Yale J40

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PARTS MANUAL

ERP030/035/040TH
(F807)

Yale Materials Handling Corporation


1400 Sullivan Drive P/N 524204495
Caller No. 12011 © Yale Corp.
Greenville, NC 27834-2011 06/2004
MODEL NOMENCLATURE

NOTE:
This parts manual contains alternate pages for certain assemblies. The truck model code can be used to determine
many of the assemblies on your lift truck (power, tire type, mast type). The complete truck model and serial number
are stamped into the nameplate. See Identification of Truck Serial Number on Page viii for further information.
SECTIONS

1 GENERAL TRUCK

2 ELECTRICAL SYSTEM

3 DRIVE UNIT

4 STEERING SYSTEM

5 BRAKE SYSTEM

6 HYDRAULIC SYSTEM

7 LIFTING MECHANISM

8 OPTIONS

9 FIELD CONVERSION KITS

10 NUMERICAL INDEX

11 USER SUPPORT INFORMATION

This Parts Manual is divided into 11 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

ALPHABETICAL INDEX

DESCRIPTION PAGE NO.

A
ABBREVIATIONS QUICK REFERENCE SHEET .................................................................................................... v
ACCELERATOR ASSEMBLY .............................................................................................................................. 5-2
ACCELERATOR PEDAL....................................................................................................................................... 5-4
ALPHABETICAL INDEX............................................................................................................................................ i

B
BACK-UP ALARM ................................................................................................................................................ 8-2
BATTERY COMPARTMENT AND COVERS ........................................................................................................ 1-2
BATTERY CONNECTOR ..................................................................................................................................... 2-2
BATTERY SLIDER AND RETAINER .................................................................................................................... 8-4
BATTERY SPACER .............................................................................................................................................. 8-6
BRAKE ASSEMBLY ............................................................................................................................................. 5-6

C
CARRIAGE
THREE STAGE FULL FREE-LIFT .................................................................................................................. 7-28
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 7-48
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 7-10
CONTACTOR ....................................................................................................................................................... 2-4
CONTACTOR PANEL ........................................................................................................................................... 2-6
COUNTERWEIGHT ............................................................................................................................................. 1-6

D
DASH DISPLAY.................................................................................................................................................... 2-8
DC CONVERTER
36/48 VOLT TO 12 VOLT .................................................................................................................................. 8-8
PREMIUM ....................................................................................................................................................... 8-10
DECAL AND PLATE LOCATION .......................................................................................................................... 1-8
DRIVE TIRE AND WHEEL ASSEMBLY ............................................................................................................... 3-2
DRIVE UNIT ......................................................................................................................................................... 3-4

E
ELECTRO-HYDRAULIC AUXILIARY ONE VALVE SECTION............................................................................ 6-34
ELECTRO-HYDRAULIC AUXILIARY TWO VALVE SECTION ........................................................................... 6-36
ELECTRO-HYDRAULIC CONTROL ................................................................................................................. 2-10
ELECTRO-HYDRAULIC CONTROL VALVE ...................................................................................................... 6-28
ELECTRO-HYDRAULIC LEVERS...................................................................................................................... 6-38
ELECTRO-HYDRAULIC MAIN CONTROL VALVE SECTION ........................................................................... 6-30
ELECTRO-HYDRAULIC TILT VALVE SECTION ................................................................................................ 6-32
EMERGENCY STOP.......................................................................................................................................... 2-12

F
FLOOR PLATES................................................................................................................................................. 1-10
FORKS ............................................................................................................................................................... 1-12
FREE LIFT
THREE STAGE FULL FREE-LIFT .................................................................................................................. 7-24

i
GENERAL INFORMATION

DESCRIPTION PAGE NO.

F (continued)

TWO STAGE FULL FREE-LIFT ...................................................................................................................... 7-44


FREE LIFT CYLINDER
THREE STAGE FULL FREE-LIFT .................................................................................................................. 7-26
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 7-46
FRONT LIGHTS ................................................................................................................................................. 8-12

G
GEAR PUMP ........................................................................................................................................................ 4-2

H
HAND PUMP ........................................................................................................................................................ 4-4
HANDLEVER...................................................................................................................................................... 6-24
HEADER HOSE
THREE STAGE FULL FREE-LIFT .................................................................................................................. 7-30
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 7-50
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 7-12
HOW TO FIND THE DESIRED PART NUMBER.................................................................................................... vii
HOW TO USE THE ILLUSTRATED PARTS MANUAL ........................................................................................... vii
HYDRAULIC ......................................................................................................................................................... 9-2
HYDRAULIC GEAR PUMP .................................................................................................................................. 6-6
HYDRAULIC HOSE AND FITTINGS
ELECTRO ....................................................................................................................................................... 6-40
MANUAL ........................................................................................................................................................... 6-2
HYDRAULIC PUMP MOTOR ............................................................................................................................... 6-8
HYDRAULIC TANK ASSEMBLY......................................................................................................................... 6-42
HYDRAULIC VALVE AND ATTACHING PARTS
MANUAL ......................................................................................................................................................... 6-22

I
IDENTIFICATION OF ATTACHMENT AND SIDE-SHIFT CARRIAGE SERIAL NUMBERS..................................... x
IDENTIFICATION OF MAST SERIAL NUMBER ..................................................................................................... ix
IDENTIFICATION OF TRUCK SERIAL NUMBER................................................................................................. viii
INNER MAST
THREE STAGE FULL FREE-LIFT .................................................................................................................. 7-18
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 7-36
TWO STAGE LIMITED FREE-LIFT................................................................................................................... 7-4
INTEGRAL SIDE-SHIFT CARRIAGE
THREE STAGE FULL FREE-LIFT .................................................................................................................. 8-16
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 8-18
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 8-14
INTERFACE CABLE........................................................................................................................................... 8-20
INTERMEDIATE MAST
THREE STAGE FULL FREE-LIFT .................................................................................................................. 7-16

ii
GENERAL INFORMATION

DESCRIPTION PAGE NO.

L
LIGHT OPTION .................................................................................................................................................... 9-2
LOAD BACKREST EXTENSION........................................................................................................................ 1-14

M
MAIN LIFT ASSEMBLY
THREE STAGE FULL FREE-LIFT .................................................................................................................. 7-20
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 7-38
TWO STAGE LIMITED FREE-LIFT................................................................................................................... 7-6
MAIN LIFT CYLINDER
LEFT HAND
TWO STAGE FULL FREE-LIFT .................................................................................................................. 7-40
RIGHT HAND
TWO STAGE FULL FREE-LIFT .................................................................................................................. 7-42
THREE STAGE FULL FREE-LIFT .................................................................................................................. 7-22
TWO STAGE LIMITED FREE-LIFT................................................................................................................... 7-8
MAIN WIRE HARNESS...................................................................................................................................... 2-14
MANUAL CONTROL VALVE .............................................................................................................................. 6-26
MASTER CYLINDER ........................................................................................................................................... 5-8
MASTER PART SHEET CROSS-REFERENCE ..................................................................................................... xi

O
OUTER MAST
THREE STAGE FULL FREE-LIFT .................................................................................................................. 7-14
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 7-34
TWO STAGE LIMITED FREE-LIFT................................................................................................................... 7-2
OVERHEAD GUARD.......................................................................................................................................... 1-16

P
PARKING BRAKE............................................................................................................................................... 5-10

R
REAR WORK LIGHT.......................................................................................................................................... 8-24

S
SEAT
FULL SUSPENSION....................................................................................................................................... 1-22
NON-SUSPENSION ....................................................................................................................................... 1-18
SEMI-SUSPENSION ...................................................................................................................................... 1-20
SHIFT LEVER ...................................................................................................................................................... 4-6
STATIC STRAP................................................................................................................................................... 1-24
STEER AXLE ....................................................................................................................................................... 4-8
STEER COLUMN ............................................................................................................................................... 4-12
STEER PUMP AND MOTOR ............................................................................................................................. 4-16
STEER TIRE AND WHEEL ASSEMBLY
CUSHION ....................................................................................................................................................... 4-19
NON-MARKING CUSHION ............................................................................................................................ 4-20
SOLID PNEUMATIC ....................................................................................................................................... 4-18
STROBE LIGHT ................................................................................................................................................. 8-28
STROBE LIGHT/REAR LIGHT COMBINATION................................................................................................. 8-26
iii
GENERAL INFORMATION

DESCRIPTION PAGE NO.

T
TAIL, BRAKE, AND BACK-UP LIGHTS.............................................................................................................. 8-22
TILT....................................................................................................................................................................... 9-2
TILT CYLINDER
THREE STAGE FULL FREE-LIFT .................................................................................................................. 6-14
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 6-18
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 6-10
TILT CYLINDER ATTACHING PARTS
THREE STAGE FULL FREE-LIFT .................................................................................................................. 6-16
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 6-20
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 6-12
TRACTION CONTROLLER
CONTACTOR HYDRAULIC ............................................................................................................................ 2-18
TRANSISTOR/PREMIUM ............................................................................................................................... 2-20
TRACTION MOTOR ............................................................................................................................................. 3-6
TRANSMISSION .................................................................................................................................................. 3-8

iv
GENERAL INFORMATION

ABBREVIATIONS QUICK REFERENCE SHEET

Listed below are abbreviations used in parts manuals to denote the following expressions:

TERM DEFINITION TERM DEFINITION


Amp Amperes MSTS Microprocessor Spark Timing System
AR As Required NPT National Pipe Threads
BDI Battery Discharge Indicators O/S Oversize
BWI Brush Wear Indicator PTO Power Take Off
CE Communicator End RPM Revolutions per Minute
CRE Corrosive Environment S/N Serial Number
D/B Date Break TMM Truck Management Module
dbA Decibel "A" Scale UL Type D Diesel-Powered Safety Rating
DE Drive End UL Type DS Diesel-Powered Safety Rating
ECM Electronic Control Module UL Type E Battery-Powered Safety Rating
ECN Engineering Change Notice UL Type EE Battery-Powered Safety Rating
EEPROM Electrically Erasable Programmable UL Type ES Battery-Powered Safety Rating
Read Only Memory
UL Type G Gasoline-Powered Safety Rating
EPROM Electrically Programmable Read Only
UL Type GS Gasoline-Powered Safety Rating
Memory
UL Type LP Gas-Powered Safety Rating
FRE Freezer Environment
UL Type LPS LP Gas-Powered Safety Rating
in. inches
U/S Undersize
LPG Liquefied Petroleum Gas
UL Underwriters Laboratory
MAP Manifold Absolute Pressure
V Volts
mm millimeters

v
GENERAL INFORMATION

HOW TO USE THE ILLUSTRATED PARTS MANUAL

This parts manual describes and illustrates assemblies, The different constructions are indicated by keys and
subassemblies, and detail parts needed for service footnotes. The callouts correspond to descriptions
replacement. found on the next page.

vi
GENERAL INFORMATION

HOW TO FIND THE DESIRED PART NUMBER

WHEN THE PART NUMBER AND THE NEXT 9. Quantities shown are for one assembly. The
HIGHER ASSEMBLY IS NOT KNOWN: quantities of the subpart BEARING CAP are
indicated as two and two. This means two per
1. Determine the function and application of the part CASE assembly.
required. Turn to the Sections Page. Choose the
general area of reference most likely to include 10. Serial number breaks identify the most current
the part. parts information and are shown as follows:
⇒ S/N A810N-2639
2. Turn to the section you chose. Use the Section Indicates last serial number affected.
Table of Contents to determine the assembly which S/N A810N-2640 ⇒
would normally contain the part required. Then Indicates the first serial number affected.
locate the part on the assembly breakdown page. S/N A810N-1553 ⇔ S/N A810N-3291
WHEN THE PART NUMBER IS NOT KNOWN Indicates a range of serial numbers affected.
AND THE NEXT HIGHER ASSEMBLY IS ECN numbers for pending serial numbers are
KNOWN: shown to allow for the inclusion of the most current
3. Determine the assembly the required part is used parts information and are identified as follows:
on. Turn to the Alphabetical Index on Page i. ⇒ S/N Pending Per ECN 63243
Indicates a pending serial number for last unit
4. Locate the assembly the required part is used on affected.
and turn to the page indicated for that assembly. S/N Pending Per ECN 63243 ⇒
Then locate the part on the assembly breakdown Indicates a pending serial number for first unit
page. affected.
WHEN THE PART NUMBER IS KNOWN: Date breaks are used to indicate when a change
occurred but a subsequent serial number break
5. Use the Numerical Index on Page 10-1 to find the
was not recorded. This is an arbitrary date usually
part number. Turn to the page listed and locate the
based on the ECN release and are identified as
part as indicated by the item number.
follows:
GENERAL: ⇒ D/B 3/00
Indicates that a change occurred sometime
The assembly breakdowns include part numbers, within that month for the item affected.
descriptions, quantities required, keys and D/B 3/00 ⇒
footnotes to help in selecting correct parts. Indicates that a change occurred sometime
within that month for the item affected.
6. Five periods in the PART NO. column (. . . . .)
D/B 3/00 ⇔ D/B 4/00
indicate that the part is either Not Serviced
Indicates a range of production dates of the
Separately or there is a reference to another
item affected.
figure. A figure reference is denoted by a pointing
hand followed by a parts page number in the Contact your local dealer for Yale lift trucks for
DESCRIPTION column (☞7A56) 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 When ordering replacement parts, give the unit serial
required parts. Two periods in the QTY column (..) number, part number, name of part and quantity
indicate that the part is not used for that assembly. required.
8. Indented descriptions under the DESCRIPTION
For any further information on parts, service, or
column are used to indicate assemblies and
ordering, consult your local dealer for Yale lift trucks.
subparts of assemblies. In the example on the
previous page, BEARING CAP (Item 2) is a
subpart of the major assembly CASE.

vii
GENERAL INFORMATION

IDENTIFICATION OF TRUCK SERIAL NUMBER

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 and 1980.
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.

viii
GENERAL INFORMATION

IDENTIFICATION OF MAST SERIAL NUMBER

(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.

LIFT EQUIPMENT IDENTIFICATION

1. Fork part number, capacity rating, plant code


letter, and date of manufacture are stamped
approximately six inches below the top of most
forks.

2. The carriage group number is stamped on the


right hand side of the top crossmember (pin type)
or on the back of the right hand end of the bottom
crossmember (hook type). A date code has two
letters in line with or below the carriage group
number.

3. The mast identification number has a unit code,


a letter indicating the plant of manufacture, and
a serial number. Underneath the production
sequence number is a four digit number that
indicates the carriage travel in millimeters.

4. Tilt and lift cylinder group numbers are stamped


on the cylinder shell.

Always refer to the group, serial, or part number


when ordering service parts.

Modification of masts and 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.

ix
GENERAL INFORMATION

IDENTIFICATION OF ATTACHMENT AND SIDE-SHIFT CARRIAGE SERIAL NUMBERS

(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.

x
GENERAL INFORMATION

MASTER PART SHEET CROSS-REFERENCE

NOTE: Throughout this manual are references to Part Sheet Numbers. These references are usually found after
the description of a part or assembly. The Part Sheet Number is found on the upper left- or righthand corner of
the parts pages.

EXAMPLE:

ITEM PART NO. DESCRIPTION QTY


31 505965530 Steering Cylinder (☞ 6E67)..................................................................................... 1
32 504224261 Pin ............................................................................................................................ 4

Below is a numerical listing of Part Sheet Numbers found in this parts book and what page number they are on.

PART SHEET PAGE NO. PART SHEET PAGE NO. PART SHEET PAGE NO.

G10934................................. 2-2 G11044................................. 5-2 G11112............................... 6-30


G10936................................. 3-6 G11045................................. 5-6 G11113............................... 6-32
G10938................................. 6-8 G11048............................... 8-20 G11114............................... 6-34
G10940............................... 1-10 G11049............................... 6-26 G11115............................... 6-40
G10941............................... 1-18 G11050............................... 6-24 G11115................................. 7-2
G10945............................... 1-16 G11051................................. 2-6 G11116................................. 7-4
G10958................................. 4-8 G11052............................... 2-12 G11117................................. 7-6
G10963................................. 1-2 G11054............................... 5-10 G11118................................. 7-8
G10965............................... 4-12 G11057................................. 3-8 G11119............................... 7-10
G10968................................. 1-6 G11058................................. 4-4 G11120............................... 7-12
G10971............................... 1-24 G11059................................. 6-2 G11121............................... 7-34
G10995................................. 1-8 G11060............................... 6-22 G11122............................... 7-36
G11002............................... 6-42 G11061............................... 6-28 G11123............................... 7-38
G11011............................... 8-12 G11062............................... 2-14 G11124............................... 7-40
G11012................................. 5-4 G11081................................. 2-4 G11125............................... 7-42
G11014............................... 8-10 G11091................................. 3-4 G11126............................... 7-44
G11016................................. 8-8 G11092............................... 2-18 G11127............................... 7-48
G11017................................. 8-2 G11093............................... 2-20 G11128............................... 7-50
G11018............................... 8-28 G11094................................. 8-6 G11129............................... 7-46
G11019............................... 8-24 G11095................................. 8-4 G11133............................... 7-14
G11020............................... 8-26 G11097................................. 6-6 G11134............................... 7-16
G11021............................... 8-22 G11098............................... 6-20 G11135............................... 7-18
G11022................................. 4-2 G11099............................... 6-12 G11136............................... 7-20
G11023............................... 4-16 G11100............................... 6-16 G11137............................... 7-22
G11024............................... 1-14 G11102............................... 2-10 G11138............................... 7-24
G11030................................. 4-6 G11103............................... 6-38 G11139............................... 7-26
G11032................................. 5-8 G11105............................... 1-20 G11140............................... 7-28
G11033................................. 2-8 G11107............................... 1-22 G11141............................... 7-30
G11035................................. 3-2 G11108............................... 1-12 G11142............................... 8-14
G11041............................... 4-18 G11109............................... 6-10 G11143............................... 8-16
G11042............................... 4-19 G11110............................... 6-14 G11144............................... 8-18
G11043............................... 4-20 G11111............................... 6-18 G11148............................... 6-36

xi
NOTES

xii
SECTION 1

1 GENERAL TRUCK

1 GENERAL TRUCK
CONTENTS

SECTION 1
GENERAL TRUCK

DESCRIPTION PAGE

BATTERY COMPARTMENT AND COVERS ........................................................................................................ 1-2


COUNTERWEIGHT ............................................................................................................................................. 1-6
DECAL AND PLATE LOCATION .......................................................................................................................... 1-8
FLOOR PLATES................................................................................................................................................. 1-10
FORKS ............................................................................................................................................................... 1-12
LOAD BACKREST EXTENSION........................................................................................................................ 1-14
OVERHEAD GUARD.......................................................................................................................................... 1-16
SEAT
FULL SUSPENSION....................................................................................................................................... 1-22
NON-SUSPENSION ....................................................................................................................................... 1-18
SEMI-SUSPENSION ...................................................................................................................................... 1-20
STATIC STRAP................................................................................................................................................... 1-24

1-1
G10963 06-04

BATTERY COMPARTMENT AND COVERS

BATTERY COMPARTMENT AND COVERS

1-2
G10963 06-04

BATTERY COMPARTMENT AND COVERS

ITEM PART NO. DESCRIPTION QTY

1 580049625 Cowl Cover ................................................................................................................ 1


2 505970553 Capscrew................................................................................................................... 5
3 449021003 Washer ...................................................................................................................... 5
4 449015002 Nut ............................................................................................................................. 5
5 524171252 Cover ......................................................................................................................... 1
6 580043132 Frame (1290 mm) ...................................................................................................... 1
6 580043133 Frame (1385 mm) ...................................................................................................... 1
7 524172424 Battery Cover (1290 mm) .......................................................................................... 1
7 524172426 Battery Cover (1385 mm) .......................................................................................... 1
8 932729905 Screw......................................................................................................................... 6
9 449015014 Nut ............................................................................................................................. 6
10 449022016 Lockwasher ............................................................................................................... 6
11 504226242 Washer ...................................................................................................................... 6
12 580043127 Backing Plate............................................................................................................. 1
13 449001272 Capscrew................................................................................................................... 2
14 449021003 Washer ...................................................................................................................... 2
15 449022018 Lockwasher ............................................................................................................... 2
16 449015002 Nut ............................................................................................................................. 2
17 504235245 Handle ....................................................................................................................... 1
18 580043126 Latch Handle ............................................................................................................. 1
19 580043128 Microswitch................................................................................................................ 1
20 580043129 Standoff ..................................................................................................................... 4
21 580049624 Screw......................................................................................................................... 4
22 064401300 Lockwasher ............................................................................................................... 4
23 580004704 Switch ........................................................................................................................ 1
24 505008200 Spring ........................................................................................................................ 1
25 449021010 Washer ...................................................................................................................... 1
26 023338500 Retaining Ring ........................................................................................................... 1
27 580047572 Pin ............................................................................................................................. 1
28 580042104 Seal Strip................................................................................................................... 1
29 580054940 Seal Strip................................................................................................................... 1
30 580053619 Seal Strip................................................................................................................... 1
31 580036355 Bracket Weldment (RH)............................................................................................. 1
32 580036357 Bracket Weldment (LH) ............................................................................................. 1
33 580043130 Bracket (RH) .............................................................................................................. 1
34 580043131 Bracket (LH) .............................................................................................................. 1
35 502793901 Bearing ...................................................................................................................... 2
36 580046808 Gas Spring ................................................................................................................ 1
37 504226242 Washer ...................................................................................................................... 4
38 449022016 Lockwasher ............................................................................................................... 4
39 449001415 Capscrew................................................................................................................... 4
40 504236222 Nut ............................................................................................................................. 2
41 449021006 Washer ...................................................................................................................... 4
42 449022013 Lockwasher ............................................................................................................... 4
43 931014905 Capscrew................................................................................................................... 4
44 502398906 Washer ...................................................................................................................... 2
45 502512901 Screw......................................................................................................................... 2
46 580036354 Short Arm .................................................................................................................. 2
47 023338500 Retaining Ring ........................................................................................................... 8
48 580036363 Bracket Weldment (LH) ............................................................................................. 1

1-3
G10963 06-04

BATTERY COMPARTMENT AND COVERS

ITEM PART NO. DESCRIPTION QTY

49 524171398 Bearing ...................................................................................................................... 8


50 449021010 Washer ...................................................................................................................... 8
51 580036362 Bracket Weldment (RH)............................................................................................. 1
52 580036370 Long Arm................................................................................................................... 2
53 580036357 Bracket Weldment (LH) ............................................................................................. 1
54 580036367 Bracket Weldment (LH) ............................................................................................. 1
55 449021001 Washer ...................................................................................................................... 4
56 931013904 Capscrew................................................................................................................... 4
57 449022016 Lockwasher ............................................................................................................... 4
58 580036366 Bracket Weldment (RH)............................................................................................. 1
59 580036355 Bracket Weldment (RH)............................................................................................. 1
60 580001470 Bolt ............................................................................................................................ 4
61 580041378 Cowl........................................................................................................................... 1
62 580047631 Seal Strip................................................................................................................... 2
63 580047632 Seal Strip................................................................................................................... 1
64 524168493 Frame (1290 mm) ...................................................................................................... 1
64 524168495 Frame (1385 mm) ...................................................................................................... 1
64 a 524168496 Frame (Optional)........................................................................................................ 1
64 b 524168497 Frame (Optional)........................................................................................................ 1
65 520041817 Panel ......................................................................................................................... 2
66 520041892 Panel ......................................................................................................................... 1
67 520041863 Cover ......................................................................................................................... 3
68 580018725 Horn........................................................................................................................... 1
69 449021003 Washer ...................................................................................................................... 2
70 449022018 Lockwasher ............................................................................................................... 2
71 449015002 Nut ............................................................................................................................. 2
72 932728910 Capscrew................................................................................................................... 2
73 580003569 Washer ...................................................................................................................... 6
74 502512901 Screw......................................................................................................................... 2
75 580052619 Nut Plate Assembly ................................................................................................... 1
76 580051526 Plug ........................................................................................................................... 1
77 504900200 Stud ........................................................................................................................... 1
78 014972900 Nut ............................................................................................................................. 1
79 580033881 Standoff ..................................................................................................................... 1
80 059079500 Capscrew................................................................................................................... 1
81 015026400 Lockwasher ............................................................................................................... 1
82 502398906 Washer ...................................................................................................................... 2
d 520041835 Switch ........................................................................................................................ 1
d 520041894 Switch ........................................................................................................................ 1
cd 580052995 Wire Harness (Light Switch)...................................................................................... 1
d 900003245 Grommet.................................................................................................................... 1

FOOTNOTES:
a 1290 mm - Side Removal
b 1385 mm - Side Removal
c Connects with 580040475 Standard Harness
d Not Illustrated

1-4
NOTES

1-5
G10968 06-04

COUNTERWEIGHT

COUNTERWEIGHT

1-6
G10968 06-04

COUNTERWEIGHT

ITEM PART NO. DESCRIPTION QTY

1 524174472 Counterweight ........................................................................................................... 1


2 931018905 Capscrew................................................................................................................... 4
3 504061794 Washer ...................................................................................................................... 4
4 580036554 Tow Pin ...................................................................................................................... 1

1-7
G10995 06-04

DECAL AND PLATE LOCATION

D ECAL AND PL ATE LOCATION

1-8
G10995 06-04

DECAL AND PLATE LOCATION

ITEM PART NO. DESCRIPTION QTY

1 505972545 Label (Mast Warning) ................................................................................................ 2


2 580031628 Label (Battery Disconnect) ........................................................................................ 1
3 504231248 Label (No Riders) ...................................................................................................... 1
4 580044043 Label (Lift) ................................................................................................................. 1
5 580044040 Label (Tilt).................................................................................................................. 1
6 505890500 Label (Patents and Trademarks) ............................................................................... 1
7 752953402 Label (Warning) ......................................................................................................... 1
8 502157204 Label (Yale)................................................................................................................ 2
9 504231230 Label (Battery Spacer) .............................................................................................. 1
10 524139228 Nameplate ................................................................................................................. 1
11 505976530 Rivet .......................................................................................................................... 4
12 504231215 Label (Mast Warning) ................................................................................................ 1
13 b 505974557 Label (Pinch Point) .................................................................................................... 2
13 504231252 Label (Pinch Point) .................................................................................................... 1
14 504955200 Label (Tilt Column) .................................................................................................... 1
15 b 504575216 Label (Pinch Point) .................................................................................................... 1
16 258985000 Strip Decal ................................................................................................................. 2
17 580008064 Cover ......................................................................................................................... 1
18 518803661 Washer ...................................................................................................................... 4
19 520045119 Label (Hydraulic Oil Fill) ............................................................................................ 1
20 524221058 Decal (Yale) ............................................................................................................... 1
21 .. . . . Label (Brake System Fluid) ....................................................................................... 1
21 .. . . . Label (Brake System Fluid) (Freezer)........................................................................ 1
22 505977535 Label (Operator Warning).......................................................................................... 1
23 504231296 Label (Operator Restraint)......................................................................................... 2
24 524146559 Inspection Plate ......................................................................................................... 1
24 524135489 UL Inspection Plate (Type EE)................................................................................... 1
25 504575235 Label (UL Type EE) ................................................................................................... 2
26 580044038 Label (Sideshift)......................................................................................................... 1
26 580044039 Label (Auxiliary)......................................................................................................... 1
26 580048569 Label (Fork Rotate).................................................................................................... 1
26 580048636 Label (Clamp) ............................................................................................................ 1
27 504231234 Label (Freezer) .......................................................................................................... 2
28 524196756 Label (AC Power) ...................................................................................................... 2
29 580049767 Label (Brake System Fluid Tag) ................................................................................ 1
29 580049768 Label (Brake System Fluid Tag) (Freezer) ................................................................. 1
30 580011638 Label (Lift/Tilt)............................................................................................................ 1
31 504231256 Label (Auxiliary Function - Side-Shift) ....................................................................... 1
31 504236257 Label (Auxiliary Function - Spread) ........................................................................... 1
31 504236228 Label (Auxiliary Function - Rotate) ............................................................................ 1
31 504236212 Label (Auxiliary Function - Clamp) ............................................................................ 1
32 580043658 Label (Lock/Unlock) ................................................................................................... 1
33 524208364 Decal (Yale) ............................................................................................................... 2
a 504231290 Label (Corrosion)....................................................................................................... 2

FOOTNOTES:
a Not Illustrated
b Only uses 1 for Manual Hydraulics

1-9
G10940 06-04

FLOOR PLATES

FLOOR PLATES

1-10
G10940 06-04

FLOOR PLATES

KEY:
A: Electric Valve
B: Manual Valve

QTY
ITEM PART NO. DESCRIPTION A B
1 580041969 Floor Plate (LH) ................................................................................................. 1 1
2 580041965 Floor Plate (Center) ........................................................................................... 1 1
3 580041967 Floor Plate (RH)................................................................................................. .. 1
4 580041966 Floor Plate (RH) (With Step).............................................................................. 1 ..
5 506752500 Anti-Slip Pad...................................................................................................... 2 1
6 506751500 Anti-Slip Pad...................................................................................................... 2 1
7 580045713 Hose Cover........................................................................................................ 1 1
8 580045714 Harness Cover................................................................................................... 1 ..
8 580045721 Harness Cover................................................................................................... .. 1
9 518796682 Clip Nut.............................................................................................................. 7 6
10 520038861 Capscrew........................................................................................................... 6 6
11 932727905 Capscrew........................................................................................................... 1 ..
a 580039126 Floor Mat ........................................................................................................... .. 1
a 580039128 Floor Mat ........................................................................................................... 1 ..

FOOTNOTES:
a Not Illustrated

1-11
G11108 06-04

FORKS

FORKS

1-12
G11108 06-04

FORKS

KEY:
A: Standard
B: Option

QTY
ITEM PART NO. DESCRIPTION A B

1 504111201 Fork (36 in.) (100 x 40 x 914) ............................................................................ 2 ..


1 504111202 Fork (42 in.) (100 x 40 x 1067).......................................................................... 2 ..
1 504111203 Fork (48 in.) (100 x 40 x 1219).......................................................................... 2 ..
1 504111204 Fork (54 in.) (100 x 40 x 1372).......................................................................... 2 ..
1 504111205 Fork (60 in.) (100 x 40 x 1524).......................................................................... 2 ..
1 518648601 Fork (36 in.) (100 x 40 x 914) ............................................................................ 2 ..
1 518648602 Fork (42 in.) (100 x 40 x 1067).......................................................................... 2 ..
1 518648603 Fork (48 in.) (100 x 40 x 1219).......................................................................... 2 ..
1 518648604 Fork (54 in.) (100 x 40 x 1372).......................................................................... 2 ..
1 518648605 Fork (60 in.) (100 x 40 x 1524).......................................................................... 2 ..
1 505861501 Fork (36 in.) (100 x 40 914)............................................................................... 2 ..
1 505861502 Fork (42 in.) (100 x 40 x 1067).......................................................................... 2 ..
1 505861503 Fork (48 in.) (100 x 40 x 1219).......................................................................... 2 ..
1 505861504 Fork (54 in.) (100 x 40 x 1372).......................................................................... 1 ..
1 505861505 Fork (60 in.) (100 x 40 x 1524).......................................................................... 1 ..
2 580034999 Knob .................................................................................................................. 1 ..
3 580035000 Pin ..................................................................................................................... 1 ..
4 580026749 Spring ................................................................................................................ 1 ..
5 524199302 Fork (36 in.) (100 x 40 x 914) ............................................................................ .. 2
5 524199303 Fork (42 in) (100 x 40 x 1067) ........................................................................... .. 2
5 524199304 Fork (48 in) (100 x 40 x 1219) ........................................................................... .. 2
5 524199305 Fork (54 in.) (100 x 40 x 1372).......................................................................... .. 2
5 524199306 Fork (60 in.) (100 x 40 x 1524).......................................................................... .. 2
6 580006844 Pin ..................................................................................................................... .. 1
7 580006843 Latch.................................................................................................................. .. 1
8 580006842 Spring ................................................................................................................ .. 1
9 580049861 Pin ..................................................................................................................... .. 1

580049860 Latch Kit (Includes Items 6-9)............................................................................ .. 1


a 580035001 Retainer Pin....................................................................................................... 1 ..

FOOTNOTES:
a Not Illustrated

1-13
G11024 06-04

LOAD BACKREST EXTENSION

LOAD BACKREST EXTENSION

1-14
G11024 06-04

LOAD BACKREST EXTENSION

ITEM PART NO. DESCRIPTION QTY

1 504242751 Load Backrest Extension (38 in.)............................................................................... 1


2 501749902 Capscrew................................................................................................................... 4
3 061278200 Washer ...................................................................................................................... 4
3 504233271 Washer (Optional) ..................................................................................................... 4
4 580033885 Nut ............................................................................................................................. 4
5 449022017 Lockwasher ............................................................................................................... 4

1-15
G10945 06-04

OVERHEAD GUARD

OVERHEAD GUARD

1-16
G10945 06-04

OVERHEAD GUARD

ITEM PART NO. DESCRIPTION QTY

1 501749901 Capscrew................................................................................................................... 4
2 504225227 Washer ...................................................................................................................... 12
3 449015029 Nut ............................................................................................................................. 6
4 900001242 Handle ....................................................................................................................... 1
5 504230231 Screw......................................................................................................................... 2
6 524170894 Overhead Guard (1290 mm) ..................................................................................... 1
6 524170895 Overhead Guard (1385 mm) ..................................................................................... 1
6 c 524170897 Overhead Guard (Low Profile - 1290 mm) ................................................................ 1
6 c 524170898 Overhead Guard (Low Profile - 1385 mm) ................................................................ 1
6 c 524176266 Overhead Guard (Drive-in-Rack - 1290 mm)............................................................. 1
6 c 524176267 Overhead Guard (Drive-in-Rack - 1385 mm)............................................................. 1
7 b 504241782 Plug ........................................................................................................................... 13
8 a 504241783 Plug ........................................................................................................................... 7
9 501749903 Capscrew................................................................................................................... 2
10 580047213 Bushing ..................................................................................................................... 2
11 580047208 Bushing ..................................................................................................................... 4

FOOTNOTES:
a Drive-in-Rack only requires 3 plugs
b Drive-in-Rack only requires 7 plugs
c Optional

1-17
G10941 06-04

SEAT
(NON-SUSPENSION)

SEATNON-SUSPENSION

1-18
G10941 06-04

SEAT
(NON-SUSPENSION)

ITEM PART NO. DESCRIPTION QTY

580035792 Seat (Vinyl) ................................................................................................................ 1


580035793 Seat (Cloth) ............................................................................................................... 1
1 580049892 Hip Restraint (LH) ................................................................................................ 1
1 580049893 Hip Restraint (RH)................................................................................................ 1
2 580049894 Slide ..................................................................................................................... 1
3 580049906 Cushion (Vinyl) ..................................................................................................... 1
3 580049895 Cushion (Cloth) .................................................................................................... 1
4 580046857 Harness................................................................................................................ 1
5 023604600 Washer ...................................................................................................................... 4
6 580011878 Nut ............................................................................................................................. 4
7 580049933 Grommet.................................................................................................................... 1
a 580049891 Sensor.................................................................................................................. 1
a 580014468 Seat Belt Kit ......................................................................................................... 1
a 580051943 Harness................................................................................................................ 1

FOOTNOTES:
a Not Illustrated

1-19
G11105 06-04

SEAT
(SEMI-SUSPENSION)

SEATSEMI-SUSPENSION

1-20
G11105 06-04

SEAT
(SEMI-SUSPENSION)

ITEM PART NO. DESCRIPTION QTY

580035794 Seat (Vinyl) ................................................................................................................ 1


580035795 Seat (Cloth) ............................................................................................................... 1
580041573 Seat (Vinyl) With E-Control Arm ................................................................................ 1
580041575 Seat (Cloth) With E-Control Arm ............................................................................... 1
1 580049897 Hip Restraint (LH) ................................................................................................ 1
1 580049898 Hip Restraint (RH)................................................................................................ 1
2 580049899 Slide ..................................................................................................................... 1
3 580051572 Back Cushion (Vinyl) ............................................................................................ 1
3 580051573 Back Cushion (Cloth) ........................................................................................... 1
4 580051574 Seat Cushion (Vinyl) ............................................................................................ 1
4 580051575 Seat Cushion (Cloth)............................................................................................ 1
5 580049900 Weight Adjust Knob.............................................................................................. 1
6 023604600 Washer ...................................................................................................................... 4
7 580011878 Nut ............................................................................................................................. 4
8 580049933 Grommet.................................................................................................................... 1
9 580046857 Harness................................................................................................................ 1
9 b 580046856 Harness ..................................................................................................................... 1
a 580014468 Seat Belt Kit ......................................................................................................... 1
a 520041836 Shock Absorber Kit .............................................................................................. 1
a 580049891 Sensor.................................................................................................................. 1
a 580051943 Harness................................................................................................................ 1
a 580049886 Foam Cap ............................................................................................................ 1
a 580049887 Knob..................................................................................................................... 1
a 580050221 Slide ..................................................................................................................... 1
a 504305734 Switch................................................................................................................... 1

FOOTNOTES:
a Not Illustrated
b Used on seats with E-Control Arm

1-21
G11107 06-04

SEAT
(FULL SUSPENSION)

SEATFUL L SUSPENSION

1-22
G11107 06-04

SEAT
(FULL SUSPENSION)

KEY:
A: Full Suspension Vinyl
B: Full Suspension Cloth
C: Full Suspension Vinyl with E-Control Arm
D: Full Suspension Cloth with E-Control Arm

QTY
ITEM PART NO. DESCRIPTION A B C D

580038858 Seat (Vinyl) .................................................................................. 1 .. .. ..


580038857 Seat (Cloth) ................................................................................. .. 1 .. ..
580038849 Seat (Vinyl) .................................................................................. .. .. 1 ..
580038851 Seat (Cloth) ................................................................................. .. .. .. 1
1 580049883 Seat Cushion........................................................................... 1 1 1 1
2 580049885 Slide ........................................................................................ 1 1 1 1
3 580014462 Back Cushion (Vinyl) ............................................................... 1 .. .. ..
3 580014463 Back Cushion (Cloth) .............................................................. .. 1 .. 1
3 580051805 Back Cushion .......................................................................... .. .. 1 ..
4 580046857 Harness................................................................................... 1 1 .. ..
4 580046856 Harness................................................................................... .. .. 1 1
5 023604600 Washer ........................................................................................ 4 4 4 4
6 580011878 Nut ............................................................................................... 4 4 4 4
7 580049933 Grommet...................................................................................... 1 1 1 1
a 580014467 Hip Restraint Kit (LH) .............................................................. 1 1 1 1
a 580014466 Hip Restraint Kit (RH).............................................................. 1 1 .. ..
a 580014468 Seat Belt Kit ............................................................................ 1 1 1 1
a 580013425 Suspension Spring Kit............................................................. 1 1 1 1
a 580018888 Shock Absorber....................................................................... 1 1 1 1
a 580049886 Foam Cap ............................................................................... .. .. 1 1
a 580049887 Knob........................................................................................ .. .. 1 1
a 580049884 Sensor..................................................................................... 1 1 1 1
a 580051943 Harness................................................................................... 1 1 1 1

FOOTNOTES:
a Not Illustrated

1-23
G10971 06-04

STATIC STRAP

STATIC STRAP

1-24
G10971 06-04

STATIC STRAP

ITEM PART NO. DESCRIPTION QTY

1 504232275 Static Strap ................................................................................................................ 1


2 449001302 Capscrew................................................................................................................... 1
3 502398906 Washer ...................................................................................................................... 1
4 449021006 Washer ...................................................................................................................... 1
5 449022013 Lockwasher ............................................................................................................... 1
6 449015044 Nut ............................................................................................................................. 1

1-25
NOTES

1-26
SECTION 2

2 ELECTRICAL SYSTEM

2 ELECTRICAL SYSTEM
CONTENTS

SECTION 2
ELECTRICAL SYSTEM

DESCRIPTION PAGE

BATTERY CONNECTOR ..................................................................................................................................... 2-2


CONTACTOR ....................................................................................................................................................... 2-4
CONTACTOR PANEL ........................................................................................................................................... 2-6
DASH DISPLAY.................................................................................................................................................... 2-8
ELECTRO-HYDRAULIC CONTROL ................................................................................................................. 2-10
EMERGENCY STOP.......................................................................................................................................... 2-12
MAIN WIRE HARNESS...................................................................................................................................... 2-14
TRACTION CONTROLLER
CONTACTOR HYDRAULIC ............................................................................................................................ 2-18
TRANSISTOR/PREMIUM ............................................................................................................................... 2-20

2-1
G10934 06-04

BATTERY CONNECTOR

BATTERY CONNECTOR

2-2
G10934 06-04

BATTERY CONNECTOR

ITEM PART NO. DESCRIPTION QTY

1 580042172 Battery Connector (36 Volt-Gray) .............................................................................. 1


1 514268301 Battery Connector (Gray) ..................................................................................... 1
1 502164907 Cable.................................................................................................................... AR
1 012472200 Terminal................................................................................................................ 2
1 580042174 Battery Connector (48 Volt-Blue)............................................................................... 1
1 514268309 Battery Connector (Blue) ..................................................................................... 1
1 502164907 Cable.................................................................................................................... AR
1 012472200 Terminal................................................................................................................ 2
2 449007021 Screw......................................................................................................................... 2
3 449022018 Lockwasher ............................................................................................................... 2
4 449015002 Nut ............................................................................................................................. 2
5 580050900 Plate .......................................................................................................................... 1
6 449022016 Lockwasher ............................................................................................................... 2
7 449001013 Capscrew................................................................................................................... 2

2-3
G11081 06-04

CONTACTOR

CONTACTOR

2-4
G11081 06-04

CONTACTOR

ITEM PART NO. DESCRIPTION QTY

580047573 Contactor ................................................................................................................... 1


1 519739813 Screw ................................................................................................................... 2
2 520371801 Top Cover ............................................................................................................. 1
3 519739877 Contactor (Fixed) ................................................................................................. 2
4 296321382 Contactor (Moving)............................................................................................... 1
5 519739815 Spring................................................................................................................... 1
6 580052240 Molding................................................................................................................. 1
7 519739820 Plunger................................................................................................................. 1
8 580052241 Magnet ................................................................................................................. 1
9 519739878 End Cap ............................................................................................................... 1

519739821 Contactor Kit (Includes Items 3-4)........................................................................ 1

2-5
G11051 06-04

CONTACTOR PANEL

CONTACTOR PANEL

2-6
G11051 06-04

CONTACTOR PANEL

KEY:
A: Contactor Hydraulics
B: Transistor Hydraulics
C: "EE"

QTY
ITEM PART NO. DESCRIPTION A B C

580037154 Contactor Panel...................................................................................... 1 .. ..


580037155 Contactor Panel...................................................................................... .. 1 ..
580049350 Contactor Panel...................................................................................... .. .. 1
1 580001392 Fuse (15 Amp) ................................................................................... 4 4 4
2 580044159 Fuse (20 Amp) ................................................................................... 1 1 1
3 580001982 Fuse Holder........................................................................................ 1 1 1
4 520357890 Screw ................................................................................................. 2 2 2
5 519433632 Washer ............................................................................................... 2 2 2
6 520357857 Washer ............................................................................................... 2 2 2
7 520357806 Screw ................................................................................................. 2 2 2
8 520357805 Washer ............................................................................................... 2 2 2
9 580044359 Contactor............................................................................................ .. .. 1
9 580044210 Contactor............................................................................................ 1 1 ..
10 520357854 Buss Bar............................................................................................. 1 .. 1
11 580001385 Terminal Post...................................................................................... 5 1 5
12 580025967 Terminal Post...................................................................................... .. .. 4
13 580044209 Baseplate ........................................................................................... 1 1 1
14 580044211 Washer ............................................................................................... 10 2 10
15 580025953 Screw ................................................................................................. .. 2 10
15 449007004 Screw ................................................................................................. 10 .. ..
16 520357818 Nut...................................................................................................... 5 1 5
17 519433612 Lockwasher ........................................................................................ 5 1 5
18 520357853 Fuse Box ............................................................................................ .. .. 1
19 520357849 Insulator (Bottom)............................................................................... .. .. 1
20 520357850 Insulator (Side)................................................................................... .. .. 1
21 520357820 Spacer................................................................................................ .. .. 4
22 520357821 Insulator ............................................................................................. .. .. 4
23 520357810 Screw ................................................................................................. .. .. 4
24 520357835 Lockwasher ........................................................................................ .. .. 4
25 520357892 Washer ............................................................................................... .. .. 4
26 580044745 Fuse (60 Amp) ................................................................................... .. .. 1
27 580044369 Fuse (500 Amp) ................................................................................. .. .. 1
28 580035780 Thermistor Assembly ......................................................................... 1 1 1
a 580041633 Power Cable ........................................................................................... 1 1 1
a 580041602 Power Cable ........................................................................................... 1 .. ..
a 580041606 Power Cable ........................................................................................... .. 1 ..

FOOTNOTES:
a Not Illustrated

2-7
G11033 06-04

DASH DISPLAY

DASH DISPLAY

2-8
G11033 06-04

DASH DISPLAY

ITEM PART NO. DESCRIPTION QTY

1 580041063 Dash Display (Premium)............................................................................................ 1


1 580041062 Dash Display (Standard) ........................................................................................... 1
1 580042348 Dash Display (Standard Freezer) .............................................................................. 1
1 580042349 Dash Display (Freezer Premium) .............................................................................. 1

2-9
G11102 06-04

ELECTRO-HYDRAULIC CONTROL

ELEC TRO-HYDRAULIC CONTROL

2-10
G11102 06-04

ELECTRO-HYDRAULIC CONTROL

KEY:
A: Three Function Premium
B: Three Function Premium with Interlock
C: Four Function Premium
D: Four Function Premium with Interlock

QTY
ITEM PART NO. DESCRIPTION A B C D

1 580035668 Valve Controller ........................................................................... 1 1 1 1


2 449022021 Lockwasher ................................................................................. 2 2 2 2
3 449015021 Nut ............................................................................................... 2 2 2 2
4 932727905 Capscrew..................................................................................... 2 2 2 2
5 580050290 Wire Harness............................................................................... 1 1 .. ..
5 580050291 Wire Harness............................................................................... .. .. 1 1
6 505018207 Jumper Assembly ........................................................................ 1 1 1 1

2-11
G11052 06-04

EMERGENCY STOP

EMERGENCY STOP

2-12
G11052 06-04

EMERGENCY STOP

KEY:
A: "E"
B: "EE"

QTY
ITEM PART NO. DESCRIPTION A B
580042245 Emergency Stop Switch .................................................................................... .. 1
580041660 Emergency Stop Switch .................................................................................... 1 ..
1 580044387 Top Cover Assembly ..................................................................................... 1 1
2 580052054 Washer .......................................................................................................... 2 2
3 580044389 Circup............................................................................................................ 1 1
4 580044390 Insulator ........................................................................................................ 1 1
5 580044391 Spring (Contact) ............................................................................................ 1 1
6 580044392 Contact Kit..................................................................................................... 1 1
7 580044393 Washer .......................................................................................................... 1 1
8 580044394 Dust Shield.................................................................................................... 2 2
9 580044396 Housing ......................................................................................................... 1 1
10 580044395 Spring (Actuator) ........................................................................................... 2 2
11 580044397 Shaft.............................................................................................................. 1 1
12 580044398 O-Ring........................................................................................................... 1 1
13 580044399 Guide............................................................................................................. 1 1
14 580044400 Backplate ...................................................................................................... 1 1
15 580044401 Gasket........................................................................................................... 1 1
16 580044402 Hardware Kit ................................................................................................. 1 1
17 580044404 Auxiliary Contact Kit ...................................................................................... 1 1
18 580044405 Insulator (White)............................................................................................ 1 1
19 580052052 Bushing ............................................................................................................. 2 2
20 a 580044376 Shroud (Lower) ............................................................................................. .. 1
21 a 580044377 Shroud (Upper) ............................................................................................. .. 1
22 a 580044564 Spring Washer .............................................................................................. .. 4
23 a 580044378 Screw ............................................................................................................ .. 4
24 a 580044380 Insulator ........................................................................................................ .. 2
25 a 580044381 Insulator (Contact Fixed) ............................................................................... .. 2

FOOTNOTES:
a Not Illustrated

2-13
G11062 06-04

MAIN WIRE HARNESS

MAIN WIRE HARNESS

2-14
G11062 06-04

MAIN WIRE HARNESS

ITEM PART NO. DESCRIPTION QTY

580036604 Wire Harness............................................................................................................. 1


1 580019139 Housing (Socket).................................................................................................. 1
1 580019140 Secondary Lock ................................................................................................... 1
1 505968568 Socket .................................................................................................................. 3
2 504059730 Blade .................................................................................................................... 2
3 500383916 Blade .................................................................................................................... 2
4 502701508 Plug ...................................................................................................................... 1
4 502701502 Contact................................................................................................................. 3
4 502701532 Interface Seal ....................................................................................................... 1
4 502701539 Amp Wire Seal ..................................................................................................... 1
5 520202604 Seal ...................................................................................................................... 6
5 520202602 Connector............................................................................................................. 1
5 520202601 Socket .................................................................................................................. 17
6 520202604 Seal ...................................................................................................................... 8
6 520202607 Electrical Connector ............................................................................................. 1
6 520202601 Socket .................................................................................................................. 6
7 752943309 Resistor ................................................................................................................ 1
8 502701506 Connector............................................................................................................. 1
8 502701502 Contact................................................................................................................. 2
8 502701538 Wire Seal.............................................................................................................. 1
8 502701531 Amp Interface Seal............................................................................................... 1
9 317222556 Terminal................................................................................................................ 1
10 751303337 Diode Assembly ................................................................................................... 1
11 502701508 Plug ...................................................................................................................... 1
11 502701502 Contact................................................................................................................. 3
11 502701532 Interface Seal ....................................................................................................... 1
11 502701539 Amp Wire Seal ..................................................................................................... 1
12 580022893 Connector............................................................................................................. 1
12 505968540 Secondary Lock ................................................................................................... 1
12 505968514 Pin ........................................................................................................................ 2
13 580021087 Housing (Socket).................................................................................................. 1
13 580021088 Secondary Lock ................................................................................................... 1
13 505968568 Socket .................................................................................................................. 2
14 580021087 Housing (Socket).................................................................................................. 2
14 580021088 Secondary Lock ................................................................................................... 2
14 505968568 Socket .................................................................................................................. 4
15 580019139 Housing (Socket).................................................................................................. 1
15 580039194 Secondary Lock ................................................................................................... 1
15 505968568 Socket .................................................................................................................. 3
15 580010571 End Cap ............................................................................................................... 1
16 580019139 Housing (Socket).................................................................................................. 1
16 580019140 Secondary Lock ................................................................................................... 1
16 505968568 Socket .................................................................................................................. 3
17 580022861 Housing ................................................................................................................ 1
17 580036992 Secondary Lock ................................................................................................... 1
17 505968568 Socket .................................................................................................................. 2
17 505064713 Terminal................................................................................................................ 4
18 580022861 Housing ................................................................................................................ 1
18 580036992 Secondary Lock ................................................................................................... 1
18 505968568 Socket .................................................................................................................. 2

2-15
G11062 06-04

MAIN WIRE HARNESS

ITEM PART NO. DESCRIPTION QTY

18 505064713 Terminal................................................................................................................ 4
19 520038820 End Cap ............................................................................................................... 1
20 503927202 Electrical Fitting.................................................................................................... 2
21 518807689 Terminal................................................................................................................ 1
22 518802686 Fitting ................................................................................................................... 1
22 505968565 Heat Shrink Tube.................................................................................................. 1
23 504059730 Blade .................................................................................................................... 2
24 504059726 Blade .................................................................................................................... 1
25 502701505 Connector............................................................................................................. 2
25 502701501 Pin ........................................................................................................................ 4
25 502701538 Wire Seal.............................................................................................................. 2
26 580019139 Housing (Socket).................................................................................................. 1
26 580019140 Secondary Lock ................................................................................................... 1
26 505968568 Socket .................................................................................................................. 3
27 502701508 Plug ...................................................................................................................... 2
27 502701502 Contact................................................................................................................. 6
27 502701532 Interface Seal ....................................................................................................... 2
27 502701539 Amp Wire Seal ..................................................................................................... 2
28 502701506 Connector............................................................................................................. 1
28 502701502 Contact................................................................................................................. 2
28 502701538 Wire Seal.............................................................................................................. 1
28 502701531 Amp Interface Seal............................................................................................... 1
29 501997903 Terminal Ring ....................................................................................................... 1
30 502701513 Cap....................................................................................................................... 1
30 502701542 Seal ...................................................................................................................... 1
30 502701501 Pin ........................................................................................................................ 12
31 580021087 Housing (Socket).................................................................................................. 1
31 580021088 Secondary Lock ................................................................................................... 1
31 505968568 Socket .................................................................................................................. 2
32 502701518 Plug ...................................................................................................................... 1
32 502701537 Connector............................................................................................................. 1
32 502701544 Connector............................................................................................................. 1
32 502701502 Contact................................................................................................................. 4
33 580044197 Wire Harness ....................................................................................................... 1
34 720098904 Tube ..................................................................................................................... AR
35 065354200 Terminal Wire ....................................................................................................... 1
36 501997902 Terminal (Ring)..................................................................................................... 5
37 065353900 Terminal Wire ....................................................................................................... 4
38 502250902 Terminal Wire ....................................................................................................... 1
39 317222556 Terminal................................................................................................................ 2
40 520202604 Seal ...................................................................................................................... 1
40 520202606 Connector............................................................................................................. 1
40 520202601 Socket .................................................................................................................. 34
41 520202604 Seal ...................................................................................................................... 4
41 520202603 Connector and Cable Assembly........................................................................... 1
41 520202601 Socket .................................................................................................................. 4
42 054466300 Terminal Wire ....................................................................................................... 1
43 520202604 Seal ...................................................................................................................... 7
43 520202607 Electrical Connector ............................................................................................. 1
43 520202601 Socket .................................................................................................................. 7

2-16
G11062 06-04

MAIN WIRE HARNESS

ITEM PART NO. DESCRIPTION QTY

44 752943309 Resistor ................................................................................................................ 1


45 317222556 Terminal................................................................................................................ 2
46 502701506 Connector............................................................................................................. 1
46 502701502 Contact................................................................................................................. 2
46 502701538 Wire Seal.............................................................................................................. 1
46 502701531 Amp Interface Seal............................................................................................... 1
47 580042221 Connector............................................................................................................. 1
47 580042222 Connector............................................................................................................. 1
47 580039513 Terminal................................................................................................................ 8
48 500383922 Terminal................................................................................................................ 4
49 720098901 Tubing................................................................................................................... AR
50 580022861 Housing ................................................................................................................ 1
50 580036992 Secondary Lock ................................................................................................... 1
50 505968568 Socket .................................................................................................................. 4
50 505968593 Electrical Fitting.................................................................................................... 2
50 580012291 Connector............................................................................................................. 1
51 518445620 Connector............................................................................................................. 1
51 518445602 Socket .................................................................................................................. 3
52 317220006 Terminal Wire ....................................................................................................... 1
53 500383916 Blade .................................................................................................................... 1
54 502250903 Wire Terminal ....................................................................................................... 1

2-17
G11092 06-04

TRACTION CONTROLLER
(CONTACTOR HYDRAULIC)

TRACTION CONTROLLERCONTACTOR HYDRAULIC

2-18
G11092 06-04

TRACTION CONTROLLER
(CONTACTOR HYDRAULIC)

ITEM PART NO. DESCRIPTION QTY

1 580036018 Traction Controller ..................................................................................................... 1


1 580047401 Software ............................................................................................................... 1
1 580047573 Contactor.............................................................................................................. 1
2 449021003 Washer ...................................................................................................................... 8
3 449022018 Lockwasher ............................................................................................................... 8
4 b 932200909 Capscrew................................................................................................................... 8
4 c 932200909 Capscrew................................................................................................................... 5
5 580041603 Power Cable Assembly.............................................................................................. 1
6 580041602 Power Cable .............................................................................................................. 1
7 580037281 Power Cable Assembly.............................................................................................. 1
8 580037283 Power Cable Assembly.............................................................................................. 1
9 580037241 Power Cable Assembly.............................................................................................. 1
10 580041628 Power Cable Assembly.............................................................................................. 1
11 580042074 Power Cable Assembly.............................................................................................. 1
12 580050377 Ferrite ........................................................................................................................ 3
13 580041632 Power Cable .............................................................................................................. 1
14 580041633 Power Cable .............................................................................................................. 1
15 449021003 Washer ...................................................................................................................... 2
16 449022018 Lockwasher ............................................................................................................... 2
17 449001412 Capscrew................................................................................................................... 2
a 580040411 Wire Harness (Two Function) .................................................................................... 1
a 580040412 Wire Harness (Three Function) ................................................................................. 1
a 580040413 Wire Harness (Four Function) ................................................................................... 1
ac 580037732 Capscrew................................................................................................................... 3
ac 580052216 Cap ............................................................................................................................ 2
ac 580052236 Bracket ...................................................................................................................... 1
ac 580052232 Spacer ....................................................................................................................... 3

FOOTNOTES:
a Not Illustrated
b ⇒ Pending Per ECN 10203101
c Pending Per ECN 10203101 ⇒

2-19
G11093 06-04

TRACTION CONTROLLER
(TRANSISTOR/PREMIUM)

TRACTION CONTROLLERTRANSISTOR/PREMIUM

2-20
G11093 06-04

TRACTION CONTROLLER
(TRANSISTOR/PREMIUM)

ITEM PART NO. DESCRIPTION QTY

1 580036020 Traction Controller ..................................................................................................... 1


580047402 Software ............................................................................................................... 1
2 449021003 Washer ...................................................................................................................... 8
3 449022018 Lockwasher ............................................................................................................... 8
4 b 932200909 Capscrew................................................................................................................... 8
4 c 932200909 Capscrew................................................................................................................... 5
5 580041606 Power Cable .............................................................................................................. 1
6 580041603 Power Cable Assembly.............................................................................................. 1
7 580037281 Power Cable Assembly.............................................................................................. 1
8 580037283 Power Cable Assembly.............................................................................................. 1
9 580037241 Power Cable Assembly.............................................................................................. 1
10 580041628 Power Cable Assembly.............................................................................................. 1
11 580041630 Power Cable Assembly.............................................................................................. 1
12 580050377 Ferrite ........................................................................................................................ 5
13 580050364 Capacitor ................................................................................................................... 1
14 580041632 Power Cable .............................................................................................................. 1
15 580041633 Power Cable .............................................................................................................. 1
16 449021003 Washer ...................................................................................................................... 2
17 449022018 Lockwasher ............................................................................................................... 2
18 449001412 Capscrew................................................................................................................... 2
19 a 580040414 Wire Harness (Two Function) .................................................................................... 1
a 580040415 Wire Harness (Three Function) ................................................................................. 1
a 580040416 Wire Harness (Four Function) ................................................................................... 1
a 580054080 Wire Harness (Two Function) .................................................................................... 1
a 580050290 Wire Harness (Three Function) ................................................................................. 1
a 580050291 Wire Harness (Four Function) ................................................................................... 1
ac 580037732 Capscrew................................................................................................................... 3
ac 580052216 Cap ............................................................................................................................ 2
ac 580052236 Bracket ...................................................................................................................... 1
ac 580052232 Spacer ....................................................................................................................... 3

FOOTNOTES:
a Not Illustrated
b ⇒ Pending Per ECN 10203101
c Pending Per ECN 10203101 ⇒

2-21
NOTES

2-22
SECTION 3

3 D RIVE UNIT

3 DRIVE UNIT
CONTENTS

SECTION 3
DRIVE UNIT

DESCRIPTION PAGE

DRIVE TIRE AND WHEEL ASSEMBLY ............................................................................................................... 3-2


DRIVE UNIT ......................................................................................................................................................... 3-4
TRACTION MOTOR ............................................................................................................................................. 3-6
TRANSMISSION .................................................................................................................................................. 3-8

3-1
G11035 06-04

DRIVE TIRE AND WHEEL ASSEMBLY

DRIVE T IRE AND WHEEL ASSEMBLY

ITEM PART NO. DESCRIPTION QTY

258514000 Tire and Wheel Assembly (4000 lb.).......................................................................... 2


258465500 Tire and Wheel Assembly (3000 and 3500 lb.).......................................................... 2
b 520082891 Tire and Wheel Assembly (3000-4000 lb.) ................................................................ 2
e 524139245 Tire and Wheel Assembly (3000-4000 lb.) ................................................................ 2
c .. . . . Tire and Wheel Assembly.......................................................................................... 2
1 258484400 Tire (200 x 50 x 10) ................................................................................................... 1
1 258157200 Tire (18 x 7 x 8) ......................................................................................................... 1
1 a 504223216 Tire (18 x 7 x 12) ....................................................................................................... 1
1 d 504223218 Tire (18 x 7 x 12) ....................................................................................................... 1
1 c 504223278 Tire (18 x 7 x 12) ....................................................................................................... 1
2 258484300 Wheel Assembly (200 x 50 x 10)............................................................................... 1
2 440066700 Wheel Assembly (18 x 7 x 8)..................................................................................... 1
2 f 520082892 Wheel Assembly (18 x 7 x 12)................................................................................... 1
3 449077093 Lug Nut ...................................................................................................................... 5

FOOTNOTES:
a Cushion
b Cushion Option
c Lug Cushion Option
d Non-Marking
e Non-Marking Option
f Used for Cushion, Non-Marking and Lug Cushion Option

3-2
NOTES

3-3
G11091 06-04

DRIVE UNIT

DRIVE UNIT

3-4
G11091 06-04

DRIVE UNIT

ITEM PART NO. DESCRIPTION QTY

1 580041265 Drive Unit (LH) (☞ G11057) .................................................................................... 1


2 580041266 Drive Unit (RH) (☞ G11057) .................................................................................... 1
3 580035499 Traction Motor (36V) (☞ G10936) ............................................................................ 2
3 580043032 Traction Motor (48V) (☞ G10936) ............................................................................ 2
4 502566904 Washer ...................................................................................................................... 8
5 931014906 Capscrew................................................................................................................... 8
ab 580037281 Power Cable Assembly (LH)...................................................................................... 1
ab 580037241 Power Cable Assembly (RH) ..................................................................................... 1

FOOTNOTES:
a Not Illustrated
b Used on 1290 and 1385 mm

3-5
G10936 06-04

TRACTION MOTOR

TRACTION MOTOR

3-6
G10936 06-04

TRACTION MOTOR

ITEM PART NO. DESCRIPTION QTY

580035499 Traction Motor (36V) .................................................................................................. 1


580043032 Traction Motor (48V) .................................................................................................. 1
1 580050695 Drive End Bracket (With Encoder Bearing) .......................................................... 1
2 580050696 Armature .............................................................................................................. 1
3 580050697 Bolt ....................................................................................................................... 1
4 580050714 Stator.................................................................................................................... 1
5 580050715 Connection Plate.................................................................................................. 1
6 580050716 Bracket ................................................................................................................. 1
7 580050717 Connector............................................................................................................. 1

3-7
G11057 06-04

TRANSMISSION

TRANSMISSION

3-8
G11057 06-04

TRANSMISSION

KEY:
A: Left
B: Right

QTY
ITEM PART NO. DESCRIPTION A B

580041265 Drive Unit (Left) ................................................................................................. 1 ..


580041266 Drive Unit (Right) ............................................................................................... .. 1
1 580049380 Housing Assembly (Left) ............................................................................... 1 ..
1 580048193 Housing Assembly (Right)............................................................................. .. 1
2 580048194 Pin............................................................................................................. 1 1
3 580048197 Bolt............................................................................................................ 4 4
4 580048200 Bolt............................................................................................................ 8 8
5 580025305 Oil Fill Gasket................................................................................................ 2 2
6 580025303 Oil Fill Plug .................................................................................................... 2 2
7 580048198 Plug ............................................................................................................... 2 2
8 580048199 Pin ................................................................................................................. 2 2
9 580048201 Plug ............................................................................................................... 1 1
10 580048202 Washer .......................................................................................................... 1 1
11 580048203 Bearing.......................................................................................................... 3 3
12 580048204 Gear Assembly.............................................................................................. 1 1
13 580048208 O-Ring........................................................................................................... 2 2
14 580048209 Spacer........................................................................................................... 2 2
15 580048210 Snap Ring ..................................................................................................... 2 2
16 580048211 Seal Ring....................................................................................................... 1 1
17 580048228 Bolt ................................................................................................................ 1 1
18 580048234 O-Ring........................................................................................................... 1 1
19 580048235 Washer .......................................................................................................... 1 1
20 580048236 Output Shaft .................................................................................................. 1 1
21 580039643 Bolt ................................................................................................................ 5 5
22 580048237 Seal Ring....................................................................................................... 1 1
23 580048238 Bearing.......................................................................................................... 2 2
24 580048239 Carrier ........................................................................................................... 1 1
25 580048240 Washer .......................................................................................................... 2 2
26 580048241 Ring............................................................................................................... 3 3
27 580048242 Bearing.......................................................................................................... 3 3
28 580048243 Gear .............................................................................................................. 3 3
29 580048244 Snap Ring ..................................................................................................... 3 3
30 580048245 Bearing.......................................................................................................... 1 1
31 580048246 Gear .............................................................................................................. 1 1
32 580048247 Pinion ............................................................................................................ 1 1
33 580048256 Plug ............................................................................................................... 1 1
34 580048257 Piston ............................................................................................................ 2 2
35 580048258 O-Ring........................................................................................................... 2 2
36 580048259 Pin ................................................................................................................. 2 2
37 580048260 Washer .......................................................................................................... 24 24
38 580048261 Backing Plate ................................................................................................ 1 1
39 580048262 Brake Assembly ............................................................................................ 1 1
40 580048196 Breather ........................................................................................................ 1 1
41 580048195 Breather (Brake System)............................................................................... 1 1
42 580048205 Shim (0,05 mm)............................................................................................. 5 5
42 580048206 Shim (0,10 mm)............................................................................................. 5 5

3-9
G11057 06-04

TRANSMISSION

QTY
ITEM PART NO. DESCRIPTION A B

42 580048207 Shim (0,30 mm)............................................................................................. 5 5


43 580048229 Washer .......................................................................................................... 1 1
44 580048230 Shim (0,05 mm)............................................................................................. AR ..
44 580048231 Shim (0,10 mm)............................................................................................. AR ..
44 580048232 Shim (0,30 mm)............................................................................................. AR ..
44 580048233 Shim (0,50 mm)............................................................................................. AR ..
45 502566903 Washer (Hardened) ........................................................................................... 10 10
46 311323021 Capscrew........................................................................................................... 10 10
a 449077093 Lug Nut (Wheel Mounting)................................................................................. 10 10

FOOTNOTES:
a Not Illustrated

3-10
SECTION 4

4 STEERING SYSTEM

4 STEERING SYSTEM
CONTENTS

SECTION 4
STEERING SYSTEM

DESCRIPTION PAGE

GEAR PUMP ........................................................................................................................................................ 4-2


HAND PUMP ........................................................................................................................................................ 4-4
SHIFT LEVER ...................................................................................................................................................... 4-6
STEER AXLE ....................................................................................................................................................... 4-8
STEER COLUMN ............................................................................................................................................... 4-12
STEER PUMP AND MOTOR ............................................................................................................................. 4-16
STEER TIRE AND WHEEL ASSEMBLY
CUSHION ....................................................................................................................................................... 4-19
NON-MARKING CUSHION ............................................................................................................................ 4-20
SOLID PNEUMATIC ....................................................................................................................................... 4-18

4-1
G11022 06-04

GEAR PUMP

GEAR PUMP

4-2
G11022 06-04

GEAR PUMP

ITEM PART NO. DESCRIPTION QTY

580000127 Gear Pump ................................................................................................................ 1


1 580000821 Screw ................................................................................................................... 8
2 519249804 Gasket Kit............................................................................................................. 1
3 131635419 Needle Bearing .................................................................................................... 4
4 503144800 Snap Ring ............................................................................................................ 2
5 515685804 Gear ..................................................................................................................... 3
6 .. . . . Spacer Plate .................................................................................................... 1
7 515686846 Idler Shaft Kit........................................................................................................ 1
8 515689803 Pin ........................................................................................................................ 2
9 519729801 Plug ...................................................................................................................... 1
10 506395589 Key ....................................................................................................................... 2
11 504226234 Shaft..................................................................................................................... 1
12 a 580000702 Plug (Plastic) ........................................................................................................ 1
13 a 580000822 Plug (Plastic) ........................................................................................................ 1
14 a 580000823 Plug (Steel) .......................................................................................................... 1

FOOTNOTES:
a Not Illustrated

4-3
G11058 06-04

HAND PUMP

HAND PUMP

4-4
G11058 06-04

HAND PUMP

ITEM PART NO. DESCRIPTION QTY

580011007 Hand Pump ............................................................................................................... 1


1 580013339 Dust Seal.............................................................................................................. 1
2 .. . . . Housing ................................................................................................................ 1
3 518794667 Ball ....................................................................................................................... 1
4 580000349 Stop...................................................................................................................... 1
5 .. . . . Dust Ring Seal ..................................................................................................... 1
5 580013347 Shaft Seal............................................................................................................. 1
6 580000350 Bearing Assembly ................................................................................................ 1
7 580002113 Ring...................................................................................................................... 1
8 580000351 Pin ........................................................................................................................ 1
9 580002114 Spring Set ............................................................................................................ 1
10 .. . . . Shaft..................................................................................................................... 1
11 580013349 Spacer.................................................................................................................. 1
12 .. . . . O-Ring.................................................................................................................. 1
13 580000356 Plate ..................................................................................................................... 1
14 580013340 Gear Set............................................................................................................... 1
15 .. . . . O-Ring.................................................................................................................. 2
16 580002115 Cover.................................................................................................................... 1
17 .. . . . O-Ring.................................................................................................................. 5
17 580013348 O-Ring.................................................................................................................. 1
18 580013341 Screw ................................................................................................................... 1
19 580013350 Screw ................................................................................................................... 5
20 .. . . . Nameplate ................................................................................................................. 1
21 580002110 Relief Valve................................................................................................................ 1
22 580002117 Spring ........................................................................................................................ 1
23 580000360 Ball ............................................................................................................................ 1

580013351 Seal Kit (Includes Items 1, 5, 12, 15, 17)................................................................... 1

4-5
G11030 06-04

SHIFT LEVER

SHIFT LEVER

4-6
G11030 06-04

SHIFT LEVER

ITEM PART NO. DESCRIPTION QTY

504574275 Shift Lever Assembly ................................................................................................. 1


1 505977516 Bolt ....................................................................................................................... 2
2 504574277 Link....................................................................................................................... 1
3 505977500 Washer ................................................................................................................. 2
4 505977569 Crank.................................................................................................................... 1
5 505977542 Crank.................................................................................................................... 1
6 449015002 Nut........................................................................................................................ 2
7 449015112 Nut........................................................................................................................ 4
8 505977598 Shift Lever ............................................................................................................ 1
9 505977590 Capscrew ............................................................................................................. 4
10 504574276 Base ..................................................................................................................... 1
11 580022130 Spring Plunger ..................................................................................................... 2
12 449021003 Washer ...................................................................................................................... 4
13 449022018 Lockwasher ............................................................................................................... 4
14 449001170 Capscrew................................................................................................................... 4
15 505977550 Plate .......................................................................................................................... 1
16 580025784 Switch ........................................................................................................................ 2
17 504225202 Screw......................................................................................................................... 4
18 500552902 Lockwasher ............................................................................................................... 4
19 032643500 Nut ............................................................................................................................. 4
20 505977573 Bracket ...................................................................................................................... 2

4-7
G10958 06-04

STEER AXLE

STEER AXLE

4-8
G10958 06-04

STEER AXLE

ITEM PART NO. DESCRIPTION QTY

580023262 Hydraulic Steer Unit................................................................................................... 1


1 580012502 Housing ................................................................................................................ 1
2 580024136 Wheel Hub ........................................................................................................... 2
3 580012505 Cylinder ................................................................................................................ 2
4 580024137 Bushing ................................................................................................................ 2
5 580012507 Piston ................................................................................................................... 2
6 580012508 Shaft..................................................................................................................... 1
7 580012509 Gear Rack ............................................................................................................ 1
8 580012510 Wheel Stud........................................................................................................... 10
9 580012511 Bushing ................................................................................................................ 1
10 580012512 Bearing Cover ...................................................................................................... 2
11 580012515 Bearing................................................................................................................. 2
12 580012516 Bearing................................................................................................................. 2
13 580012526 Bearing................................................................................................................. 1
14 580012527 Bearing................................................................................................................. 1
15 580024141 Seal Ring.............................................................................................................. 2
16 580012529 Seal ...................................................................................................................... 1
17 580012530 Seal ...................................................................................................................... 1
18 580012531 Safety Ring........................................................................................................... 1
19 580012532 Shim ..................................................................................................................... 1
20 580012533 Shim ..................................................................................................................... 2
20 580012534 Shim ..................................................................................................................... 1
20 580024140 Shim ..................................................................................................................... 1
21 580024138 Ring...................................................................................................................... 2
22 580012536 Shaft Seal............................................................................................................. 1
23 580012535 Shaft Seal............................................................................................................. 1
24 580012537 O-Ring.................................................................................................................. 2
25 580012538 Compact Seal....................................................................................................... 2
26 580012539 Guide Ring ........................................................................................................... 4
27 580012540 Nut........................................................................................................................ 1
28 580012541 Washer ................................................................................................................. 1
29 580014898 Screw ................................................................................................................... 8
30 580024143 Nut........................................................................................................................ 2
31 580024144 Seal ...................................................................................................................... 2
32 580024145 Split Pin ................................................................................................................ 2
33 580012546 Plug Screw ........................................................................................................... 1
34 580011058 Bolt ....................................................................................................................... 3
35 502566903 Washer (Hardened).............................................................................................. 6
36 580011059 Nut........................................................................................................................ 3
37 580024135 Yoke...................................................................................................................... 1
37 580024134 Wheel Shaft.......................................................................................................... 1
38 580000849 Potentiometer ............................................................................................................ 1
39 504070790 Strap Clamp............................................................................................................... AR
40 449001202 Capscrew................................................................................................................... 1
41 580001768 Bracket ...................................................................................................................... 1
42 580030395 Set Screw .................................................................................................................. 1
43 449015002 Nut ............................................................................................................................. 1
44 580036582 Fitting......................................................................................................................... 1
45 580036604 Wire Harness (Main) ................................................................................................. 1
46 580038271 Hose Assembly (2642 mm) ....................................................................................... 1

4-9
G10958 06-04

STEER AXLE

ITEM PART NO. DESCRIPTION QTY

46 580038272 Hose Assembly (2743 mm) ....................................................................................... 1


47 316534106 Fitting......................................................................................................................... 2
48 580038274 Hose Assembly (2820 mm) ....................................................................................... 1
48 580038275 Hose Assembly (2921 mm) ....................................................................................... 1
a 580000275 Guard ........................................................................................................................ 7
a 580024139 Nameplate ................................................................................................................. 1
a 580014906 Pin ............................................................................................................................. 2
a 580024146 Plastic Cover ............................................................................................................. 2

580025499 Axle Seal Kit (Includes Items 15, 21) ................................................................... 1


580015902 Axle Seal Kit (Includes Items 9, 16-17, 22-23, 33) .......................................... 1
580015901 Cylinder Seal Kit (Includes Items 24-26) ......................................................... 1

FOOTNOTES:
a Not Illustrated

4-10
NOTES

4-11
G10965 06-04

STEER COLUMN

STEER COLUMN

4-12
G10965 06-04

STEER COLUMN

ITEM PART NO. DESCRIPTION QTY

524175790 Steer Column (Directional) ........................................................................................ 1


524175789 Steer Column (With Levers) ...................................................................................... 1
1 505977597 Bracket ................................................................................................................. 1
2 580023576 Steering Column .................................................................................................. 1
2 518794682 Nut ................................................................................................................... 1
2 580000284 Horn Contact Kit .............................................................................................. 1
2 580041282 Rivet................................................................................................................. 2
2 580028072 Sensor ............................................................................................................. 1
3 518796642 Latch .................................................................................................................... 1
4 580011007 Hand Pump (☞ G11058) .................................................................................... 1
5 016104000 Washer ................................................................................................................. 4
6 015026400 Lockwasher .......................................................................................................... 4
7 059719100 Capscrew ............................................................................................................. 4
8 518807647 Lockwasher .......................................................................................................... 4
9 932200902 Capscrew ............................................................................................................. 4
10 505977589 Pin ........................................................................................................................ 1
11 015416200 Cotter Pin ............................................................................................................. 1
12 505977562 Shaft..................................................................................................................... 1
13 520037801 Spring................................................................................................................... 1
14 505977538 Plate ..................................................................................................................... 2
15 449022016 Lockwasher .......................................................................................................... 4
16 449001014 Capscrew ............................................................................................................. 4
17 505977509 Rod....................................................................................................................... 1
18 449021002 Washer ................................................................................................................. 1
19 504574273 Spring................................................................................................................... 1
20 520038825 Shift Lever Assembly (With Levers) (☞ G11030) ............................................... 1
21 504227269 Steering Wheel (14 in.).............................................................................................. 1
21 b 580045338 Steering Wheel (12 in.).............................................................................................. 1
22 580038270 Cover (Upper) ............................................................................................................ 1
23 506768501 Tube........................................................................................................................... 1
24 502056906 Clamp ........................................................................................................................ 2
25 580034132 Static Ground Patch .................................................................................................. 1
26 504240838 Ignition Switch ........................................................................................................... 1
27 504574274 Screw......................................................................................................................... 6
28 580038269 Cover (Lower) ............................................................................................................ 1
29 505977566 Latch Knob ................................................................................................................ 1
30 449004080 Screw......................................................................................................................... 2
31 580014160 Plug ........................................................................................................................... 1
32 520045057 Plug ........................................................................................................................... 2
33 b 504238241 Knob .......................................................................................................................... 1
34 524135211 Horn Button ............................................................................................................... 1
35 449021003 Washer ...................................................................................................................... 4
36 449022018 Lockwasher ............................................................................................................... 4
37 449001170 Capscrew................................................................................................................... 4
38 580032663 Wire Harness............................................................................................................. 1
39 505977573 Bracket ...................................................................................................................... 2
a 580037873 Hose (2540 mm)........................................................................................................ 1
a 580038277 Hose (1270 mm)........................................................................................................ 1
a 580034850 Insulated Clamp......................................................................................................... 2
a 449001302 Capscrew................................................................................................................... 1

4-13
G10965 06-04

STEER COLUMN

ITEM PART NO. DESCRIPTION QTY

a 449021006 Washer ...................................................................................................................... 1


a 449022013 Lockwasher ............................................................................................................... 1
a 937300910 Nut ............................................................................................................................. 1
a 580022964 Capscrew................................................................................................................... 1
a 449015098 Locknut ...................................................................................................................... 1
a 524207120 Jumper Assembly ...................................................................................................... 1

FOOTNOTES:
a Not Illustrated
b Optional

4-14
NOTES

4-15
G11023 06-04

STEER PUMP AND MOTOR

STEER PUMP AND MOTOR

4-16
G11023 06-04

STEER PUMP AND MOTOR

ITEM PART NO. DESCRIPTION QTY

1 580026217 Steer Motor (36V) ...................................................................................................... 1


1 580029797 Steer Motor (48V) ...................................................................................................... 1
2 504223274 O-Ring ....................................................................................................................... 1
3 580000127 Gear Pump (☞ G11022) .......................................................................................... 1
4 580043636 Weldment .................................................................................................................. 1
5 055746400 Fitting......................................................................................................................... 1
6 580011625 Fitting......................................................................................................................... 1
7 449022016 Lockwasher ............................................................................................................... 4
8 931013904 Capscrew................................................................................................................... 4
9 580043635 Spacer ....................................................................................................................... 1
10 449022021 Lockwasher ............................................................................................................... 2
11 930102903 Screw......................................................................................................................... 2
12 449001040 Capscrew................................................................................................................... 3
13 518796686 Washer ...................................................................................................................... 3
14 449021006 Washer ..................................................................................................................... 4
15 080143400 Mount ........................................................................................................................ 3
a 524163286 Hose .......................................................................................................................... 1
a 062159500 Clamp ........................................................................................................................ 2

FOOTNOTES:
a Not Illustrated

4-17
G11041 06-04

STEER TIRE AND WHEEL ASSEMBLY


(SOLID PNEUMATIC)

STEER T IRE AND WHEEL ASSEMBLYSOLID PNEUMATIC

ITEM PART NO. DESCRIPTION QTY

1 580010864 Tire and Wheel Assembly (Solid Pneumatic) ............................................................ 2


2 580008946 Tire (15 in. x 4.5-8) .............................................................................................. 1
3 580010868 Wheel ................................................................................................................... 1

4-18
G11042 06-04

STEER TIRE AND WHEEL ASSEMBLY


(CUSHION)

STEER TIRE AND WHEEL ASSEMBLYCUSHION

ITEM PART NO. DESCRIPTION QTY

1 580008920 Tire and Wheel Assembly (Cushion) ......................................................................... 2


2 580008918 Wheel (11.25 in.).................................................................................................. 1
3 580008926 Tire (15 in. x 4 in. x 11.25 in.) .............................................................................. 2

4-19
G11043 06-04

STEER TIRE AND WHEEL ASSEMBLY


(NON-MARKING CUSHION)

STEER T IRE AND WHEEL ASSEMBLYNON-MAR KING CUSHION

ITEM PART NO. DESCRIPTION QTY

1 524139249 Tire and Wheel Assembly.......................................................................................... 2


2 580008918 Wheel ................................................................................................................... 1
3 524139248 Tire ....................................................................................................................... 1

4-20
SECTION 5

5 BRAKE SYSTEM

5 BRAKE SYSTEM
CONTENTS

SECTION 5
BRAKE SYSTEM

DESCRIPTION PAGE

ACCELERATOR ASSEMBLY .............................................................................................................................. 5-2


ACCELERATOR PEDAL....................................................................................................................................... 5-4
BRAKE ASSEMBLY ............................................................................................................................................. 5-6
MASTER CYLINDER ........................................................................................................................................... 5-8
PARKING BRAKE............................................................................................................................................... 5-10

5-1
G11044 06-04

ACCELERATOR ASSEMBLY

ACCELERATOR ASSEMBLY

5-2
G11044 06-04

ACCELERATOR ASSEMBLY

ITEM PART NO. DESCRIPTION QTY

524163809 Accelerator Assembly................................................................................................ 1


1 524163803 Accelerator Weldment .......................................................................................... 1
2 505977537 Pedal Stop............................................................................................................ 2
3 504228295 Switch................................................................................................................... 1
4 580010427 Insulator ............................................................................................................... 1
5 505966574 Throttle Position Sensor ....................................................................................... 1
6 504057758 Electrical Connector ............................................................................................. 1
7 940004903 Washer ................................................................................................................. 4
8 449022019 Lockwasher .......................................................................................................... 4
9 931109909 Screw ................................................................................................................... 2
10 937100903 Nut........................................................................................................................ 4
11 449007040 Screw ................................................................................................................... 2
12 449021001 Washer ................................................................................................................. 4
13 449022016 Lockwasher .......................................................................................................... 4
14 449001134 Capscrew ............................................................................................................. 2
15 505977519 Tube........................................................................................................................... 1
16 449021006 Washer ...................................................................................................................... 7
17 449001078 Capscrew................................................................................................................... 1
18 449015044 Nut ............................................................................................................................. 5
19 449022016 Lockwasher ............................................................................................................... 1
20 449015014 Nut ............................................................................................................................. 2
21 449001052 Capscrew................................................................................................................... 1
22 505974576 Spring ........................................................................................................................ 1
23 449022013 Lockwasher ............................................................................................................... 2
24 449001040 Capscrew................................................................................................................... 4
a 505018208 Jumper Assembly ...................................................................................................... 1

FOOTNOTES:
a Not Illustrated

5-3
G11012 06-04

ACCELERATOR PEDAL

ACCEL ERATOR PEDAL

5-4
G11012 06-04

ACCELERATOR PEDAL

KEY:
A: Foot Directional Control
B: Forward/Reverse

QTY
ITEM PART NO. DESCRIPTION A B
505974543 Accelerator Pedal .............................................................................................. .. 1
524137528 Foot Directional Control Pedal........................................................................... 1 ..
1 580010428 Pedal ............................................................................................................. 1 ..
1 505974506 Pedal ............................................................................................................. .. 1
2 504228276 Bushing ......................................................................................................... 2 2
3 505974595 Pin ................................................................................................................. 1 1
4 524137230 Pad ................................................................................................................ 1 ..
4 504228259 Pad ................................................................................................................ .. 1
5 580014196 Switch............................................................................................................ 1 ..
6 580010432 Spring............................................................................................................ 2 ..
7 500552902 Lockwasher ................................................................................................... 4 ..
8 032643500 Nut................................................................................................................. 4 ..
9 502634904 Screw ............................................................................................................ 6 ..
9 518821818 Screw (Optional) ........................................................................................... 4 ..
10 065619300 Lockwasher ................................................................................................... 4 ..
10 580010434 Washer (Optional) ......................................................................................... 2 ..
11 580010433 Washer .......................................................................................................... 2 ..
12 312850042 Strap Clamp .................................................................................................. 3 ..
13 504225201 Screw ............................................................................................................ 4 ..

5-5
G11045 06-04

BRAKE ASSEMBLY

BRAKE ASSEMBLY

5-6
G11045 06-04

BRAKE ASSEMBLY

ITEM PART NO. DESCRIPTION QTY

1 580044937 Brake Weldment................................................................................................... 1


2 .. . . . Brake Pedal .......................................................................................................... 1
2 900001201 Pad ............................................................................................................................ 1
3 580044939 Tube ..................................................................................................................... 1
4 449021019 Washer ................................................................................................................. 1
5 449001019 Capscrew ............................................................................................................. 1
6 504225240 Nut........................................................................................................................ 1
7 751199100 Insulator ............................................................................................................... 1
8 580041501 Brake Switch Assembly........................................................................................ 1
8 580041501 Brake Switch Assembly (Optional Light Kit) ......................................................... 1
9 505977537 Pedal Stop............................................................................................................ 2
10 449015014 Nut........................................................................................................................ 2
11 449022016 Lockwasher .......................................................................................................... 4
12 449001134 Capscrew ............................................................................................................. 2
13 518803628 Capscrew ............................................................................................................. 2
14 580052619 Nut Plate Assembly .............................................................................................. 1
15 505966598 Spring................................................................................................................... 1
16 580040494 Master Cylinder .................................................................................................... 1
17 932201907 Capscrew ............................................................................................................. 2
18 449021001 Washer ................................................................................................................. 4
19 580052066 Plate .......................................................................................................................... 1
20 580052065 Label.......................................................................................................................... 1
21 449001170 Capscrew................................................................................................................... 8
22 580039364 O-Ring ....................................................................................................................... 1
23 580036773 Hydraulic Tube........................................................................................................... 1
24 580036774 Hydraulic Tube........................................................................................................... 1
25 580036775 Hydraulic Tube........................................................................................................... 1
26 580019835 Fitting......................................................................................................................... 1
27 580019805 Fitting......................................................................................................................... 3
28 518807647 Lockwasher ............................................................................................................... 8
29 449021003 Washer ...................................................................................................................... 8
30 015914900 Snap Ring.................................................................................................................. 2
31 027678700 Key............................................................................................................................. 2

5-7
G11032 06-04

MASTER CYLINDER

MASTER CYLINDER

5-8
G11032 06-04

MASTER CYLINDER

ITEM PART NO. DESCRIPTION QTY

580040494 Master Cylinder ......................................................................................................... 1


1 580047595 Stop Plate............................................................................................................. 1
2 580047596 Push Rod ............................................................................................................. 1
3 580047597 Yoke...................................................................................................................... 1
4 580047598 Nut........................................................................................................................ 1
5 580047599 Pin ........................................................................................................................ 1
6 580047600 Washer ................................................................................................................. 1
7 580047601 Snap Pin............................................................................................................... 1
8 580047602 Stop Pin................................................................................................................ 1
9 580047603 Filter ..................................................................................................................... 1
10 580047604 Indicator ............................................................................................................... 1
11 580047605 Clamp................................................................................................................... 1
12 580047673 Boot...................................................................................................................... 1
a 580047757 Repair Kit ............................................................................................................. 1

FOOTNOTES:
a Not Illustrated

5-9
G11054 06-04

PARKING BRAKE

PARK ING BRAKE

5-10
G11054 06-04

PARKING BRAKE

ITEM PART NO. DESCRIPTION QTY

580034580 Brake ......................................................................................................................... 1


1 a .. . . . Brake Coil .................................................................................................................. 1
2 a .. . . . Springs ...................................................................................................................... 6
3 a .. . . . Pressure Plate ........................................................................................................... 1
4 a .. . . . Spacers ..................................................................................................................... 3
5 a .. . . . Shims ........................................................................................................................ 12
6 a .. . . . Friction Disk............................................................................................................... 1
7 a .. . . . Mounting Plate .......................................................................................................... 1
8 a .. . . . Screws....................................................................................................................... 3
9 a .. . . . Capscrews................................................................................................................. 4
10 a .. . . . Lockwashers.............................................................................................................. 4
11 a .. . . . Washers .................................................................................................................... 4
12 a .. . . . Wiring Harness.......................................................................................................... 1
13 015914900 Snap Ring.................................................................................................................. 2
14 027678700 Key............................................................................................................................. 2

FOOTNOTES:
a Not Serviced Separately

5-11
NOTES

5-12
SECTION 6

6 HYDRAULIC SYSTEM

6 HYDRAULIC SYSTEM
CONTENTS

SECTION 6
HYDRAULIC SYSTEM

DESCRIPTION PAGE

ELECTRO-HYDRAULIC AUXILIARY ONE VALVE SECTION............................................................................ 6-34


ELECTRO-HYDRAULIC AUXILIARY TWO VALVE SECTION ........................................................................... 6-36
ELECTRO-HYDRAULIC CONTROL VALVE ...................................................................................................... 6-28
ELECTRO-HYDRAULIC LEVERS...................................................................................................................... 6-38
ELECTRO-HYDRAULIC MAIN CONTROL VALVE SECTION ........................................................................... 6-30
ELECTRO-HYDRAULIC TILT VALVE SECTION ................................................................................................ 6-32
HANDLEVER...................................................................................................................................................... 6-24
HYDRAULIC GEAR PUMP .................................................................................................................................. 6-6
HYDRAULIC HOSE AND FITTINGS
ELECTRO ....................................................................................................................................................... 6-40
MANUAL ........................................................................................................................................................... 6-2
HYDRAULIC PUMP MOTOR ............................................................................................................................... 6-8
HYDRAULIC TANK ASSEMBLY......................................................................................................................... 6-42
HYDRAULIC VALVE AND ATTACHING PARTS
MANUAL ......................................................................................................................................................... 6-22
MANUAL CONTROL VALVE .............................................................................................................................. 6-26
TILT CYLINDER
THREE STAGE FULL FREE-LIFT .................................................................................................................. 6-14
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 6-18
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 6-10
TILT CYLINDER ATTACHING PARTS
THREE STAGE FULL FREE-LIFT .................................................................................................................. 6-16
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 6-20
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 6-12

6-1
G11059 06-04

HYDRAULIC HOSE AND FITTINGS


(MANUAL)

HYDRAULIC HOSE AND FITTIN GSMA NUAL

6-2
G11059 06-04

HYDRAULIC HOSE AND FITTINGS


(MANUAL)

KEY:
A: Two Function
B: Three Function
C: Four Function

QTY
ITEM PART NO. DESCRIPTION A B C

1 502654911 Hose Assembly....................................................................................... 1 1 1


2 580053994 Hose Assembly....................................................................................... 1 1 1
3 524191515 Hose Assembly....................................................................................... 1 1 1
4 524191516 Hose Assembly....................................................................................... 1 1 1
5 524163287 Hose ....................................................................................................... 1 1 1
6 580041329 Plate ....................................................................................................... .. 1 1
7 449001040 Capscrew................................................................................................ .. 2 2
8 449021006 Washer ................................................................................................... .. 2 2
9 504785209 Fastener ................................................................................................. .. 2 2
10 019899200 Fitting...................................................................................................... .. 2 4
11 580050232 Hose Assembly....................................................................................... .. 1 1
12 580050231 Hose Assembly....................................................................................... .. 1 1
13 580050234 Hose Assembly....................................................................................... .. .. 1
14 580050233 Hose Assembly....................................................................................... .. .. 1
15 b .. . . . Hoist Motor Bracket ................................................................................ 1 1 1
16 056363100 Fitting...................................................................................................... 4 4 4
17 720307903 Fitting...................................................................................................... 2 2 2
18 524191513 Hose Assembly....................................................................................... 1 1 1
19 524191514 Hose Assembly....................................................................................... 1 1 1
20 580044777 Hose Assembly....................................................................................... 1 1 1
21 580044776 Rivet ....................................................................................................... 1 1 1
22 580041328 Hose ....................................................................................................... 1 1 1
23 502056904 Clamp ..................................................................................................... 4 4 4
24 502056906 Clamp ..................................................................................................... 2 2 2
25 449001040 Capscrew................................................................................................ 4 4 4
26 449001069 Capscrew................................................................................................ 3 3 3
27 449022013 Lockwasher ............................................................................................ 3 3 3
28 449021006 Washer ................................................................................................... 8 8 8
29 449015044 Nut .......................................................................................................... 1 1 1
30 080143400 Mount ..................................................................................................... 4 4 4
31 518796686 Washer ................................................................................................... 4 4 4
32 580044605 Spacer .................................................................................................... 1 1 1
33 580044606 Bracket Weldment .................................................................................. 1 1 1
34 312850032 Strap Clamp............................................................................................ AR AR AR
35 449022013 Lockwasher ............................................................................................ .. 2 2
a 066002600 Clamp ..................................................................................................... 1 1 1
a 449001415 Capscrew................................................................................................ 1 1 1
a 449001014 Capscrew................................................................................................ 1 1 1
a 449022016 Lockwasher ............................................................................................ 2 2 2

6-3
G11059 06-04

HYDRAULIC HOSE AND FITTINGS


(MANUAL)

QTY
ITEM PART NO. DESCRIPTION A B C

a 449021001 Washer ................................................................................................... 2 2 2


a 449015014 Nut .......................................................................................................... 1 1 1

FOOTNOTES:
a Not Illustrated
b Not Serviced Separately

6-4
NOTES

6-5
G11097 06-04

HYDRAULIC GEAR PUMP

HYDRAULIC GEAR PUMP

6-6
G11097 06-04

HYDRAULIC GEAR PUMP

ITEM PART NO. DESCRIPTION QTY

580035967 Hydraulic Gear Pump........................................................................................... 1


1 580042233 Screw ............................................................................................................... 4
2 580006359 Mounting Flange .............................................................................................. 1
3 580006358 Cover ............................................................................................................... 1
4 580042248 Body................................................................................................................. 1

524192425 Kit (Includes Items 5-8) .................................................................................... 1


5 580042242 Bushing........................................................................................................ 2
6 580042241 Bushing........................................................................................................ 2
7 580042240 Gear............................................................................................................. 1
8 580042239 Gear............................................................................................................. 1
524144007 Seal Kit ............................................................................................................ 1
9 b .. . . . Seal ............................................................................................................. 2
10 b .. . . . Seal ............................................................................................................. 2
11 b .. . . . Ring ............................................................................................................. 2
12 b .. . . . Ring ............................................................................................................. 2
13 b .. . . . Oil Seal ........................................................................................................ 1
14 b .. . . . Snap Ring.................................................................................................... 1
a 061353000 Fitting ................................................................................................................... 1
a 052229600 Fitting ................................................................................................................... 1
a 580026611 Capscrew ............................................................................................................. 2

FOOTNOTES:
a Not Illustrated
b Not Serviced Separately

6-7
G10938 06-04

HYDRAULIC PUMP MOTOR

HYDRAULIC PUMP MOTOR

6-8
G10938 06-04

HYDRAULIC PUMP MOTOR

ITEM PART NO. DESCRIPTION QTY

580045697 Hydraulic Pump Motor ............................................................................................... 1


1 580027246 Bracket ................................................................................................................. 1
2 580027247 Bearing................................................................................................................. 1
3 580027248 Armature .............................................................................................................. 1
4 580027249 Gasket.................................................................................................................. 1
5 580027250 Plate ..................................................................................................................... 1
6 580050404 Stator.................................................................................................................... 1
7 580027252 Brush Holder ........................................................................................................ 1
8 580027253 Brush (with Spring) .............................................................................................. 1
9 580050405 Thermal Protector ................................................................................................ 1
10 580027255 Commutator End Head ........................................................................................ 1
11 580026438 Bearing................................................................................................................. 1
12 580027256 Fan ....................................................................................................................... 1
13 580027257 Cover.................................................................................................................... 1
a 524144772 Enclosure Kit ............................................................................................................. 1

FOOTNOTES:
a Not Illustrated

6-9
G11109 06-04

TILT CYLINDER
(TWO STAGE LIMITED FREE-LIFT)

TILT CYLINDERTWO STAGE LIMITED FREE-LIFT

6-10
G11109 06-04

TILT CYLINDER
(TWO STAGE LIMITED FREE-LIFT)

KEY:
A: 5 Forward Tilt/7 Back Tilt
B: 10 Forward Tilt/5 Back Tilt
C: 5 Forward Tilt/5 Back Tilt

QTY
ITEM PART NO. DESCRIPTION A B C

580035367 Tilt Cylinder (Group No. 8603391) ......................................................... .. 2 ..


580035368 Tilt Cylinder (Group No. 8604718) ......................................................... 2 .. ..
580035369 Tilt Cylinder (Group No. 8604719) ......................................................... .. .. 2
1 520041606 Tube ................................................................................................... 1 .. 1
1 520041607 Tube ................................................................................................... .. 1 ..
2 519517601 Piston Rod.......................................................................................... 1 .. ..
2 519517603 Piston Rod.......................................................................................... .. 1 ..
2 519517615 Piston Rod.......................................................................................... .. .. 1
3 .. . . . Wiper Ring ......................................................................................... 1 1 1
4 504143500 Gland.................................................................................................. 1 1 1
5 .. . . . Seal .................................................................................................... 1 1 1
6 .. . . . Back-up Ring...................................................................................... 1 1 1
7 .. . . . O-Ring................................................................................................ 1 1 1
8 519477600 Piston ................................................................................................. 1 1 1
9 .. . . . Seal .................................................................................................... 1 1 1
10 502637902 Nut...................................................................................................... 1 1 1
a 501802906 O-Ring .................................................................................................... 1 1 1

580023425 Seal Kit (Includes Items 3, 5-7, 9) ...................................................... 1 1 1

FOOTNOTES:
a Not Illustrated

6-11
G11099 06-04

TILT CYLINDER ATTACHING PARTS


(TWO STAGE LIMITED FREE-LIFT)

TILT CYLINDER ATTACHING PART STWO STAGE LIMITED FREE-LIFT

6-12
G11099 06-04

TILT CYLINDER ATTACHING PARTS


(TWO STAGE LIMITED FREE-LIFT)

ITEM PART NO. DESCRIPTION QTY

1 931015909 Capscrew................................................................................................................... 2
2 449022017 Lockwasher ............................................................................................................... 2
3 580033885 Nut ............................................................................................................................. 2
4 449001016 Capscrew................................................................................................................... 2
5 449022013 Lockwasher ............................................................................................................... 2
6 520039885 Washer ...................................................................................................................... 2
7 015627900 Lube Fitting................................................................................................................ 2
8 900005215 Rod End Pin .............................................................................................................. 2
9 900003275 Rod End .................................................................................................................... 1
9 900003276 Rod End .................................................................................................................... 1
10 580035367 Tilt Cylinder (Group No. 8603391) ............................................................................ 1
10 580035368 Tilt Cylinder (Group No. 8604718) ............................................................................ 1
10 580035369 Tilt Cylinder (Group No. 8604719) ............................................................................ 1
11 518801677 Rod End Pin .............................................................................................................. 2
11 015627900 Lube Fitting................................................................................................................ 2
12 015420300 Cotter Pin .................................................................................................................. 2
13 504574267 Washer ...................................................................................................................... 6
14 504229225 Bushing ..................................................................................................................... 2
15 012828800 O-Ring ....................................................................................................................... 2
16 580052276 Shim .......................................................................................................................... 2
17 580052277 Bushing ..................................................................................................................... 2

6-13
G11110 06-04

TILT CYLINDER
(THREE STAGE FULL FREE-LIFT)

TILT CYLINDERTHREE STAGE F ULL FREE-LIFT

6-14
G11110 06-04

TILT CYLINDER
(THREE STAGE FULL FREE-LIFT)

KEY:
A: 5 Forward Tilt/7 Back Tilt
B: 10 Forward Tilt/5 Back Tilt
C: 5 Forward Tilt/5 Back Tilt

QTY
ITEM PART NO. DESCRIPTION A B C

580035367 Tilt Cylinder (Group No. 8603391) ......................................................... .. 2 ..


580035368 Tilt Cylinder (Group No. 8604718) ......................................................... 2 .. ..
580035369 Tilt Cylinder (Group No. 8604719) ......................................................... .. .. 2
1 520041606 Tube ................................................................................................... 1 .. 1
1 520041607 Tube ................................................................................................... .. 1 ..
2 519517601 Piston Rod.......................................................................................... 1 .. ..
2 519517603 Piston Rod.......................................................................................... .. 1 ..
2 519517615 Piston Rod.......................................................................................... .. .. 1
3 .. . . . Wiper Ring ......................................................................................... 1 1 1
4 504143500 Gland.................................................................................................. 1 1 1
5 .. . . . Seal .................................................................................................... 1 1 1
6 .. . . . Back-up Ring...................................................................................... 1 1 1
7 .. . . . O-Ring................................................................................................ 1 1 1
8 519477600 Piston ................................................................................................. 1 1 1
9 .. . . . Seal .................................................................................................... 1 1 1
10 502637902 Nut...................................................................................................... 1 1 1
a 501802906 O-Ring .................................................................................................... 1 1 1

580023425 Seal Kit (Includes Items 3, 5-7, 9) ...................................................... 1 1 1

FOOTNOTES:
a Not Illustrated

6-15
G11100 06-04

TILT CYLINDER ATTACHING PARTS


(THREE STAGE FULL FREE-LIFT)

TILT CYLINDER ATTACHING PART STHREE STAGE FULL FREE-LIFT

6-16
G11100 06-04

TILT CYLINDER ATTACHING PARTS


(THREE STAGE FULL FREE-LIFT)

ITEM PART NO. DESCRIPTION QTY

1 931015909 Capscrew................................................................................................................... 2
2 449022017 Lockwasher ............................................................................................................... 2
3 580033885 Nut ............................................................................................................................. 2
4 449001016 Capscrew................................................................................................................... 2
5 449022013 Lockwasher ............................................................................................................... 2
6 520039885 Washer ...................................................................................................................... 2
7 015627900 Lube Fitting................................................................................................................ 2
8 900005215 Rod End Pin .............................................................................................................. 2
9 900003275 Rod End (RH) ............................................................................................................ 1
9 900003276 Rod End (LH)............................................................................................................. 1
10 580035367 Tilt Cylinder (Group No. 8603391) ............................................................................ 1
10 580035368 Tilt Cylinder (Group No. 8604718) ............................................................................ 1
10 580035369 Tilt Cylinder (Group No. 8604719) ............................................................................ 1
11 518801677 Rod End Pin .............................................................................................................. 2
11 015627900 Lube Fitting................................................................................................................ 2
12 015420300 Cotter Pin .................................................................................................................. 2
13 504574267 Washer ...................................................................................................................... 6
14 504229225 Bushing ..................................................................................................................... 2
15 580052276 Shim .......................................................................................................................... 2
16 012828800 O-Ring ....................................................................................................................... 2

6-17
G11111 06-04

TILT CYLINDER
(TWO STAGE FULL FREE-LIFT)

TILT C YLINDERTWO STAGE FULL FREE-LIFT

6-18
G11111 06-04

TILT CYLINDER
(TWO STAGE FULL FREE-LIFT)

KEY:
A: 5 Forward Tilt/7 Back Tilt
B: 10 Forward Tilt/5 Back Tilt
C: 5 Forward Tilt/5 Back Tilt

QTY
ITEM PART NO. DESCRIPTION A B C

580035367 Tilt Cylinder (Group No. 8603391) ......................................................... .. 2 ..


580035368 Tilt Cylinder (Group No. 8604718) ......................................................... 2 .. ..
580035369 Tilt Cylinder (Group No. 8604719) ......................................................... .. .. 2
1 520041606 Tube ................................................................................................... 1 .. 1
1 520041607 Tube ................................................................................................... .. 1 ..
2 519517601 Piston Rod.......................................................................................... 1 .. ..
2 519517603 Piston Rod.......................................................................................... .. 1 ..
2 519517615 Piston Rod.......................................................................................... .. .. 1
3 .. . . . Wiper Ring ......................................................................................... 1 1 1
4 504143500 Gland.................................................................................................. 1 1 1
5 .. . . . Seal .................................................................................................... 1 1 1
6 .. . . . Back-up Ring...................................................................................... 1 1 1
7 .. . . . O-Ring................................................................................................ 1 1 1
8 519477600 Piston ................................................................................................. 1 1 1
9 .. . . . Seal .................................................................................................... 1 1 1
10 502637902 Nut...................................................................................................... 1 1 1
a 501802906 O-Ring .................................................................................................... 1 1 1

580023425 Seal Kit (Includes Items 3, 5-7, 9) ...................................................... 1 1 1

FOOTNOTES:
a Not Illustrated

6-19
G11098 06-04

TILT CYLINDER ATTACHING PARTS


(TWO STAGE FULL FREE-LIFT)

TILT CYLINDER ATTACHING PART STWO STAGE FULL FREE-LIFT

6-20
G11098 06-04

TILT CYLINDER ATTACHING PARTS


(TWO STAGE FULL FREE-LIFT)

ITEM PART NO. DESCRIPTION QTY

1 931015909 Capscrew................................................................................................................... 2
2 449022017 Lockwasher ............................................................................................................... 2
3 580033885 Nut ............................................................................................................................. 2
4 449001016 Capscrew................................................................................................................... 2
5 449022013 Lockwasher ............................................................................................................... 2
6 520039885 Washer ...................................................................................................................... 2
7 015627900 Lube Fitting................................................................................................................ 2
8 900005215 Rod End Pin .............................................................................................................. 2
9 900003275 Rod End .................................................................................................................... 1
9 900003276 Rod End .................................................................................................................... 1
10 580035367 Tilt Cylinder (Group No. 8603391) ............................................................................ 1
10 580035368 Tilt Cylinder (Group No. 8604718) ............................................................................ 1
10 580035369 Tilt Cylinder (Group No. 8604719) ............................................................................ 1
11 518801677 Rod End Pin .............................................................................................................. 2
11 015627900 Lube Fitting................................................................................................................ 2
12 015420300 Cotter Pin .................................................................................................................. 2
13 504574267 Washer ...................................................................................................................... 6
14 504229225 Bushing ..................................................................................................................... 2
15 012828800 O-Ring ....................................................................................................................... 2
16 580052276 Shim .......................................................................................................................... 2
17 580052277 Bushing ..................................................................................................................... 2

6-21
G11060 06-04

HYDRAULIC VALVE AND ATTACHING PARTS


(MANUAL)

HYDRAULIC VALVE AND AT TACHING PARTSMANUAL

6-22
G11060 06-04

HYDRAULIC VALVE AND ATTACHING PARTS


(MANUAL)

ITEM PART NO. DESCRIPTION QTY

1 580003242 Capscrew................................................................................................................... 2
2 580041699 Lower Cover .............................................................................................................. 1
3 504871201 Standoff ..................................................................................................................... 1
4 504871206 Standoff ..................................................................................................................... 1
5 449001114 Capscrew................................................................................................................... 2
6 580041701 Link ............................................................................................................................ 2
7 015414700 Cotter Pin .................................................................................................................. 4
8 504574254 Pin ............................................................................................................................. 4
9 504634200 Pin ............................................................................................................................. 1
10 015918200 Snap Ring.................................................................................................................. 2
11 016139700 Shim .......................................................................................................................... AR
12 504230239 Spring ........................................................................................................................ 1
13 504235252 Pin ............................................................................................................................. 1
14 504887200 Pin ............................................................................................................................. 1
15 504695203 Spacer ....................................................................................................................... 2
16 504228208 Bracket ...................................................................................................................... 5
17 449001023 Capscrew................................................................................................................... 1
18 449021006 Washer ...................................................................................................................... 1
19 449022013 Lockwasher ............................................................................................................... 1
20 449015044 Nut ............................................................................................................................. 1
21 504228261 Channel (Rubber) ...................................................................................................... 5
22 580052468 Control Valve (Two Function) (☞ G11049) .............................................................. 1
22 580052469 Control Valve (Three Function) (☞ G11049) ........................................................... 1
22 580052470 Control Valve (Four Function) (☞ G11049) ............................................................. 1
23 449001015 Capscrew................................................................................................................... 1
24 449021006 Washer ...................................................................................................................... 1
25 449022013 Lockwasher ............................................................................................................... 1
26 449015044 Nut ............................................................................................................................. 1
27 524163291 Bracket Weldment ..................................................................................................... 1
28 506726504 Stud ........................................................................................................................... 1
29 449022018 Lockwasher ............................................................................................................... 1
30 449015002 Nut ............................................................................................................................. 1

6-23
G11050 06-04

HANDLEVER

HANDLEVER

6-24
G11050 06-04

HANDLEVER

ITEM PART NO. DESCRIPTION QTY

1 580003242 Capscrew................................................................................................................... 8
2 580041698 Cover (Upper) ............................................................................................................ 1
2 580051526 Plug (4 Function Lever Slot) ...................................................................................... 1
3 504628701 Hand Lever (Lift) ........................................................................................................ 1
4 504628702 Hand Lever (Tilt) ........................................................................................................ 1
5 504628703 Hand Lever (Aux 1).................................................................................................... 1
6 504628704 Hand Lever (Last Function) ....................................................................................... 1
7 449001170 Capscrew................................................................................................................... 4
8 449021003 Washer ...................................................................................................................... 2
9 449022018 Lockwasher ............................................................................................................... 4
10 449015002 Nut ............................................................................................................................. 4
11 504871207 Spacer ....................................................................................................................... 4
12 504871202 Spacer ....................................................................................................................... 4
13 449001114 Capscrew................................................................................................................... 8
14 504919200 Knob .......................................................................................................................... 1
15 015414700 Cotter Pin .................................................................................................................. 1
16 504920200 Rod ............................................................................................................................ 1
17 504901200 Latch.......................................................................................................................... 1
18 506395532 Capscrew................................................................................................................... 2
19 580019388 Washer ...................................................................................................................... 2
20 504673200 Strap .......................................................................................................................... 2
21 449001170 Capscrew................................................................................................................... 2
22 449021003 Washer ...................................................................................................................... 2
23 449015135 Nut ............................................................................................................................. 2
24 504235252 Pin ............................................................................................................................. 2
25 504230239 Spring ........................................................................................................................ 1
26 504631200 Crank ......................................................................................................................... 1
27 504632200 Pivot........................................................................................................................... 1
28 504627200 Crank ......................................................................................................................... 2
29 504695202 Spacer ....................................................................................................................... 4
30 504693200 Link ............................................................................................................................ 4
31 015414700 Cotter Pin .................................................................................................................. 4
32 504574254 Pin ............................................................................................................................. 4
33 504629200 Rocker Arm................................................................................................................ 2
34 504574255 Snap Ring.................................................................................................................. 4
35 504633200 Pivot Pin .................................................................................................................... 2
36 502793901 Bearing ...................................................................................................................... 8
37 580044046 Frame ........................................................................................................................ 1
38 580034133 Nut Plate Assembly ................................................................................................... 1

6-25
G11049 06-04

MANUAL CONTROL VALVE

MANUAL CONT ROL VALVE

6-26
G11049 06-04

MANUAL CONTROL VALVE

ITEM PART NO. DESCRIPTION QTY

580052468 Control Valve (Two Function)..................................................................................... 1


580052469 Control Valve (Three Function).................................................................................. 1
580052470 Control Valve (Four Function).................................................................................... 1
1 580044183 Inlet Section ......................................................................................................... 1
1 580052730 Insert................................................................................................................ 1
1 061643400 Fitting ............................................................................................................... 1
2 580046267 Lift Section ........................................................................................................... 1
2 580052731 Seal.................................................................................................................. 1
3 580046268 Tilt Section ........................................................................................................... 1
3 580052732 Insert................................................................................................................ 2
4 580044184 Outlet Section....................................................................................................... 1
a 580047139 Switch and Bracket Kit (Lift Section) .................................................................... 1
a 580047140 Switch and Bracket Kit (Tilt/Auxiliary Section)...................................................... 1
a 580048438 Seal Kit................................................................................................................. 1
5 580046269 Auxiliary One Section (Three and Four Function) ..................................................... 1
6 580046270 Auxiliary Two Section (Four Function) ....................................................................... 1
7 580054642 Main Relief Valve (2400 pressure) ............................................................................ 1
8 b 580044189 Secondary Relief Valve ............................................................................................. 1
a 580025665 Manifold (Three Function) ......................................................................................... 1
a 052643400 Fitting......................................................................................................................... 1
a 052643300 Fitting......................................................................................................................... 1
a 580054926 Fitting......................................................................................................................... 1
a 052642200 Fitting......................................................................................................................... 1
a 122310101 Fitting......................................................................................................................... 1

FOOTNOTES:
a Not Illustrated
b Used on 3 and 4 function

6-27
G11061 06-04

ELECTRO-HYDRAULIC CONTROL VALVE

ELECTRO-HYDRAUL IC CONTROL VALVE

6-28
G11061 06-04

ELECTRO-HYDRAULIC CONTROL VALVE

ITEM PART NO. DESCRIPTION QTY

1 580052471 Electro-Hydraulic Control Valve (Two Function) ........................................................ 1


1 580052472 Electro-Hydraulic Control Valve (Three Function) ..................................................... 1
1 580052473 Electro-Hydraulic Control Valve (Four Function) ....................................................... 1
2 524171318 Plate (Two Function).................................................................................................. 1
2 524171319 Plate (Three Function)............................................................................................... 1
2 524171320 Plate (Four Function)................................................................................................. 1
3 062254800 Fitting......................................................................................................................... 1
4 501967903 Fitting......................................................................................................................... 1
5 052229600 Fitting......................................................................................................................... 1
6 b 052643200 Fitting (Three and Four Function only) ...................................................................... 2
7 504228208 Bracket ...................................................................................................................... 3
8 504228261 Channel (Rubber) ...................................................................................................... 3
9 449001114 Capscrew................................................................................................................... 1
10 449021003 Washer ...................................................................................................................... 1
11 449001415 Capscrew................................................................................................................... 2
12 504226242 Washer ...................................................................................................................... 2
13 449001023 Capscrew................................................................................................................... 3
14 449021006 Washer ...................................................................................................................... 3
15 449022013 Lockwasher ............................................................................................................... 3
16 449015044 Nut ............................................................................................................................. 3
17 277286800 Plate .......................................................................................................................... 1
18 580043738 Washer ...................................................................................................................... 2
19 580043744 Tension Rod (Four Function) ..................................................................................... 1
20 580043740 Screw (Three Function) ............................................................................................. 2
21 580043745 Nut (Four Function) ................................................................................................... 1
22 580047776 Connection Block....................................................................................................... 1
23 580047778 Valve Section (Tilt)..................................................................................................... 1
24 580048535 Valve Section (Auxiliary One) .................................................................................... 1
25 580053135 Valve Section (Auxiliary Two)..................................................................................... 1
a 580043804 Seal Kit ...................................................................................................................... 1
a 580041208 Fitting......................................................................................................................... 1

FOOTNOTES:
a Not Illustrated
b Quantity is 4 for Four Function

6-29
G11112 06-04

ELECTRO-HYDRAULIC MAIN CONTROL VALVE SECTION

ELECTRO-HYDRAUL IC MAIN CONTROL VALVE SECTION

6-30
G11112 06-04

ELECTRO-HYDRAULIC MAIN CONTROL VALVE SECTION

ITEM PART NO. DESCRIPTION QTY

1 580047776 Connection Block....................................................................................................... 1


2 580043824 Valve.......................................................................................................................... 1
3 580043766 Piston ........................................................................................................................ 1
4 580043768 Spring Guide ............................................................................................................. 1
5 580043769 Spring ........................................................................................................................ 1
6 580043770 Disc ........................................................................................................................... 1
7 a .. . . . Seal Ring ................................................................................................................... 1
8 580043774 Screw......................................................................................................................... 1
9 a .. . . . Seal ........................................................................................................................... 1
10 a .. . . . Screw......................................................................................................................... 1
11 580043824 Valve.......................................................................................................................... 2

FOOTNOTES:
a Not Serviced Separately

6-31
G11113 06-04

ELECTRO-HYDRAULIC TILT VALVE SECTION

ELECTRO-HYDRAULIC TILT VALVE SECTION

6-32
G11113 06-04

ELECTRO-HYDRAULIC TILT VALVE SECTION

ITEM PART NO. DESCRIPTION QTY

1 580047778 Valve Section............................................................................................................. 1


2 580047779 Actuator ..................................................................................................................... 1
3 580043803 Block.......................................................................................................................... 1
4 b .. . . . Solenoid Coil ............................................................................................................. 2
5 b .. . . . O-Ring ....................................................................................................................... 2
6 580043889 O-Ring ....................................................................................................................... 1
7 580043891 O-Ring ....................................................................................................................... 3
8 b .. . . . O-Ring ....................................................................................................................... 4
9 b .. . . . O-Ring ....................................................................................................................... 4
ab .. . . . O-Ring ....................................................................................................................... 2

580043804 Seal Kit (Includes Item ) ............................................................................................ 1

FOOTNOTES:
a Not Illustrated
b Not Serviced Separately

6-33
G11114 06-04

ELECTRO-HYDRAULIC AUXILIARY ONE VALVE SECTION

EL ECTRO-HYDRAULIC AUXILIARY ONE VALVE SECTION

6-34
G11114 06-04

ELECTRO-HYDRAULIC AUXILIARY ONE VALVE SECTION

ITEM PART NO. DESCRIPTION QTY

1 580048535 Valve Section............................................................................................................. 1


2 580047779 Actuator ..................................................................................................................... 1
3 580047781 Block.......................................................................................................................... 1
4 b .. . . . Solenoid Coil ............................................................................................................. 2
5 b .. . . . O-Ring ....................................................................................................................... 2
6 580043889 O-Ring ....................................................................................................................... 1
7 580043891 O-Ring ....................................................................................................................... 3
8 b .. . . . O-Ring ....................................................................................................................... 4
9 b .. . . . O-Ring ....................................................................................................................... 4
ab .. . . . O-Ring ....................................................................................................................... 2

580043804 Seal Kit (Includes Item ) ............................................................................................ 1

FOOTNOTES:
a Not Illustrated
b Not Serviced Separately

6-35
G11148 06-04

ELECTRO-HYDRAULIC AUXILIARY TWO VALVE SECTION

ELECTRO-HYDRAULIC AUXILIARY TWO VALVE SECTION

6-36
G11148 06-04

ELECTRO-HYDRAULIC AUXILIARY TWO VALVE SECTION

ITEM PART NO. DESCRIPTION QTY

1 580048535 Valve Section............................................................................................................. 1


2 580047779 Actuator ..................................................................................................................... 1
3 580047781 Block.......................................................................................................................... 1
4 b .. . . . Solenoid Coil ............................................................................................................. 2
5 b .. . . . O-Ring ....................................................................................................................... 2
6 580043889 O-Ring ....................................................................................................................... 1
7 580043891 O-Ring ....................................................................................................................... 3
8 b .. . . . O-Ring ....................................................................................................................... 4
9 b .. . . . O-Ring ....................................................................................................................... 4
10 580053136 Valve Spool................................................................................................................ 1
ab .. . . . O-Ring ....................................................................................................................... 2

580043804 Seal Kit (Includes Item ) ............................................................................................ 1

FOOTNOTES:
a Not Illustrated
b Not Serviced Separately

6-37
G11103 06-04

ELECTRO-HYDRAULIC LEVERS

ELECTRO-HYDRAULIC LEVERS

6-38
G11103 06-04

ELECTRO-HYDRAULIC LEVERS

ITEM PART NO. DESCRIPTION QTY

1 580041579 Control Handle (Three Function) ............................................................................... 1


1 580046869 Software ............................................................................................................... 1
1 580050222 Lever Kit (Self-Calibrating) ................................................................................... 3
1 580045366 Control Handle (Three Function Clamping)............................................................... 1
1 580046869 Software ............................................................................................................... 1
2 449015002 Nut ............................................................................................................................. 4
2 580041580 Control Handle (Four Function) ................................................................................. 1
2 580046869 Software ............................................................................................................... 1
2 580050222 Lever Kit (Self-Calibrating) ................................................................................... 4
2 580045367 Control Handle (Four Function Clamping) ................................................................. 1
2 580046869 Software ............................................................................................................... 1
3 449022018 Lockwasher ............................................................................................................... 4
4 449021003 Washer ...................................................................................................................... 4

6-39
G11115 06-04

HYDRAULIC HOSE AND FITTINGS


(ELECTRO)

HYDRAULIC HOSE AND FITTIN GSELECTRO

6-40
G11115 06-04

HYDRAULIC HOSE AND FITTINGS


(ELECTRO)

KEY:
A: Two Function
B: Three Function
C: Four Function

QTY
ITEM PART NO. DESCRIPTION A B C

1 502654912 Hose Assembly....................................................................................... 1 1 1


1 518792674 Hose Assembly (Option)......................................................................... 1 1 1
2 580051162 Hose Assembly....................................................................................... 1 1 1
3 524211424 Hose Assembly....................................................................................... 1 1 1
4 524191518 Hose Assembly....................................................................................... 1 1 1
5 580041338 Hose ....................................................................................................... 1 1 1
6 580041329 Plate ....................................................................................................... .. 1 1
7 449001040 Capscrew................................................................................................ .. 2 2
8 449021006 Washer ................................................................................................... .. 2 2
9 504785209 Fastener ................................................................................................. .. 2 2
10 019899200 Fitting...................................................................................................... .. 2 4
11 580050232 Hose Assembly....................................................................................... .. 1 1
12 580050231 Hose Assembly....................................................................................... .. 1 1
13 580050234 Hose Assembly....................................................................................... .. .. 1
14 580050233 Hose Assembly....................................................................................... .. .. 1
15 449022013 Lockwasher ............................................................................................ .. 2 2
a 900015239 Clamp (Option) ....................................................................................... 1 1 1
a 312850032 Strap Clamp (Option).............................................................................. 1 1 1

FOOTNOTES:
a Not Illustrated

6-41
G11002 06-04

HYDRAULIC TANK ASSEMBLY

HYDRAULIC TANK ASSEMBLY

6-42
G11002 06-04

HYDRAULIC TANK ASSEMBLY

ITEM PART NO. DESCRIPTION QTY

1 580034992 Hydraulic Tank ........................................................................................................... 1


2 524180977 Breather and Dipstick ................................................................................................ 1
3 524143330 Hydraulic Oil Filter Assembly..................................................................................... 1
3 524148312 Oil Filter Element.................................................................................................. 1
4 580039074 Switch Assembly (Oil Level) ...................................................................................... 1
5 316441036 Fitting......................................................................................................................... 1
6 059726400 Fitting......................................................................................................................... 1
7 449001415 Capscrew................................................................................................................... 2
8 449001014 Capscrew................................................................................................................... 2
9 449022016 Lockwasher ............................................................................................................... 4
10 449021001 Washer ...................................................................................................................... 4
11 449022021 Lockwasher ............................................................................................................... 3
12 580038834 Capscrew................................................................................................................... 3
13 580050217 Ground Wire .............................................................................................................. 1

6-43
NOTES

6-44
SECTION 7

7 LIF TING MECHANISM

7 LIFTING MECHANISM
CONTENTS

SECTION 7
LIFTING MECHANISM

DESCRIPTION PAGE

CARRIAGE
THREE STAGE FULL FREE-LIFT .................................................................................................................. 7-28
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 7-48
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 7-10
FREE LIFT
THREE STAGE FULL FREE-LIFT .................................................................................................................. 7-24
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 7-44
FREE LIFT CYLINDER
THREE STAGE FULL FREE-LIFT .................................................................................................................. 7-26
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 7-46
HEADER HOSE
THREE STAGE FULL FREE-LIFT .................................................................................................................. 7-30
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 7-50
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 7-12
INNER MAST
THREE STAGE FULL FREE-LIFT .................................................................................................................. 7-18
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 7-36
TWO STAGE LIMITED FREE-LIFT................................................................................................................... 7-4
INTERMEDIATE MAST
THREE STAGE FULL FREE-LIFT .................................................................................................................. 7-16
MAIN LIFT ASSEMBLY
THREE STAGE FULL FREE-LIFT .................................................................................................................. 7-20
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 7-38
TWO STAGE LIMITED FREE-LIFT................................................................................................................... 7-6
MAIN LIFT CYLINDER
LEFT HAND
TWO STAGE FULL FREE-LIFT .................................................................................................................. 7-40
RIGHT HAND
TWO STAGE FULL FREE-LIFT .................................................................................................................. 7-42
THREE STAGE FULL FREE-LIFT .................................................................................................................. 7-22
TWO STAGE LIMITED FREE-LIFT................................................................................................................... 7-8
OUTER MAST
THREE STAGE FULL FREE-LIFT .................................................................................................................. 7-14
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 7-34
TWO STAGE LIMITED FREE-LIFT................................................................................................................... 7-2

7-1
G11115 06-04

OUTER MAST
(TWO STAGE LIMITED FREE-LIFT)

OUTER MASTT WO STAGE LIMITED FREE-LIFT

7-2
G11115 06-04

OUTER MAST
(TWO STAGE LIMITED FREE-LIFT)

OALH

ITEM DESCRIPTION
Mast A661 A661 A661 A661
Group Number 2692 2992 3192 3792
Mast Assembly 580036132 580036135 580036137 580036143
1 Outer Mast 580036205 580036171 580036173 580036178

ITEM PART NO. DESCRIPTION QTY

a .. . . . Mast Assembly .......................................................................................................... 1


1 a .. . . . Outer Mast ........................................................................................................... 1
2 504066700 Stubshaft.......................................................................................................... 2
3 504075764 Bearing Strip ........................................................................................................ 2
4 504234265 Shim (0.020 in.).................................................................................................... 4
5 012824300 O-Ring.................................................................................................................. 4
6 520036852 Load Roller........................................................................................................... 2
6 520052899 Load Roller (Optional) .......................................................................................... 2
7 015916300 Snap Ring ............................................................................................................ 2
8 504233232 Shim (0.020 in.).................................................................................................... AR
9 900003277 Bushing ................................................................................................................ 2
10 580052791 Stub Shaft ............................................................................................................ 2

FOOTNOTES:
a Refer to Table

7-3
G11116 06-04

INNER MAST
(TWO STAGE LIMITED FREE-LIFT)

INNER MASTTWO STAGE LIMITED FREE-LIFT

7-4
G11116 06-04

INNER MAST
(TWO STAGE LIMITED FREE-LIFT)

OALH

ITEM DESCRIPTION
Mast A661 A661 A661 A661
Group Number 2692 2992 3192 3792
Mast Assembly 580036132 580036135 580036137 580036143
1 Inner Mast 504067766 504067736 504067709 504067770

ITEM PART NO. DESCRIPTION QTY

a .. . . . Mast Assembly .......................................................................................................... 1


1 a .. . . . Inner Mast ................................................................................................................. 1
2 504066700 Stubshaft.......................................................................................................... 2
3 520036852 Load Roller ................................................................................................................ 2
3 520052899 Load Roller ................................................................................................................ 2
4 015916300 Snap Ring ............................................................................................................ 2
5 504233232 Shim (0.020 in.).................................................................................................... AR
6 500227910 Snap Ring ............................................................................................................ 2
7 504281794 Chain Sheave Assembly ...................................................................................... 2
8 504282703 Chain Sheave .................................................................................................. 1
9 520040899 Bearing ............................................................................................................ 1
10 500343914 Snap Ring ........................................................................................................ 1

FOOTNOTES:
a Refer to Table

7-5
G11117 06-04

MAIN LIFT ASSEMBLY


(TWO STAGE LIMITED FREE-LIFT)

MAIN LIFT ASSEMBLYTWO STAGE LIMITED FREE-LIFT

7-6
G11117 06-04

MAIN LIFT ASSEMBLY


(TWO STAGE LIMITED FREE-LIFT)

OALH

ITEM DESCRIPTION
Mast A661 A661 A661 A661
Group Number 2692 2992 3192 3792
Mast Assembly 580036132 580036135 580036137 580036143
25 Chain 900002253 504064784 518791609 504065747

ITEM PART NO. DESCRIPTION QTY

b .. . . . Mast Assembly .......................................................................................................... 1


1 .. . . . Lift Cylinder (LH) (☞ G11118) ................................................................................. 1
2 .. . . . Lift Cylinder (RH) (☞ G11118) ................................................................................ 1
3 015003800 Nut ............................................................................................................................. 2
4 502566903 Washer (Hardened) ................................................................................................... 2
5 449001068 Capscrew................................................................................................................... 2
6 502566902 Washer ...................................................................................................................... 4
7 504064739 Spacer ....................................................................................................................... 2
8 909882405 Locknut ...................................................................................................................... 2
9 052229600 Fitting......................................................................................................................... 2
9 052645400 O-Ring.................................................................................................................. 1
10 052645600 O-Ring ....................................................................................................................... 1
10 504233229 Control Valve ............................................................................................................. 1
11 520044803 Housing ..................................................................................................................... 1
11 a 504064742 Housing (Optional)..................................................................................................... 1
12 449001050 Capscrew................................................................................................................... 2
13 504230271 Nut ............................................................................................................................. 2
14 501801901 Fitting......................................................................................................................... 1
15 504075776 Spring ........................................................................................................................ 1
16 504236253 Washer ...................................................................................................................... 1
17 504064729 Fitting......................................................................................................................... 1
17 052645400 O-Ring ....................................................................................................................... 1
18 c 080437000 Fitting (Optional) ........................................................................................................ 1
18 c 052645500 O-Ring (Optional) ...................................................................................................... 1
19 500227907 Snap Ring.................................................................................................................. 2
20 504064767 Washer ...................................................................................................................... 2
21 504064769 Washer (0.010 in.) ..................................................................................................... AR
21 504069702 Washer (0.060 in.) ..................................................................................................... AR
21 504069791 Washer (0.030 in.) ..................................................................................................... AR
22 580033718 Pin ............................................................................................................................. 2
23 015415900 Cotter Pin .................................................................................................................. 2
24 518801644 Chain Anchor............................................................................................................. 2
25 b .. . . . Chain ......................................................................................................................... 2
26 518803629 Hose .......................................................................................................................... 2
27 053349600 Fitting......................................................................................................................... 1

FOOTNOTES:
a Must Use With Item 18
b Refer to Table
c Use With 504064742

7-7
G11118 06-04

MAIN LIFT CYLINDER


(TWO STAGE LIMITED FREE-LIFT)

MAIN LIFT CYLINDERTWO STAGE LIMITED F REE-L IFT

7-8
G11118 06-04

MAIN LIFT CYLINDER


(TWO STAGE LIMITED FREE-LIFT)

LEFT HAND

OALH

ITEM DESCRIPTION
Mast A661 A661 A661 A661
Group Number 2692 2992 3192 3792
Lift Cylinder 519524603 519524606 519524608 519524614
7 Rod 519521603 519521606 519521608 519521614
15 Shell 519523603 519523606 519523608 519523614

RIGHT HAND

OALH

ITEM DESCRIPTION
Mast A661 A661 A661 A661
Group Number 2692 2992 3192 3792
Lift Cylinder 519524653 519524656 519524658 519524664
7 Rod 519521603 519521606 519521608 519521614
15 Shell 519523653 519523656 519523658 519523664

ITEM PART NO. DESCRIPTION QTY

b .. . . . Lift Cylinder................................................................................................................ 1
1 504163200 Wiper Ring ........................................................................................................... 1
2 504154200 Back-Up Ring ....................................................................................................... 1
3 580022502 Rod Seal .............................................................................................................. 1
4 506845500 Gland.................................................................................................................... 1
5 012825700 O-Ring.................................................................................................................. 1
6 518794659 Wear Ring ............................................................................................................ 1
7 b .. . . . Rod....................................................................................................................... 1
8 504154200 Back-Up Ring ....................................................................................................... 1
9 504153200 Seal ...................................................................................................................... 1
10 504024201 Wear Ring ............................................................................................................ 1
11 504235239 Check Valve ......................................................................................................... 1
12 504232230 O-Ring.................................................................................................................. 1
13 504148200 Washer ................................................................................................................. 1
13 504233257 Washer (Option) ........................................................................................................ 1
14 501850904 Snap Ring ............................................................................................................ 1
15 b .. . . . Shell ..................................................................................................................... 1
ac 505657521 Spacer ....................................................................................................................... 1

505136043 Seal Kit (Includes Items 1-6, 8-9) .............................................................................. 1

FOOTNOTES:
a Not Illustrated
b Refer to Table
c Used with A661-4292

7-9
G11119 06-04

CARRIAGE
(TWO STAGE LIMITED FREE-LIFT)

CARRIAGETWO STAGE LIMITED F REE-L IFT

ITEM PART NO. DESCRIPTION QTY

580035910 Carriage..................................................................................................................... 1
1 580035916 Frame ................................................................................................................... 1
2 504066700 Stubshaft.......................................................................................................... 6
3 015916300 Snap Ring ............................................................................................................ 6
3 449029011 Snap Ring (Optional)............................................................................................ 6
4 504233232 Shim (0.020 in.).................................................................................................... AR
5 504235278 Spacer.................................................................................................................. 2
6 520036852 Load Roller........................................................................................................... 6
6 520052899 Load Roller (Optional) .......................................................................................... 6
7 505978544 Chain Anchor ....................................................................................................... 2
7 580027878 Chain Anchor (Single Hole) (Optional)................................................................. 2
8 504075781 Pin ........................................................................................................................ 2
9 500227907 Snap Ring ............................................................................................................ 4
10 580033718 Pin ........................................................................................................................ 2
11 015415900 Cotter Pin ............................................................................................................. 2

7-10
NOTES

7-11
G11120 06-04

HEADER HOSE
(TWO STAGE LIMITED FREE-LIFT)

HEADER HOSET WO STAGE LIMITED FREE-LIF T

7-12
G11120 06-04

HEADER HOSE
(TWO STAGE LIMITED FREE-LIFT)

OALH

ITEM DESCRIPTION
Mast A661 A661 A661 A661
Group Number 2692 2992 3192 3792
1 Hose 580050796 580050800 580050802 580050808
KEY:
A: Three Function
B: Four Function

QTY
ITEM PART NO. DESCRIPTION A B

1 a .. . . . Hose .................................................................................................................. 2 4
2 505965599 Clamp ................................................................................................................ 1 2
3 504068704 Clamp ................................................................................................................ 4 8
4 449001028 Capscrew........................................................................................................... 4 4
5 504069707 Bracket (RH) ...................................................................................................... 1 ..
6 504069711 Bracket (LH) ...................................................................................................... .. 1
7 504230271 Nut ..................................................................................................................... 6 6
8 505962571 Bracket .............................................................................................................. 1 1
9 505961568 Stubshaft ........................................................................................................... 1 1
10 580023124 Sheave .............................................................................................................. 1 1
11 504070716 Washer .............................................................................................................. 2 2
12 504231270 Nut ..................................................................................................................... 2 2
13 449001389 Capscrew........................................................................................................... 1 1
14 504068794 Clamp ................................................................................................................ 1 1
15 449022017 Lockwasher ....................................................................................................... 1 1
16 449001072 Capscrew........................................................................................................... 2 2
17 449001272 Capscrew........................................................................................................... 2 2
18 505965586 Clamp ................................................................................................................ 2 2
19 505962578 Clamp ................................................................................................................ 2 2
20 505965586 Clamp ................................................................................................................ 2 4
21 500403901 Strap .................................................................................................................. 2 2
22 505962533 Spacer ............................................................................................................... 1 1
23 019905000 Fitting................................................................................................................. 2 2

FOOTNOTES:
a Refer to Table

7-13
G11133 06-04

OUTER MAST
(THREE STAGE FULL FREE-LIFT)

OUTER MASTT HREE STAGE FULL FREE-LIFT

7-14
G11133 06-04

OUTER MAST
(THREE STAGE FULL FREE-LIFT)

OALH

ITEM DESCRIPTION
Mast A662 A662 A662 A662
Group Number 4010 4460 4760 5510
Mast Assembly 580036260 580036263 580036265 580036270
1 Outer Mast 580036205 580036171 580036173 580036178

ITEM PART NO. DESCRIPTION QTY

a .. . . . Mast Assembly .......................................................................................................... 1


1 a .. . . . Outer Mast................................................................................................................. 1
2 504066700 Stubshaft.......................................................................................................... 2
3 504075764 Bearing Strip ........................................................................................................ 2
4 504234265 Shim (0.020 in.).................................................................................................... 4
5 012824300 O-Ring.................................................................................................................. 4
6 520036852 Load Roller ................................................................................................................ 2
6 520052899 Load Roller (Optional) ............................................................................................... 2
7 015916300 Snap Ring ............................................................................................................ 2
7 449029011 Snap Ring (Optional)............................................................................................ 2
8 504233232 Shim (0.020 in.).................................................................................................... AR
9 900003277 Bushing ................................................................................................................ 2

FOOTNOTES:
a Refer to Table

7-15
G11134 06-04

INTERMEDIATE MAST
(THREE STAGE FULL FREE-LIFT)

INTERMEDIATE MASTTHREE STAGE FUL L F REE-L IFT

7-16
G11134 06-04

INTERMEDIATE MAST
(THREE STAGE FULL FREE-LIFT)

OALH

ITEM DESCRIPTION
Mast A662 A662 A662 A662
Group Number 4010 4460 4760 5510
Mast Assembly 580036260 580036263 580036265 580036270
1 Intermediate Mast 504074771 504074723 504074714 504074730

ITEM PART NO. DESCRIPTION QTY

a .. . . . Mast Assembly .......................................................................................................... 1


1 a .. . . . Intermediate Mast...................................................................................................... 1
2 504066700 Stubshaft.......................................................................................................... 4
3 504075764 Bearing Strip ........................................................................................................ 2
4 504234265 Shim (0.020 in.).................................................................................................... 4
5 012824300 O-Ring.................................................................................................................. 4
6 520036852 Load Roller ................................................................................................................ 4
6 520052899 Load Roller (Optional) ............................................................................................... 4
7 015916300 Snap Ring ............................................................................................................ 4
7 449029011 Snap Ring (Optional)............................................................................................ 4
8 504233232 Shim (0.020 in.).................................................................................................... AR
9 506395595 Plug ...................................................................................................................... 2
10 504281794 Chain Sheave Assembly ...................................................................................... 2
11 504282703 Chain Sheave .................................................................................................. 1
12 520040899 Bearing ............................................................................................................ 1
13 500343914 Snap Ring ........................................................................................................ 2

FOOTNOTES:
a Refer to Table

7-17
G11135 06-04

INNER MAST
(THREE STAGE FULL FREE-LIFT)

INNER MASTTHREE STAGE FULL FREE-LIFT

7-18
G11135 06-04

INNER MAST
(THREE STAGE FULL FREE-LIFT)

OALH

ITEM DESCRIPTION
Mast A662 A662 A662 A662
Group Number 4010 4460 4760 5510
Mast Assembly 580036260 580036263 580036265 580036270
1 Inner Mast 504073758 504073772 504073771 504073791

ITEM PART NO. DESCRIPTION QTY

a .. . . . Mast Assembly .......................................................................................................... 1


1 a .. . . . Inner Mast ................................................................................................................. 1
2 504066700 Stubshaft.......................................................................................................... 2
3 015916300 Snap Ring ............................................................................................................ 2
3 449029011 Snap Ring (Optional)............................................................................................ 2
4 504233232 Shim (0.020 in.).................................................................................................... AR
5 520036852 Load Roller........................................................................................................... 2
5 520052899 Load Roller (Optional) .......................................................................................... 2

FOOTNOTES:
a Refer to Table

7-19
G11136 06-04

MAIN LIFT ASSEMBLY


(THREE STAGE FULL FREE-LIFT)

MAIN LIFT ASSEMBLYTHREE STAGE FULL FREE-LIFT

7-20
G11136 06-04

MAIN LIFT ASSEMBLY


(THREE STAGE FULL FREE-LIFT)

OALH

ITEM DESCRIPTION
Mast A662 A662 A662 A662
Group Number 4010 4460 4760 5510
Mast Assembly 580036260 580036263 580036265 580036270
1 Chain 900002253 504064764 518791609 504065747

ITEM PART NO. DESCRIPTION QTY

a .. . . . Mast Assembly .......................................................................................................... 1


1 a .. . . . Chain ......................................................................................................................... 2
2 .. . . . Lift Cylinder (LH) (☞ G11137) ................................................................................. 1
3 .. . . . Lift Cylinder (RH) (☞ G11137) ................................................................................ 1
4 449001068 Capscrew................................................................................................................... 2
5 502566902 Washer ...................................................................................................................... 4
6 504064739 Spacer ....................................................................................................................... 2
7 909882405 Locknut ...................................................................................................................... 2
8 500227907 Snap Ring.................................................................................................................. 2
9 504064767 Washer ...................................................................................................................... 2
10 504064769 Washer (0.010 in.) ..................................................................................................... AR
10 504069791 Washer (0.030 in.) ..................................................................................................... AR
10 504069702 Washer (0.060 in.) ..................................................................................................... AR
11 449001050 Capscrew................................................................................................................... 2
12 504230271 Nut ............................................................................................................................. 4
13 900003212 Plate .......................................................................................................................... 1
14 449001415 Capscrew................................................................................................................... 2
15 900003213 Clamp ........................................................................................................................ 1
16 900003214 Tube........................................................................................................................... 1
17 504233229 Control Valve ............................................................................................................. 1
17 052645600 O-Ring.................................................................................................................. 1
18 504064742 Housing ..................................................................................................................... 1
19 052229600 Fitting......................................................................................................................... 2
19 052645400 O-Ring.................................................................................................................. 1
20 052643500 Fitting......................................................................................................................... 1
20 052645500 O-Ring.................................................................................................................. 1
21 518803629 Hose .......................................................................................................................... 2
22 501801901 Fitting......................................................................................................................... 1
23 504075776 Spring ........................................................................................................................ 2
24 504236253 Washer ...................................................................................................................... 2
25 504064729 Fitting......................................................................................................................... 2
25 052645400 O-Ring.................................................................................................................. 1
26 518801644 Chain Anchor............................................................................................................. 2
27 580033718 Pin ............................................................................................................................. 4
28 015415900 Cotter Pin .................................................................................................................. 4
29 504075767 Chain Anchor............................................................................................................. 2
30 015418200 Cotter Pin .................................................................................................................. 2
31 015003800 Nut ............................................................................................................................. 4
32 502566903 Washer (Hardened) ................................................................................................... 4
33 053349600 Fitting......................................................................................................................... 1

FOOTNOTES:
a Refer to Table

7-21
G11137 06-04

MAIN LIFT CYLINDER


(THREE STAGE FULL FREE-LIFT)

MAIN LIFT CYLINDERTHREE STAGE FUL L FR EE-LIFT

7-22
G11137 06-04

MAIN LIFT CYLINDER


(THREE STAGE FULL FREE-LIFT)

LEFT HAND

OALH
DESCRIPTION
ITEM Mast A662 A662 A662 A662
Group Number 4010 4460 4760 5510
Cylinder
8601703 8601706 8601708 8601713
Group Number
Lift Cylinder 519530603 519530606 519530608 519530613
1 Shell 519529603 519529606 519529608 519529613
2 Rod 519528603 519528606 519528608 519528613

RIGHT HAND

OALH
DESCRIPTION
ITEM Mast A662 A662 A662 A662
Group Number 4010 4460 4760 5510
Cylinder
8601753 8601756 8601758 8601763
Group Number
Lift Cylinder 519530653 519530656 519530658 519530663
1 Shell 519529653 519529656 519529658 519529663
2 Rod 519528603 519528606 519528608 519528613

ITEM PART NO. DESCRIPTION QTY

a .. . . . Lift Cylinder................................................................................................................ 1
1 a .. . . . Shell ..................................................................................................................... 1
2 a .. . . . Rod....................................................................................................................... 1
3 506845500 Gland.................................................................................................................... 1
4 505657522 Spacer.................................................................................................................. 1
5 504235239 Check Valve ......................................................................................................... 1
6 504148200 Washer ................................................................................................................. 1
7 501850904 Snap Ring ............................................................................................................ 1
8 580011167 O-Ring.................................................................................................................. 1
9 504163200 Wiper Ring ........................................................................................................... 1
10 580022502 Rod Seal .............................................................................................................. 1
11 012825700 O-Ring.................................................................................................................. 1
12 504153200 Seal ...................................................................................................................... 1
13 504154200 Back-Up Ring ....................................................................................................... 2
14 504024201 Wear Ring ............................................................................................................ 1
15 502895202 Piston Ring........................................................................................................... 1
16 518794659 Wear Ring ............................................................................................................ 1

505136042 Seal Kit (Includes Item ) ............................................................................................ 1

FOOTNOTES:
a Refer to Table

7-23
G11138 06-04

FREE LIFT
(THREE STAGE FULL FREE-LIFT)

FREE LIFTT HREE STAGE FULL FREE-LIFT

7-24
G11138 06-04

FREE LIFT
(THREE STAGE FULL FREE-LIFT)

OALH

ITEM DESCRIPTION
Mast A662 A662 A662 A662
Group Number 4010 4460 4760 5510
Mast Assembly 580036260 580036263 580036265 580036270
1 Chain 518791614 504064799 504064792 504233265
2 Hose 900002263 900002265 505978593 900002269

ITEM PART NO. DESCRIPTION QTY

a .. . . . Mast Assembly .......................................................................................................... 1


1 a .. . . . Chain ......................................................................................................................... 2
2 a .. . . . Hose .......................................................................................................................... 1
3 015003800 Nut........................................................................................................................ 2
4 502566903 Washer (Hardened).............................................................................................. 2
5 580033718 Pin ........................................................................................................................ 2
6 015415900 Cotter Pin ............................................................................................................. 2
7 518801644 Chain Anchor ....................................................................................................... 2
8 504301785 Chain Guard......................................................................................................... 2
9 449001003 Capscrew ............................................................................................................. 2
10 .. . . . Lockwasher .......................................................................................................... 3
11 505978519 Bracket ................................................................................................................. 1
12 449034054 Pin ........................................................................................................................ 2
13 580024920 Bracket ................................................................................................................. 1
14 449001058 Capscrew ............................................................................................................. 4
15 449021010 Washer ................................................................................................................. 6
16 909882405 Locknut................................................................................................................. 4
17 520043867 Valve..................................................................................................................... 1
18 504064705 Crosshead............................................................................................................ 1
19 449001389 Capscrew ............................................................................................................. 1
20 900002259 Stubshaft .............................................................................................................. 1
21 504064782 Hose Sheave........................................................................................................ 1
21 504064715 Bushing............................................................................................................ 1
22 504281794 Chain Sheave Assembly ...................................................................................... 2
23 500343914 Snap Ring ........................................................................................................ 2
24 520040899 Bearing ............................................................................................................ 1
25 504282703 Chain Sheave .................................................................................................. 1
26 500227910 Snap Ring ............................................................................................................ 2
27 500227907 Snap Ring ............................................................................................................ 1
28 .. . . . Free Lift Cylinder .................................................................................................. 1

FOOTNOTES:
a Refer to Table

7-25
G11139 06-04

FREE LIFT CYLINDER


(THREE STAGE FULL FREE-LIFT)

FREE LIFT CYLINDERTHREE STAGE FULL FREE-LIFT

7-26
G11139 06-04

FREE LIFT CYLINDER


(THREE STAGE FULL FREE-LIFT)

OALH
DESCRIPTION
ITEM Mast A662 A662 A662 A662
Group Number 4010 4460 4760 5510
Cylinder
8601903 8601906 8601908 8601914
Group Number
Lift Cylinder 519534603 519534606 519534608 519534614
1 Shell 519541603 519541606 519541608 519541614
2 Rod 519540603 519540606 519540608 519540614

ITEM PART NO. DESCRIPTION QTY

a .. . . . Lift Cylinder................................................................................................................ 1
1 a .. . . . Shell ..................................................................................................................... 1
2 a .. . . . Rod....................................................................................................................... 1
3 504450758 Wiper Ring ........................................................................................................... 1
4 502787903 Seal ...................................................................................................................... 1
5 519537600 Gland.................................................................................................................... 1
6 502011903 Back-Up Ring ....................................................................................................... 1
7 015493200 O-Ring.................................................................................................................. 1
8 504450732 Back-Up Ring ....................................................................................................... 1
9 504232205 Rod Seal .............................................................................................................. 1
10 504024207 Wear Ring ............................................................................................................ 1
11 504235239 Check Valve ......................................................................................................... 1
12 580011167 O-Ring.................................................................................................................. 1
13 504148200 Washer ................................................................................................................. 1
14 501850904 Snap Ring ............................................................................................................ 1
15 501753904 Screw ................................................................................................................... 1
16 502687901 Seal ...................................................................................................................... 1

505136049 Seal Kit (Includes Items 3-4, 6-10, 12, 16) ................................................................ 1

FOOTNOTES:
a Refer to Table

7-27
G11140 06-04

CARRIAGE
(THREE STAGE FULL FREE-LIFT)

CARRIAGETHREE STAGE FULL FREE-LIFT

ITEM PART NO. DESCRIPTION QTY

580035907 Carriage..................................................................................................................... 1
1 580035917 Frame ........................................................................................................................ 1
2 504066700 Stubshaft .............................................................................................................. 6
3 015916300 Snap Ring.................................................................................................................. 6
3 449029011 Snap Ring (Optional) ................................................................................................. 6
4 504233232 Shim (0.020 in.) ......................................................................................................... AR
5 504235278 Spacer ....................................................................................................................... 2
6 518797634 Load Roller ................................................................................................................ 6
6 520053821 Load Roller (Optional) ............................................................................................... 6
7 505978544 Chain Anchor............................................................................................................. 2
7 580027878 Chain Anchor (Single Hole) (Optional) ...................................................................... 2
8 504075781 Pin ............................................................................................................................. 2
9 500227907 Snap Ring.................................................................................................................. 4
10 580033718 Pin ............................................................................................................................. 2
11 015415900 Cotter Pin .................................................................................................................. 2

7-28
NOTES

7-29
G11141 06-04

HEADER HOSE
(THREE STAGE FULL FREE-LIFT)

HEADER HOSET HREE STAGE FULL FREE-LIFT

7-30
G11141 06-04

HEADER HOSE
(THREE STAGE FULL FREE-LIFT)

OALH

ITEM DESCRIPTION
Mast A662 A662 A662 A662
Group Number 4010 4460 4760 5510
1 Hose 506254523 580043964 580043966 580043972
KEY:
A: Three Function
B: Four Function

QTY
ITEM PART NO. DESCRIPTION A B

1 b .. . . . Hose .................................................................................................................. 2 4
2 505962507 Bracket (RH) ...................................................................................................... 1 1
2 505961592 Bracket (LH) ...................................................................................................... .. 1
3 .. . . . Bracket .............................................................................................................. 1 1
4 449001072 Capscrew........................................................................................................... 2 4
5 449001014 Capscrew........................................................................................................... 6 12
6 504230271 Nut ..................................................................................................................... 6 12
7 504070756 Hose Guide ....................................................................................................... 2 4
8 504070721 Snap Ring.......................................................................................................... 2 4
9 505978597 Clamp ................................................................................................................ 1 2
10 580009290 Stubshaft ........................................................................................................... 1 2
11 580023124 Sheave .............................................................................................................. 1 2
11 .. . . . Bushing ......................................................................................................... 1 1
12 504301776 Bracket (RH) ...................................................................................................... 1 1
13 504301777 Bracket (LH) ...................................................................................................... .. 1
14 504070716 Washer .............................................................................................................. 2 2
15 449001389 Capscrew........................................................................................................... 2 2
16 449021010 Washer .............................................................................................................. 1 2
17 909882405 Locknut .............................................................................................................. 1 1
18 505962533 Spacer ............................................................................................................... 1 2
19 932200905 Capscrew........................................................................................................... 4 4
20 932200907 Capscrew........................................................................................................... 2 4
21 504231270 Nut ..................................................................................................................... 2 4
22 504068794 Clamp ................................................................................................................ 2 4
23 504069740 Plate .................................................................................................................. 1 1
24 520039872 Hose Guide ....................................................................................................... 1 1
25 520039810 Hose Guide ....................................................................................................... .. 1
26 449001233 Capscrew........................................................................................................... 1 2
27 504071785 Washer .............................................................................................................. 2 4
28 909882404 Nut ..................................................................................................................... 1 2
29 504068704 Clamp ................................................................................................................ 4 8
30 505965586 Clamp ................................................................................................................ 2 4
31 500403901 Strap .................................................................................................................. 2 4
32 580009289 Bracket (LH) ...................................................................................................... .. 1
33 580009288 Bracket (RH) ...................................................................................................... 1 ..
34 520053804 Nut ..................................................................................................................... 1 1
35 520045181 Washer .............................................................................................................. 1 1
a 580051876 Cap .................................................................................................................... 1 1
a 449034054 Pin ..................................................................................................................... 1 1
a 019905000 Fitting................................................................................................................. 2 2

7-31
G11141 06-04

HEADER HOSE
(THREE STAGE FULL FREE-LIFT)

QTY
ITEM PART NO. DESCRIPTION A B

a 504301779 Stubshaft ........................................................................................................... 2 2


a 504301778 Stubshaft ........................................................................................................... 2 2

FOOTNOTES:
a Not Illustrated
b Refer to Table

7-32
NOTES

7-33
G11121 06-04

OUTER MAST
(TWO STAGE FULL FREE-LIFT)

OUTER MASTT WO STAGE FULL FREE-LIFT

7-34
G11121 06-04

OUTER MAST
(TWO STAGE FULL FREE-LIFT)

OALH

ITEM DESCRIPTION
Mast A663 A663 A663 A663
Group Number 2728 3028 3228 3828
Mast Assembly 580036304 580036307 580036309 580036315
1 Outer Mast 580036205 580036171 580036173 580036178

ITEM PART NO. DESCRIPTION QTY

a .. . . . Mast Assembly .......................................................................................................... 1


1 a .. . . . Outer Mast ........................................................................................................... 1
2 504066700 Stubshaft.......................................................................................................... 2
3 504075764 Bearing Strip ........................................................................................................ 2
4 504234265 Shim (0.020 in.).................................................................................................... 4
5 012824300 O-Ring.................................................................................................................. 4
6 520036852 Load Roller ................................................................................................................ 2
6 520052899 Load Roller (Optional) ............................................................................................... 2
7 015916300 Snap Ring ............................................................................................................ 2
7 449029011 Snap Ring (Optional)............................................................................................ 2
8 504233232 Shim (0.020 in.).................................................................................................... AR
9 900003277 Bushing ................................................................................................................ 2

FOOTNOTES:
a Refer to Table

7-35
G11122 06-04

INNER MAST
(TWO STAGE FULL FREE-LIFT)

INNER MASTTWO STAGE FULL FREE-LIFT

7-36
G11122 06-04

INNER MAST
(TWO STAGE FULL FREE-LIFT)

OALH

ITEM DESCRIPTION
Mast A663 A663 A663 A663
Group Number 2728 3028 3228 3828
Mast Assembly 580036304 580036307 580036309 580036315
1 Inner Mast 504068744 504068721 504068731 504068761

ITEM PART NO. DESCRIPTION QTY

a .. . . . Mast Assembly .......................................................................................................... 1


1 a .. . . . Inner Mast ............................................................................................................ 1
2 504066700 Stubshaft.......................................................................................................... 2
3 015916300 Snap Ring ............................................................................................................ 2
4 504233232 Shim (0.020 in.).................................................................................................... AR
5 520036852 Load Roller........................................................................................................... 2
5 520052899 Load Roller (Optional) .......................................................................................... 2

FOOTNOTES:
a Refer to Table

7-37
G11123 06-04

MAIN LIFT ASSEMBLY


(TWO STAGE FULL FREE-LIFT)

MAIN LIFT ASSEMBLYTWO STAGE FULL FREE-LIFT

7-38
G11123 06-04

MAIN LIFT ASSEMBLY


(TWO STAGE FULL FREE-LIFT)

ITEM PART NO. DESCRIPTION QTY

1 .. . . . Lift Cylinder (LH) (☞ G11124) ................................................................................. 1


2 .. . . . Lift Cylinder (RH) (☞ G11125) ................................................................................ 1
3 449001068 Capscrew................................................................................................................... 2
4 502566902 Washer ...................................................................................................................... 4
5 504064739 Spacer ....................................................................................................................... 2
6 909882405 Locknut ...................................................................................................................... 2
7 500227907 Snap Ring.................................................................................................................. 2
8 504064767 Washer ...................................................................................................................... 2
9 504064769 Washer (0.010 in.) ..................................................................................................... AR
9 504069791 Washer (0.030 in.) ..................................................................................................... AR
9 504069702 Washer (0.060 in.) ..................................................................................................... AR
10 504233229 Control Valve ............................................................................................................. 1
10 052645600 O-Ring.................................................................................................................. 1
11 520044803 Housing ..................................................................................................................... 1
11 504064742 Housing (Optional)..................................................................................................... 1
12 449001050 Capscrew................................................................................................................... 2
13 504230271 Nut ............................................................................................................................. 2
14 501801901 Fitting......................................................................................................................... 1
15 504075776 Spring ........................................................................................................................ 1
16 504236253 Washer ...................................................................................................................... 1
17 504064729 Fitting......................................................................................................................... 1
17 052645400 O-Ring.................................................................................................................. 1
18 080437000 Fitting (Optional) ........................................................................................................ 1
18 052645500 O-Ring (Optional) ................................................................................................. 1
19 052229600 Fitting......................................................................................................................... 2
19 052645400 O-Ring.................................................................................................................. 1
20 518803629 Hose .......................................................................................................................... 2
21 053349600 Fitting......................................................................................................................... 1

7-39
G11124 06-04

MAIN LIFT CYLINDER


(LEFT HAND) (TWO STAGE FULL FREE-LIFT)

MAIN LIFT CYLINDERLEFT HANDTWO STAGE FULL FREE-LIFT

7-40
G11124 06-04

MAIN LIFT CYLINDER


(LEFT HAND) (TWO STAGE FULL FREE-LIFT)

LEFT HAND

OALH
DESCRIPTION
ITEM Mast A663 A663 A663 A663
Group Number 2728 3028 3228 3828
Cylinder
8510253 8510256 8510258 8510264
Group Number
Lift Cylinder 580026362 580026365 580026367 580026373
1 Shell 519639603 519639606 519639608 519639614
2 Rod 519638653 519638656 519638658 519638664

ITEM PART NO. DESCRIPTION QTY


a .. . . . Lift Cylinder................................................................................................................ 1
1 a .. . . . Shell ..................................................................................................................... 1
2 a .. . . . Rod....................................................................................................................... 1
3 504158200 Wiper Ring ........................................................................................................... 1
4 580022505 Rod Seal .............................................................................................................. 1
5 580025603 Gland.................................................................................................................... 1
6 502011927 Back-Up Ring ....................................................................................................... 1
7 012825700 O-Ring.................................................................................................................. 1
8 504017204 Wear Ring ............................................................................................................ 1
9 502895202 Piston Ring........................................................................................................... 1
10 501753914 Screw ................................................................................................................... 1
11 502687901 Seal ...................................................................................................................... 1

580025602 Seal Kit (Includes Items 3-4, 6-8, 11) ........................................................................ 1

FOOTNOTES:
a Refer to Table

7-41
G11125 06-04

MAIN LIFT CYLINDER


(RIGHT HAND) (TWO STAGE FULL FREE-LIFT)

MAIN LIFT CYLINDERRIGHT HANDTWO STAGE FULL FREE-LIFT

7-42
G11125 06-04

MAIN LIFT CYLINDER


(RIGHT HAND) (TWO STAGE FULL FREE-LIFT)

OALH
DESCRIPTION
ITEM Mast A663 A663 A663 A663
Group Number 2728 3028 3228 3828
Cylinder
8510203 8510206 8510208 8510214
Group Number
Lift Cylinder 580026330 580026333 580026335 580026341
1 Shell 519639603 519639606 519639608 519639614
2 Rod 519638603 519638606 519638608 519638614

ITEM PART NO. DESCRIPTION QTY

a .. . . . Lift Cylinder (RH) ....................................................................................................... 1


1 a .. . . . Shell ..................................................................................................................... 1
2 a .. . . . Rod....................................................................................................................... 1
3 504158200 Wiper Ring ........................................................................................................... 1
4 580022505 Rod Seal .............................................................................................................. 1
5 580025603 Gland.................................................................................................................... 1
6 502011927 Back-Up Ring ....................................................................................................... 1
7 012825700 O-Ring.................................................................................................................. 1
8 504024201 Wear Ring ............................................................................................................ 1
9 501753914 Screw ................................................................................................................... 1
10 502687901 Seal ...................................................................................................................... 1

580025602 Seal Kit (Includes Items 3-4, 6-8) .............................................................................. 1

FOOTNOTES:
a Refer to Table

7-43
G11126 06-04

FREE LIFT
(TWO STAGE FULL FREE-LIFT)

FREE LIFTT WO STAGE FULL FREE-LIF T

7-44
G11126 06-04

FREE LIFT
(TWO STAGE FULL FREE-LIFT)

OALH

ITEM DESCRIPTION
Mast A663 A663 A663 A663
Group Number 2728 3028 3228 3828
Mast Assembly 580036304 580036307 580036309 580036315
1 Chain 518791614 504064799 504064792 504233265
2 Hose 518792681 518792629 518792663 518792621

ITEM PART NO. DESCRIPTION QTY

a .. . . . Mast Assembly .......................................................................................................... 1


1 a .. . . . Chain.................................................................................................................... 2
2 a .. . . . Hose..................................................................................................................... 1
3 015003800 Nut........................................................................................................................ 2
4 502566903 Washer (Hardened).............................................................................................. 2
5 580033718 Pin ........................................................................................................................ 2
6 015415900 Cotter Pin ............................................................................................................. 2
7 518801644 Chain Anchor ....................................................................................................... 2
8 504301785 Chain Guard......................................................................................................... 2
9 449001007 Capscrew ............................................................................................................. 2
10 449022017 Lockwasher .......................................................................................................... 2
11 504075799 Bracket ................................................................................................................. 1
12 449034054 Pin ........................................................................................................................ 2
13 580024920 Bracket ................................................................................................................. 1
14 449001058 Capscrew ............................................................................................................. 4
15 449021010 Washer ................................................................................................................. 2
16 909882405 Locknut................................................................................................................. 4
17 520043867 Valve..................................................................................................................... 1
17 052645400 O-Ring ............................................................................................................. 1
18 504281795 Crosshead............................................................................................................ 2
19 504226242 Washer ................................................................................................................. 2
20 449022016 Lockwasher .......................................................................................................... 2
21 449001343 Capscrew ............................................................................................................. 1
22 504069724 Clamp................................................................................................................... 2
23 449015014 Nut........................................................................................................................ 1
24 520039855 Fitting ................................................................................................................... 1
24 052645300 O-Ring ............................................................................................................. 1
25 053349600 Fitting ................................................................................................................... 1
26 500227910 Snap Ring ............................................................................................................ 2
27 504281796 Chain Sheave Assembly ...................................................................................... 2
28 500343914 Snap Ring ........................................................................................................ 2
29 520040899 Bearing ............................................................................................................ 1
30 504281799 Sheave............................................................................................................. 1
31 519534608 Lift Cylinder .......................................................................................................... 1
32 500227907 Snap Ring ............................................................................................................ 1
33 060023700 Clamp................................................................................................................... 1
34 502566902 Washer ...................................................................................................................... 4

FOOTNOTES:
a Refer to Table

7-45
G11129 06-04

FREE LIFT CYLINDER


(TWO STAGE FULL FREE-LIFT)

FREE LIFT CYLINDERTWO STAGE FULL FREE-LIFT

7-46
G11129 06-04

FREE LIFT CYLINDER


(TWO STAGE FULL FREE-LIFT)

OALH
DESCRIPTION
ITEM Mast A663 A663 A663 A663
Group Number 2728 3028 3228 3828
Cylinder
8601903 8601906 8601908 8601914
Group Number
Lift Cylinder 519534603 519534606 519534608 519534614
1 Shell 519541603 519541606 519541608 519541614
2 Rod 519540603 519540606 519540608 519540614

ITEM PART NO. DESCRIPTION QTY

a .. . . . Lift Cylinder................................................................................................................ 1
1 a .. . . . Shell ..................................................................................................................... 1
2 a .. . . . Rod....................................................................................................................... 1
3 504450758 Wiper Ring ........................................................................................................... 1
4 502787903 Seal ...................................................................................................................... 1
5 519537600 Gland.................................................................................................................... 1
6 502011903 Back-Up Ring ....................................................................................................... 1
7 015493200 O-Ring.................................................................................................................. 1
8 504450732 Back-Up Ring ....................................................................................................... 1
9 504232205 Rod Seal .............................................................................................................. 1
10 504024207 Wear Ring ............................................................................................................ 1
11 504235239 Check Valve ......................................................................................................... 1
12 580011167 O-Ring.................................................................................................................. 1
13 504148200 Washer ................................................................................................................. 1
14 501850904 Snap Ring ............................................................................................................ 1
15 501753904 Screw ................................................................................................................... 1
16 502687901 Seal ...................................................................................................................... 1

505136049 Seal Kit (Includes Items 3-4, 6-10, 12, 16) ................................................................ 1

FOOTNOTES:
a Refer to Table

7-47
G11127 06-04

CARRIAGE
(TWO STAGE FULL FREE-LIFT)

CARRIAGETWO STAGE FULL FR EE-LIFT

ITEM PART NO. DESCRIPTION QTY


580035909 Carriage..................................................................................................................... 1
1 580035918 Frame ........................................................................................................................ 1
2 504066700 Stubshaft ................................................................................................................... 6
3 015916300 Snap Ring.................................................................................................................. 6
3 449029011 Snap Ring (Optional) ................................................................................................. 6
4 504233232 Shim (0.020 in.) ......................................................................................................... AR
5 504235278 Spacer ....................................................................................................................... 2
6 520036852 Load Roller ................................................................................................................ 6
6 520052899 Load Roller (Optional) ............................................................................................... 6
7 505978544 Chain Anchor............................................................................................................. 2
7 580027878 Chain Anchor (Single Hole) (Optional) ..................................................................... 2
8 504075781 Pin ............................................................................................................................. 2
9 500227907 Snap Ring.................................................................................................................. 4
10 580033718 Pin ............................................................................................................................. 2
11 015415900 Cotter Pin .................................................................................................................. 2

7-48
NOTES

7-49
G11128 06-04

HEADER HOSE
(TWO STAGE FULL FREE-LIFT)

HEADER HOSET WO STAGE FULL FREE-LIFT

7-50
G11128 06-04

HEADER HOSE
(TWO STAGE FULL FREE-LIFT)

KEY:
A: Three-Function
B: Four-Function

QTY
ITEM PART NO. DESCRIPTION A B
1 900004214 Channel ............................................................................................................. 1 1
2 505976588 Channel ............................................................................................................. 1 1
3 504063719 Hose .................................................................................................................. 2 ..
4 504063781 Hose .................................................................................................................. .. 2
5 504068704 Clamp ................................................................................................................ 5 5
6 505965599 Clamp ................................................................................................................ 4 4
7 505965586 Clamp ................................................................................................................ 7 3
8 504068794 Clamp ................................................................................................................ 3 3
9 505959500 Clamp ................................................................................................................ 2 2
10 505961505 Bracket .............................................................................................................. 1 1
11 932200905 Capscrew........................................................................................................... 4 2
12 .. . . . Bracket .............................................................................................................. 1 1
13 505978597 Clamp ................................................................................................................ 1 1
14 449001014 Capscrew........................................................................................................... 2 2
15 504230271 Nut ..................................................................................................................... 2 2
16 504070756 Hose Guide ....................................................................................................... 2 2
17 504070721 Snap Ring.......................................................................................................... 2 2
18 504070790 Strap Clamp....................................................................................................... 1 2
19 518798650 Clip .................................................................................................................... 1 1
20 013397900 Fitting................................................................................................................. 2 2
21 500403901 Strap .................................................................................................................. 2 4
22 518799698 Tube................................................................................................................... 1 1
23 518799654 Tube................................................................................................................... 1 1
24 504243752 Hose .................................................................................................................. 2 4
25 932200909 Capscrew........................................................................................................... .. 4
26 a 580052881 Clamp ................................................................................................................ 2 ..
27 a 449021010 Washer .............................................................................................................. 1 1

FOOTNOTES:
a Not Illustrated

7-51
NOTES

7-52
SECTION 8

8 OPTIONS

8 OPTIONS
CONTENTS

SECTION 8
OPTIONS

DESCRIPTION PAGE

BACK-UP ALARM ................................................................................................................................................ 8-2


BATTERY SLIDER AND RETAINER .................................................................................................................... 8-4
BATTERY SPACER .............................................................................................................................................. 8-6
DC CONVERTER
36/48 VOLT TO 12 VOLT .................................................................................................................................. 8-8
PREMIUM ....................................................................................................................................................... 8-10
FRONT LIGHTS ................................................................................................................................................. 8-12
INTEGRAL SIDE-SHIFT CARRIAGE
THREE STAGE FULL FREE-LIFT .................................................................................................................. 8-16
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 8-18
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 8-14
INTERFACE CABLE........................................................................................................................................... 8-20
REAR WORK LIGHT.......................................................................................................................................... 8-24
STROBE LIGHT ................................................................................................................................................. 8-28
STROBE LIGHT/REAR LIGHT COMBINATION................................................................................................. 8-26
TAIL, BRAKE, AND BACK-UP LIGHTS.............................................................................................................. 8-22

8-1
G11017 06-04

BACK-UP ALARM

BACK-UP ALARM

8-2
G11017 06-04

BACK-UP ALARM

ITEM PART NO. DESCRIPTION QTY

1 580041651 Bracket ...................................................................................................................... 1


2 524169018 Audible Alarm ............................................................................................................ 1
3 720098901 Tubing ........................................................................................................................ AR
4 502719903 Blade ......................................................................................................................... 2
5 900003245 Grommet.................................................................................................................... 1
6 504230231 Screw......................................................................................................................... 2
7 449001013 Capscrew................................................................................................................... 2
8 449021001 Washer ...................................................................................................................... 2
9 504229298 Nut ............................................................................................................................. 2
10 580040476 Alarm Harness........................................................................................................... 1
11 502701505 Connector .................................................................................................................. 1
12 502701538 Wire Seal ................................................................................................................... 1

8-3
G11095 06-04

BATTERY SLIDER AND RETAINER

BATT ERY SLIDER AND RETAINER

8-4
G11095 06-04

BATTERY SLIDER AND RETAINER

ITEM PART NO. DESCRIPTION QTY

1 a 520222602 Side Plate Assembly.................................................................................................. 1


1 520221602 Side Plate .................................................................................................................. 1
1 b 520222603 Side Plate Assembly.................................................................................................. 1
1 520221603 Side Plate .................................................................................................................. 1
2 505008200 Spring ........................................................................................................................ 2
3 520082889 Roll Pin ...................................................................................................................... 2
4 505195200 Lock Pin..................................................................................................................... 2
5 520082888 Rod End Pin .............................................................................................................. 2
6 505218200 Radial Bumper........................................................................................................... 2
7 505227200 Retainer ..................................................................................................................... 2
8 449015044 Nut ............................................................................................................................. 2
9 449022013 Lockwasher ............................................................................................................... 2
10 449001069 Capscrew................................................................................................................... 2
11 580051571 Plate .......................................................................................................................... 1
12 504231285 Screw......................................................................................................................... 2
13 504231232 Spacer ....................................................................................................................... 10
14 449021006 Washer ...................................................................................................................... 2
15 449022013 Lockwasher ............................................................................................................... 2
16 449015044 Nut ............................................................................................................................. 2
17 a 580034638 Slide Platform (ERP16ATF) ....................................................................................... 1
17 c 580034639 Slide Platform (ERP18ATF) ....................................................................................... 1
17 d 580034640 Slide Platform (ERP18ATF) ....................................................................................... 1

FOOTNOTES:
a 1290 mm Wheel Base
b 1385 mm Wheel Base
c 1385 mm Wheel Base - 3500 lb.
d 1385 mm Wheel Base - 4000 lb.

8-5
G11094 06-04

BATTERY SPACER

BATTERY SPACER

8-6
G11094 06-04

BATTERY SPACER

ITEM PART NO. DESCRIPTION QTY

1 504707701 Platform (82 lb) .......................................................................................................... 1


1 504707702 Platform (97 lb) .......................................................................................................... 1
1 504707703 Platform (168 lb) ........................................................................................................ 1
1 504707714 Platform (249 lb) ........................................................................................................ 1
1 504707704 Platform (293 lb) ........................................................................................................ 1
1 504707705 Platform (399 lb) ........................................................................................................ 1
1 504707715 Platform (606 lb) ........................................................................................................ 1
2 d 519920602 Acid Tray .................................................................................................................... 1
2 519920603 Acid Tray .................................................................................................................... 1
3 580051571 Plate .......................................................................................................................... 1
4 504231232 Spacer ....................................................................................................................... 10
5 449021006 Washer ...................................................................................................................... 2
6 449022013 Lockwasher ............................................................................................................... 2
7 449015044 Nut ............................................................................................................................. 2
8 504231285 Screw......................................................................................................................... 2
9 b 449001078 Capscrew................................................................................................................... 2
9 c 449001233 Capscrew................................................................................................................... 2
9 e 449001067 Capscrew................................................................................................................... 2
9 a 449001069 Capscrew................................................................................................................... 1

FOOTNOTES:
a Used on 168 and 606 lb platform
b Used on 249 and 293 lb platform
c Used on 399 lb platform
d Used on 82 and 249 lb platform
e Used on 82 and 97 lb platform

8-7
G11016 06-04

DC CONVERTER
(36/48 VOLT TO 12 VOLT)

DC CONVERTER36/48 VOLT TO 12 VOLT

8-8
G11016 06-04

DC CONVERTER
(36/48 VOLT TO 12 VOLT)

ITEM PART NO. DESCRIPTION QTY

1 520086612 DC Converter............................................................................................................. 1
2 449022018 Lockwasher ............................................................................................................... 11
3 449001170 Capscrew................................................................................................................... 4
4 016103500 Washer ...................................................................................................................... 6
5 449001412 Capscrew................................................................................................................... 7
6 449015002 Nut ............................................................................................................................. 5
7 524138691 Mounting Bracket....................................................................................................... 1
8 506979500 Panel Assembly ......................................................................................................... 1
9 449021003 Washer ...................................................................................................................... 2
10 a 751199100 Insulator..................................................................................................................... 1
11 a 580041501 Brake Switch Assembly ............................................................................................. 1

FOOTNOTES:
a Not Illustrated

8-9
G11014 06-04

DC CONVERTER
(PREMIUM)

DC CONVERTERPREMIUM

8-10
G11014 06-04

DC CONVERTER
(PREMIUM)

ITEM PART NO. DESCRIPTION QTY

1 520045144 DC Converter (36V)................................................................................................... 1


1 520045145 DC Converter (48V)................................................................................................... 1
2 449022018 Lockwasher ............................................................................................................... 4
3 449001170 Capscrew................................................................................................................... 4

8-11
G11011 06-04

FRONT LIGHTS

FRONT LIGHTS

8-12
G11011 06-04

FRONT LIGHTS

ITEM PART NO. DESCRIPTION QTY

1 580043504 Plate .......................................................................................................................... 2


2 580041652 Bracket Weldment (RH)............................................................................................. 1
3 580041653 Bracket Weldment (LH) ............................................................................................. 1
4 900003245 Grommet.................................................................................................................... 2
5 504230231 Screw......................................................................................................................... 4
6 580023049 Bolt ............................................................................................................................ 2
7 502566901 Washer ...................................................................................................................... 2
8 504229298 Nut ............................................................................................................................. 2
9 580040370 Head Light Assembly................................................................................................. 2
9 580043207 Bulb ...................................................................................................................... 1
9 580051616 Wire Harness ....................................................................................................... 1
10 580035444 Washer ...................................................................................................................... 2
11 580040131 Wire Harness (Front Light) ........................................................................................ 2
ab 580040475 Wire Harness............................................................................................................. 1
b 312850034 Strap Clamp............................................................................................................... 6

FOOTNOTES:
a Connects with Front Light Harness
b Not Illustrated

8-13
G11142 06-04

INTEGRAL SIDE-SHIFT CARRIAGE


(TWO STAGE LIMITED FREE-LIFT)

INTEGRAL SIDE-SHIFT CARRIAGETWO STAGE LIMIT ED FREE-LIFT

8-14
G11142 06-04

INTEGRAL SIDE-SHIFT CARRIAGE


(TWO STAGE LIMITED FREE-LIFT)

ITEM PART NO. DESCRIPTION QTY

580037260 Side-Shift Carriage Assembly.................................................................................... 1


1 580037254 Frame (Inner) ....................................................................................................... 1
2 580023799 Frame (38 in.) (Outer) .......................................................................................... 1
3 580020708 Cylinder Assembly ............................................................................................... 1
4 580020724 Bearing (Upper).................................................................................................... 2
5 580020726 Bearing (Lower).................................................................................................... 2
6 580020723 Hook (Lower)........................................................................................................ 2
7 449001400 Capscrew ............................................................................................................. 4
8 502566903 Washer (Hardened).............................................................................................. 4
9 580026721 Pin ........................................................................................................................ 2
10 580026723 Cotter Pin ............................................................................................................. 2
11 015628700 Lube Fitting .......................................................................................................... 2
12 520036852 Load Roller........................................................................................................... 6
12 520052899 Load Roller........................................................................................................... 6
13 015916300 Snap Ring ............................................................................................................ 6
13 449029011 Snap Ring (Optional)............................................................................................ 6
14 504233232 Shim (0.020 in.).................................................................................................... 28
15 504235278 Spacer.................................................................................................................. 2
16 505978544 Chain Anchor ....................................................................................................... 2
16 580027878 Chain Anchor (Single Hole) (Optional)................................................................. 2
17 504075781 Pin ........................................................................................................................ 2
18 500227907 Snap Ring ............................................................................................................ 4
19 580033718 Pin ........................................................................................................................ 2
20 015415900 Cotter Pin ............................................................................................................. 2
21 580026720 Shim ..................................................................................................................... AR

8-15
G11143 06-04

INTEGRAL SIDE-SHIFT CARRIAGE


(THREE STAGE FULL FREE-LIFT)

INTEGRAL SIDE-SHIFT CARRIAGETHREE STAGE FULL FREE-LIFT

8-16
G11143 06-04

INTEGRAL SIDE-SHIFT CARRIAGE


(THREE STAGE FULL FREE-LIFT)

ITEM PART NO. DESCRIPTION QTY

580037259 Side-Shift Carriage .................................................................................................... 1


1 580037252 Frame (Inner) ....................................................................................................... 1
2 580023799 Frame (38 in.) (Outer) .......................................................................................... 1
3 580020708 Cylinder Assembly ............................................................................................... 1
4 580020724 Bearing (Upper).................................................................................................... 2
5 580020726 Bearing (Lower).................................................................................................... 2
6 580020723 Hook (Lower)........................................................................................................ 2
7 449001400 Capscrew ............................................................................................................. 4
8 502566903 Washer (Hardened).............................................................................................. 4
9 580026721 Pin ........................................................................................................................ 2
10 580026723 Cotter Pin ............................................................................................................. 2
11 015628700 Lube Fitting .......................................................................................................... 2
12 504071702 Pin ........................................................................................................................ 2
13 505978544 Chain Anchor ....................................................................................................... 2
13 580027878 Chain Anchor (Single Hole) (Optional)................................................................. 2
14 500227907 Snap Ring ............................................................................................................ 4
15 580033718 Pin ........................................................................................................................ 2
16 015415900 Cotter Pin ............................................................................................................. 2
17 518797634 Load Roller........................................................................................................... 6
17 520053821 Load Roller ................................................................................................................ 6
17 520036852 Load Roller ................................................................................................................ 6
18 504233232 Shim (0.020 in.).................................................................................................... 28
19 504235278 Spacer.................................................................................................................. 2
20 015916300 Snap Ring ............................................................................................................ 6
20 449029011 Snap Ring (Optional) ................................................................................................. 6
21 580026720 Shim ..................................................................................................................... AR

8-17
G11144 06-04

INTEGRAL SIDE-SHIFT CARRIAGE


(TWO STAGE FULL FREE-LIFT)

INTEGRAL SIDE-SHIFT CARRIAGETWO STAGE FULL FREE-LIFT

8-18
G11144 06-04

INTEGRAL SIDE-SHIFT CARRIAGE


(TWO STAGE FULL FREE-LIFT)

ITEM PART NO. DESCRIPTION QTY

580037258 Side-Shift Carriage .................................................................................................... 1


1 580037255 Frame (Inner) ....................................................................................................... 1
2 580023799 Frame (38 in.) (Outer) .......................................................................................... 1
3 580020708 Cylinder Assembly ............................................................................................... 1
4 580020724 Bearing (Upper).................................................................................................... 2
5 580020726 Bearing (Lower).................................................................................................... 2
6 580020723 Hook (Lower)........................................................................................................ 2
7 449001400 Capscrew ............................................................................................................. 4
8 502566903 Washer (Hardened).............................................................................................. 4
9 580026721 Pin ........................................................................................................................ 2
10 580026723 Cotter Pin ............................................................................................................. 2
11 015628700 Lube Fitting .......................................................................................................... 2
12 504071702 Pin ........................................................................................................................ 2
13 505978544 Chain Anchor ....................................................................................................... 2
13 580027878 Chain Anchor (Single Hole) (Optional)................................................................. 2
14 500227907 Snap Ring ............................................................................................................ 4
15 580033718 Pin ........................................................................................................................ 2
16 015415900 Cotter Pin ............................................................................................................. 2
17 520036852 Load Roller ................................................................................................................ 6
17 520052899 Load Roller (Optional) ............................................................................................... 6
18 504233232 Shim (0.020 in.).................................................................................................... 28
19 504235278 Spacer.................................................................................................................. 2
20 015916300 Snap Ring ............................................................................................................ 6
20 449029011 Snap Ring (Optional) ................................................................................................. 6
21 580026720 Shim ..................................................................................................................... AR

8-19
G11048 06-04

INTERFACE CABLE

INTERFACE CABLE

ITEM PART NO. DESCRIPTION QTY

580039670 Interface Cable .......................................................................................................... 1


1 580039163 Interface Cable Adapter ....................................................................................... 1
2 580039669 Wire Harness ....................................................................................................... 1
2 580039193 Connector ........................................................................................................ 1
2 505968538 Conduit ............................................................................................................ AR
3 524187015 Service Software ....................................................................................................... 1
3 524190264 Service Software Data (Not Illustrated)................................................................ 1

8-20
NOTES

8-21
G11021 06-04

TAIL, BRAKE, AND BACK-UP LIGHTS

TAIL, BRAKE, AND BACK-UP LIGHTS

8-22
G11021 06-04

TAIL, BRAKE, AND BACK-UP LIGHTS

ITEM PART NO. DESCRIPTION QTY

1 900003245 Grommet.................................................................................................................... 2
2 580050859 Bracket ...................................................................................................................... 2
3 580050860 Bracket ...................................................................................................................... 2
4 518796682 Clip Nut...................................................................................................................... 2
5 504230231 Screw......................................................................................................................... 2
6 580050307 Brake and Back-Up Light........................................................................................... 2
7 449007043 Screw......................................................................................................................... 2
8 580041206 Harness (Rear Light) ................................................................................................. 2
9 a 502701517 Connector .................................................................................................................. 2
10 a 502701544 Connector .................................................................................................................. 2

FOOTNOTES:
a Not Illustrated

8-23
G11019 06-04

REAR WORK LIGHT

REAR WORK LIGHT

8-24
G11019 06-04

REAR WORK LIGHT

ITEM PART NO. DESCRIPTION QTY

1 580041461 Plate .......................................................................................................................... 1


2 449001134 Capscrew................................................................................................................... 2
3 504226242 Washer ...................................................................................................................... 2
4 504229298 Nut ............................................................................................................................. 2
5 580040370 Head Light Assembly................................................................................................. 1
5 580043207 Bulb ...................................................................................................................... 1
5 580051616 Wire Harness............................................................................................................. 1
6 580049821 Bracket Weldment ................................................................................................ 1
7 580035444 Washer ...................................................................................................................... 1
8 580040479 Wire Harness (Rear Light)......................................................................................... 1
9 502701505 Connector .................................................................................................................. 1
10 502701538 Wire Seal ................................................................................................................... 1
11 516905800 Clamp ........................................................................................................................ 1
12 900003245 Grommet.................................................................................................................... 1

8-25
G11020 06-04

STROBE LIGHT/REAR LIGHT COMBINATION

STROBE LIGHT/R EAR LIGHT COMBIN ATION

8-26
G11020 06-04

STROBE LIGHT/REAR LIGHT COMBINATION

ITEM PART NO. DESCRIPTION QTY

1 580000037 Strobe Light ............................................................................................................... 1


1 504232212 Bulb ...................................................................................................................... 1
1 580035844 Lens (Amber) ....................................................................................................... 1
2 580035444 Washer ...................................................................................................................... 1
3 720098901 Tubing ........................................................................................................................ AR
4 580041654 Plate .......................................................................................................................... 1
5 580040478 Wire Harness (Strobe Light)...................................................................................... 1
6 580040479 Wire Harness (Rear Light)......................................................................................... 1
7 501739903 Screw......................................................................................................................... 2
8 940004903 Washer ...................................................................................................................... 2
9 504575277 Lockwasher ............................................................................................................... 2
10 937100903 Nut ............................................................................................................................. 2
11 504232297 Guard ........................................................................................................................ 1
12 449001014 Capscrew................................................................................................................... 2
13 504226242 Washer ...................................................................................................................... 2
14 504229298 Nut ............................................................................................................................. 2
15 580040370 Head Light Assembly................................................................................................. 1
15 580043207 Bulb ...................................................................................................................... 1
15 580051616 Wire Harness ....................................................................................................... 1
16 900003245 Grommet.................................................................................................................... 1
17 504059726 Blade ......................................................................................................................... 2
18 504059730 Blade ......................................................................................................................... 2
19 516905800 Clamp ........................................................................................................................ 1
a 502701505 Connector .................................................................................................................. 2
a 502701538 Wire Seal ................................................................................................................... 2

FOOTNOTES:
a Not Illustrated

8-27
G11018 06-04

STROBE LIGHT

STROBE LIGHT

8-28
G11018 06-04

STROBE LIGHT

ITEM PART NO. DESCRIPTION QTY

1 580041654 Plate .......................................................................................................................... 1


2 900003245 Grommet.................................................................................................................... 1
3 580000037 Strobe Light ............................................................................................................... 1
3 580035844 Lens (Amber) ....................................................................................................... 1
3 504232212 Bulb ...................................................................................................................... 1
4 720098901 Tubing ........................................................................................................................ AR
5 504059726 Blade ......................................................................................................................... 2
6 504232297 Guard ........................................................................................................................ 1
7 449001134 Capscrew................................................................................................................... 2
8 504226242 Washer ...................................................................................................................... 2
9 504229298 Nut ............................................................................................................................. 2
10 501739903 Screw......................................................................................................................... 2
11 016103200 Washer ...................................................................................................................... 2
12 449022019 Lockwasher ............................................................................................................... 2
13 937100903 Nut ............................................................................................................................. 2
14 580040478 Wire Harness (Strobe Light)...................................................................................... 1
15 502701505 Connector .................................................................................................................. 1
16 502701538 Wire Seal ................................................................................................................... 1
17 516905800 Clamp ........................................................................................................................ 1

8-29
NOTES

8-30
SECTION 9

9 FIELD CONVERSION KITS

9 FIELD CONVERSION KITS


CONTENTS

SECTION 9
FIELD CONVERSION KITS

DESCRIPTION PAGE

HYDRAULIC ......................................................................................................................................................... 9-2


LIGHT OPTION .................................................................................................................................................... 9-2
TILT....................................................................................................................................................................... 9-2

9-1
FIELD CONVERSION KITS

TILT

DESCRIPTION PART NUMBER


5 Forward/7 Back 150023888
5 Forward/5 Back 150023889
10 Forward/5 Back 150023890

LIGHT OPTION

DESCRIPTION PART NUMBER


Front Work Lights (36/48V Standard) 150102440
Front Work Lights (36V Premium) 150102441
Front Work Lights (48V Premium) 150102442
Rear Strobe Light 150102458
Backup Alarm 150102459

HYDRAULIC

DESCRIPTION PART NUMBER


Contactor Hydraulic 3 Function Without Lockout to 4 Function With Lockout 150104937
Contactor Hydraulic 3 Function With Lockout to 4 Function With Lockout 150104938
Transistor Hydraulic 3 Function Without Lockout to 4 Function With Lockout 150104939
Transistor Hydraulic 3 Function With Lockout to 4 Function With Lockout 150104940
Manual Hydraulic 3 Function Without Lockout to 3 Function With Lockout 150104944
Manual Hydraulic 3 Function With Lockout to 3 Function Without Lockout 150104946
Electro Hydraulic 3 Function to 4 Function With Interlock 150104931
Electro Hydraulic 3 Function to 4 Function Without Interlock 150104932

9-2
SECTION 10

10 NUMERICAL INDEX
NUMERICAL INDEX

PART NO. PG. ITEM PART NO. PG. ITEM PART NO. PG. ITEM PART NO. PG. ITEM
012472200 2-3 1 5-11 13 7-21 20 440066700 3-2 2
2-3 1 015916300 7-3 7 7-39 18 449001003 7-25 9
012824300 7-3 5 7-5 4 052645600 7-7 10 449001007 7-45 9
7-15 5 7-10 3 7-21 17 449001013 2-3 7
7-17 5 7-15 7 7-39 10 8-3 7
7-35 5 7-17 7 053349600 7-7 27 449001014 4-13 16
012825700 7-9 5 7-19 3 7-21 33 6-3 38
7-23 11 7-28 3 7-39 21 6-43 8
7-41 7 7-35 7 7-45 25 7-31 5
7-43 7 7-37 3 054466300 2-16 42 7-51 14
012828800 6-13 15 7-48 3 055746400 4-17 5 8-27 12
6-17 16 8-15 13 056363100 6-3 16 449001015 6-23 23
6-21 15 8-17 20 059079500 1-4 80 449001016 6-13 4
013397900 7-51 20 8-19 20 059719100 4-13 7 6-17 4
014972900 1-4 78 015918200 6-23 10 059726400 6-43 6 6-21 4
015003800 7-7 3 016103200 8-29 11 060023700 7-45 33 449001019 5-7 5
7-21 31 016103500 8-9 4 061278200 1-15 3 449001023 6-23 17
7-25 3 016104000 4-13 5 061353000 6-7 15 6-29 13
7-45 3 016139700 6-23 11 061643400 6-27 1 449001028 7-13 4
015026400 1-4 81 019899200 6-3 10 062159500 4-17 17 449001040 4-17 12
4-13 6 6-41 10 062254800 6-29 3 5-3 24
015414700 6-23 7 019905000 7-13 23 064401300 1-3 22 6-3 7
6-25 15 7-31 38 065353900 2-16 37 6-3 25
6-25 31 023338500 1-3 26 065354200 2-16 35 6-41 7
015415900 7-7 23 1-3 47 065619300 5-5 10 449001050 7-7 12
7-10 11 023604600 1-19 5 066002600 6-3 36 7-21 11
7-21 28 1-21 6 080143400 4-17 15 7-39 12
7-25 6 1-23 5 6-3 30 449001052 5-3 21
7-28 11 027678700 5-7 31 080437000 7-7 18 449001058 7-25 14
7-45 6 5-11 14 7-39 18 7-45 14
7-48 11 032643500 4-7 19 122310101 6-27 14 449001067 8-7 9
8-15 20 5-5 8 131635419 4-3 3 449001068 7-7 5
8-17 16 052229600 6-7 16 258157200 3-2 1 7-21 4
8-19 16 6-29 5 258465500 3-2 7-39 3
015416200 4-13 11 7-7 9 258484300 3-2 2 449001069 6-3 26
015418200 7-21 30 7-21 19 258484400 3-2 1 8-5 10
015420300 6-13 12 7-39 19 258514000 3-2 8-7 9
6-17 12 052642200 6-27 13 258985000 1-9 16 449001072 7-13 16
6-21 12 052643200 6-29 6 277286800 6-29 17 7-31 4
015493200 7-27 7 052643300 6-27 11 296321382 2-5 4 449001078 5-3 17
7-47 7 052643400 6-27 10 311323021 3-10 46 8-7 9
015627900 6-13 7 052643500 7-21 20 312850032 6-3 34 449001114 6-23 5
6-13 11 052645300 7-45 24 6-41 17 6-25 13
6-17 7 052645400 7-7 9 312850034 8-13 13 6-29 9
6-17 11 7-7 17 312850042 5-5 12 449001134 5-3 14
6-21 7 7-21 19 316441036 6-43 5 5-7 12
6-21 11 7-21 25 316534106 4-10 47 8-25 2
015628700 8-15 11 7-39 17 317220006 2-17 52 8-29 7
8-17 11 7-39 19 317222556 2-15 9 449001170 4-7 14
8-19 11 7-45 17 2-16 39 4-13 37
015914900 5-7 30 052645500 7-7 18 2-17 45 5-7 21

10-1
NUMERICAL INDEX

PART NO. PG. ITEM PART NO. PG. ITEM PART NO. PG. ITEM PART NO. PG. ITEM
6-25 7 6-23 20 449022013 1-3 42 4-17 10
6-25 21 6-23 26 1-25 5 6-43 11
8-9 3 6-29 16 4-14 45 449029011 7-10 3
8-11 3 8-5 8 5-3 23 7-15 7
449001202 4-9 40 8-5 16 6-3 27 7-17 7
449001233 7-31 26 8-7 7 6-3 35 7-19 3
8-7 9 449015098 4-14 48 6-13 5 7-28 3
449001272 1-3 13 449015112 4-7 7 6-17 5 7-35 7
7-13 17 449015135 6-25 23 6-21 5 7-48 3
449001302 1-25 2 449021001 1-4 55 6-23 19 8-15 13
4-13 43 5-3 12 6-23 25 8-17 20
449001343 7-45 21 5-7 18 6-29 15 8-19 20
449001389 7-13 13 6-3 40 6-41 15 449034054 7-25 12
7-25 19 6-43 10 8-5 9 7-31 37
7-31 15 8-3 8 8-5 15 7-45 12
449001400 8-15 7 449021002 4-13 18 8-7 6 449077093 3-2 3
8-17 7 449021003 1-3 3 449022016 1-3 10 3-10 47
8-19 7 1-3 14 1-3 38 500227907 7-7 19
449001412 2-19 17 1-4 69 1-4 57 7-10 9
2-21 18 2-19 2 2-3 6 7-21 8
8-9 5 2-19 15 4-13 15 7-25 27
449001415 1-3 39 2-21 2 4-17 7 7-28 9
6-3 37 2-21 16 5-3 13 7-39 7
6-29 11 4-7 12 5-3 19 7-45 32
6-43 7 4-13 35 5-7 11 7-48 9
7-21 14 5-7 29 6-3 39 8-15 18
449004080 4-13 30 6-25 8 6-43 9 8-17 14
449007004 2-7 15 6-25 22 7-45 20 8-19 14
449007021 2-3 2 6-29 10 449022017 1-15 5 500227910 7-5 6
449007040 5-3 11 6-39 4 6-13 2 7-25 26
449007043 8-23 7 8-9 9 6-17 2 7-45 26
449015002 1-3 4 449021006 1-3 41 6-21 2 500343914 7-5 10
1-3 16 1-25 4 7-13 15 7-17 13
1-4 71 4-13 44 7-45 10 7-25 23
2-3 4 4-17 14 449022018 1-3 15 7-45 28
4-7 6 5-3 16 1-4 70 500383916 2-15 3
4-9 43 6-3 8 2-3 3 2-17 53
6-23 30 6-3 28 2-19 3 500383922 2-17 48
6-25 10 6-23 18 2-19 16 500403901 7-13 21
6-39 2 6-23 24 2-21 3 7-31 31
8-9 6 6-29 14 2-21 17 7-51 21
449015014 1-3 9 6-41 8 4-7 13 500552902 4-7 18
5-3 20 8-5 14 4-13 36 5-5 7
5-7 10 8-7 5 6-23 29 501739903 8-27 7
6-4 41 449021010 1-3 25 6-25 9 8-29 10
7-45 23 1-4 50 6-39 3 501749901 1-17 1
449015021 2-11 3 7-25 15 8-9 2 501749902 1-15 2
449015029 1-17 3 7-31 16 8-11 2 501749903 1-17 9
449015044 1-25 6 7-45 15 449022019 5-3 8 501753904 7-27 15
5-3 18 7-51 27 8-29 12 7-47 15
6-3 29 449021019 5-7 4 449022021 2-11 2 501753914 7-41 10

10-2
NUMERICAL INDEX

PART NO. PG. ITEM PART NO. PG. ITEM PART NO. PG. ITEM PART NO. PG. ITEM
7-43 9 502654912 6-41 1 7-47 4 7-10 2
501801901 7-7 14 502687901 7-27 16 502793901 1-3 35 7-15 2
7-21 22 7-41 11 6-25 36 7-17 2
7-39 14 7-43 10 502895202 7-23 15 7-19 2
501802906 6-11 11 7-47 16 7-41 9 7-28 2
6-15 11 502701501 2-16 25 503144800 4-3 4 7-35 2
6-19 11 2-16 30 503927202 2-16 20 7-37 2
501850904 7-9 14 502701502 2-15 4 504017204 7-41 8 7-48 2
7-23 7 2-15 8 504024201 7-9 10 504067709 7-5 1
7-27 14 2-15 11 7-23 14 504067736 7-5 1
7-47 14 2-16 27 7-43 8 504067766 7-5 1
501967903 6-29 4 2-16 28 504024207 7-27 10 504067770 7-5 1
501997902 2-16 36 2-16 32 7-47 10 504068704 7-13 3
501997903 2-16 29 2-17 46 504057758 5-3 6 7-31 29
502011903 7-27 6 502701505 2-16 25 504059726 2-16 24 7-51 5
7-47 6 8-3 11 8-27 17 504068721 7-37 1
502011927 7-41 6 8-25 9 8-29 5 504068731 7-37 1
7-43 6 8-27 20 504059730 2-15 2 504068744 7-37 1
502056904 6-3 23 8-29 15 2-16 23 504068761 7-37 1
502056906 4-13 24 502701506 2-15 8 8-27 18 504068794 7-13 14
6-3 24 2-16 28 504061794 1-7 3 7-31 22
502157204 1-9 8 2-17 46 504063719 7-51 3 7-51 8
502164907 2-3 1 502701508 2-15 4 504063781 7-51 4 504069702 7-7 21
2-3 1 2-15 11 504064705 7-25 18 7-21 10
502250902 2-16 38 2-16 27 504064715 7-25 21 7-39 9
502250903 2-17 54 502701513 2-16 30 504064729 7-7 17 504069707 7-13 5
502398906 1-3 44 502701517 8-23 9 7-21 25 504069711 7-13 6
1-4 82 502701518 2-16 32 7-39 17 504069724 7-45 22
1-25 3 502701531 2-15 8 504064739 7-7 7 504069740 7-31 23
502512901 1-3 45 2-16 28 7-21 6 504069791 7-7 21
1-4 74 2-17 46 7-39 5 7-21 10
502566901 8-13 7 502701532 2-15 4 504064742 7-7 11 7-39 9
502566902 7-7 6 2-15 11 7-21 18 504070716 7-13 11
7-21 5 2-16 27 7-39 11 7-31 14
7-39 4 502701537 2-16 32 504064764 7-21 1 504070721 7-31 8
7-45 34 502701538 2-15 8 504064767 7-7 20 7-51 17
502566903 3-10 45 2-16 25 7-21 9 504070756 7-31 7
4-9 35 2-16 28 7-39 8 7-51 16
7-7 4 2-17 46 504064769 7-7 21 504070790 4-9 39
7-21 32 8-3 12 7-21 10 7-51 18
7-25 4 8-25 10 7-39 9 504071702 8-17 12
7-45 4 8-27 21 504064782 7-25 21 8-19 12
8-15 8 8-29 16 504064784 7-7 25 504071785 7-31 27
8-17 8 502701539 2-15 4 504064792 7-25 1 504073758 7-19 1
8-19 8 2-15 11 7-45 1 504073771 7-19 1
502566904 3-5 4 2-16 27 504064799 7-25 1 504073772 7-19 1
502634904 5-5 9 502701542 2-16 30 7-45 1 504073791 7-19 1
502637902 6-11 10 502701544 2-16 32 504065747 7-7 25 504074714 7-17 1
6-15 10 8-23 10 7-21 1 504074723 7-17 1
6-19 10 502719903 8-3 4 504066700 7-3 2 504074730 7-17 1
502654911 6-3 1 502787903 7-27 4 7-5 2 504074771 7-17 1

10-3
NUMERICAL INDEX

PART NO. PG. ITEM PART NO. PG. ITEM PART NO. PG. ITEM PART NO. PG. ITEM
504075764 7-3 3 504228208 6-23 16 7-39 10 504281795 7-45 18
7-15 3 6-29 7 504233232 7-3 8 504281796 7-45 27
7-17 3 504228259 5-5 4 7-5 5 504281799 7-45 30
7-35 3 504228261 6-23 21 7-10 4 504282703 7-5 8
504075767 7-21 29 6-29 8 7-15 8 7-17 11
504075776 7-7 15 504228276 5-5 2 7-17 8 7-25 25
7-21 23 504228295 5-3 3 7-19 4 504301776 7-31 12
7-39 15 504229225 6-13 14 7-28 4 504301777 7-31 13
504075781 7-10 8 6-17 14 7-35 8 504301778 7-32 40
7-28 8 6-21 14 7-37 4 504301779 7-31 39
7-48 8 504229298 8-3 9 7-48 4 504301785 7-25 8
8-15 17 8-13 8 8-15 14 7-45 8
504075799 7-45 11 8-25 4 8-17 18 504305734 1-21 17
504111201 1-13 1 8-27 14 8-19 18 504450732 7-27 8
504111202 1-13 1 8-29 9 504233257 7-9 13 7-47 8
504111203 1-13 1 504230231 1-17 5 504233265 7-25 1 504450758 7-27 3
504111204 1-13 1 8-3 6 7-45 1 7-47 3
504111205 1-13 1 8-13 5 504233271 1-15 3 504574254 6-23 8
504143500 6-11 4 8-23 5 504234265 7-3 4 6-25 32
6-15 4 504230239 6-23 12 7-15 4 504574255 6-25 34
6-19 4 6-25 25 7-17 4 504574267 6-13 13
504148200 7-9 13 504230271 7-7 13 7-35 4 6-17 13
7-23 6 7-13 7 504235239 7-9 11 6-21 13
7-27 13 7-21 12 7-23 5 504574273 4-13 19
7-47 13 7-31 6 7-27 11 504574274 4-13 27
504153200 7-9 9 7-39 13 7-47 11 504574275 4-7
7-23 12 7-51 15 504235245 1-3 17 504574276 4-7 10
504154200 7-9 2 504231215 1-9 12 504235252 6-23 13 504574277 4-7 2
7-9 8 504231230 1-9 9 6-25 24 504575216 1-9 15
7-23 13 504231232 8-5 13 504235278 7-10 5 504575235 1-9 25
504158200 7-41 3 8-7 4 7-28 5 504575277 8-27 9
7-43 3 504231234 1-9 27 7-48 5 504627200 6-25 28
504163200 7-9 1 504231248 1-9 3 8-15 15 504628701 6-25 3
7-23 9 504231252 1-9 13 8-17 19 504628702 6-25 4
504223216 3-2 1 504231256 1-9 31 8-19 19 504628703 6-25 5
504223218 3-2 1 504231270 7-13 12 504236212 1-9 31 504628704 6-25 6
504223274 4-17 2 7-31 21 504236222 1-3 40 504629200 6-25 33
504223278 3-2 1 504231285 8-5 12 504236228 1-9 31 504631200 6-25 26
504225201 5-5 13 8-7 8 504236253 7-7 16 504632200 6-25 27
504225202 4-7 17 504231290 1-9 34 7-21 24 504633200 6-25 35
504225227 1-17 2 504231296 1-9 23 7-39 16 504634200 6-23 9
504225240 5-7 6 504232205 7-27 9 504236257 1-9 31 504673200 6-25 20
504226234 4-3 11 7-47 9 504238241 4-13 33 504693200 6-25 30
504226242 1-3 11 504232212 8-27 1 504240838 4-13 26 504695202 6-25 29
1-3 37 8-29 3 504241782 1-17 7 504695203 6-23 15
6-29 12 504232230 7-9 12 504241783 1-17 8 504707701 8-7 1
7-45 19 504232275 1-25 1 504242751 1-15 1 504707702 8-7 1
8-25 3 504232297 8-27 11 504243752 7-51 24 504707703 8-7 1
8-27 13 8-29 6 504281794 7-5 7 504707704 8-7 1
8-29 8 504233229 7-7 10 7-17 10 504707705 8-7 1
504227269 4-13 21 7-21 17 7-25 22 504707714 8-7 1

10-4
NUMERICAL INDEX

PART NO. PG. ITEM PART NO. PG. ITEM PART NO. PG. ITEM PART NO. PG. ITEM
504707715 8-7 1 505968514 2-15 12 505978597 7-31 9 518801644 7-7 24
504785209 6-3 9 505968538 8-20 2 7-51 13 7-21 26
6-41 9 505968540 2-15 12 506254523 7-31 1 7-25 7
504871201 6-23 3 505968565 2-16 22 506395532 6-25 18 7-45 7
504871202 6-25 12 505968568 2-15 1 506395589 4-3 10 518801677 6-13 11
504871206 6-23 4 2-15 13 506395595 7-17 9 6-17 11
504871207 6-25 11 2-15 14 506726504 6-23 28 6-21 11
504887200 6-23 14 2-15 15 506751500 1-11 6 518802686 2-16 22
504900200 1-4 77 2-15 16 506752500 1-11 5 518803628 5-7 13
504901200 6-25 17 2-15 17 506768501 4-13 23 518803629 7-7 26
504919200 6-25 14 2-15 18 506845500 7-9 4 7-21 21
504920200 6-25 16 2-16 26 7-23 3 7-39 20
504955200 1-9 14 2-16 31 506979500 8-9 8 518803661 1-9 18
505008200 1-3 24 2-17 50 514268301 2-3 1 518807647 4-13 8
8-5 2 505968593 2-17 50 514268309 2-3 1 5-7 28
505018207 2-11 6 505970553 1-3 2 515685804 4-3 5 518807689 2-16 21
505018208 5-3 25 505972545 1-9 1 515686846 4-3 7 518821818 5-5 9
505064713 2-15 17 505974506 5-5 1 515689803 4-3 8 519249804 4-3 2
2-15 18 505974543 5-5 516905800 8-25 11 519433612 2-7 17
505136042 7-23 17 505974557 1-9 13 8-27 19 519433632 2-7 5
505136043 7-9 17 505974576 5-3 22 8-29 17 519477600 6-11 8
505136049 7-27 17 505974595 5-5 3 518445602 2-17 51 6-15 8
7-47 17 505976530 1-9 11 518445620 2-17 51 6-19 8
505195200 8-5 4 505976588 7-51 2 518648601 1-13 1 519517601 6-11 2
505218200 8-5 6 505977500 4-7 3 518648602 1-13 1 6-15 2
505227200 8-5 7 505977509 4-13 17 518648603 1-13 1 6-19 2
505657521 7-9 16 505977516 4-7 1 518648604 1-13 1 519517603 6-11 2
505657522 7-23 4 505977519 5-3 15 518648605 1-13 1 6-15 2
505861501 1-13 1 505977535 1-9 22 518791609 7-7 25 6-19 2
505861502 1-13 1 505977537 5-3 2 7-21 1 519517615 6-11 2
505861503 1-13 1 5-7 9 518791614 7-25 1 6-15 2
505861504 1-13 1 505977538 4-13 14 7-45 1 6-19 2
505861505 1-13 1 505977542 4-7 5 518792621 7-45 2 519521603 7-9 7
505890500 1-9 6 505977550 4-7 15 518792629 7-45 2 519521606 7-9 7
505959500 7-51 9 505977562 4-13 12 518792663 7-45 2 519521608 7-9 7
505961505 7-51 10 505977566 4-13 29 518792674 6-41 1 519521614 7-9 7
505961568 7-13 9 505977569 4-7 4 518792681 7-45 2 519523603 7-9 15
505961592 7-31 2 505977573 4-7 20 518794659 7-9 6 519523606 7-9 15
505962507 7-31 2 4-13 39 7-23 16 519523608 7-9 15
505962533 7-13 22 505977589 4-13 10 518794667 4-5 3 519523614 7-9 15
7-31 18 505977590 4-7 9 518794682 4-13 2 519523653 7-9 15
505962571 7-13 8 505977597 4-13 1 518796642 4-13 3 519523656 7-9 15
505962578 7-13 19 505977598 4-7 8 518796682 1-11 9 519523658 7-9 15
505965586 7-13 18 505978519 7-25 11 8-23 4 519523664 7-9 15
7-13 20 505978544 7-10 7 518796686 4-17 13 519524603 7-9
7-31 30 7-28 7 6-3 31 519524606 7-9
7-51 7 7-48 7 518797634 7-28 6 519524608 7-9
505965599 7-13 2 8-15 16 8-17 17 519524614 7-9
7-51 6 8-17 13 518798650 7-51 19 519524653 7-9
505966574 5-3 5 8-19 13 518799654 7-51 23 519524656 7-9
505966598 5-7 15 505978593 7-25 2 518799698 7-51 22 519524658 7-9

10-5
NUMERICAL INDEX

PART NO. PG. ITEM PART NO. PG. ITEM PART NO. PG. ITEM PART NO. PG. ITEM
519524664 7-9 519638614 7-43 2 520041607 6-11 1 2-16 43
519528603 7-23 2 519638653 7-41 2 6-15 1 520221602 8-5 1
519528606 7-23 2 519638656 7-41 2 6-19 1 520221603 8-5 1
519528608 7-23 2 519638658 7-41 2 520041817 1-4 65 520222602 8-5 1
519528613 7-23 2 519638664 7-41 2 520041835 1-4 83 520222603 8-5 1
519529603 7-23 1 519639603 7-41 1 520041836 1-21 11 520357805 2-7 8
519529606 7-23 1 7-43 1 520041863 1-4 67 520357806 2-7 7
519529608 7-23 1 519639606 7-41 1 520041892 1-4 66 520357810 2-7 23
519529613 7-23 1 7-43 1 520041894 1-4 84 520357818 2-7 16
519529653 7-23 1 519639608 7-41 1 520043867 7-25 17 520357820 2-7 21
519529656 7-23 1 7-43 1 7-45 17 520357821 2-7 22
519529658 7-23 1 519639614 7-41 1 520044803 7-7 11 520357835 2-7 24
519529663 7-23 1 7-43 1 7-39 11 520357849 2-7 19
519530603 7-23 519729801 4-3 9 520045057 4-13 32 520357850 2-7 20
519530606 7-23 519739813 2-5 1 520045119 1-9 19 520357853 2-7 18
519530608 7-23 519739815 2-5 5 520045144 8-11 1 520357854 2-7 10
519530613 7-23 519739820 2-5 7 520045145 8-11 1 520357857 2-7 6
519530653 7-23 519739821 2-5 10 520045181 7-31 35 520357890 2-7 4
519530656 7-23 519739877 2-5 3 520052899 7-3 6 520357892 2-7 25
519530658 7-23 519739878 2-5 9 7-5 3 520371801 2-5 2
519530663 7-23 519920602 8-7 2 7-10 6 524135211 4-13 34
519534603 7-27 519920603 8-7 2 7-15 6 524135489 1-9 24
7-47 520036852 7-3 6 7-17 6 524137230 5-5 4
519534606 7-27 7-5 3 7-19 5 524137528 5-5
7-47 7-10 6 7-35 6 524138691 8-9 7
519534608 7-27 7-15 6 7-37 5 524139228 1-9 10
7-45 31 7-17 6 7-48 6 524139245 3-2
7-47 7-19 5 8-15 12 524139248 4-20 3
519534614 7-27 7-35 6 8-19 17 524139249 4-20 1
7-47 7-37 5 520053804 7-31 34 524143330 6-43 3
519537600 7-27 5 7-48 6 520053821 7-28 6 524144007 6-7 8
7-47 5 8-15 12 8-17 17 524144772 6-9 14
519540603 7-27 2 8-17 17 520082888 8-5 5 524146559 1-9 24
7-47 2 8-19 17 520082889 8-5 3 524148312 6-43 3
519540606 7-27 2 520037801 4-13 13 520082891 3-2 524163286 4-17 16
7-47 2 520038820 2-16 19 520082892 3-2 2 524163287 6-3 5
519540608 7-27 2 520038825 4-13 20 520086612 8-9 1 524163291 6-23 27
7-47 2 520038861 1-11 10 520202601 2-15 5 524163803 5-3 1
519540614 7-27 2 520039810 7-31 25 2-15 6 524163809 5-3
7-47 2 520039855 7-45 24 2-16 40 524168493 1-4 64
519541603 7-27 1 520039872 7-31 24 2-16 41 524168495 1-4 64
7-47 1 520039885 6-13 6 2-16 43 524168496 1-4 64
519541606 7-27 1 6-17 6 520202602 2-15 5 524168497 1-4 64
7-47 1 6-21 6 520202603 2-16 41 524169018 8-3 2
519541608 7-27 1 520040899 7-5 9 520202604 2-15 5 524170894 1-17 6
7-47 1 7-17 12 2-15 6 524170895 1-17 6
519541614 7-27 1 7-25 24 2-16 40 524170897 1-17 6
7-47 1 7-45 29 2-16 41 524170898 1-17 6
519638603 7-43 2 520041606 6-11 1 2-16 43 524171252 1-3 5
519638606 7-43 2 6-15 1 520202606 2-16 40 524171318 6-29 2
519638608 7-43 2 6-19 1 520202607 2-15 6 524171319 6-29 2

10-6
NUMERICAL INDEX

PART NO. PG. ITEM PART NO. PG. ITEM PART NO. PG. ITEM PART NO. PG. ITEM
524171320 6-29 2 580002114 4-5 9 580012516 4-9 12 580020708 8-15 3
524171398 1-3 49 580002115 4-5 16 580012526 4-9 13 8-17 3
524172424 1-3 7 580002117 4-5 22 580012527 4-9 14 8-19 3
524172426 1-3 7 580003242 6-23 1 580012529 4-9 16 580020723 8-15 6
524174472 1-7 1 6-25 1 580012530 4-9 17 8-17 6
524175789 4-13 580003569 1-4 73 580012531 4-9 18 8-19 6
524175790 4-13 580004704 1-3 23 580012532 4-9 19 580020724 8-15 4
524176266 1-17 6 580006358 6-7 3 580012533 4-9 20 8-17 4
524176267 1-17 6 580006359 6-7 2 580012534 4-9 20 8-19 4
524180977 6-43 2 580006842 1-13 8 580012535 4-9 23 580020726 8-15 5
524187015 8-20 3 580006843 1-13 7 580012536 4-9 22 8-17 5
524190264 8-20 3 580006844 1-13 6 580012537 4-9 24 8-19 5
524191513 6-3 18 580008064 1-9 17 580012538 4-9 25 580021087 2-15 13
524191514 6-3 19 580008918 4-19 2 580012539 4-9 26 2-15 14
524191515 6-3 3 4-20 2 580012540 4-9 27 2-16 31
524191516 6-3 4 580008920 4-19 1 580012541 4-9 28 580021088 2-15 13
524191518 6-41 4 580008926 4-19 3 580012546 4-9 33 2-15 14
524192425 6-7 4 580008946 4-18 2 580013339 4-5 1 2-16 31
524196756 1-9 28 580009288 7-31 33 580013340 4-5 14 580022130 4-7 11
524199302 1-13 5 580009289 7-31 32 580013341 4-5 18 580022502 7-9 3
524199303 1-13 5 580009290 7-31 10 580013347 4-5 5 7-23 10
524199304 1-13 5 580010427 5-3 4 580013348 4-5 17 580022505 7-41 4
524199305 1-13 5 580010428 5-5 1 580013349 4-5 11 7-43 4
524199306 1-13 5 580010432 5-5 6 580013350 4-5 19 580022861 2-15 17
524207120 4-14 49 580010433 5-5 11 580013351 4-5 24 2-15 18
524208364 1-9 33 580010434 5-5 10 580013425 1-23 11 2-17 50
524211424 6-41 3 580010571 2-15 15 580014160 4-13 31 580022893 2-15 12
524221058 1-9 20 580010864 4-18 1 580014196 5-5 5 580022964 4-14 47
580000037 8-27 1 580010868 4-18 3 580014462 1-23 3 580023049 8-13 6
8-29 3 580011007 4-5 580014463 1-23 3 580023124 7-13 10
580000127 4-3 4-13 4 580014466 1-23 9 7-31 11
4-17 3 580011058 4-9 34 580014467 1-23 8 580023262 4-9
580000275 4-10 49 580011059 4-9 36 580014468 1-19 9 580023425 6-11 11
580000284 4-13 2 580011167 7-23 8 1-21 10 6-15 11
580000349 4-5 4 7-27 12 1-23 10 6-19 11
580000350 4-5 6 7-47 12 580014898 4-9 29 580023576 4-13 2
580000351 4-5 8 580011625 4-17 6 580014906 4-10 51 580023799 8-15 2
580000356 4-5 13 580011638 1-9 30 580015901 4-10 55 8-17 2
580000360 4-5 23 580011878 1-19 6 580015902 4-10 54 8-19 2
580000702 4-3 12 1-21 7 580018725 1-4 68 580024134 4-9 37
580000821 4-3 1 1-23 6 580018888 1-23 12 580024135 4-9 37
580000822 4-3 13 580012291 2-17 50 580019139 2-15 1 580024136 4-9 2
580000823 4-3 14 580012502 4-9 1 2-15 15 580024137 4-9 4
580000849 4-9 38 580012505 4-9 3 2-15 16 580024138 4-9 21
580001385 2-7 11 580012507 4-9 5 2-16 26 580024139 4-10 50
580001392 2-7 1 580012508 4-9 6 580019140 2-15 1 580024140 4-9 20
580001470 1-4 60 580012509 4-9 7 2-15 16 580024141 4-9 15
580001768 4-9 41 580012510 4-9 8 2-16 26 580024143 4-9 30
580001982 2-7 3 580012511 4-9 9 580019388 6-25 19 580024144 4-9 31
580002110 4-5 21 580012512 4-9 10 580019805 5-7 27 580024145 4-9 32
580002113 4-5 7 580012515 4-9 11 580019835 5-7 26 580024146 4-10 52

10-7
NUMERICAL INDEX

PART NO. PG. ITEM PART NO. PG. ITEM PART NO. PG. ITEM PART NO. PG. ITEM
580024920 7-25 13 580029797 4-17 1 580035499 3-5 3 7-21
7-45 13 580030395 4-9 42 3-7 7-25
580025303 3-9 6 580031628 1-9 2 580035668 2-11 1 580036265 7-15
580025305 3-9 5 580032663 4-13 38 580035780 2-7 28 7-17
580025499 4-10 53 580033718 7-7 22 580035792 1-19 7-19
580025602 7-41 17 7-10 10 580035793 1-19 7-21
7-43 11 7-21 27 580035794 1-21 7-25
580025603 7-41 5 7-25 5 580035795 1-21 580036270 7-15
7-43 5 7-28 10 580035844 8-27 1 7-17
580025665 6-27 9 7-45 5 8-29 3 7-19
580025784 4-7 16 7-48 10 580035907 7-28 7-21
580025953 2-7 15 8-15 19 580035909 7-48 7-25
580025967 2-7 12 8-17 15 580035910 7-10 580036304 7-35
580026217 4-17 1 8-19 15 580035916 7-10 1 7-37
580026330 7-43 580033881 1-4 79 580035917 7-28 1 7-45
580026333 7-43 580033885 1-15 4 580035918 7-48 1 580036307 7-35
580026335 7-43 6-13 3 580035967 6-7 7-37
580026341 7-43 6-17 3 580036018 2-19 1 7-45
580026362 7-41 6-21 3 580036020 2-21 1 580036309 7-35
580026365 7-41 580034132 4-13 25 580036132 7-3 7-37
580026367 7-41 580034133 6-25 38 7-5 7-45
580026373 7-41 580034580 5-11 7-7 580036315 7-35
580026438 6-9 11 580034638 8-5 17 580036135 7-3 7-37
580026611 6-7 17 580034639 8-5 17 7-5 7-45
580026720 8-15 21 580034640 8-5 17 7-7 580036354 1-3 46
8-17 21 580034850 4-13 42 580036137 7-3 580036355 1-3 31
8-19 21 580034992 6-43 1 7-5 1-4 59
580026721 8-15 9 580034999 1-13 2 7-7 580036357 1-3 32
8-17 9 580035000 1-13 3 580036143 7-3 1-4 53
8-19 9 580035001 1-13 11 7-5 580036362 1-4 51
580026723 8-15 10 580035367 6-11 7-7 580036363 1-3 48
8-17 10 6-13 10 580036171 7-3 1 580036366 1-4 58
8-19 10 6-15 7-15 1 580036367 1-4 54
580026749 1-13 4 6-17 10 7-35 1 580036370 1-4 52
580027246 6-9 1 6-19 580036173 7-3 1 580036554 1-7 4
580027247 6-9 2 6-21 10 7-15 1 580036582 4-9 44
580027248 6-9 3 580035368 6-11 7-35 1 580036604 2-15
580027249 6-9 4 6-13 10 580036178 7-3 1 4-9 45
580027250 6-9 5 6-15 7-15 1 580036773 5-7 23
580027252 6-9 7 6-17 10 7-35 1 580036774 5-7 24
580027253 6-9 8 6-19 580036205 7-3 1 580036775 5-7 25
580027255 6-9 10 6-21 10 7-15 1 580036992 2-15 17
580027256 6-9 12 580035369 6-11 7-35 1 2-15 18
580027257 6-9 13 6-13 10 580036260 7-15 2-17 50
580027878 7-10 7 6-15 7-17 580037154 2-7
7-28 7 6-17 10 7-19 580037155 2-7
7-48 7 6-19 7-21 580037241 2-19 9
8-15 16 6-21 10 7-25 2-21 9
8-17 13 580035444 8-13 10 580036263 7-15 3-5 7
8-19 13 8-25 7 7-17 580037252 8-17 1
580028072 4-13 2 8-27 2 7-19 580037254 8-15 1

10-8
NUMERICAL INDEX

PART NO. PG. ITEM PART NO. PG. ITEM PART NO. PG. ITEM PART NO. PG. ITEM
580037255 8-19 1 580040494 5-7 16 580042074 2-19 11 580043891 6-33 7
580037258 8-19 5-9 580042104 1-3 28 6-35 7
580037259 8-17 580041062 2-9 1 580042172 2-3 1 6-37 7
580037260 8-15 580041063 2-9 1 580042174 2-3 1 580043964 7-31 1
580037281 2-19 7 580041206 8-23 8 580042221 2-17 47 580043966 7-31 1
2-21 7 580041208 6-29 27 580042222 2-17 47 580043972 7-31 1
3-5 6 580041265 3-5 1 580042233 6-7 1 580044038 1-9 26
580037283 2-19 8 3-9 580042239 6-7 8 580044039 1-9 26
2-21 8 580041266 3-5 2 580042240 6-7 7 580044040 1-9 5
580037732 2-19 21 3-9 580042241 6-7 6 580044043 1-9 4
2-21 25 580041282 4-13 2 580042242 6-7 5 580044046 6-25 37
580037873 4-13 40 580041328 6-3 22 580042245 2-13 580044159 2-7 2
580038269 4-13 28 580041329 6-3 6 580042248 6-7 4 580044183 6-27 1
580038270 4-13 22 6-41 6 580042348 2-9 1 580044184 6-27 4
580038271 4-9 46 580041338 6-41 5 580042349 2-9 1 580044189 6-27 8
580038272 4-9 46 580041378 1-4 61 580043032 3-5 3 580044197 2-16 33
580038274 4-10 48 580041461 8-25 1 3-7 580044209 2-7 13
580038275 4-10 48 580041501 5-7 8 580043126 1-3 18 580044210 2-7 9
580038277 4-13 41 5-7 8 580043127 1-3 12 580044211 2-7 14
580038834 6-43 12 8-9 11 580043128 1-3 19 580044359 2-7 9
580038849 1-23 580041573 1-21 580043129 1-3 20 580044369 2-7 27
580038851 1-23 580041575 1-21 580043130 1-3 33 580044376 2-13 20
580038857 1-23 580041579 6-39 1 580043131 1-3 34 580044377 2-13 21
580038858 1-23 580041580 6-39 2 580043132 1-3 6 580044378 2-13 23
580039074 6-43 4 580041602 2-7 30 580043133 1-3 6 580044380 2-13 24
580039126 1-11 12 2-19 6 580043207 8-13 9 580044381 2-13 25
580039128 1-11 13 580041603 2-19 5 8-25 5 580044387 2-13 1
580039163 8-20 1 2-21 6 8-27 15 580044389 2-13 3
580039193 8-20 2 580041606 2-7 31 580043504 8-13 1 580044390 2-13 4
580039194 2-15 15 2-21 5 580043635 4-17 9 580044391 2-13 5
580039364 5-7 22 580041628 2-19 10 580043636 4-17 4 580044392 2-13 6
580039513 2-17 47 2-21 10 580043658 1-9 32 580044393 2-13 7
580039643 3-9 21 580041630 2-21 11 580043738 6-29 18 580044394 2-13 8
580039669 8-20 2 580041632 2-19 13 580043740 6-29 20 580044395 2-13 10
580039670 8-20 2-21 14 580043744 6-29 19 580044396 2-13 9
580040131 8-13 11 580041633 2-7 29 580043745 6-29 21 580044397 2-13 11
580040370 8-13 9 2-19 14 580043766 6-31 3 580044398 2-13 12
8-25 5 2-21 15 580043768 6-31 4 580044399 2-13 13
8-27 15 580041651 8-3 1 580043769 6-31 5 580044400 2-13 14
580040411 2-19 18 580041652 8-13 2 580043770 6-31 6 580044401 2-13 15
580040412 2-19 19 580041653 8-13 3 580043774 6-31 8 580044402 2-13 16
580040413 2-19 20 580041654 8-27 4 580043803 6-33 3 580044404 2-13 17
580040414 2-21 19 8-29 1 580043804 6-29 26 580044405 2-13 18
580040415 2-21 20 580041660 2-13 6-33 11 580044564 2-13 22
580040416 2-21 21 580041698 6-25 2 6-35 11 580044605 6-3 32
580040475 8-13 12 580041699 6-23 2 6-37 12 580044606 6-3 33
580040476 8-3 10 580041701 6-23 6 580043824 6-31 2 580044745 2-7 26
580040478 8-27 5 580041965 1-11 2 6-31 11 580044776 6-3 21
8-29 14 580041966 1-11 4 580043889 6-33 6 580044777 6-3 20
580040479 8-25 8 580041967 1-11 3 6-35 6 580044937 5-7 1
8-27 6 580041969 1-11 1 6-37 6 580044939 5-7 3

10-9
NUMERICAL INDEX

PART NO. PG. ITEM PART NO. PG. ITEM PART NO. PG. ITEM PART NO. PG. ITEM
580045338 4-13 21 6-37 2 6-35 1 580050364 2-21 13
580045366 6-39 1 580047781 6-35 3 6-37 1 580050377 2-19 12
580045367 6-39 2 6-37 3 580048569 1-9 26 2-21 12
580045697 6-9 580048193 3-9 1 580048636 1-9 26 580050404 6-9 6
580045713 1-11 7 580048194 3-9 2 580049350 2-7 580050405 6-9 9
580045714 1-11 8 580048195 3-9 41 580049380 3-9 1 580050695 3-7 1
580045721 1-11 8 580048196 3-9 40 580049624 1-3 21 580050696 3-7 2
580046267 6-27 2 580048197 3-9 3 580049625 1-3 1 580050697 3-7 3
580046268 6-27 3 580048198 3-9 7 580049767 1-9 29 580050714 3-7 4
580046269 6-27 5 580048199 3-9 8 580049768 1-9 29 580050715 3-7 5
580046270 6-27 6 580048200 3-9 4 580049821 8-25 6 580050716 3-7 6
580046808 1-3 36 580048201 3-9 9 580049860 1-13 10 580050717 3-7 7
580046856 1-21 9 580048202 3-9 10 580049861 1-13 9 580050796 7-13 1
1-23 4 580048203 3-9 11 580049883 1-23 1 580050800 7-13 1
580046857 1-19 4 580048204 3-9 12 580049884 1-23 15 580050802 7-13 1
1-21 9 580048205 3-9 42 580049885 1-23 2 580050808 7-13 1
1-23 4 580048206 3-9 42 580049886 1-21 14 580050859 8-23 2
580046869 6-39 1 580048207 3-9 42 1-23 13 580050860 8-23 3
6-39 1 580048208 3-9 13 580049887 1-21 15 580050900 2-3 5
6-39 2 580048209 3-9 14 1-23 14 580051162 6-41 2
6-39 2 580048210 3-9 15 580049891 1-19 8 580051526 1-4 76
580047139 6-27 5 580048211 3-9 16 1-21 12 6-25 2
580047140 6-27 5 580048228 3-9 17 580049892 1-19 1 580051571 8-5 11
580047208 1-17 11 580048229 3-10 43 580049893 1-19 1 8-7 3
580047213 1-17 10 580048230 3-10 44 580049894 1-19 2 580051572 1-21 3
580047401 2-19 1 580048231 3-10 44 580049895 1-19 3 580051573 1-21 3
580047402 2-21 1 580048232 3-10 44 580049897 1-21 1 580051574 1-21 4
580047572 1-3 27 580048233 3-10 44 580049898 1-21 1 580051575 1-21 4
580047573 2-5 580048234 3-9 18 580049899 1-21 2 580051616 8-13 9
2-19 1 580048235 3-9 19 580049900 1-21 5 8-25 5
580047595 5-9 1 580048236 3-9 20 580049906 1-19 3 8-27 15
580047596 5-9 2 580048237 3-9 22 580049933 1-19 7 580051805 1-23 3
580047597 5-9 3 580048238 3-9 23 1-21 8 580051876 7-31 36
580047598 5-9 4 580048239 3-9 24 1-23 7 580051943 1-19 10
580047599 5-9 5 580048240 3-9 25 580050217 6-43 13 1-21 13
580047600 5-9 6 580048241 3-9 26 580050221 1-21 16 1-23 16
580047601 5-9 7 580048242 3-9 27 580050222 6-39 1 580052052 2-13 19
580047602 5-9 8 580048243 3-9 28 6-39 2 580052054 2-13 2
580047603 5-9 9 580048244 3-9 29 580050231 6-3 12 580052065 5-7 20
580047604 5-9 10 580048245 3-9 30 6-41 12 580052066 5-7 19
580047605 5-9 11 580048246 3-9 31 580050232 6-3 11 580052216 2-19 22
580047631 1-4 62 580048247 3-9 32 6-41 11 2-21 26
580047632 1-4 63 580048256 3-9 33 580050233 6-3 14 580052232 2-19 24
580047673 5-9 12 580048257 3-9 34 6-41 14 2-21 28
580047757 5-9 13 580048258 3-9 35 580050234 6-3 13 580052236 2-19 23
580047776 6-29 22 580048259 3-9 36 6-41 13 2-21 27
6-31 1 580048260 3-9 37 580050290 2-11 5 580052240 2-5 6
580047778 6-29 23 580048261 3-9 38 2-21 23 580052241 2-5 8
6-33 1 580048262 3-9 39 580050291 2-11 5 580052276 6-13 16
580047779 6-33 2 580048438 6-27 5 2-21 24 6-17 15
6-35 2 580048535 6-29 24 580050307 8-23 6 6-21 16

10-10
NUMERICAL INDEX

PART NO. PG. ITEM PART NO. PG. ITEM PART NO. PG. ITEM PART NO. PG. ITEM
580052277 6-13 17 720098901 2-17 49 8-25 12 931014905 1-3 43
6-21 17 8-3 3 8-27 16 931014906 3-5 5
580052468 6-23 22 8-27 3 8-29 2 931015909 6-13 1
6-27 8-29 4 900003275 6-13 9 6-17 1
580052469 6-23 22 720098904 2-16 34 6-17 9 6-21 1
6-27 720307903 6-3 17 6-21 9 931018905 1-7 2
580052470 6-23 22 751199100 5-7 7 900003276 6-13 9 931109909 5-3 9
6-27 8-9 10 6-17 9 932200902 4-13 9
580052471 6-29 1 751303337 2-15 10 6-21 9 932200905 7-31 19
580052472 6-29 1 752943309 2-15 7 900003277 7-3 9 7-51 11
580052473 6-29 1 2-16 44 7-15 9 932200907 7-31 20
580052619 1-4 75 752953402 1-9 7 7-35 9 932200909 2-19 4
5-7 14 900001201 5-7 2 900004214 7-51 1 2-19 4
580052730 6-27 1 900001242 1-17 4 900005215 6-13 8 2-21 4
580052731 6-27 2 900002253 7-7 25 6-17 8 2-21 4
580052732 6-27 3 7-21 1 6-21 8 7-51 25
580052791 7-3 10 900002259 7-25 20 900015239 6-41 16 932201907 5-7 17
580052881 7-51 26 900002263 7-25 2 909882404 7-31 28 932727905 1-11 11
580052995 1-4 85 900002265 7-25 2 909882405 7-7 8 2-11 4
580053135 6-29 25 900002269 7-25 2 7-21 7 932728910 1-4 72
580053136 6-37 10 900003212 7-21 13 7-25 16 932729905 1-3 8
580053619 1-3 30 900003213 7-21 15 7-31 17 937100903 5-3 10
580053994 6-3 2 900003214 7-21 16 7-39 6 8-27 10
580054080 2-21 22 900003245 1-4 86 7-45 16 8-29 13
580054642 6-27 7 8-3 5 930102903 4-17 11 937300910 4-14 46
580054926 6-27 12 8-13 4 931013904 1-4 56 940004903 5-3 7
580054940 1-3 29 8-23 1 4-17 8 8-27 8

10-11
NOTES

10-12
SECTION 11

11 USER SUPPORT INFORMATION


USER SUPPORT INFORMATION

SECTION 11
USER SUPPORT INFORMATION

DESCRIPTION PAGE

OPERATOR TRAINING...................................................................................................................................... 11-2


SERVICE PARTS ORDERING INSTRUCTIONS ............................................................................................... 11-2
SERVICE TRAINING COURSE ......................................................................................................................... 11-2
SERVICE TRAINING MATERIALS..................................................................................................................... 11-2
TECHNICAL SERVICE PUBLICATIONS............................................................................................................ 11-2

11-1
USER SUPPORT INFORMATION

Your investment in a Yale Industrial Truck is important to you and to your Yale Dealer. You measure the return on
that investment through the performance of these trucks and the drivers who operate and the mechanics who
service them safely and efficiency. The following information and programs are intended to help you to achieve
your investments objectives:

SERVICE PARTS ORDERING INSTRUCTIONS for maintenance. If the operators manual is missing
from any Yale Industrial Truck, it should be replaced.
HOW TO ORDER SERVICE PARTS Replacement copies are available for a nominal fee
from your Yale Dealer.
In order to prevent delay, too much communication
and to have your orders filled correctly, quickly, and OPERATOR TRAINING
at the least possible cost, the following is the correct
procedure to use to order replacement parts. The Yale "Basic Operator Training" program helps
industrial truck users increase their materials handling
WHEN ORDERING PARTS production and safety through correct lift truck
operation, training, and motivation. The Yale program
Contact your authorized Yale Industrial Truck Dealer is based upon real life experience–not theoretical
giving them the following information: concepts. We developed a "complete" program
that is totally self-contained–incorporating the most
1. Your Purchase order number.
modern instructional techniques including elements
2. Complete addresses for sending the invoice and
of self-study, audio-visual support (both video and
parts.
slides), and classroom study.
3. Tell us how you want your parts sent. If we do not
get this information, we will send the parts using SERVICE TRAINING COURSE
the lowest priced method.
4. Correct part number(s) and description(s). Use Operators and Yale dealer service technicians can
your parts manual as a reference. improve their technical ability for maintaining and
5. Model and serial number of the truck. repairing Yale Industrial Trucks, which decreases
repair time and cost, by taking Yale Service Training
TECHNICAL SERVICE PUBLICATIONS courses. Different types of mechanical, electric, and
electronic subjects are available. Courses can be held
Technical literature, with detailed information, is at customer or Dealer locations in addition to regularly
available at a nominal fee to assist users to effectively scheduled courses which are held at Yale Corporate
maintain Yale Industrial Trucks in a safe, useful Headquarters in Greenville, NC.
condition. Part Manuals with complete replacement
parts identification, Service Maintenance Manuals SERVICE TRAINING MATERIALS
which provide service and overhaul procedures and
additional copies of the Operating Manual can be Your own service training can be supported through a
obtained from your Yale Industrial Truck Dealer. complete line of Yale Service Training materials. An
Index is available from your Yale Dealer which lists
SERVICE MAINTENANCE MANUAL- textbooks, audio-visual programs and films. These
PART NO. 524204496 materials will provide your training staff with everything
necessary for training your group.
OPERATING MANUAL-
PART NO. 524197914 For additional information or assistance in obtaining
these user support publications and programs, contact:
To provide instructions for safely operating and
servicing Yale Industrial Trucks, each truck is Yale Materials Handling Corporation
equipped with an operators manual. It describes 1400 Sullivan Drive
various operating techniques and safety warnings Caller No. 12011
to the operator. It contains a guide to safe Greenville, NC 27834-2011
maintenance practices and recommended schedules

11-2
Yale Materials Handling Corporation
1400 Sullivan Drive
Caller No. 12011
Greenville, NC 27834-2011 524204495

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