................................................................................ 2 .. ..
10 580017492 Chain Anchor ................................................................................ .. 2 2
11 580007125 Pin (Anchor) .................................................................................. 2 .. ..
11 520045195 Pin (Anchor) .................................................................................. .. 2 ..
12 015417900 Cotter Pin ...................................................................................... 2 2 ..
13 580012093 Snap Ring ..................................................................................... 6 6 ..
14 580011609 Spacer ........................................................................................... 2 2 ..
15 520045153 Shim (0.020 in.) ............................................................................. AR AR ..
16 580031673 Load Roller (101.67 mm ) ............................................................. 6 6 ..
17 520045171 Spacer ........................................................................................... 4 4 ..
18 062144100 Capscrew ...................................................................................... 4 4 ..
19 015026200 Lockwasher ................................................................................... 4 4 ..
20 580014169 Plate .............................................................................................. 1 .. ..
21 580014174 Spacer ........................................................................................... 1 .. ..
22 449001028 Capscrew ...................................................................................... 1 .. ..
23 520045182 Pin ................................................................................................. .. 2 ..
24 500227907 Snap Ring ..................................................................................... .. 2 ..
25 520045150 Roll Pin .......................................................................................... .. .. 2
26 015627900 Grease Fitting ................................................................................ .. .. 2
27 520045395 Shim (0.062 in.) ............................................................................. .. .. AR
28 520045159 Shim (0.030 in.) ............................................................................. .. .. AR
NOTES
SECTION 15
ATTACHMENTS AND HEADER HOSE GROUP
DESCRIPTION PAGE
ACCUMULATOR
MAST LOAD DAMPENING ......................................................................................................................... 15-35
AUXILIARY TUBE EXTENSION KIT
THREE STAGE FULL FREE-LIFT .............................................................................................................. 15-24
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 15-22
HEADER HOSE
THREE STAGE FULL FREE-LIFT .............................................................................................................. 15-32
TWO STAGE FULL FREE-LIFT .................................................................................................................. 15-28
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 15-26
INTEGRAL SIDE-SHIFT ASSEMBLY
TWO AND THREE STAGE FULL FREE-LIFT - 48 AND 60-INCH (GP/GLP/GDP70LJ, GP/GLP/GDP80LJ,
GP/GLP/GDP90LJ) ..................................................................................................................................... 15-10
TWO AND THREE STAGE FULL FREE-LIFT - 54 AND 60-INCH ............................................................. 15-16
TWO STAGE LIMITED FREE-LIFT - 48 AND 60-INCH (GP/GLP/GDP70LJ, GP/GLP/GDP80LJ, GP/GLP/
GDP90LJ) .................................................................................................................................................... 15-2
TWO STAGE LIMITED FREE-LIFT - 54 AND 60-INCH (GP/GLP/GDP100MJ, GP/GLP/GDP110MJ, GP/
GLP/GDP120MJ) ........................................................................................................................................ 15-6
INTEGRAL SIDE-SHIFT CARRIAGE
TWO AND THREE STAGE FULL FREE-LIFT - 48-INCH (GP/GLP/GDP70LJ, GP/GLP/GDP80LJ, GP/
GLP/GDP90LJ) ........................................................................................................................................... 15-12
TWO AND THREE STAGE FULL FREE-LIFT - 60-INCH (GP/GLP/GDP70LJ, GP/GLP/GDP80LJ, GP/
GLP/GDP90LJ) ........................................................................................................................................... 15-14
TWO AND THREE STAGE FULL FREE-LIFT - 54 AND 60-INCH ............................................................. 15-18
TWO STAGE LIMITED FREE-LIFT - 48 AND 60-INCH (GP/GLP/GDP70LJ, GP/GLP/GDP80LJ, GP/GLP/
GDP90LJ) .................................................................................................................................................... 15-4
TWO STAGE LIMITED FREE-LIFT - 54 AND 60-INCH (GP/GLP/GDP100MJ, GP/GLP/GDP110MJ, GP/
GLP/GDP120MJ) ........................................................................................................................................ 15-8
QUICK DISCONNECT FITTINGS ................................................................................................................... 15-20
FOOTNOTES:
a Three Stage Full Free-Lift b Two Stage Full Free-Lift
FOOTNOTES:
a Three Stage Full Free-Lift b Two Stage Full Free-Lift
FOOTNOTES:
a Three Stage Full Free-Lift b Two Stage Full Free-Lift
FOOTNOTES:
a Three Stage Full Free-Lift b Two Stage Full Free-Lift
FOOTNOTES:
a Three Stage Full Free-Lift b Two Stage Full Free-Lift
NOTES
HEADER HOSE
TWO STAGE LIMITED FREE-LIFT
70-90LJ
100-200MJ
KEY:
A: Three Function
B: Four Function
QTY
ITEM PART NO. DESCRIPTION A B
1 a. . . . . Hose Assy .............................................................................................. 2 2
2 a. . . . . Hose Assy (RH) ..................................................................................... 1 1
3 a. . . . . Hose Assy (LH) ...................................................................................... 1 1
4 580012772 Hose Clamp ........................................................................................... 2 2
5 580028717 Spacer ................................................................................................... 1 1
6 580029125 Hose Sheave ......................................................................................... 1 1
6 520045187 Bushing ............................................................................................. 1 1
7 580028718 Stubshaft ................................................................................................ 1 1
8 449022017 Lockwasher ............................................................................................ 1 1
9 449001350 Capscrew ............................................................................................... 1 1
10 580006903 Hose Clamp ........................................................................................... 2 2
11 449001056 Capscrew ............................................................................................... 2 2
12 449001204 Capscrew ............................................................................................... 2 2
13 504231270 Nut ......................................................................................................... 4 4
14 056056700 Fitting ..................................................................................................... 2 2
FOOTNOTES:
a Refer to Table
HEADER HOSE
TWO STAGE FULL FREE-LIFT
70-90LJ (FOUR FUNCTION)
HEADER HOSE
TWO STAGE FULL FREE-LIFT
100-120MJ (THREE FUNCTION)
KEY:
A: Three Function
B: Four Function
QTY
ITEM PART NO. DESCRIPTION A B
1 a. . . . . Hose Assy .............................................................................................. 2 ..
2 a. . . . . Hose Assy (LH) ...................................................................................... 1 ..
3 a. . . . . Hose Assy (RH) ..................................................................................... 1 ..
4 a. . . . . Hose Assy .............................................................................................. .. 2
5 a. . . . . Hose Assy (LH) ...................................................................................... .. 1
6 a. . . . . Hose Assy (LH) ...................................................................................... .. 1
7 580041883 Bracket Wldmt (RH) ............................................................................... 1 ..
7 580041884 Bracket Wldmt (LH) ............................................................................... 1 1
8 580029125 Hose Sheave ......................................................................................... 1 2
8 520045187 Bushing ............................................................................................. 1 2
9 520045181 Washer .................................................................................................. 1 2
10 015915200 Snap Ring .............................................................................................. 1 2
11 449021001 Washer .................................................................................................. 1 2
12 580012670 Clamp .................................................................................................... 2 2
13 580006903 Hose Clamp ........................................................................................... 3 6
13 932200907 Capscrew ............................................................................................... 2 4
14 580014107 Bracket (70, 80, 90LJ) ........................................................................... 1 1
14 580016693 Bracket (100, 110, 120MJ) .................................................................... 2 2
15 013398000 Fitting ..................................................................................................... 1 2
16 056056700 Fitting ..................................................................................................... 1 2
17 059986600 Fitting ..................................................................................................... 1 2
18 580012772 Hose Clamp ........................................................................................... 4 8
19 504058787 Hose Clamp ........................................................................................... 2 4
20 580024707 Capscrew ............................................................................................... 4 8
21 449001013 Capscrew ............................................................................................... 1 2
22 504230271 Nut ......................................................................................................... 1 2
23 449001014 Screw ..................................................................................................... 1 1
24 449022016 Lockwasher ............................................................................................ 1 1
25 505970524 Hose Clamp ........................................................................................... 1 ..
26 a. . . . . Hose Guide ............................................................................................ 1 ..
HEADER HOSE
TWO STAGE FULL FREE-LIFT
KEY:
A: Three Function
B: Four Function
QTY
ITEM PART NO. DESCRIPTION A B
27 a. . . . . Channel (Free-Lift) ................................................................................. 1 ..
28 a. . . . . Channel ................................................................................................. .. 1
29 954512901 Roll Pin .................................................................................................. 1 1
FOOTNOTES:
a Refer to Table
HEADER HOSE
THREE STAGE FULL FREE-LIFT
70-90LJ (FOUR FUNCTION)
KEY:
A: Three Function
B: Four Function
QTY
ITEM PART NO. DESCRIPTION A B
1 a. . . . . Hose Assy .............................................................................................. 1 ..
HEADER HOSE
THREE STAGE FULL FREE-LIFT
KEY:
A: Three Function
B: Four Function
QTY
ITEM PART NO. DESCRIPTION A B
2 a. . . . . Hose Assy .............................................................................................. .. 1
3 580012772 Hose Clamp ........................................................................................... 2 4
4 909882404 Nut ......................................................................................................... 1 1
5 504231270 Nut ......................................................................................................... 4 8
6 449022013 Lockwasher ............................................................................................ 2 4
7 580041884 Bracket Wldmt (LH) ............................................................................... .. 1
8 580009401 Bracket Wldmt (Hose and Chain Guard) ............................................... 2 4
9 449001302 Capscrew ............................................................................................... 2 4
10 580029125 Hose Sheave ......................................................................................... 2 2
11 520045181 Washer .................................................................................................. 2 2
12 015915200 Snap Ring .............................................................................................. 2 2
13 580009402 Bracket ................................................................................................... 1 1
14 449001023 Capscrew ............................................................................................... 1 1
15 580006903 Hose Clamp ........................................................................................... 3 6
16 580024707 Capscrew ............................................................................................... 2 4
17 580026923 Bracket (RH) .......................................................................................... 1 ..
18 449001056 Capscrew ............................................................................................... 4 8
19 580009399 Bracket (RH) .......................................................................................... 1 1
20 449022016 Lockwasher ............................................................................................ 2 4
21 449001415 Capscrew ............................................................................................... 2 4
22 580041883 Bracket Wldmt (Hose Mounting) (RH) ................................................... 1 ..
23 013398000 Fitting ..................................................................................................... 1 2
24 056056700 Fitting ..................................................................................................... 1 2
25 059986600 Fitting ..................................................................................................... 1 2
26 580007856 Spacer ................................................................................................... 1 1
27 580012670 Clamp .................................................................................................... 1 1
28 954512901 Roll Pin (Spring) ..................................................................................... 1 2
29 580026924 Bracket (LH) ........................................................................................... .. 1
30 580009403 Bracket ................................................................................................... .. 1
31 a. . . . . Hose Assy .................................................................................................. .. 1
32 a. . . . . Hose Assy .................................................................................................. .. 1
33 580070718 Shim ........................................................................................................... 2 4
FOOTNOTES:
a Refer to Table
NOTES
16 OPTIONS
CONTENTS
SECTION 16
OPTIONS
DESCRIPTION PAGE
CAB
ATTACHING PARTS – SHEET 1 OF 6
CAB
ATTACHING PARTS – SHEET 2 OF 6
CAB
ATTACHING PARTS – SHEET 3 OF 6
CAB
ATTACHING PARTS – SHEET 4 OF 6
FOOTNOTES:
a 8/2004 → b S/N E813V01594B →
CAB
ATTACHING PARTS – SHEET 5 OF 6
CAB
ATTACHING PARTS – SHEET 6 OF 6
CAB
DOOR ASSEMBLY – LEFT HAND
CAB
DOOR ASSEMBLY – RIGHT HAND
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Not Illustrated
HEATER INSTALLATION
GASOLINE
HEATER INSTALLATION
LPG
HEATER INSTALLATION
DIESEL TIER II
KEY:
A: 7.00 x 15 Solid (H70-90XM)
B: 7.00 x 15 Pneumatic (H70-90XM)
C: 8.25 x 15 Solid (H100-120XM)
D: 8.25 x 15 - 12 Ply (H100-120XM)
QTY
ITEM PART NO. DESCRIPTION A B C D
1 580008796 Solid Pneumatic Tire (Standard Hardness) .............................. 4 .. .. ..
1 580006805 Tire (Standard Hardness) ......................................................... .. .. 4 ..
2 580008809 Tire Flap .................................................................................... .. 4 .. ..
2 580006800 Tire Flap .................................................................................... .. .. .. 4
2 580008810 Tire Flap (With Flap) ............................................................. .. 1 .. ..
2 580006803 Tire Flap (With Flap) ............................................................. .. .. .. 1
2 580008811 Tire Flap ............................................................................... .. 1 .. ..
2 580006808 Tire Flap ............................................................................... .. .. .. 1
3 580001897 Wheel Assy (5.50 x 15) (5.50 x 15) .......................................... 4 4 .. ..
3 580001899 Wheel Assy (6.50 x 15) (6.50 x 15) .......................................... .. .. 4 4
4 505971549 Wheel Side Ring ................................................................... 1 1 1 1
5 505971526 Wheel Lock Ring .................................................................. 1 1 1 1
6 580009119 Plate (Valve Stem) ................................................................ 4 4 4 4
7 580001925 Adapter (Not Illustrated) ............................................................ 2 2 2 2
NOTES
BACK-UP ALARM
ITEM PART NO. DESCRIPTION QTY
1 505969593 Back-Up Alarm (82-102 dbA) .............................................................................. 1
1 150019310 Back-Up Alarm (87 dbA) ..................................................................................... 1
1 150019322 Back-Up Alarm (97 dbA) ..................................................................................... 1
1 505969500 Back-Up Alarm (102 dbA) ................................................................................... 1
1 505969543 Back-Up Alarm (107 dbA) ................................................................................... 1
2 580057338 Bracket ................................................................................................................ 1
3 449001412 Capscrew ............................................................................................................ 2
4 449021003 Washer ............................................................................................................... 2
5 449015135 Nut ...................................................................................................................... 2
6 504226242 Washer ............................................................................................................... 1
7 580010442 Wire Harness ...................................................................................................... 1
8 580006543 Boot .................................................................................................................... 2
NOTES
FENDER EXTENSIONS
KEY:
A: 250 x 15 Single Wheel (H70-90XM)
B: 300 x 15 Single Wheel (H100-120XM)
C: 7.00 x 15 Dual Wheel (H70-90XM)
D: 8.25 x 15 Dual Wheel (H100-120XM)
QTY
ITEM PART NO. DESCRIPTION A B C D
1 504312723 Fender Extension (RH) ............................................................. 1 .. .. ..
1 504304700 Fender Extension (RH) ............................................................. .. 1 .. ..
1 504312724 Fender Extension (RH) ............................................................. .. .. 1 ..
1 504312725 Fender Extension (RH) ............................................................. .. .. .. 1
2 504312731 Fender Extension (LH) .............................................................. 1 .. .. ..
2 504304702 Fender Extension (LH) .............................................................. .. 1 .. ..
2 504312732 Fender Extension (LH) .............................................................. .. .. 1 ..
2 504312733 Fender Extension (LH) .............................................................. .. .. .. 1
3 580009413 Mud Flap (RH) .......................................................................... .. .. 1 ..
3 580009414 Mud Flap (RH) .......................................................................... .. .. .. 1
4 580009416 Mud Flap (LH) ........................................................................... .. .. .. 1
4 580009415 Mud Flap (LH) ........................................................................... .. .. 1 ..
5 449001023 Capscrew .................................................................................. 1 1 1 1
6 449022013 Lockwasher ............................................................................... 8 8 .. ..
6 449022013 Lockwasher ............................................................................... .. .. 12 12
7 502566904 Washer ..................................................................................... 8 8 8 8
8 449015044 Nut ............................................................................................ 8 8 .. ..
8 449015044 Nut ............................................................................................ .. .. 12 12
9 580009440 Plate .......................................................................................... .. .. 2 2
10 932730905 Capscrew .................................................................................. .. .. 4 4
NOTES
FRONT HEADLIGHTS
WITHOUT CAB
FOOTNOTES:
a Not Illustrated
STROBE LIGHT
AMBER – WITHOUT CAB (→ S/N E813V03418B)
LIFTING EYES
ITEM PART NO. DESCRIPTION QTY
1 524141426 Lifting Eye ........................................................................................................... 2
2 580015437 Anchor ................................................................................................................ 2
3 937701930 Nut ...................................................................................................................... 2
4 937300930 Nut ...................................................................................................................... 2
5 015421700 Cotter Pin ............................................................................................................ 2
6 580015441 Lifting Eye (Front) ............................................................................................... 2
7 505974597 Label (Lifting Eye) ............................................................................................... 4
8 580033592 Pin (Extended) .................................................................................................... 2
9 063071300 Capscrew ............................................................................................................ 2
10 015026600 Washer ............................................................................................................... 2
11 580033581 Retainer (Tilt Pin) ................................................................................................ 2
FOOTNOTES:
a Not Illustrated
WIRE HARNESS
PRESSURE SWITCH – LED BRAKE LIGHTS
SECTION 17
FIELD CONVERSION KITS
DESCRIPTION PAGE
18 NUMERICAL INDEX
NUMERICAL INDEX
SECTION 18
NUMERICAL INDEX
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
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PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
SECTION 19
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