(A955e) Erp 16-20 Vf-Y-Pm-Uk-En - (01-2009)
(A955e) Erp 16-20 Vf-Y-Pm-Uk-En - (01-2009)
(A955e) Erp 16-20 Vf-Y-Pm-Uk-En - (01-2009)
ERP16-20VF
(A955)
1 GENERAL TRUCK
2 ELECTRICAL SYSTEM
3 DRIVE UNIT
4 STEERING SYSTEM
5 BRAKE SYSTEM
6 HYDRAULIC SYSTEM
10 OPTIONS
11 NUMERICAL INDEX
This Parts Manual is divided into 12 major sections which are listed above. Quick reference to these sections can
be made by placing the right thumb on the tab of the desired section, bending the book back and thumbing the pages
to the corresponding tab.
GENERAL INFORMATION
TABLE OF CONTENTS
DESCRIPTION PAGE
A
ACCELERATOR PEDAL
FOOT DIRECTIONAL CONTROL ............................................................................................................... 5-10
STANDARD ................................................................................................................................................. 5-8
ARMREST ATTACHMENT ............................................................................................................................. 1-52
AUDIBLE ALARM ............................................................................................................................................ 10-2
AUXILIARY KEY SWITCH ASSEMBLY .......................................................................................................... 2-20
B
BATTERY CONNECTOR ................................................................................................................................ 2-12
BATTERY RETENTION .................................................................................................................................. 1-26
BATTERY TRAY OPTIONS
DROP-IN ..................................................................................................................................................... 1-22
SIDE-REMOVAL ......................................................................................................................................... 1-24
BRAKE PEDAL LINKAGE ............................................................................................................................... 5-2
C
CAB
DOOR INSTALLATION ............................................................................................................................... 1-4
FRONT PANEL ASSEMBLY ....................................................................................................................... 1-10
FRONT WIPER ASSEMBLY ....................................................................................................................... 1-16
HEADLINER ASSEMBLY ........................................................................................................................... 1-18
LH DOOR ASSEMBLY ................................................................................................................................ 1-8
REAR PANEL ASSEMBLY ......................................................................................................................... 1-14
RH DOOR ASSEMBLY ............................................................................................................................... 1-6
TOP PANEL ASSEMBLY ............................................................................................................................ 1-12
CAB ASSEMBLY
FULL STEEL CAB ....................................................................................................................................... 1-2
CARRIAGE ASSEMBLY
THREE STAGE FULL FREE LIFT - A271 - STANDARD ............................................................................ 8-14
THREE STAGE FULL FREE LIFT - A271 - INTEGRAL SIDE-SHIFT ........................................................ 10-20
THREE STAGE FULL FREE LIFT - C662 - STANDARD ........................................................................... 8-34
THREE STAGE FULL FREE LIFT - C662 - INTEGRAL SIDE-SHIFT ........................................................ 10-22
TWO STAGE FULL FREE- LIFT - STANDARD .......................................................................................... 9-14
TWO STAGE FULL FREE- LIFT - C663 - INTEGRAL SIDE-SHIFT ........................................................... 10-24
TWO STAGE LIMITED FREE LIFT - A270 - STANDARD .......................................................................... 7-8
TWO STAGE LIMITED FREE LIFT - C661 - STANDARD .......................................................................... 7-20
TWO STAGE LIMITED FREE LIFT - C661 - INTEGRAL SIDE-SHIFT ....................................................... 10-18
TWO STAGE LIMITED FREE-LIFT - A270 - INTEGRAL SIDE-SHIFT ....................................................... 10-16
CONTACTOR
E .................................................................................................................................................................. 2-10
CONTROL VALVE
ELECTRO-HYDRAULIC - 3 AND 4 FUNCTION ......................................................................................... 6-26
MANUAL - 3 AND 4 FUNCTION ................................................................................................................. 6-14
CONTROLLER
HOIST ASSEMBLY ..................................................................................................................................... 2-6
TRACTION AND FAN ASSEMBLY ............................................................................................................. 2-8
CONTROLLERS .............................................................................................................................................. 2-4
COUNTERWEIGHT ........................................................................................................................................ 1-28
DESCRIPTION PAGE
COWL MOUNT ................................................................................................................................................ 1-30
D
DASH AND STEERING COLUMN COVERS
FIXED COLUMN ......................................................................................................................................... 1-32
TELESCOPIC COLUMN ............................................................................................................................. 1-34
DC/DC CONVERTER ...................................................................................................................................... 10-28
DISPLAY ......................................................................................................................................................... 2-16
DISPLAY WIRE HARNESS
PREMIUM ................................................................................................................................................... 2-17
STANDARD ................................................................................................................................................. 2-18
DRIVE TIRE AND WHEEL ASSEMBLY .......................................................................................................... 3-2
DRIVE UNIT ASSEMBLY ................................................................................................................................ 3-4
E
ELECTRICAL ARRANGEMENT ..................................................................................................................... 2-2
F
FLOOR PLATES ............................................................................................................................................. 1-36
FORKS ............................................................................................................................................................ 1-38
FREE LIFT ASSEMBLY
THREE STAGE FULL FREE LIFT - A271 ................................................................................................... 8-6
THREE STAGE FULL FREE LIFT - C662 .................................................................................................. 8-24
TWO STAGE FULL FREE LIFT - C663 ...................................................................................................... 9-10
FREE LIFT CYLINDER ASSEMBLY
THREE STAGE FULL FREE LIFT - A271 ................................................................................................... 8-12
THREE STAGE FULL FREE LIFT - C662 .................................................................................................. 8-32
TWO STAGE FULL FREE LIFT - C663 ...................................................................................................... 9-12
FRONT WORK AND MARKER LIGHTS ......................................................................................................... 10-4
FUSE PANEL AND FUSES ............................................................................................................................. 2-14
H
HEADER HOSE ASSEMBLY
THREE STAGE FULL FREE LIFT - A271 - 3 FUNCTION .......................................................................... 8-16
THREE STAGE FULL FREE LIFT - A271 - 4TH FUNCTION ..................................................................... 8-18
THREE STAGE FULL FREE LIFT - C662 - 3 FUNCTION .......................................................................... 8-36
THREE STAGE FULL FREE LIFT - C662 - 4 FUNCTION .......................................................................... 8-38
TWO STAGE FULL FREE LIFT - C663 - 3 AND 4 FUNCTION .................................................................. 9-16
TWO STAGE FULL FREE LIFT - C663 - 4TH FUNCTION ......................................................................... 9-20
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 7-10
TWO STAGE LIMITED FREE-LIFT - C661 ................................................................................................. 7-22
HOOD AND COVERS ..................................................................................................................................... 1-20
HYDRAULIC CONTROLS
ELECTRO-HYDRAULIC ............................................................................................................................. 6-24
MANUAL ..................................................................................................................................................... 6-10
HYDRAULIC HOSES AND FITTINGS
STEERING .................................................................................................................................................. 6-36
SUPPLY AND RETURN .............................................................................................................................. 6-34
TILT, MAST AND AUXILIARY - ELECTRO-HYDRAULIC .......................................................................... 6-42
TILT, MAST AND AUXILIARY - MANUAL-HYDRAULIC ............................................................................ 6-44
DESCRIPTION PAGE
HYDRAULIC LEVERS - LINKAGE ASSEMBLY
MANUAL ..................................................................................................................................................... 6-38
HYDRAULIC MOTOR ..................................................................................................................................... 6-6
HYDRAULIC POWER UNIT INSTALLATION ................................................................................................. 6-2
HYDRAULIC PUMP ........................................................................................................................................ 6-8
HYDRAULIC PUMP AND MOTOR ASSEMBLY ............................................................................................. 6-4
HYDRAULIC TANK ASSEMBLY ..................................................................................................................... 6-12
I
INLET SECTION
ELECTRO-HYDRAULIC CONTROL VALVE .............................................................................................. 6-28
MANUAL HYDRAULIC CONTROL VALVE ................................................................................................ 6-16
INTEGRAL SIDE-SHIFT CYLINDER .............................................................................................................. 10-26
L
LABELS
EXTERIOR .................................................................................................................................................. 1-40
INTERIOR ................................................................................................................................................... 1-42
LIFT CYLINDER ASSEMBLY
TWO STAGE LIMITED FREE LIFT - A270 ................................................................................................. 7-6
TWO STAGE LIMITED FREE LIFT - C661 ................................................................................................. 7-16
LIFT/TILT SECTION
ELECTRO-HYDRAULIC CONTROL VALVE .............................................................................................. 6-30
LIFT/TILT/AUXILIARY SECTION
MANUAL HYDRAULIC CONTROL VALVE ................................................................................................ 6-18
LOAD BACKREST EXTENSION ..................................................................................................................... 1-44
M
MAIN LIFT ASSEMBLY
THREE STAGE FULL FREE LIFT - A271 ................................................................................................... 8-4
THREE STAGE FULL FREE LIFT - C662 .................................................................................................. 8-22
TWO STAGE FULL FREE LIFT - C663 ...................................................................................................... 9-4
MAIN LIFT CYLINDER ASSEMBLY
THREE STAGE FULL FREE LIFT - A271 ................................................................................................... 8-10
THREE STAGE FULL FREE LIFT - C662 .................................................................................................. 8-28
MAIN LIFT CYLINDER LH
TWO STAGE FULL FREE LIFT - C663 ...................................................................................................... 9-6
MAIN LIFT CYLINDER RH
TWO STAGE FULL FREE- LIFT - C663 ..................................................................................................... 9-8
MAIN WIRE HARNESS
ELECTRO-HYDRAULIC - PAGE 1 0F 2 ..................................................................................................... 2-26
ELECTRO-HYDRAULIC - PAGE 2 0F 2 ..................................................................................................... 2-30
MANUAL-HYDRAULIC - PAGE 1 0F 2 ....................................................................................................... 2-34
MANUAL-HYDRAULIC - PAGE 2 0F 2 ....................................................................................................... 2-38
MAST ASSEMBLY
THREE STAGE FULL FREE LIFT - A271 - INNER, INTERMEDIATE AND OUTER ................................. 8-2
THREE STAGE FULL FREE LIFT - C662 - INNER, INTERMEDIATE AND OUTER ................................. 8-20
TWO STAGE FULL FREE LIFT - C663 ...................................................................................................... 9-2
TWO STAGE LIMITED FREE LIFT - A270 ................................................................................................. 7-2
TWO STAGE LIMITED FREE LIFT - C661 ................................................................................................. 7-12
DESCRIPTION PAGE
MAST/TILT CYLINDER INSTALLATION ........................................................................................................ 6-40
MASTER CYLINDER ...................................................................................................................................... 5-4
MINI-LEVER CONTROLS AND ARMREST ASSEMBLY ............................................................................... 2-24
MIRROR
CONVEX REAR VIEW ................................................................................................................................ 10-12
DUAL REAR VIEW ...................................................................................................................................... 10-14
O
OUTLET SECTION
MANUAL HYDRAULIC CONTROL VALVE ................................................................................................ 6-20
OVERHEAD GUARD ...................................................................................................................................... 1-46
P
PARKING BRAKE RELEASE .......................................................................................................................... 5-6
POSITIONER SENSOR
MANUAL HYDRAULIC CONTROL VALVE ................................................................................................ 6-22
R
REAR REFLECTORS ..................................................................................................................................... 10-6
REVERSE HANDLE ........................................................................................................................................ 10-8
S
SEAT (FULL SUSPENSION) .......................................................................................................................... 1-48
STATIC STRAP ............................................................................................................................................... 1-50
STEER AXLE ASSEMBLY .............................................................................................................................. 4-6
STEER AXLE MOUNTING .............................................................................................................................. 4-4
STEER COLUMN
FIXED .......................................................................................................................................................... 4-8
TELESCOPIC .............................................................................................................................................. 4-10
STEER TIRE AND WHEEL ASSEMBLY ......................................................................................................... 4-2
STEERING HAND PUMP ASSEMBLY ........................................................................................................... 4-12
STROBE LIGHT ASSEMBLY AND REAR WORK LIGHT .............................................................................. 10-10
T
TIE RODS
ELECTRO-HYDRAULIC CONTROL VALVE .............................................................................................. 6-32
MANUAL HYDRAULIC CONTROL VALVE ................................................................................................ 6-21
TILT CYLINDER ASSEMBLY .......................................................................................................................... 6-46
TILT SENSOR GROUP ................................................................................................................................... 6-48
TRACTION MOTOR ........................................................................................................................................ 3-6
TRANSMISSION
BRAKE ........................................................................................................................................................ 3-8
BRAKE PISTON .......................................................................................................................................... 3-10
INPUT PINION AND COVER ...................................................................................................................... 3-12
PLANETARY AND COVER ......................................................................................................................... 3-14
W
WIRE HARNESS
TURN SIGNAL ............................................................................................................................................ 2-42
Listed below are abbreviations used in parts manuals to denote the following expressions:
spacer
TERM DEFINITION TERM DEFINITION
Amp Amperes FRE Freezer Environment
AR As Required in. inches
BDI Battery Discharge Indicators LPG Liquefied Petroleum Gas
BWI Brush Wear Indicator MAP Manifold Absolute Pressure
CE Communicator End mm millimeters
CRE Corrosive Environment MSTS Microprocessor Spark Timing System
D/B Date Break NPT National Pipe Threads
dbA Decibel "A" Scale O/S Oversize
DE Drive End PTO Power Take Off
ECH Empty Container Handler RPM Revolutions per Minute
ECH-3 Empty Container Handler - 3 High S/N Serial Number
Stacking TMM Truck Management Module
ECH-4 Empty Container Handler - 4 High UL Type D Diesel-Powered Safety Rating
Stacking
UL Type DS Diesel-Powered Safety Rating
ECH-5 Empty Container Handler - 5 High
Stacking UL Type E Battery-Powered Safety Rating
This parts manual describes and illustrates assemblies, The different constructions are indicated by keys and
subassemblies, and detail parts needed for service footnotes. The callouts correspond to descriptions
replacement. found on the next page.
1. Determine the function and application of the part 9. Quantities shown are for one assembly. The
required. Turn to the Sections Page. Choose the quantities of the subpart BEARING CAP are
general area of reference most likely to include the indicated as two and two. This means two per
part. CASE assembly.
2. Turn to the section you chose. Use the Section 10. Serial number breaks identify the most current
Table of Contents to determine the assembly parts information and are shown as follows:
which would normally contain the part required. → S/N A810N2639
Then locate the part on the assembly breakdown Indicates last serial number affected.
page. S/N A810N2640 →
Indicates the first serial number affected.
WHEN THE PART NUMBER IS NOT KNOWN S/N A810N1553 ↔ S/N A810N3291
AND THE NEXT HIGHER ASSEMBLY IS Indicates a range of serial numbers affected.
KNOWN:
ECN numbers for pending serial numbers are
3. Determine the assembly the required part is used shown to allow for the inclusion of the most current
on. Turn to the Table of Contents (Page i). parts information and are identified as follows:
→ S/N Pending Per ECN 63243
4. Locate the assembly the required part is used on
Indicates a pending serial number for last unit
and turn to the page indicated for that assembly.
affected.
Then locate the part on the assembly breakdown
S/N Pending Per ECN 63243 →
page.
Indicates a pending serial number for first unit
WHEN THE PART NUMBER IS KNOWN: affected.
5. Use the Numerical Index (Page 11-1) to find the Date breaks are used to indicate when a change
part number. Turn to the page listed and locate the occurred but a subsequent serial number break
part as indicated by the item number. was not recorded. This is an arbitrary date usually
based on the ECN release and are identified as
GENERAL: follows:
→ D/B 3/00
The assembly breakdowns include part numbers, Indicates that a change occurred sometime
descriptions, quantities required, keys and within that month for the item affected.
footnotes to help in selecting correct parts. D/B 3/00 →
Indicates that a change occurred sometime
6. Five periods in the PART NO. column (. . . . .)
within that month for the item affected.
indicate that the part is either Not Serviced
D/B 3/00 ↔ D/B 4/00
Separately or there is a reference to another figure.
Indicates a range of production dates of the item
A figure reference is denoted by a pointing hand
affected.
followed by a page number in the DESCRIPTION
column (FPage 3-4) Contact your local dealer for Yale lift trucks for
serial number information for items with a ECN or
7. Keys are used to show two or more similar
a date break.
assemblies, RH and LH assembly parts, etc.
Select the appropriate key, "A", "B", "C", "D", or "E" ORDERING PARTS:
and the corresponding quantity column to find the
required parts. Two periods in the QTY column (..) When ordering replacement parts, give the unit serial
indicate that the part is not used for that assembly. number, part number, name of part and quantity
required.
8. Indented descriptions under the DESCRIPTION
column are used to indicate assemblies and For any further information on parts, service, or
subparts of assemblies. In the example on the ordering, consult your local dealer for Yale lift trucks.
NOTE: Serial Number breakdown is only for trucks built after 1994.
(1) and (2) The first letter and three numbers indicate the truck unit code.
(3) The second letter indicates the plant of manufacture.
(4) The four or five digit number indicates the production sequence number of the truck.
(5) The final letter indicates the year of manufacture starting with "A" in 1957, 1980, and 2003.
The letters "I", "O", and "Q" will not be used.
For pending serial numbers contact your local dealer for Yale lift trucks.
Parts referred to in this book as right or left hand parts are in accordance with the illustration above.
(1) and (2) The first letter and number indicates the mast unit code.
(3) The second letter indicates the plant of manufacture.
(4) The four or five digit number indicates the production sequence number of the mast.
(5) Carriage travel in millimeters stamped just below the serial number.
Mast Group identification consists of mast unit code (1) and (2) plus carriage travel (5).
For pending production sequence numbers contact your local dealer for Yale lift trucks.
(1) and (2) The first letter and three numbers indicate the attachment unit code.
(3) The second letter indicates the plant of manufacture.
(4) The four or five digit number indicates the production sequence number.
For pending production sequence numbers contact your local dealer for Yale lift trucks.
Side-shift carriages and attachments have nameplates. Use the serial number found on the nameplate to identify
the attachment.
Always refer to the group, serial, or part number when ordering service parts.
Modifications of attachments and side-shift carriages by SPED (Special Products Engineering Department) are
identified by a model prefix code beginning with the letter "S". Contact your dealer for Yale lift trucks for information
on these assemblies.
PUBLICATIONS
Every new lift truck is provided with an OPERATING MANUALS with complete replacement part
MANUAL. This manual has information that the identification, are available at a nominal fee from your
operator must know for inspection and operation of the Yale dealer to assist users in effectively maintaining
lift truck. Yale lift trucks in a safe, useful condition. See the list
below for information on ordering specific publications
SERVICE MAINTENANCE MANUALS, which provide for this model lift truck.
service and overhaul procedures, and PARTS
NOTES
1 GENERAL TRUCK
CONTENTS
SECTION 1
GENERAL TRUCK
DESCRIPTION PAGE
CAB ASSEMBLY
FULL STEEL CAB
KEY:
A: 546 mm Battery Compartment
B: 642 mm Battery Compartment
C: 750 mm Battery Compartment
QTY
ITEM PART NO. DESCRIPTION A B C
1 580096324 Kit-Front Screen (FPage 1-10)......................................................... 1 1 1
2 580096200 Kit-Top Screen (FPage 1-12)........................................................... 1 .. ..
2 580096201 Kit-Top Screen (FPage 1-12)........................................................... .. 1 ..
2 580096202 Kit-Top Screen (FPage 1-12)........................................................... .. .. 1
3 524310923 Cab (Door Assembly) (FPage 1-4)................................................... 2 .. ..
3 524310929 Cab (Door Assembly) (FPage 1-4)................................................... .. 2 ..
3 524310930 Cab (Door Assembly) (FPage 1-4)................................................... .. .. 2
4 580096322 Kit-Rear Screen (Standard Hood) (FPage 1-14).............................. 1 1 1
4 580096323 Kit-Rear Screen (Low Hood) (FPage 1-14)...................................... 1 1 1
5 580091709 Kit-Window Washer (FPage 1-16)................................................... 1 1 1
CAB
DOOR INSTALLATION
KEY:
A: 546mm Battery Compartment
B: 642mm Battery Compartment
C: 750mm Battery Compartment
QTY
ITEM PART NO. DESCRIPTION A B C
524310923 Cab (Door Assembly) ........................................................................ 1 .. ..
524310929 Cab (Door Assembly) ........................................................................ .. 1 ..
524310930 Cab (Door Assembly) ........................................................................ .. .. 1
1 580086545 Cab (Door Assembly) (LH) (FPage 1-8)...................................... 1 .. ..
1 580086547 Cab (Door Assembly) (LH) (FPage 1-8)...................................... .. 1 ..
1 580086549 Cab (Door Assembly) (LH) (FPage 1-8)...................................... .. .. 1
2 580086546 Cab (Door Assembly) (RH) (FPage 1-6)...................................... 1 .. ..
2 580086548 Cab (Door Assembly) (RH) (FPage 1-6)...................................... .. 1 ..
2 580086550 Cab (Door Assembly) (RH) (FPage 1-6)...................................... .. .. 1
3 580095371 Gas Spring (LH) ............................................................................ 1 1 1
3 580095372 Gas Spring (RH) ............................................................................ 1 1 1
4 580096199 Bracket .......................................................................................... 2 2 2
5 449021003 Washer .......................................................................................... 4 4 4
6 449001170 Capscrew ...................................................................................... 4 4 4
7 580041704 Insert ............................................................................................. 4 4 4
8 580095375 Mounting Plate .............................................................................. 4 4 4
9 580095374 Hinge ............................................................................................. 4 4 4
10 524329711 Capscrew ...................................................................................... 8 8 8
11 524329712 Capscrew ...................................................................................... 12 12 12
12 449001013 Capscrew ...................................................................................... 6 6 6
13 449021001 Washer .......................................................................................... 6 6 6
14 580028816 Block ............................................................................................. 2 2 2
15 580096197 Bracket (LH) .................................................................................. 1 1 1
15 580096198 Bracket (RH) ................................................................................. 1 1 1
16 580028817 Guard ............................................................................................ 2 2 2
17 580028818 Bolt ................................................................................................ 2 2 2
a 580044861 Insert ............................................................................................. 18 18 18
a 501702902 Loctite ............................................................................................ AR AR AR
FOOTNOTES:
a Not Illustrated
CAB
RH DOOR ASSEMBLY
KEY:
A: 546mm Battery Compartment
B: 642mm Battery Compartment
C: 750mm Battery Compartment
QTY
ITEM PART NO. DESCRIPTION A B C
580086546 Cab (Door Assembly) ........................................................................ 1 .. ..
580086548 Cab (Door Assembly) ........................................................................ .. 1 ..
580086550 Cab (Door Assembly) ........................................................................ .. .. 1
1 524337824 Door .............................................................................................. 1 .. ..
1 524337826 Door .............................................................................................. .. 1 ..
1 524337828 Door .............................................................................................. .. .. 1
2 580097108 Screen ........................................................................................... 1 .. ..
2 580097105 Screen ........................................................................................... .. 1 ..
2 580097096 Sliding Window .............................................................................. .. .. 1
3 580048647 Seal (4 meters) .............................................................................. AR AR AR
4 580032669 Seal ............................................................................................... AR AR AR
5 580092803 Door (Grip) .................................................................................... 1 1 1
6 580048647 Seal ............................................................................................... 1 1 1
7 449021003 Washer .......................................................................................... 3 3 3
8 449007018 Screw ............................................................................................ 3 3 3
9 580097084 Screw ............................................................................................ 1 1 1
10 580092794 Plate .............................................................................................. 1 1 1
11 580092795 Screw ............................................................................................ 2 2 2
12 580048654 Latch ............................................................................................. 1 1 1
13 580097103 Plate .............................................................................................. 1 1 1
14 580048529 Washer .......................................................................................... 6 6 6
15 449001268 Capscrew ...................................................................................... 6 6 6
16 580097102 Plate .............................................................................................. 1 1 1
17 580097098 Lever ............................................................................................. 1 1 1
18 580022274 Nut ................................................................................................. 1 1 1
19 580062036 Lever ............................................................................................. 1 1 1
20 580097106 Enclosure ...................................................................................... 1 .. ..
20 580097109 Door Panel .................................................................................... .. 1 ..
20 580097097 Cover ............................................................................................. .. .. 1
21 580062102 Fastener ........................................................................................ 7 7 7
22 580062032 Handle ........................................................................................... 1 1 1
23 580062025 Screw ............................................................................................ 4 4 4
24 580097100 Cover ............................................................................................. 1 1 1
25 580014813 Screw ............................................................................................ 6 6 6
26 580097101 Clamp ............................................................................................ 1 1 1
27 580097099 Seal ............................................................................................... AR AR AR
CAB
LH DOOR ASSEMBLY
KEY:
A: 546mm Battery Compartment
B: 642mm Battery Compartment
C: 750mm Battery Compartment
QTY
ITEM PART NO. DESCRIPTION A B C
580086545 Cab (Door Assembly) ........................................................................ 1 .. ..
580086547 Cab (Door Assembly) ........................................................................ .. 1 ..
580086549 Cab (Door Assembly) ........................................................................ .. .. 1
1 580032669 Seal ............................................................................................... 1 1 1
2 580097080 Sliding Window .............................................................................. 1 .. ..
2 580097090 Screen ........................................................................................... .. 1 ..
2 580097086 Screen ........................................................................................... .. .. 1
3 524337823 Door .............................................................................................. 1 .. ..
3 524337825 Door .............................................................................................. .. 1 ..
3 524337827 Door .............................................................................................. .. .. 1
4 580048647 Seal ............................................................................................... 1 1 1
5 580097081 Screen ........................................................................................... 1 1 1
6 580092792 Grip ............................................................................................... 1 1 1
7 580048647 Seal ............................................................................................... 1 1 1
8 580097091 Cover ............................................................................................. 1 .. ..
8 580097082 Cover ............................................................................................. .. 1 ..
8 580097087 Cover ............................................................................................. .. .. 1
9 580097084 Screw ............................................................................................ 1 1 1
10 580048678 Latch ............................................................................................. 1 1 1
11 580092795 Screw ............................................................................................ 2 2 2
12 580048655 Plate .............................................................................................. 1 1 1
13 580021028 Cover ............................................................................................. 1 1 1
14 580048656 Washer .......................................................................................... 1 1 1
15 580016583 Screw ............................................................................................ 1 1 1
16 580092800 Screw ............................................................................................ 1 1 1
17 580092798 Washer .......................................................................................... 1 1 1
18 580092797 Door Handle .................................................................................. 1 1 1
19 580062102 Fastener ........................................................................................ 7 7 7
20 580092796 Tube .............................................................................................. 1 1 1
21 449021003 Washer .......................................................................................... 3 3 3
22 580029110 Screw ............................................................................................ 3 3 3
23 580048658 Lock ............................................................................................... 1 1 1
24 580092794 Plate .............................................................................................. 1 1 1
a 580092801 Rod ................................................................................................ 1 1 1
FOOTNOTES:
a Not Illustrated
CAB
FRONT PANEL ASSEMBLY
CAB
TOP PANEL ASSEMBLY
KEY:
A: 546mm Battery Compartment
B: 642mm Battery Compartment
C: 750mm Battery Compartment
QTY
ITEM PART NO. DESCRIPTION A B C
580096200 Kit-Top Screen .................................................................................. 1 .. ..
580096201 Kit-Top Screen .................................................................................. .. 1 ..
580096202 Kit-Top Screen .................................................................................. .. .. 1
1 580096203 Cab (Rear Top Assembly) ............................................................. 1 .. ..
1 580096204 Cab (Rear Top Assembly) ............................................................. .. 1 ..
1 580096205 Cab (Rear Top Assembly) ............................................................. .. .. 1
2 580097077 Roof Panel ................................................................................ 1 1 1
2 580097078 Roof Panel ................................................................................ 1 .. 1
2 580097075 Roof Panel ................................................................................ 1 1 1
3 580097076 Flap ........................................................................................... 1 1 1
4 449001412 Capscrew .................................................................................. 4 4 4
5 449021003 Washer ..................................................................................... 4 4 4
6 449015002 Nut ............................................................................................ 4 4 4
7 580095364 Screen ........................................................................................... 1 .. ..
7 580095366 Screen ........................................................................................... .. 1 ..
7 580095367 Screen ........................................................................................... .. .. 1
8 a 580095365 Shim .............................................................................................. 2 2 2
9 449021003 Washer .............................................................................................. 8 8 8
10 449001121 Capscrew .......................................................................................... 4 4 4
11 449015002 Nut ..................................................................................................... 4 4 4
a 580094577 Cap .................................................................................................... 4 4 4
a 580096546 Adhesive ............................................................................................ 1 1 1
a 580096547 Activator ............................................................................................ AR AR AR
a 580096548 Primer ................................................................................................ AR AR AR
FOOTNOTES:
a Not Illustrated
CAB
REAR PANEL ASSEMBLY
CAB
FRONT WIPER ASSEMBLY
CAB
HEADLINER ASSEMBLY
KEY:
A: 546mm Battery Compartment
B: 642mm Battery Compartment
C: 750mm Battery Compartment
QTY
ITEM PART NO. DESCRIPTION A B C
580091706 Headliner ........................................................................................... 1 .. ..
580091707 Headliner ........................................................................................... .. 1 ..
580091708 Headliner ........................................................................................... .. .. 1
1 580095402 Headliner ....................................................................................... 1 .. ..
1 580095401 Roof Panel .................................................................................... .. 1 ..
1 580095379 Headliner ....................................................................................... .. .. 1
2 580095380 Bracket .......................................................................................... 1 1 1
3 580095381 Bracket .......................................................................................... 1 1 1
4 580095382 Clamp ............................................................................................ 1 1 1
5 580062048 Cover ............................................................................................. 2 2 2
6 580095384 Screw ............................................................................................ 8 8 8
7 580075011 Capscrew ...................................................................................... 7 7 7
8 580095385 Screw ............................................................................................ 7 7 7
9 580095386 Cap ................................................................................................ 4 4 4
10 580064170 Cover ............................................................................................. 1 1 1
11 580095392 Bracket .......................................................................................... 1 1 1
12 580095393 Screw ............................................................................................ 2 2 2
13 580048529 Washer .......................................................................................... 2 2 2
FOOTNOTES:
a Models: 16-18VF c Not Illustrated
b Models: 20VF
FOOTNOTES:
a Model: 20VF c Not Illustrated
b Models: 16-18VF
BATTERY RETENTION
ITEM PART NO. DESCRIPTION QTY
1 524328789 Retainer (Assembly) ........................................................................................... 1
2 524327738 Bracket ........................................................................................................... 1
3 524327744 Spring ............................................................................................................. 1
4 524327741 Pin .................................................................................................................. 1
5 580071587 Switch ............................................................................................................. 1
6 940004902 Washer ........................................................................................................... 4
7 449007032 Screw ............................................................................................................. 4
8 580051442 Magnet ........................................................................................................... 1
9 580023049 Bolt ...................................................................................................................... 1
10 504226242 Washer ............................................................................................................... 1
11 580027573 Nut (Flange) ........................................................................................................ 1
COUNTERWEIGHT
ITEM PART NO. DESCRIPTION QTY
1 524300820 Counterweight ..................................................................................................... 1
2 504061794 Washer ............................................................................................................... 6
3 931018905 Capscrew ............................................................................................................ 2
4 931018911 Capscrew ............................................................................................................ 2
5 580095400 Nut ...................................................................................................................... 2
6 501702903 Loctite ................................................................................................................. 1
COWL MOUNT
ITEM PART NO. DESCRIPTION QTY
1 524332752 Cowl .................................................................................................................... 1
2 580056527 Capscrew ............................................................................................................ 6
FOOTNOTES:
a With Cab b Without Cab
FOOTNOTES:
a With Cab b Without Cab
FLOOR PLATES
KEY:
A: Manual Hydraulics
B: E. Hydraulics
QTY
ITEM PART NO. DESCRIPTION A B
1 580087966 Floorplate ................................................................................................... 1 1
2 580087967 Floorplate (Standard Height) ...................................................................... 1 ..
2 580087968 Floorplate (Standard Height) ...................................................................... .. 1
2 580087969 Floorplate (Low Height) .............................................................................. 1 ..
2 580087970 Floorplate (Low Height) .............................................................................. .. 1
3 580087971 Floorplate (Standard Step) ......................................................................... 1 1
3 580087972 Floorplate (Low Step) ................................................................................. 1 1
4 580087973 Floorplate (Extension-Standard Height) ..................................................... 1 1
5 580003569 Washer ....................................................................................................... 6 6
6 932729908 Capscrew ................................................................................................... 3 3
7 504230271 Nut .............................................................................................................. 3 3
8 580092460 Floormat ..................................................................................................... 1 ..
8 580092459 Floormat ..................................................................................................... .. 1
FORKS
KEY:
A: Standard Latch
B: Optional Latch
QTY
ITEM PART NO. DESCRIPTION A B
1 504242721 Fork (1000 mm) .......................................................................................... 2 ..
1 253937205 Fork (1000 mm) .......................................................................................... 2 ..
1 277961500 Fork (1000 mm) .......................................................................................... .. 2
1 504242722 Fork (1100 mm) .......................................................................................... 2 ..
1 253937218 Fork (1100 mm) .......................................................................................... 2 ..
1 580032657 Fork (1100 mm) .......................................................................................... .. 2
1 504242723 Fork (1200 mm) .......................................................................................... 2 ..
1 253937208 Fork (1200 mm) .......................................................................................... 2 ..
1 277558300 Fork (1200 mm) .......................................................................................... .. 2
2 580034999 Knob ........................................................................................................... .. 1
3 580035000 Pin .............................................................................................................. .. 1
4 580026749 Spring ......................................................................................................... .. 1
5 580006844 Roll Pin ....................................................................................................... 1 ..
6 580006843 Latch .......................................................................................................... 1 ..
7 580006842 Spring ......................................................................................................... 1 ..
8 580049861 Pin .............................................................................................................. 1 ..
a 580035001 Pin .............................................................................................................. 1 ..
580049860 Kit-Latch (Class II) ................................................................................. .. 1
FOOTNOTES:
a Not Illustrated
LABELS
EXTERIOR
LABELS
INTERIOR
OVERHEAD GUARD
KEY:
A: With Cab
B: Without Cab
QTY
ITEM PART NO. DESCRIPTION A B
1 524286264 Overhead Guard (Standard Height - 546 mm Battery Compartment) ....... 1 ..
1 524304003 Overhead Guard (Standard Height - 642 mm Battery Compartment) ....... .. 1
1 524286265 Overhead Guard (Standard Height - 750 mm Battery Compartment) ....... 1 ..
1 524304004 Overhead Guard (Standard Height - 546 mm Battery Compartment) ....... .. 1
1 524286266 Overhead Guard (Standard Height - 642 mm Battery Compartment) ....... 1 ..
1 524304003 Overhead Guard (Standard Height - 750 mm Battery Compartment) ....... .. 1
2 449001351 Capscrew ................................................................................................... 2 2
3 580086916 Washer ....................................................................................................... 2 2
4 580004721 Mount ......................................................................................................... 4 4
5 580004761 Washer ....................................................................................................... 4 4
6 505970501 Washer ....................................................................................................... 4 4
7 909882405 Nut .............................................................................................................. 2 2
8 449001059 Capscrew ................................................................................................... 2 2
9 580049229 Capscrew ................................................................................................... 2 2
10 580044861 Insert .......................................................................................................... 2 2
11 580091639 Handle ........................................................................................................ 1 1
12 524201323 Grommet .................................................................................................... 4 4
13 580059493 Plug ............................................................................................................ 12 12
14 580010741 Plug ............................................................................................................ 2 2
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Not Illustrated
NOTES
ARMREST ATTACHMENT
ITEM PART NO. DESCRIPTION QTY
1 580096837 Armrest ............................................................................................................... 1
1 ..... Armrest (Handle Slide Assy) .......................................................................... 1
1 580083302 Armrest (Slide) ........................................................................................... 1
1 580097245 Screw ......................................................................................................... 2
1 580096260 Handle (Slider) ........................................................................................... 1
1 ..... Armrest (Handle slide - Upper) ....................................................................... 1
1 580096260 Handle (Slider) ........................................................................................... 1
2 580083302 Armrest (Slide) ........................................................................................... 1
3 580097245 Screw ......................................................................................................... 2
4 580092816 Bracket Wldmt ................................................................................................ 1
5 580092817 Bracket Wldmt (Slide) ..................................................................................... 1
6 580032377 Capscrew ....................................................................................................... 2
7 504230271 Nut .................................................................................................................. 6
8 580092815 Washer ........................................................................................................... 2
9 504071785 Washer ........................................................................................................... 1
10 909882404 Nut .................................................................................................................. 1
11 580041704 Insert .............................................................................................................. 3
12 580083301 Washer ............................................................................................................... 1
13 580012279 Capscrew ............................................................................................................ 1
14 580083620 Cover .................................................................................................................. 1
15 932728910 Capscrew ............................................................................................................ 3
16 580086959 Cover (MLM Inner) .............................................................................................. 1
17 062151200 Capscrew ............................................................................................................ 1
18 518803677 Nut ...................................................................................................................... 2
19 062151600 Capscrew ............................................................................................................ 1
20 580046139 Clip ...................................................................................................................... 2
a 900014292 Capscrew ............................................................................................................ 2
a. . . . . Mini-Lever Assembly .......................................................................................... 1
FOOTNOTES:
a Not Illustrated
NOTES
2 ELECTRICAL SYSTEM
CONTENTS
SECTION 2
ELECTRICAL SYSTEM
DESCRIPTION PAGE
ELECTRICAL ARRANGEMENT
ITEM PART NO. DESCRIPTION QTY
1 580097300 Wire Harness (E Hydraulics) (FPage 2-26, FPage 2-30)................................. 1
1 580097301 Wire Harness (Manual) (FPage 2-34, FPage 2-38)......................................... 1
2 a 580089657 Wire Harness (Seat Jumper) .............................................................................. 1
3 580089658 Wire Harness (Mini-lever Module Jumper) ......................................................... 1
4 580093195 Grommet ............................................................................................................. 1
5 580090545 Power Cable (Hoist Controller) ........................................................................... 3
6 580093825 Power Cable (546 mm Battery Compartment) .................................................... 1
6 580093827 Power Cable (642 mm Battery Compartment) .................................................... 1
6 580093829 Power Cable (750 mm Battery Compartment) .................................................... 1
7 580093824 Power Cable (546 mm Battery Compartment) .................................................... 1
7 580093826 Power Cable (642 mm Battery Compartment) .................................................... 1
7 580093828 Power Cable (750 mm Battery Compartment) .................................................... 1
8 580049231 Capscrew ............................................................................................................ 1
9 580090484 Horn .................................................................................................................... 1
10 580086511 Power Cable ....................................................................................................... 1
11 580086512 Power Cable ....................................................................................................... 1
12 580086510 Power Cable ....................................................................................................... 1
13 580085374 Relay (Micro) ...................................................................................................... 1
14 580085375 Relay (Mini) ......................................................................................................... 1
15 449007004 Screw .................................................................................................................. 4
16 937100903 Nut ...................................................................................................................... 4
17 449021002 Washer ............................................................................................................... 4
18 580086554 Power Cable ....................................................................................................... 6
19 580047691 Key Set ............................................................................................................... 1
20 580089704 Knob (Keyless start) ........................................................................................... 1
20 580054478 Ignition Switch (FPage 2-20)............................................................................. 1
21 580092516 Wire Harness (Steering Column) ........................................................................ 1
21 580089956 Wire Harness (Synchronous Steer) .................................................................... 1
22 580085297 Wire Harness (Standard) (FPage 2-18)............................................................. 1
22 580080769 Wire Harness (Freezer) (FPage 2-17)............................................................... 1
23 580078476 Display (Standard) (FPage 2-16)....................................................................... 1
23 580078477 Display (Freezer) (FPage 2-16)......................................................................... 1
24 580047200 Screw .................................................................................................................. 2
25 580026812 Clip ...................................................................................................................... 5
26 580056613 Fastener .............................................................................................................. 5
FOOTNOTES:
a Manual Hydraulic Only
CONTROLLERS
ITEM PART NO. DESCRIPTION QTY
1 a 580074868 Master Controller (Standard-w/o Electro Hydraulics) ......................................... 1
1 a 580074863 Master Controller (Premium-w/ Electro Hydraulics) ............................................ 1
2 580088319 Bracket ................................................................................................................ 1
3 580030968 Capscrew ............................................................................................................ 3
4 580030966 Capscrew ............................................................................................................ 2
5 580044860 Insert ................................................................................................................... 2
6 580086554 Power Cable (Traction Controller/Traction Motor) .............................................. 1
7 580086510 Power Cable (Traction Controller/Traction Motor) .............................................. 1
8 580086511 Power Cable (Traction Controller/Traction Motor) .............................................. 1
9 580088694 Fuse Panel .......................................................................................................... 1
10 580093280 Controller (48v Traction Controller) .................................................................... 1
11 580044860 Insert ................................................................................................................... 1
12 580086512 Power Cable (Traction Motor) ............................................................................. 1
13 580080967 Contactor (E) ...................................................................................................... 1
14 524290014 Mounting Plate .................................................................................................... 1
15 580030970 Capscrew ............................................................................................................ 4
16 580044862 Insert ................................................................................................................... 4
17 580088696 Controller (48v Traction Motor) ........................................................................... 1
18 580047714 Capscrew ............................................................................................................ 1
19 580090545 Power Cable (Hoist Controller/Pump) ................................................................. 1
20 580086513 Power Cable (546 mm Battery Compartment) .................................................... 1
20 580086515 Power Cable (642 mm Battery Compartment) .................................................... 1
20 580086517 Power Cable (750 mm Battery Compartment) .................................................... 1
21 580086514 Power Cable (546 mm Battery Compartment) .................................................... 1
21 580086516 Power Cable (642 mm Battery Compartment) .................................................... 1
21 580086518 Power Cable (750 mm Battery Compartment) .................................................... 1
FOOTNOTES:
a Vehicle System Manager
CONTROLLER
HOIST ASSEMBLY
KEY:
A: 350 AC
B: 450 AC
QTY
ITEM PART NO. DESCRIPTION A B
1 580088695 Controller .................................................................................................... 1 ..
1 580088696 Controller .................................................................................................... .. 1
2 580088501 Plate Wldmt ........................................................................................... 1 ..
2 580088502 Plate Wldmt ........................................................................................... .. 1
3 580041704 Insert ...................................................................................................... 2 2
4 580093282 Fan ......................................................................................................... 2 2
5 580049011 Capscrew ............................................................................................... 2 2
6 449021003 Washer .................................................................................................. 4 4
7 940400907 Washer .................................................................................................. 4 4
8 932107911 Capscrew ............................................................................................... 4 4
9 580078340 Controller (AC 350 Transversal) ............................................................ 1 ..
9 580078342 Controller (AC 450 Transversal) ............................................................ .. 1
CONTROLLER
TRACTION AND FAN ASSEMBLY
CONTACTOR
E
FOOTNOTES:
a Not Illustrated
BATTERY CONNECTOR
KEY:
A: 48 volt
B: 48 volt (Side Removal)
QTY
ITEM PART NO. DESCRIPTION A B
1 580090524 Battery Connector (48V DIN) ..................................................................... 1 1
2 580088366 Bracket ....................................................................................................... .. 1
2 580088367 Bracket ....................................................................................................... 1 ..
3 449007053 Cross Recess Screw .................................................................................. 4 4
4 580044859 Insert .......................................................................................................... .. 4
5 580087876 Insert .......................................................................................................... 1 2
6 449022018 Washer ....................................................................................................... 4 ..
7 449015002 Nut .............................................................................................................. 4 ..
8 580087820 Washer ....................................................................................................... 2 ..
9 580081322 Clip ............................................................................................................. 1 ..
10 580012352 Bolt ............................................................................................................. 1 ..
11 449001013 Capscrew ................................................................................................... .. 2
NOTES
FOOTNOTES:
a Not Illustrated
NOTES
WIRE HARNESS
TURN SIGNAL
NOTES
3 DRIVE UNIT
CONTENTS
SECTION 3
DRIVE UNIT
DESCRIPTION PAGE
KEY:
A: Key A: 18x7-8 (1.5-1.8VF)
B: Key B: 200/50-10 (2.0VF)
QTY
ITEM PART NO. DESCRIPTION A B
1 524291984 Drive Tire Assembly (Sit Solid) .................................................................. 2 ..
1 524292922 Tire Rim ................................................................................................. 1 ..
1 580041532 Solid Pneumatic Tire .............................................................................. 1 ..
1 524292651 Drive Tire Assembly (Sit Solid) .................................................................. .. 2
1 524292169 Tire Rim ................................................................................................. .. 1
1 524136932 Solid Pneumatic Tire .............................................................................. .. 1
1 524292997 Drive Tire Assembly (Non Marking) ........................................................... 2 ..
1 524292922 Tire Rim ................................................................................................. 1 ..
1 580064617 Solid Pneumatic Tire (Non Marking) ...................................................... 1 ..
1 524293967 Drive Tire Assembly (Non Marking) ........................................................... .. 2
1 524292169 Tire Rim ................................................................................................. .. 1
1 580067308 Solid Pneumatic Tire .............................................................................. .. 1
2 449077093 Wheel Nut .................................................................................................. 10 10
NOTES
TRACTION MOTOR
ITEM PART NO. DESCRIPTION QTY
580076354 Traction Motor ..................................................................................................... 1
1 580086736 Bracket ........................................................................................................... 1
2 580086739 Armature ......................................................................................................... 1
3 580086741 Bolt ................................................................................................................. 1
4 580086745 Stator .............................................................................................................. 1
5 580050715 Plate ............................................................................................................... 1
6 580086747 End Bracket .................................................................................................... 1
7 580086748 Temperature Sensor ...................................................................................... 1
8 580086749 Bearing (With Snap Ring) ............................................................................... 1
FOOTNOTES:
a Not Illustrated
NOTES
TRANSMISSION
BRAKE PISTON
TRANSMISSION
INPUT PINION AND COVER
FOOTNOTES:
a Not Illustrated
TRANSMISSION
PLANETARY AND COVER
NOTES
4 STEERING SYSTEM
CONTENTS
SECTION 4
STEERING SYSTEM
DESCRIPTION PAGE
NOTES
STEER COLUMN
FIXED
STEER COLUMN
TELESCOPIC
NOTES
5 BRAKE SYSTEM
CONTENTS
SECTION 5
BRAKE SYSTEM
DESCRIPTION PAGE
ACCELERATOR PEDAL
FOOT DIRECTIONAL CONTROL ............................................................................................................... 5-10
STANDARD ................................................................................................................................................. 5-8
BRAKE PEDAL LINKAGE ............................................................................................................................... 5-2
MASTER CYLINDER ...................................................................................................................................... 5-4
PARKING BRAKE RELEASE .......................................................................................................................... 5-6
MASTER CYLINDER
ITEM PART NO. DESCRIPTION QTY
580084793 Master Cylinder ................................................................................................... 1
1 ..... Master Cylinder .............................................................................................. 1
2 580087331 Piston Assembly ............................................................................................. 1
3 ..... Cup ............................................................................................................. 1
4 ..... Piston ......................................................................................................... 1
5 ..... Spacer ........................................................................................................ 1
6 ..... Cup ............................................................................................................. 1
7 ..... Retainer ...................................................................................................... 1
8 ..... Spring ............................................................................................................. 1
9 ..... Retaining Ring ................................................................................................ 1
10 580047673 Boot ................................................................................................................ 1
11 580085603 Push Rod ........................................................................................................ 1
12 580085604 Nut .................................................................................................................. 1
13 580085606 Pin .................................................................................................................. 1
14 580047597 Yoke ............................................................................................................... 1
15 580047600 Washer ........................................................................................................... 1
16 580085607 Split Pin .......................................................................................................... 1
17 580085608 Clamp ............................................................................................................. 1
18 ..... Reservoir ........................................................................................................ 1
19 ..... Gasket ............................................................................................................ 1
20 ..... Cap ................................................................................................................. 1
21 580085610 Repair Kit ........................................................................................................ 1
ACCELERATOR PEDAL
STANDARD
ACCELERATOR PEDAL
FOOT DIRECTIONAL CONTROL
NOTES
6 HYDRAULIC SYSTEM
CONTENTS
SECTION 6
HYDRAULIC SYSTEM
DESCRIPTION PAGE
CONTROL VALVE
ELECTRO-HYDRAULIC - 3 AND 4 FUNCTION ......................................................................................... 6-26
MANUAL - 3 AND 4 FUNCTION ................................................................................................................. 6-14
HYDRAULIC CONTROLS
ELECTRO-HYDRAULIC ............................................................................................................................. 6-24
MANUAL ..................................................................................................................................................... 6-10
HYDRAULIC HOSES AND FITTINGS
STEERING .................................................................................................................................................. 6-36
SUPPLY AND RETURN .............................................................................................................................. 6-34
TILT, MAST AND AUXILIARY - ELECTRO-HYDRAULIC .......................................................................... 6-42
TILT, MAST AND AUXILIARY - MANUAL-HYDRAULIC ............................................................................ 6-44
HYDRAULIC LEVERS - LINKAGE ASSEMBLY
MANUAL ..................................................................................................................................................... 6-38
HYDRAULIC MOTOR ..................................................................................................................................... 6-6
HYDRAULIC POWER UNIT INSTALLATION ................................................................................................. 6-2
HYDRAULIC PUMP ........................................................................................................................................ 6-8
HYDRAULIC PUMP AND MOTOR ASSEMBLY ............................................................................................. 6-4
HYDRAULIC TANK ASSEMBLY ..................................................................................................................... 6-12
INLET SECTION
ELECTRO-HYDRAULIC CONTROL VALVE .............................................................................................. 6-28
MANUAL HYDRAULIC CONTROL VALVE ................................................................................................ 6-16
LIFT/TILT SECTION
ELECTRO-HYDRAULIC CONTROL VALVE .............................................................................................. 6-30
LIFT/TILT/AUXILIARY SECTION
MANUAL HYDRAULIC CONTROL VALVE ................................................................................................ 6-18
MAST/TILT CYLINDER INSTALLATION ........................................................................................................ 6-40
OUTLET SECTION
MANUAL HYDRAULIC CONTROL VALVE ................................................................................................ 6-20
POSITIONER SENSOR
MANUAL HYDRAULIC CONTROL VALVE ................................................................................................ 6-22
TIE RODS
ELECTRO-HYDRAULIC CONTROL VALVE .............................................................................................. 6-32
MANUAL HYDRAULIC CONTROL VALVE ................................................................................................ 6-21
TILT CYLINDER ASSEMBLY .......................................................................................................................... 6-46
TILT SENSOR GROUP ................................................................................................................................... 6-48
NOTES
HYDRAULIC PUMP
ITEM PART NO. DESCRIPTION QTY
580087788 Hydraulic Pump .................................................................................................. 1
1 ..... Housing .......................................................................................................... 1
2 ..... Drive Gear ...................................................................................................... 1
3 ..... Gear ............................................................................................................... 1
4 580086892 Flange ............................................................................................................ 1
5 580086893 Cover Plate ..................................................................................................... 1
6 580069355 Side Plate ....................................................................................................... 2
7 ..... Seal (Plate) ..................................................................................................... 2
8 ..... Back-Up .......................................................................................................... 2
9 580089242 Screw ............................................................................................................. 4
10 580054028 Dowel ............................................................................................................. 4
11 ..... Seal ................................................................................................................ 1
12 580086894 Coupling ......................................................................................................... 1
580089241 Kit-Gear (Includes Items 2-3) ......................................................................... 1
580086895 Kit-Seal (Includes Items 7, 8, 11) ................................................................... 1
HYDRAULIC CONTROLS
MANUAL
KEY:
A: 3 Function
B: 4 Function
QTY
ITEM PART NO. DESCRIPTION A B
1 ..... Manual Lever Linkage Assembly (FPage 2-24)........................................ 1 1
2 ..... Hydraulic Control Valve Assembly (FPage 6-14)...................................... 1 1
3 580082583 Sleeve Ftg .................................................................................................. 1 1
4 580019817 Fitting ......................................................................................................... 1 1
5 580019838 Fitting ......................................................................................................... 1 1
6 580019865 Fitting ......................................................................................................... 1 3
7 501704901 Fitting ......................................................................................................... 1 1
8 580056465 Fitting ......................................................................................................... 1 1
9 580019806 Fitting ......................................................................................................... 2 2
10 580039347 Fitting ......................................................................................................... 2 2
11 524325742 Bracket Wldmt ............................................................................................ 1 1
12 580092526 Latch .......................................................................................................... 1 1
13 580092632 Handle ........................................................................................................ 1 1
14 580060018 Nut .............................................................................................................. 1 1
15 580049840 Capscrew ................................................................................................... 3 3
16 580049231 Capscrew ................................................................................................... 7 7
17 520052866 Strip Seal .................................................................................................... 4 4
18 504228208 Bracket ....................................................................................................... 2 2
19 449001023 Capscrew ................................................................................................... 2 2
20 580027572 Nut .............................................................................................................. 2 2
21 449021006 Washer ....................................................................................................... 2 2
22 580092506 Bracket Wldmt ............................................................................................ 1 1
23 580086939 Rubber Mount ............................................................................................ 2 2
24 580060019 Nut .............................................................................................................. 4 4
25 580092568 Clip ............................................................................................................. 2 2
26 580056613 Fastener ..................................................................................................... 2 2
27 580095072 Washer ....................................................................................................... 2 2
28 580092620 Pin .............................................................................................................. 2 2
29 580000868 Lockring ...................................................................................................... 2 2
30 580027573 Nut (Flange) ............................................................................................... 4 4
31 580090088 Cover .......................................................................................................... 1 1
32 580090060 Cover .......................................................................................................... 1 1
33 580038834 Capscrew ................................................................................................... 6 6
34 524325588 Link ............................................................................................................. 3 4
35 580090635 Pin .............................................................................................................. 3 4
36 580056840 Lockring ...................................................................................................... 6 8
37 580092619 Pin .............................................................................................................. 3 4
FOOTNOTES:
a Not Illustrated
CONTROL VALVE
MANUAL – 3 AND 4 FUNCTION
KEY:
A: 3 Function
B: 4 Functions
QTY
ITEM PART NO. DESCRIPTION A B
580078598 Hydraulic Control Valve Assembly (w/o Clamping) .................................... 1 ..
580078599 Hydraulic Control Valve Assembly (w/o Clamping) .................................... .. 1
1 580096029 Valve Section (Outlet) (FPage 6-20).................................................... 1 1
2 580096028 Valve Section (Aux 2) (FPage 6-18)..................................................... .. 1
3 580096027 Valve Section (Aux 1) (FPage 6-18)..................................................... 1 1
4 580096026 Valve Section (Tilt) (FPage 6-18)......................................................... 1 1
5 580096025 Valve Section (Lift) (FPage 6-18)......................................................... 1 1
6 580096023 Lowering Control Valve .......................................................................... 1 1
7 580096022 Relief Valve ............................................................................................ 1 1
8 580095686 Kit-Service (Tie Rod) (FPage 6-21)...................................................... 1 ..
8 580095689 Tie Rod (FPage 6-21)........................................................................... .. 1
9 580096024 Valve Section (Inlet) (FPage 6-16)....................................................... 1 1
10 580095976 Kit-Connector ......................................................................................... 1 1
10 580096019 Connector .......................................................................................... 1 1
10 580096020 Connector .......................................................................................... 1 1
10 580095330 Clip .................................................................................................... 1 1
10 580095331 Plug ................................................................................................... 1 1
11 580095683 Kit-Sensor (Position Sensor) (FPage 6-22).......................................... 1 1
12 580095977 Spool ...................................................................................................... 1 1
13 580096021 Kit-Seal Valve ........................................................................................ 1 1
INLET SECTION
MANUAL HYDRAULIC CONTROL VALVE
LIFT/TILT/AUXILIARY SECTION
MANUAL HYDRAULIC CONTROL VALVE
FOOTNOTES:
a Not Illustrated
KEY:
A: 3 Function
B: 4 Function
QTY
ITEM PART NO. DESCRIPTION A B
580095686 Kit-Service (Tie Rod) .................................................................................. 1 ..
580095689 Tie Rod ....................................................................................................... .. 1
1 580095687 Stud ............................................................................................................ 4 ..
1 580095690 Stud ............................................................................................................ .. 4
2 580095688 Nut .............................................................................................................. 9 9
NOTES
HYDRAULIC CONTROLS
ELECTRO-HYDRAULIC
KEY:
A: 3 Function
B: 4 Function
QTY
ITEM PART NO. DESCRIPTION A B
1 580087767 Hydraulic Control Valve (FPage 6-14)...................................................... 1 ..
1 580087772 Hydraulic Control Valve (FPage 6-14)...................................................... .. 1
2 449001013 Capscrew ................................................................................................... 3 3
3 502566901 Washer ....................................................................................................... 3 3
4 580019806 Fitting ......................................................................................................... 2 2
5 580019865 Fitting (Steering Supply) ............................................................................. 3 4
6 580039347 Fitting ......................................................................................................... .. 1
7 580056465 Fitting ......................................................................................................... 1 1
8 501704901 Fitting (Steering Return) ............................................................................. 1 1
9 580082583 Sleeve Ftg .................................................................................................. 1 1
10 580019817 Fitting ......................................................................................................... 1 1
11 580019838 Fitting ......................................................................................................... 1 1
12 580092985 Plate ........................................................................................................... 1 1
13 520052866 Strip Seal .................................................................................................... 3 3
14 504228208 Bracket ....................................................................................................... 1 1
15 449021006 Washer ....................................................................................................... 1 1
16 449022013 Lockwasher ................................................................................................ 1 1
17 449015044 Nut .............................................................................................................. 1 1
18 449001023 Capscrew ................................................................................................... 1 1
19 312850032 Strap Clamp ............................................................................................... 4 4
CONTROL VALVE
ELECTRO-HYDRAULIC – 3 AND 4 FUNCTION
FOOTNOTES:
a 3 Function b 4 Function
INLET SECTION
ELECTRO-HYDRAULIC CONTROL VALVE
LIFT/TILT SECTION
ELECTRO-HYDRAULIC CONTROL VALVE
TIE RODS
ELECTRO-HYDRAULIC CONTROL VALVE
KEY:
A: 3 Function
B: 4 Function
QTY
ITEM PART NO. DESCRIPTION A B
580095236 Tie Rod (Kit) ............................................................................................... 1 ..
580095269 Tie Rod (Kit) ............................................................................................... .. 1
1 580095547 Tie Rod (Bolt) ......................................................................................... 3 ..
1 580095544 Bolt ......................................................................................................... .. 3
2 580095545 Nut ......................................................................................................... 6 6
3 580095546 Nut ......................................................................................................... 2 2
FOOTNOTES:
a Not Illustrated b Optional
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Not Illustrated
NOTES
SECTION 7
MAST-TWO STAGE LIMITED FREE-LIFT
DESCRIPTION PAGE
CARRIAGE ASSEMBLY
TWO STAGE LIMITED FREE LIFT - A270 - STANDARD .......................................................................... 7-8
TWO STAGE LIMITED FREE LIFT - C661 - STANDARD .......................................................................... 7-20
HEADER HOSE ASSEMBLY
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 7-10
TWO STAGE LIMITED FREE-LIFT - C661 ................................................................................................. 7-22
LIFT CYLINDER ASSEMBLY
TWO STAGE LIMITED FREE LIFT - A270 ................................................................................................. 7-6
TWO STAGE LIMITED FREE LIFT - C661 ................................................................................................. 7-16
MAST ASSEMBLY
TWO STAGE LIMITED FREE LIFT - A270 ................................................................................................. 7-2
TWO STAGE LIMITED FREE LIFT - C661 ................................................................................................. 7-12
MAST ASSEMBLY
TWO STAGE LIMITED FREE LIFT - A270
A270
MAST ASSEMBLY
TWO STAGE LIMITED FREE LIFT - A270
FOOTNOTES:
a Not Illustrated b Refer to Table
NOTES
FOOTNOTES:
a Not Illustrated b Refer to Table
CARRIAGE ASSEMBLY
TWO STAGE LIMITED FREE LIFT - A270 – STANDARD
KEY:
A: 3 Function
B: 4 Function
QTY
ITEM PART NO. DESCRIPTION A B
1 a. . . . . Hose Assy .................................................................................................. 1 2
2 580055734 Capscrew ................................................................................................... 2 4
3 524198916 Stubshaft .................................................................................................... 1 2
4 580087467 Hose Sheave .............................................................................................. 1 2
5 524198559 Washer ....................................................................................................... 1 2
6 580055977 Capscrew ................................................................................................... 1 2
7 580045653 Clamp ......................................................................................................... 1 2
8 524141696 Hose Clamp ............................................................................................... 1 2
9 580087869 Plate ........................................................................................................... 1 2
10 580039401 Fitting ......................................................................................................... 2 4
11 580055651 Nut .............................................................................................................. 2 4
12 504068794 Clamp ......................................................................................................... 2 4
13 580055981 Capscrew ................................................................................................... 2 4
14 524198486 Bracket ....................................................................................................... 1 2
15 580087618 Cover Plate ................................................................................................ 1 2
16 580061870 Washer ....................................................................................................... 1 2
17 580055650 Nut .............................................................................................................. 2 4
18 580085207 Capscrew ................................................................................................... 2 4
19 580039424 Fitting ......................................................................................................... 2 4
20 580055863 Capscrew ................................................................................................... 2 4
FOOTNOTES:
a Refer to Table
MAST ASSEMBLY
TWO STAGE LIMITED FREE LIFT - C661
C661
MAST ASSEMBLY
TWO STAGE LIMITED FREE LIFT - C661
FOOTNOTES:
a Refer to Table
NOTES
RIGHT HAND
FOOTNOTES:
a Not Illustrated b Refer to Table
NOTES
CARRIAGE ASSEMBLY
TWO STAGE LIMITED FREE LIFT - C661 – STANDARD
FOOTNOTES:
a Optional
KEY:
A: 3 Function
B: 4 Function
QTY
ITEM PART NO. DESCRIPTION A B
1 a. . . . . Hose Assy .................................................................................................. 1 2
2 a. . . . . Hose Clamp ............................................................................................... 1 2
3 a. . . . . Clamp ......................................................................................................... 1 2
4 580055735 Capscrew ................................................................................................... 4 8
5 504069707 Bracket ....................................................................................................... 1 2
6 580055651 Nut .............................................................................................................. 6 12
7 580066000 Bracket ....................................................................................................... 1 2
8 505961568 Stubshaft .................................................................................................... 1 2
9 580023124 Hose Sheave .............................................................................................. 1 2
10 504070716 Washer ....................................................................................................... 2 4
11 580055977 Capscrew ................................................................................................... 1 2
12 504068794 Clamp ......................................................................................................... 1 2
13 580055649 Lockwasher ................................................................................................ 1 2
14 580055983 Capscrew ................................................................................................... 2 4
15 580055989 Capscrew ................................................................................................... 2 4
16 505962578 Clamp ......................................................................................................... 2 4
17 580039424 Fitting ......................................................................................................... 2 4
FOOTNOTES:
a Refer to Table
NOTES
SECTION 8
MAST-THREE STAGE FULL FREE-LIFT
DESCRIPTION PAGE
CARRIAGE ASSEMBLY
THREE STAGE FULL FREE LIFT - A271 - STANDARD ............................................................................ 8-14
THREE STAGE FULL FREE LIFT - C662 - STANDARD ........................................................................... 8-34
FREE LIFT ASSEMBLY
THREE STAGE FULL FREE LIFT - A271 ................................................................................................... 8-6
THREE STAGE FULL FREE LIFT - C662 .................................................................................................. 8-24
FREE LIFT CYLINDER ASSEMBLY
THREE STAGE FULL FREE LIFT - A271 ................................................................................................... 8-12
THREE STAGE FULL FREE LIFT - C662 .................................................................................................. 8-32
HEADER HOSE ASSEMBLY
THREE STAGE FULL FREE LIFT - A271 - 3 FUNCTION .......................................................................... 8-16
THREE STAGE FULL FREE LIFT - A271 - 4TH FUNCTION ..................................................................... 8-18
THREE STAGE FULL FREE LIFT - C662 - 3 FUNCTION .......................................................................... 8-36
THREE STAGE FULL FREE LIFT - C662 - 4 FUNCTION .......................................................................... 8-38
MAIN LIFT ASSEMBLY
THREE STAGE FULL FREE LIFT - A271 ................................................................................................... 8-4
THREE STAGE FULL FREE LIFT - C662 .................................................................................................. 8-22
MAIN LIFT CYLINDER ASSEMBLY
THREE STAGE FULL FREE LIFT - A271 ................................................................................................... 8-10
THREE STAGE FULL FREE LIFT - C662 .................................................................................................. 8-28
MAST ASSEMBLY
THREE STAGE FULL FREE LIFT - A271 - INNER, INTERMEDIATE AND OUTER ................................. 8-2
THREE STAGE FULL FREE LIFT - C662 - INNER, INTERMEDIATE AND OUTER ................................. 8-20
MAST ASSEMBLY
THREE STAGE FULL FREE LIFT - A271 – INNER, INTERMEDIATE AND OUTER
A271
FOOTNOTES:
a Not Illustrated b Refer to Table
FOOTNOTES:
a Refer to Table
FOOTNOTES:
a Refer to Table
NOTES
FOOTNOTES:
a Not Illustrated b Refer to Table
FOOTNOTES:
a Not Illustrated b Refer to Table
CARRIAGE ASSEMBLY
THREE STAGE FULL FREE LIFT - A271 – STANDARD
FOOTNOTES:
a Refer to Table
FOOTNOTES:
a Refer to Table
MAST ASSEMBLY
THREE STAGE FULL FREE LIFT - C662 – INNER, INTERMEDIATE AND OUTER
C662
FOOTNOTES:
a Optional b Refer to Table
FOOTNOTES:
a Refer to Table
FOOTNOTES:
a Not Illustrated b Refer to Table
NOTES
RIGHT HAND
FOOTNOTES:
a Not Illustrated b Refer to Table
NOTES
FOOTNOTES:
a Not Illustrated b Refer to Table
CARRIAGE ASSEMBLY
THREE STAGE FULL FREE LIFT - C662 – STANDARD
FOOTNOTES:
a Optional
FOOTNOTES:
a Refer to Table
FOOTNOTES:
a Refer to Table
SECTION 9
MAST-TWO STAGE FULL FREE-LIFT
DESCRIPTION PAGE
CARRIAGE ASSEMBLY
TWO STAGE FULL FREE- LIFT - STANDARD .......................................................................................... 9-14
FREE LIFT ASSEMBLY
TWO STAGE FULL FREE LIFT - C663 ...................................................................................................... 9-10
FREE LIFT CYLINDER ASSEMBLY
TWO STAGE FULL FREE LIFT - C663 ...................................................................................................... 9-12
HEADER HOSE ASSEMBLY
TWO STAGE FULL FREE LIFT - C663 - 3 AND 4 FUNCTION .................................................................. 9-16
TWO STAGE FULL FREE LIFT - C663 - 4TH FUNCTION ......................................................................... 9-20
MAIN LIFT ASSEMBLY
TWO STAGE FULL FREE LIFT - C663 ...................................................................................................... 9-4
MAIN LIFT CYLINDER LH
TWO STAGE FULL FREE LIFT - C663 ...................................................................................................... 9-6
MAIN LIFT CYLINDER RH
TWO STAGE FULL FREE- LIFT - C663 ..................................................................................................... 9-8
MAST ASSEMBLY
TWO STAGE FULL FREE LIFT - C663 ...................................................................................................... 9-2
MAST ASSEMBLY
TWO STAGE FULL FREE LIFT - C663
C663
FOOTNOTES:
a Not Illustrated b Refer to Table
FOOTNOTES:
a Not Illustrated b Refer to Table
FOOTNOTES:
a Refer to Table
FOOTNOTES:
a Refer to Table
FOOTNOTES:
a Not Illustrated b Refer to Table
CARRIAGE ASSEMBLY
TWO STAGE FULL FREE- LIFT – STANDARD
FOOTNOTES:
a Optional
FOOTNOTES:
a Refer to Table
NOTES
FOOTNOTES:
a Refer to Table
NOTES
10 OPTIONS
CONTENTS
SECTION 10
OPTIONS
DESCRIPTION PAGE
AUDIBLE ALARM
ITEM PART NO. DESCRIPTION QTY
1 580093011 Back-UP Alarm ................................................................................................... 1
2 580044859 Insert ................................................................................................................... 2
3 580086910 Capscrew ............................................................................................................ 2
FOOTNOTES:
a Not Illustrated
NOTES
REVERSE HANDLE
ITEM PART NO. DESCRIPTION QTY
1 580093110 Handle ................................................................................................................ 1
2 580041704 Insert ................................................................................................................... 2
3 932728907 Capscrew ............................................................................................................ 2
4 505968540 Connector (Secondary Lock) .............................................................................. 1
5 580022893 Connector ........................................................................................................... 1
MIRROR
CONVEX REAR VIEW
MIRROR
DUAL REAR VIEW
CARRIAGE ASSEMBLY
TWO STAGE LIMITED FREE-LIFT - A270 – INTEGRAL SIDE-SHIFT
FOOTNOTES:
a Not Illustrated b Optional
CARRIAGE ASSEMBLY
TWO STAGE LIMITED FREE LIFT - C661 – INTEGRAL SIDE-SHIFT
CARRIAGE ASSEMBLY
THREE STAGE FULL FREE LIFT - A271 – INTEGRAL SIDE-SHIFT
FOOTNOTES:
a Not Illustrated b Optional
CARRIAGE ASSEMBLY
THREE STAGE FULL FREE LIFT - C662 – INTEGRAL SIDE-SHIFT
CARRIAGE ASSEMBLY
TWO STAGE FULL FREE- LIFT - C663 – INTEGRAL SIDE-SHIFT
NOTES
DC/DC CONVERTER
ITEM PART NO. DESCRIPTION QTY
1 580047198 Dc-Dc Converter ................................................................................................. 1
2 580001471 Capscrew ............................................................................................................ 4
3 940600907 Washer ............................................................................................................... 4
4 504574259 Nut ...................................................................................................................... 4
5 580096577 Wire Harness ...................................................................................................... 1
6 580058844 Receptacle .......................................................................................................... 1
7 500403906 Strap ................................................................................................................... 1
NOTES
11 NUMERICAL INDEX
NUMERICAL INDEX
SECTION 11
NUMERICAL INDEX
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SECTION 12
USER SUPPORT INFORMATION
DESCRIPTION PAGE
Your investment in a Yale Industrial Truck is important to you and to your Yale Dealer. You measure the return on
that investment through the performance of these trucks and the drivers who operate and the mechanics who service
them safely and efficiency. The following information is intended to help you to achieve your investments objectives: