C878 - (01-2009) Hyster H155FT PDF
C878 - (01-2009) Hyster H155FT PDF
C878 - (01-2009) Hyster H155FT PDF
GDP135-155VX, GLP135-155VX,
GP135-155VX
(C878)
NOTE: This parts manual contains alternate pages for certain assemblies. The truck model code can be used to
determine many of the assemblies on your lift truck (power, tire type, mast type). The complete truck model and
serial number are stamped into the nameplate. See for further information.
SECTIONS
1 GENERAL TRUCK
2 ENGINE ASSEMBLY
3 EXHAUST SYSTEM
4 COOLING SYSTEM
5 FUEL SYSTEM
6 ELECTRICAL SYSTEM
7 TRANSMISSION
8 DRIVE AXLE
9 STEERING SYSTEM
10 BRAKE SYSTEM
11 HYDRAULIC SYSTEM
15 OPTIONS
17 NUMERICAL INDEX
This Parts Manual is divided into 18 major sections which are listed above. Quick reference to these sections can
be made by placing the right thumb on the tab of the desired section, bending the book back and thumbing the pages
to the corresponding tab.
18 USER SUPPORT INFORMATION
This Parts Manual is divided into 18 major sections which are listed above. Quick reference to these sections can
be made by placing the right thumb on the tab of the desired section, bending the book back and thumbing the pages
to the corresponding tab.
GENERAL INFORMATION
TABLE OF CONTENTS
DESCRIPTION PAGE
A
ACCUMULATOR ............................................................................................................................................. 15-10
ADD ON OPTION KITS ................................................................................................................................... 16-3
AIR FILTER ..................................................................................................................................................... 5-8
AIR HEATER STARTING AID
CUMMINS 4.5L DIESEL (PENDING PER ECN 105455 →) ...................................................................... 2-38
CUMMINS DIESEL (→ PENDING PER ECN 105455) .............................................................................. 2-40
AIR INTAKE
CUMMINS 4.5L DIESEL ............................................................................................................................. 5-6
GM 4.3L GASOLINE AND LPG (S/N C878V01855F →) ........................................................................... 5-4
GM 4.3L, GASOLINE AND LPG (→ S/N C878V01854F) .......................................................................... 5-2
ALTERNATOR AND MOUNTING
CUMMINS 4.5L DIESEL ............................................................................................................................. 6-32
ASSEMBLED ENGINE
GM 4.3L GASOLINE AND LPG - SHEET 2 OF 3 ....................................................................................... 2-10
GM 4.3L GASOLINE AND LPG - SHEET 3 OF 3 ....................................................................................... 2-14
GM 4.3L, GASOLINE AND LPG - SHEET 1 0F 3 ....................................................................................... 2-6
ATTACHMENT MOUNTING KITS .................................................................................................................. 16-2
AUXILIARY FUNCTION HOSES
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 14-18
AUXILIARY ONE AND TWO SECTIONS
MANUAL CONTROL VALVE - THREE AND FOUR FUNCTION ............................................................... 11-32
AUXILIARY ONE SECTION
ELECTRONIC CONTROL VALVE - THREE AND FOUR FUNCTION ....................................................... 11-46
AUXILIARY TUBE EXTENSION KIT ............................................................................................................... 16-6
AUXILIARY TWO SECTION
ELECTRONIC CONTROL VALVE - FOUR FUNCTION ............................................................................. 11-48
B
BACK-UP ALARM ........................................................................................................................................... 15-6
BATTERY CABLES
CUMMINS 4.5L DIESEL ............................................................................................................................. 6-22
GM 4.3L GASOLINE AND LPG .................................................................................................................. 6-14
BRAKE AND INCHING PEDAL CONVERSION .............................................................................................. 16-2
BRAKE COOLING SYSTEM
SINGLE AND DUAL PEDAL ....................................................................................................................... 10-12
BRAKE PEDAL LINKAGE
DUAL PEDAL .............................................................................................................................................. 10-6
SINGLE PEDAL .......................................................................................................................................... 10-2
DESCRIPTION PAGE
C
CAB
ATTACHING PARTS - SHEET 1 OF 2 ....................................................................................................... 1-20
ATTACHING PARTS - SHEET 2 OF 2 ....................................................................................................... 1-22
HEATER AND HOSES - GM 4.3L GASOLINE AND LPG .......................................................................... 1-34
HEATER HOSES - CUMMINS 4.5L DIESEL .............................................................................................. 1-32
LEFT HAND DOOR ASSEMBLY ................................................................................................................ 1-28
MAIN ASSEMBLY ....................................................................................................................................... 1-18
RIGHT HAND DOOR ASSEMBLY .............................................................................................................. 1-30
WINDOW WIPER SYSTEM ........................................................................................................................ 1-26
WINDOWS .................................................................................................................................................. 1-24
CAMSHAFT AND OIL PAN
GM 4.3L, GASOLINE AND LPG ................................................................................................................. 2-22
CARRIAGE
PIN TYPE - TWO STAGE LIMITED FREE-LIFT ......................................................................................... 12-12
PIN TYPE - THREE STAGE FULL FREE-LIFT .......................................................................................... 13-20
THREE STAGE FULL FREE-LIFT) - HOOK TYPE ..................................................................................... 14-4
TWO STAGE LIMITED FREE-LIFT - HOOK TYPE .................................................................................... 14-2
CHARGE PUMP .............................................................................................................................................. 7-42
COIL ASSEMBLY
GM 4.3L, GASOLINE AND LPG ................................................................................................................. 2-29
COMPARTMENT PLATFORM ........................................................................................................................ 1-12
CONTROL LEVER LABLES
MANUAL HYDRAULICS ............................................................................................................................. 1-46
CONTROL VALVE
THREE SPEED TRANSMISSION ............................................................................................................... 7-22
TWO SPEED TRANSMISSION (→ S/N C878V01747F INC. 01761-01764) ............................................. 7-36
TWO SPEED TRANSMISSION (S/N C878V01748F → EXC. 01761-01764) ............................................ 7-40
CONTROL VALVE AND STEERING UNIT ASSEMBLY
ELECTRONIC CONTROL - THREE FUNCTION ........................................................................................ 11-36
ELECTRONIC CONTROL - FOUR FUNCTION .......................................................................................... 11-38
MANUAL CONTROL - THREE FUNCTION ................................................................................................ 11-22
MANUAL CONTROL - FOUR FUNCTION .................................................................................................. 11-24
COOLING SYSTEM
GM 4.3L GASOLINE AND LPG - CUMMINS 4.5L DIESEL (→ S/N C878V01610E) ................................. 4-2
GM 4.3L LPG AND GASOLINE - CUMMINS 4.5L DIESEL (S/N C878V01611E →) ................................. 4-4
COUNTERWEIGHTS AND FENDERS ........................................................................................................... 1-38
COWL ELECTRICAL
ELECTRIC HYDRAULIC ............................................................................................................................. 6-8
COWL MOUNT ................................................................................................................................................ 1-14
CYLINDER BLOCK
GM 4.3L, GASOLINE AND LPG ................................................................................................................. 2-20
CYLINDER HEAD
GM 4.3L, GASOLINE AND LPG ................................................................................................................. 2-18
DESCRIPTION PAGE
D
DIESEL ENGINE ASSEMBLY
CAMSHAFT - CUMMINS 4.5L .................................................................................................................... 2-51
CRANKCASE BREATHER - CUMMINS 4.5L ............................................................................................. 2-58
CRANKSHAFT AND MAIN BEARINGS - CUMMINS 4.5L ......................................................................... 2-70
CYLINDER BLOCK - CUMMINS 4.5L ......................................................................................................... 2-48
CYLINDER HEAD - CUMMINS 4.5L ........................................................................................................... 2-64
FAN DRIVE AND MOUNTING - CUMMINS 4.5L ........................................................................................ 2-46
INTAKE AND EXHAUST MANIFOLDS - CUMMINS 4.5L .......................................................................... 2-62
LUBRICATION SYSTEM - CUMMINS 4.5L ................................................................................................ 2-56
OIL PAN - CUMMINS 4.5L DIESEL ............................................................................................................ 2-54
OIL PUMP AND FRONT GEAR COVER - CUMMINS 4.5L ........................................................................ 2-52
PISTON AND CONNECTING ROD - CUMMINS 4.5L ................................................................................ 2-74
REAR GEAR HOUSING - CUMMINS 4.5L DIESEL (PENDING PER ECN 105455 →) ............................ 2-42
REAR GEAR HOUSING - CUMMINS 4.5L DIESEL (→ PENDING PER ECN 105455) ............................ 2-44
REAR GEAR TRAIN ACCESSORY MOUNTING COVER - CUMMINS 4.5L ............................................. 2-61
ROCKER LEVERS - CUMMINS 4.5L ......................................................................................................... 2-68
THERMOSTAT - CUMMINS 4.5L ............................................................................................................... 2-47
VALVE TAPPETS - CUMMINS 4.5L ........................................................................................................... 2-50
VIBRATION DAMPER - CUMMINS 4.5L .................................................................................................... 2-60
WATER PUMP AND CONNECTIONS - CUMMINS 4.5L ........................................................................... 2-72
DIFFERENTIAL ............................................................................................................................................... 8-8
DISTRIBUTOR ASSEMBLY
GM 4.3L GASOLINE AND LPG .................................................................................................................. 6-35
DRIVE AXLE AND ATTACHING PARTS
WET BRAKE ............................................................................................................................................... 8-4
DRIVE AXLE HOUSING AND HUB ................................................................................................................ 8-6
DRIVE TIRE AND WHEEL .............................................................................................................................. 8-2
DUAL MIRRORS
WITH CAB ................................................................................................................................................... 15-9
WITH OVERHEAD GUARD ........................................................................................................................ 15-8
E
E-HYDRAULIC CONTROL CONVERSION KITS ........................................................................................... 16-4
ELECTRICAL SYSTEM
RIGHT HAND CHASSIS - GM 4.3L GASOLINE AND LPG ........................................................................ 6-4
RIGHT HAND CHASSIS - CUMMINS 4.5L DIESEL ................................................................................... 6-6
ELECTRO HYDRAULIC POPPET VALVE
ELECTRONIC CONTROL VALVE - THREE AND FOUR FUNCTION ....................................................... 11-44
ELECTRONIC CONTROL LEVERS
MINI-LEVER MODULE (FOUR FUNCTION) - DATE CODE 0725 THRU 0743 ......................................... 6-46
MINI-LEVER MODULE (FOUR FUNCTION) - DATE CODE 0744 ............................................................. 6-52
MINI-LEVER MODULES - DATE CODE 0724 ............................................................................................ 6-42
MINI-LEVER MODULES (THREE FUNCTION) - DATE CODE 0725 THRU 0743 ..................................... 6-44
MINI-LEVER MODULES (THREE FUNCTION) - DATE CODE 0744 ......................................................... 6-48
ELECTRONIC MINI LEVER LABELS
DUAL FUNCTION ....................................................................................................................................... 1-50
SINGLE FUNCTION .................................................................................................................................... 1-48
DESCRIPTION PAGE
ELECTRONIC THROTTLE LINKAGE
CUMMINS 4.5L DIESEL ............................................................................................................................. 5-28
ENGINE ELECTRICAL
CUMMINS 4.5L DIESEL ............................................................................................................................. 6-18
GM 4.3L GASOLINE AND LPG .................................................................................................................. 6-12
ENGINE ELECTRICAL SYSTEM
CUMMINS 4.5L DIESEL - UL TYPE DS ..................................................................................................... 6-20
ENGINE MOUNTING
CUMMINS 4.5L DIESEL ............................................................................................................................. 2-30
GM 4.3L, GASOLINE AND LPG ................................................................................................................. 2-2
EXHAUST SYSTEM
CUMMINS 4.5L DIESEL ............................................................................................................................. 3-2
GM 4.3L, GASOLINE AND LPG ................................................................................................................. 3-4
F
FAN ASSEMBLY
CUMMINS 4.5L DIESEL ............................................................................................................................. 2-36
FAN MOUNT ASSEMBLY
GM 4.3L, GASOLINE AND LPG ................................................................................................................. 2-16
FIRE EXTINGUISHER
WITH CAB ................................................................................................................................................... 15-4
WITH OVERHEAD GUARD ........................................................................................................................ 15-3
FLOORPLATES AND COVERS ...................................................................................................................... 1-10
FLYWHEEL AND HOUSING
CUMMINS 4.5L DIESEL ............................................................................................................................. 2-34
GM 4.3L, GASOLINE AND LPG ................................................................................................................. 2-4
FOOT DIRECTIONAL CONTROL PEDAL ...................................................................................................... 5-36
FORK POSITIONER ASSEMBLY ................................................................................................................... 14-16
FORK POSITIONER CYLINDER .................................................................................................................... 14-22
FORKS
PIN TYPE .................................................................................................................................................... 1-58
STANDARD ................................................................................................................................................. 1-56
FORWARD CLUTCH LOW
TWO SPEED TRANSMISSION .................................................................................................................. 7-34
FORWARD CLUTCH LOW AND SECOND SHAFT
THREE SPEED TRANSMISSION - FWD1, RANGE2 ................................................................................ 7-16
FORWARD CLUTCH, HIGH AND OUTPUT SHAFT
THREE SPEED TRANSMISSION - FWD2 ................................................................................................. 7-18
FREE-LIFT
THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-16
FREE-LIFT CYLINDER
THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-18
FUEL FILTRATION SYSTEM
CUMMINS 4.5L DIESEL ............................................................................................................................. 5-30
FUEL INJECTION PUMP AND GEAR
CUMMINS 4.5L DIESEL ............................................................................................................................. 5-26
FUEL INJECTION SYSTEM
CUMMINS 4.5L DIESEL ............................................................................................................................. 5-24
DESCRIPTION PAGE
FUEL SUPPLY SYSTEM
GM 4.3L GASOLINE ................................................................................................................................... 5-10
GM 4.3L LPG .............................................................................................................................................. 5-12
FUEL SYSTEM
CUMMINS 4.5L DIESEL ............................................................................................................................. 5-22
FULL SUSPENSION SEAT
WITH AND WITHOUT ELECTRONIC CONTROLS .................................................................................... 1-42
FULL SUSPENSION SWIVEL SEAT
WITH AND WITHOUT ELECTRONIC CONTROLS .................................................................................... 1-44
G
GEAR PUMP
→ S/N C878V01509E ................................................................................................................................ 11-8
S/N C878V01593E → ................................................................................................................................ 11-12
GEAR PUMP ASSEMBLY
→ S/N C878V01509E ................................................................................................................................ 11-6
S/N C878V01593E → ................................................................................................................................ 11-10
GM LPG REGULATOR DRAIN KIT ................................................................................................................ 15-12
H
HAND LEVERS
FOUR FUNCTION - WITH DETENTED LEVERS ....................................................................................... 11-18
FOUR FUNCTION - WITHOUT DETENTED LEVERS ............................................................................... 11-20
THREE FUNCTION - WITH DETENTED LEVERS ..................................................................................... 11-14
THREE FUNCTION - WITHOUT DETENTED LEVERS ............................................................................. 11-16
HANG ON SIDE-SHIFT CARRIAGE ............................................................................................................... 14-14
HEADER HOSE CONVERSION KITS
HEADER HOSES AND AUXILIARY TUBE
THREE STAGE FULL FREE-LIFT .............................................................................................................. 14-10
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 14-6
HEATER .......................................................................................................................................................... 1-62
HEATER CONTROL ....................................................................................................................................... 1-61
HOIST HOSE AND ATTACHING PARTS ....................................................................................................... 11-61
HOOD ASSEMBLY ......................................................................................................................................... 1-2
HYDRAULIC CONTROL CONVERSIONS ...................................................................................................... 16-4
HYDRAULIC FILTER ...................................................................................................................................... 11-58
HYDRAULIC SUPPLY AND RETURN ............................................................................................................ 11-2
I
IMPACT SENSOR ........................................................................................................................................... 6-38
INNER MAST
THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-6
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 12-4
INSTRUMENT CLUSTER ............................................................................................................................... 6-10
INTERIOR PANELS AND COVERS
→ S/N C878V01676E ................................................................................................................................ 1-4
S/N C878V01677E → EXC. 01692 ............................................................................................................ 1-6
INTERMEDIATE MAST
THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-4
DESCRIPTION PAGE
J
JUMPER HARNESS
WORK LIGHT .............................................................................................................................................. 6-126
L
LABELS
EXTERIOR .................................................................................................................................................. 1-52
INTERIOR ................................................................................................................................................... 1-54
LIFTING EYE ................................................................................................................................................... 15-14
LIGHT CONVERSION KITS ............................................................................................................................ 16-6
LIGHTS
STOP, TAIL, TURN, BACKUP, AND STROBE ........................................................................................... 6-24
LOAD BACKREST EXTENSION ..................................................................................................................... 1-60
LOAD WEIGH ELECTRICAL .......................................................................................................................... 6-40
LPG REGULATOR
GM 4.3L LPG .............................................................................................................................................. 5-18
M
MAIN LIFT
THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-8
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 12-6
MAIN LIFT CYLINDER
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 12-10
MAIN LIFT CYLINDERS
THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-12
MAST ELECTRICAL ....................................................................................................................................... 6-36
MID INLET SECTION
MANUAL AND ELECTRONIC CONTROL VALVE - THREE AND FOUR FUNCTION ............................... 11-26
MISCELLANEOUS CONVERSION KITS ........................................................................................................ 16-3
N
NON SUSPENSION SEAT .............................................................................................................................. 1-40
O
OIL PUMP
GM 4.3L, GASOLINE AND LPG ................................................................................................................. 2-32
OUTER MAST
THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-2
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 12-2
OUTLET SECTION
ELECTRONIC CONTROL VALVE - THREE AND FOUR FUNCTION ....................................................... 11-50
MANUAL CONTROL VALVE - THREE AND FOUR FUNCTION ............................................................... 11-34
OUTPUT SHAFT
TWO SPEED TRANSMISSION .................................................................................................................. 7-32
OVERHEAD GUARD ...................................................................................................................................... 1-16
P
PARK BRAKE .................................................................................................................................................. 10-10
POWER DISTRIBUTION MODULE ................................................................................................................ 6-30
PUMP DRIVE .................................................................................................................................................. 7-44
DESCRIPTION PAGE
R
REVERSE CLUTCH
TWO SPEED TRANSMISSION .................................................................................................................. 7-30
REVERSE CLUTCH AND FIRST SHAFT
THREE SPEED TRANSMISSION - REV1, RANGE 1 ................................................................................ 7-20
S
SEAT CONVERSION KITS ............................................................................................................................. 16-2
SEAT PAN AND COVERS .............................................................................................................................. 1-8
SIDE-SHIFT ASSEMBLY ................................................................................................................................ 14-20
SIDE-SHIFT CYLINDER ................................................................................................................................. 14-23
SINGLE AND DUAL LPG TANK BRACKETS ................................................................................................. 5-20
SOUND ABATEMENT ..................................................................................................................................... 1-36
STARTER
GM 4.3L (GS AND LPS) (PENDING PER ECN 105844 →) ...................................................................... 6-16
STARTER AND MOUNT
CUMMINS 4.5L DIESEL ............................................................................................................................. 6-34
STEER AXLE .................................................................................................................................................. 9-6
STEER CYLINDER ......................................................................................................................................... 9-9
STEER TIRE AND WHEEL ............................................................................................................................. 9-14
STEERING COLUMN AND ATTACHING PARTS .......................................................................................... 9-4
STEERING COLUMN ASSEMBLY ................................................................................................................. 9-2
STEERING CONTROL UNIT .......................................................................................................................... 9-12
STEERING LINES ........................................................................................................................................... 9-10
STROBE LIGHT
LED ............................................................................................................................................................. 15-2
T
THROTTLE BODY ASSEMBLY
GM 4.3L LPG .............................................................................................................................................. 5-16
THROTTLE BODY ASSEMBLY AND FUEL RAIL
GM 4.3L GASOLINE ................................................................................................................................... 5-14
THROTTLE CABLE ASSEMBLY
CUMMINS 4.5L DIESEL ............................................................................................................................. 5-32
THROTTLE PEDAL AND ATTACHING PARTS ............................................................................................. 5-34
TILT CYLINDER AND MAST INSTALLATION ................................................................................................ 11-52
TILT CYLINDERS ............................................................................................................................................ 11-54
TILT HYDRAULICS ......................................................................................................................................... 11-56
TILT SECTION
ELECTRONIC CONTROL VALVE - THREE AND FOUR FUNCTION ....................................................... 11-42
TORQUE CONVERTER
CUMMINS 4.5L DIESEL ............................................................................................................................. 7-6
GM 4.3L GASOLINE AND LPG .................................................................................................................. 7-4
TRANSMISSION ASSEMBLY
THREE SPEED - SHEET 1 OF 2 ................................................................................................................ 7-10
THREE SPEED - SHEET 2 OF 2 ................................................................................................................ 7-14
TWO SPEED - SHEET 1 OF 2 .................................................................................................................... 7-24
TWO SPEED - SHEET 2 OF 2 .................................................................................................................... 7-28
DESCRIPTION PAGE
TRANSMISSION COOLING
WITH EXTERNAL OIL COOLER ................................................................................................................ 7-8
TRANSMISSION ELECTRICAL SYSTEM
THREE SPEED TRANSMISSION ............................................................................................................... 6-28
TWO SPEED TRANSMISSION .................................................................................................................. 6-26
TRANSMISSION MOUNT ............................................................................................................................... 7-2
V
VALVE ASSEMBLY, LIFT AND LOWER
ELECTRONIC CONTROL VALVE - THREE AND FOUR FUNCTION ....................................................... 11-40
VALVE ASSEMBLY, LIFT AND TILT
MANUAL CONTROL VALVE - THREE AND FOUR FUNCTION (→ PENDING PER ECN 104512) ........ 11-28
MANUAL CONTROL VAVLE - THREE AND FOUR FUNCTION (PENDING PER ECN 104512 →) ........ 11-30
VALVE COVER AND INLET MANIFOLD
GM 4.3L, GASOLINE AND LPG ................................................................................................................. 2-26
VENT LINES .................................................................................................................................................... 11-60
W
WET BRAKE ASSEMBLY ............................................................................................................................... 8-10
WIRE HARESS
ENGINE - GM 4.3L GASOLINE (→ S/N C878V01683E) ........................................................................... 6-76
WIRE HARNESS
COWL WITH FOOT DIRECTIONAL CONTROL PEDAL - GM 4.3L GASOLINE AND LPG ....................... 6-92
COWL WITH FOOT DIRECTIONAL CONTROL PEDAL - CUMMINS 4.5L DIESEL .................................. 6-100
COWL WITH FORWARD/REVERSE LEVER - GM 4.3L GASOLINE AND LPG ........................................ 6-96
COWL WITH FORWARD/REVERSE LEVER - CUMMINS 4.5L DIESEL ................................................... 6-104
ELECTRONIC CONTROL VALVE - THREE FUNCTION ........................................................................... 6-108
ELECTRONIC CONTROL VALVE - FOUR FUNCTION ............................................................................. 6-110
ENGINE - GM 4.3L GASOLINE (S/N C878V01684E →) ........................................................................... 6-78
ENGINE - GM 4.3L LPG (→ S/N C878V01563E) ...................................................................................... 6-82
ENGINE - GM 4.3L LPG (S/N C878V01564E →) ...................................................................................... 6-84
ENGINE - CUMMINS 4.5L DIESEL ............................................................................................................ 6-88
LEFT HAND CHASSIS - GM 4.3L GASOLINE ........................................................................................... 6-72
LEFT HAND CHASSIS - GM 4.3L LPG ...................................................................................................... 6-74
LIGHTS (6/2007 →) ................................................................................................................................... 6-124
LIGHTS WITH OVERHEAD GUARD .......................................................................................................... 6-122
REAR CHASSIS .......................................................................................................................................... 6-112
RIGHT HAND CHASSIS - GM 4.3L GASOLINE AND LPG (→ S/N C878V01563E LPG)
(→ S/N C878V01683E GAS) ..................................................................................................................... 6-54
RIGHT HAND CHASSIS - GM 4.3L GASOLINE AND LPG (S/N C878V01564E → LPG)
(S/N C878V01684E → GAS) ..................................................................................................................... 6-60
RIGHT HAND CHASSIS - CUMMINS 4.5L DIESEL ................................................................................... 6-66
SEALED ALTERNATOR - CUMMINS 4.5L DIESEL ................................................................................... 6-120
TRANSMISSION - TWO SPEED ................................................................................................................ 6-114
TRANSMISSION - THREE SPEED ............................................................................................................ 6-116
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 17-1) to find the Date breaks are used to indicate when a change
part number. Turn to the page listed and locate the occurred but a subsequent serial number break
part as indicated by the item number. was not recorded. This is an arbitrary date usually
based on the ECN release and are identified as
GENERAL: follows:
→ D/B 3/00
The assembly breakdowns include part numbers, Indicates that a change occurred sometime
descriptions, quantities required, keys and within that month for the item affected.
footnotes to help in selecting correct parts. D/B 3/00 →
Indicates that a change occurred sometime
6. Five periods in the PART NO. column (. . . . .)
within that month for the item affected.
indicate that the part is either Not Serviced
D/B 3/00 ↔ D/B 4/00
Separately or there is a reference to another figure.
Indicates a range of production dates of the item
A figure reference is denoted by a pointing hand
affected.
followed by a parts page number in the
DESCRIPTION column (F7A56) Contact your local dealer for Yale lift trucks for
serial number information for items with a ECN or
7. Keys are used to show two or more similar
a date break.
assemblies, RH and LH assembly parts, etc.
Select the appropriate key, "A", "B", "C", "D", or "E" ORDERING PARTS:
and the corresponding quantity column to find the
required parts. Two periods in the QTY column (..) When ordering replacement parts, give the unit serial
indicate that the part is not used for that assembly. number, part number, name of part and quantity
required.
8. Indented descriptions under the DESCRIPTION
column are used to indicate assemblies and For any further information on parts, service, or
subparts of assemblies. In the example on the ordering, consult your local dealer for Yale lift trucks.
NOTE: Serial Number breakdown is only for trucks built after 1994.
(1) and (2) The first letter and three numbers indicate the truck unit code.
(3) The second letter indicates the plant of manufacture.
(4) The four or five digit number indicates the production sequence number of the truck.
(5) The final letter indicates the year of manufacture starting with "A" in 1957, 1980, and 2003.
The letters "I", "O", and "Q" will not be used.
For pending serial numbers contact your local dealer for Yale lift trucks.
Parts referred to in this book as right or left hand parts are in accordance with the illustration above.
(1) and (2) The first letter and number indicates the mast unit code.
(3) The second letter indicates the plant of manufacture.
(4) The four or five digit number indicates the production sequence number of the mast.
(5) Carriage travel in millimeters stamped just below the serial number.
Mast Group identification consists of mast unit code (1) and (2) plus carriage travel (5).
For pending production sequence numbers contact your local dealer for Yale lift trucks.
(1) and (2) The first letter and three numbers indicate the attachment unit code.
(3) The second letter indicates the plant of manufacture.
(4) The four or five digit number indicates the production sequence number.
For pending production sequence numbers contact your local dealer for Yale lift trucks.
Side-shift carriages and attachments have nameplates. Use the serial number found on the nameplate to identify
the attachment.
Always refer to the group, serial, or part number when ordering service parts.
Modifications of attachments and side-shift carriages by SPED (Special Products Engineering Department) are
identified by a model prefix code beginning with the letter "S". Contact your dealer for Yale lift trucks for information
on these assemblies.
PUBLICATIONS
Every new lift truck is provided with an OPERATING MANUALS with complete replacement part
MANUAL. This manual has information that the identification, are available at a nominal fee from your
operator must know for inspection and operation of the Yale dealer to assist users in effectively maintaining
lift truck. Yale lift trucks in a safe, useful condition. See the list
below for information on ordering specific publications
SERVICE MAINTENANCE MANUALS, which provide for this model lift truck.
service and overhaul procedures, and PARTS
NOTE: Throughout this manual are references to Part Sheet Numbers. These references are usually found after
the description of a part or assembly. The Part Sheet Number is found on the upper left- or righthand corner of the
parts pages.
EXAMPLE:
Below is a numerical listing of Part Sheet Numbers found in this parts book and what page number they are on.
NOTES
1 GENERAL TRUCK
CONTENTS
SECTION 1
GENERAL TRUCK
DESCRIPTION PAGE
CAB
ATTACHING PARTS - SHEET 1 OF 2 ....................................................................................................... 1-20
ATTACHING PARTS - SHEET 2 OF 2 ....................................................................................................... 1-22
HEATER AND HOSES - GM 4.3L GASOLINE AND LPG .......................................................................... 1-34
HEATER HOSES - CUMMINS 4.5L DIESEL .............................................................................................. 1-32
LEFT HAND DOOR ASSEMBLY ................................................................................................................ 1-28
MAIN ASSEMBLY ....................................................................................................................................... 1-18
RIGHT HAND DOOR ASSEMBLY .............................................................................................................. 1-30
WINDOW WIPER SYSTEM ........................................................................................................................ 1-26
WINDOWS .................................................................................................................................................. 1-24
COMPARTMENT PLATFORM ........................................................................................................................ 1-12
CONTROL LEVER LABLES
MANUAL HYDRAULICS ............................................................................................................................. 1-46
COUNTERWEIGHTS AND FENDERS ........................................................................................................... 1-38
COWL MOUNT ................................................................................................................................................ 1-14
ELECTRONIC MINI LEVER LABELS
DUAL FUNCTION ....................................................................................................................................... 1-50
SINGLE FUNCTION .................................................................................................................................... 1-48
FLOORPLATES AND COVERS ...................................................................................................................... 1-10
FORKS
PIN TYPE .................................................................................................................................................... 1-58
STANDARD ................................................................................................................................................. 1-56
FULL SUSPENSION SEAT
WITH AND WITHOUT ELECTRONIC CONTROLS .................................................................................... 1-42
FULL SUSPENSION SWIVEL SEAT
WITH AND WITHOUT ELECTRONIC CONTROLS .................................................................................... 1-44
HEATER .......................................................................................................................................................... 1-62
HEATER CONTROL ....................................................................................................................................... 1-61
HOOD ASSEMBLY ......................................................................................................................................... 1-2
INTERIOR PANELS AND COVERS
→ S/N C878V01676E ................................................................................................................................ 1-4
S/N C878V01677E → EXC. 01692 ............................................................................................................ 1-6
LABELS
EXTERIOR .................................................................................................................................................. 1-52
INTERIOR ................................................................................................................................................... 1-54
LOAD BACKREST EXTENSION ..................................................................................................................... 1-60
NON SUSPENSION SEAT .............................................................................................................................. 1-40
OVERHEAD GUARD ...................................................................................................................................... 1-16
SEAT PAN AND COVERS .............................................................................................................................. 1-8
SOUND ABATEMENT ..................................................................................................................................... 1-36
HOOD ASSEMBLY
ITEM PART NO. DESCRIPTION QTY
1 580086801 Seal ..................................................................................................................... 2
2 a 524278980 Hood (LH) (With Overhead Guard) ..................................................................... 1
2 b 524298575 Hood (LH) (With Overhead Guard) ..................................................................... 1
2 a 524273260 Hood (LH) (With Cab) ......................................................................................... 1
2 b 524298574 Hood (LH) (With Cab) ......................................................................................... 1
3 504235245 Handle ................................................................................................................ 2
4 449001121 Capscrew ............................................................................................................ 4
5 580017101 Washer ............................................................................................................... 4
6 580055650 Nut ...................................................................................................................... 4
7 580078722 Sound Liner (LH) ................................................................................................ 1
8 580078723 Sound Liner (LH) ................................................................................................ 1
9 580078724 Sound Liner (LH) ................................................................................................ 1
10 580067512 Seal ..................................................................................................................... 1
11 580060019 Nut ...................................................................................................................... 12
12 580049915 Ball Stud ............................................................................................................. 4
13 580072744 Gas Spring .......................................................................................................... 2
14 580049231 Capscrew ............................................................................................................ 16
15 580082458 Hinge .................................................................................................................. 2
15 580088049 Hinge .................................................................................................................. 2
16 580026621 Nut ...................................................................................................................... 8
17 580056624 Pin (Rod End) ..................................................................................................... 4
18 580000868 Lockring .............................................................................................................. 4
19 580044861 Insert ................................................................................................................... 8
20 580084838 Hinge (Base) ....................................................................................................... 2
20 580088048 Hinge (Base) ....................................................................................................... 2
21 580027572 Nut ...................................................................................................................... 4
22 080143400 Motor Mount ........................................................................................................ 4
23 518796686 Washer ............................................................................................................... 4
24 580049331 Capscrew ............................................................................................................ 4
25 580083446 Hood Support ...................................................................................................... 1
26 580030966 Capscrew ............................................................................................................ 3
27 580044860 Insert ................................................................................................................... 3
28 524275588 Crossmember (With Overhead Guard) ............................................................... 1
28 524275589 Crossmember (With Cab) ................................................................................... 1
29 580065933 Seal ..................................................................................................................... 1
30 580078725 Sound Liner (RH) ................................................................................................ 1
31 580078721 Sound Liner (RH) ................................................................................................ 1
32 580078720 Sound Liner (RH) ................................................................................................ 1
33 580058383 Bumper (Hood) ................................................................................................... 4
34 580067529 Seal ..................................................................................................................... 1
35 a 524278981 Hood (RH) (With Overhead Guard) .................................................................... 1
35 b 524298546 Hood (RH) (With Overhead Guard) .................................................................... 1
35 a 524273261 Hood (RH) (With Cab) ........................................................................................ 1
35 b 524298545 Hood (RH) (With Cab) ........................................................................................ 1
FOOTNOTES:
a → 6/2007 b 6/2007 →
FOOTNOTES:
a With Cab c With Swivel Seat
b With Overhead Guard d Without Swivel Seat
FOOTNOTES:
a GM 4.3L Gasoline and Cummins 4.5L Diesel c → PENDING PER ECN 136110
b GM 4.3L LPG d PENDING PER ECN 136110 →
COMPARTMENT PLATFORM
ITEM PART NO. DESCRIPTION QTY
1 524251262 Module ................................................................................................................ 1
2 909882405 Nut ...................................................................................................................... 2
3 504233271 Washer ............................................................................................................... 4
4 505966562 Washer ............................................................................................................... 4
5 580082448 Isolator ................................................................................................................ 4
6 504323759 Stud .................................................................................................................... 2
7 931015915 Capscrew ............................................................................................................ 2
COWL MOUNT
ITEM PART NO. DESCRIPTION QTY
1 a 524254762 Cowl .................................................................................................................... 1
1 b 524316721 Cowl .................................................................................................................... 1
2 580044860 Insert ................................................................................................................... 2
3 580058270 Capscrew ............................................................................................................ 6
4 580074879 Insert ................................................................................................................... 6
5 580056815 Capscrew ............................................................................................................ 2
524322891 Kit (Cowl Gusset Repair) (Not Illustrated) ........................................................... 1
FOOTNOTES:
a → S/N C878V01880F b S/N C878V01881F →
OVERHEAD GUARD
ITEM PART NO. DESCRIPTION QTY
1 524294779 Overhead Guard ................................................................................................. 1
2 258979300 Plug ..................................................................................................................... 4
3 524240692 Plug ..................................................................................................................... 1
4 524208883 Grommet ............................................................................................................. 1
5 b 580058212 Capscrew ............................................................................................................ 2
6 b 580051747 Handle (Alternate Horn Button) .......................................................................... 1
7 580050959 Handle ............................................................................................................ 1
8 580058447 Push Button Switch ........................................................................................ 1
9 580022893 Connector ....................................................................................................... 1
10 505968540 Connector (Secondary Lock) .......................................................................... 1
11 505968514 Terminal (Pin) ................................................................................................. 2
12 b 580026812 Clip ...................................................................................................................... 1
13 b 580056613 Fastener .............................................................................................................. 1
14 580066681 Capscrew ............................................................................................................ 10
15 580058194 Nut ...................................................................................................................... 2
16 580044861 Insert ................................................................................................................... 2
17 524201323 Grommet ............................................................................................................. 1
a 580083174 Grommet ............................................................................................................. 1
FOOTNOTES:
a Not Illustrated b Optional
CAB
MAIN ASSEMBLY
CAB
ATTACHING PARTS – SHEET 1 OF 2
CAB
ATTACHING PARTS – SHEET 2 OF 2
CAB
WINDOWS
CAB
WINDOW WIPER SYSTEM
FOOTNOTES:
a Not Illustrated
CAB
LEFT HAND DOOR ASSEMBLY
CAB
RIGHT HAND DOOR ASSEMBLY
CAB
HEATER HOSES – CUMMINS 4.5L DIESEL
FOOTNOTES:
a For Heater Information See Heater and Hoses GM
4.3L
CAB
HEATER AND HOSES – GM 4.3L GASOLINE AND LPG
FOOTNOTES:
a GM 4.3L Gasoline b GM 4.3L LPG
SOUND ABATEMENT
ITEM PART NO. DESCRIPTION QTY
1 580003442 Fastener .............................................................................................................. 2
2 580078736 Sound Liner (Seat Support) ................................................................................ 1
3 580078734 Sound Liner (Seat Support) ................................................................................ 1
4 580078735 Sound Liner (Seat Support) ................................................................................ 1
5 b 580083521 Liner (LH) ............................................................................................................ 1
6 580078739 Sound Liner (Seat Support LH) .......................................................................... 1
7 580083106 Plug (LH) ............................................................................................................. 1
8 580078737 Sound Liner ........................................................................................................ 1
9 580078731 Sound Liner ........................................................................................................ 1
10 580078728 Sound Liner (LH) ................................................................................................ 1
11 580078729 Sound Liner (LH) ................................................................................................ 1
12 580078730 Sound Liner ........................................................................................................ 1
13 580078733 Sound Liner ........................................................................................................ 1
14 580059607 Seal ..................................................................................................................... 1
15 580046349 Seal ..................................................................................................................... 1
16 a 580078576 Seal ..................................................................................................................... 1
17 a 580046391 Seal ..................................................................................................................... 1
18 a 580046392 Seal ..................................................................................................................... 1
19 580078727 Sound Liner ........................................................................................................ 1
20 580068080 Sound Liner (RH) ................................................................................................ 1
21 580078726 Sound Liner ........................................................................................................ 1
22 580068081 Sound Liner (LH) ................................................................................................ 1
23 580068007 Sound Liner ........................................................................................................ 1
24 580067860 Sound Liner ........................................................................................................ 1
25 580078732 Sound Liner ........................................................................................................ 1
26 580083107 Plug (RH) ............................................................................................................ 1
27 580078740 Sound Liner (Seat Pan) ...................................................................................... 1
28 580078738 Sound Liner (Seat Support RH) .......................................................................... 1
29 b 580083521 Liner (LH) ............................................................................................................ 1
30 c 580085400 Seal ..................................................................................................................... 2
31 c 580085401 Seal ..................................................................................................................... 2
FOOTNOTES:
a With Electronic Hydraulics c 5/2007 →
b → 5/2007
FOOTNOTES:
a Not Illustrated c PENDING PER ECN 105255 →
b → PENDING PER ECN 105255
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Not Illustrated
LABELS
EXTERIOR
FOOTNOTES:
a Contact Your Local Yale Dealer d Without Cab
b Diesel e → PENDING PER ECN 105354
c With Cab f PENDING PER ECN 105354 →
LABELS
INTERIOR
FOOTNOTES:
a Contact Your Local Yale Dealer c UL Type DS
b Electronic Transmission
NOTES
FORKS
PIN TYPE
HEATER
ITEM PART NO. DESCRIPTION QTY
580077680 Heater ................................................................................................................. 1
1 580083258 Heater (Blower) .............................................................................................. 1
2 580083259 Heater (Coil) ................................................................................................... 1
3 580083260 Adapter (2.0 inch) ........................................................................................... 1
4 580083261 Adapter (2.5 inch) ........................................................................................... 1
5 580083262 Adapter (3.5 inch) ........................................................................................... 1
6 580083263 Heater (Blower Plate) ..................................................................................... 1
7 ..... Casing ............................................................................................................ 1
8 580083264 Cover .............................................................................................................. 1
9 580083265 Bracket ........................................................................................................... 1
10 580083266 Cover .............................................................................................................. 1
11 580083267 Bracket ........................................................................................................... 1
12 580083268 Bracket ........................................................................................................... 1
13 580083269 Flange ............................................................................................................ 1
14 580083270 Flange ............................................................................................................ 1
15 580083271 Flange ............................................................................................................ 1
16 580083272 Wire Harness .................................................................................................. 1
17 580083273 Valve .............................................................................................................. 1
18 580083274 Filter ............................................................................................................... 1
19 580020184 Hose (Heater) ................................................................................................. 1
20 580083275 Clamp ............................................................................................................. 1
21 580083276 Gasket ............................................................................................................ 1
22 502632907 Screw ............................................................................................................. 4
23 580083278 Screw ............................................................................................................. 15
24 580083279 Screw ............................................................................................................. 6
25 203756500 Capscrew ....................................................................................................... 9
26 504231213 Rivet ............................................................................................................... 2
27 021197300 Nut .................................................................................................................. 4
28 580083277 Screw (Plastic) .................................................................................................... 2
29 504063761 Screw ............................................................................................................. 6
NOTES
2 ENGINE ASSEMBLY
CONTENTS
SECTION 2
ENGINE ASSEMBLY
DESCRIPTION PAGE
ENGINE MOUNTING
GM 4.3L, GASOLINE AND LPG
ASSEMBLED ENGINE
GM 4.3L, GASOLINE AND LPG – SHEET 1 0F 3
ASSEMBLED ENGINE
GM 4.3L, GASOLINE AND LPG – SHEET 1 0F 3
FOOTNOTES:
a → S/N C878V01563E e S/N C878V01564E →
b → S/N C878V01563E (LPG) f S/N C878V01564E → (LPG)
c → S/N C878V01683E g S/N C878V01684E →
d → S/N C878V01683E (Gasoline) h S/N C878V01684E → (Gasoline)
NOTES
ASSEMBLED ENGINE
GM 4.3L GASOLINE AND LPG – SHEET 2 OF 3
KEY:
A: Gasoline
B: LPG
QTY
ITEM PART NO. DESCRIPTION A B
c 580076822 Engine Assy-Gas (Gasoline) ...................................................................... 1 ..
e 580077730 Engine Assy-Gas ....................................................................................... 1 ..
b 580076823 Engine Assy-Lpg ........................................................................................ .. 1
d 580077674 Engine Assy-LPG ....................................................................................... .. 1
1 580047919 Nut .............................................................................................................. 1 1
2 580072090 Screw ......................................................................................................... 4 4
3 580046499 Filler Neck .................................................................................................. 1 1
4 580072047 Screw ......................................................................................................... 4 4
5 505971582 Clamp ......................................................................................................... 2 2
6 580059320 Fitting ......................................................................................................... 1 1
7 505970592 Sealant ....................................................................................................... AR AR
8 c 580071166 Wire Harness (Engine) ............................................................................... 1 ..
8 e 580077675 Wire Harness ............................................................................................. 1 ..
8 b 580071165 Wire Harness (Engine) ............................................................................... .. 1
8 d 580077676 Wire Harness ............................................................................................. .. 1
9 580073353 Bracket ....................................................................................................... 1 1
10 580051890 Pressure Transducer (Engine Oil Pressure Sensor) .................................. 1 1
11 580039900 Capscrew ................................................................................................... 3 3
12 580077964 Engine Control Module ............................................................................... 1 ..
12 580086130 Engine Control Module (Alternate Part) ..................................................... 1 ..
12 580077965 Engine Control Module (2006/2007 Engine ECU) ..................................... .. 1
12 580086129 Engine Control Module (2008 Engine ECU) (Alternate Part) ..................... .. 1
13 580039438 Capscrew ................................................................................................... 6 6
14 580072018 Clamp ......................................................................................................... 1 1
15 580047919 Nut .............................................................................................................. 6 6
16 580072019 Clamp ......................................................................................................... 2 2
17 580054232 Fitting ......................................................................................................... 1 ..
18 580073352 Bracket ....................................................................................................... 1 ..
19 580007683 Clamp ......................................................................................................... 2 ..
20 580000338 Screw ......................................................................................................... 2 2
21 580065523 Bracket ....................................................................................................... 1 ..
22 580046654 Tube ........................................................................................................... 1 ..
23 580065858 Tube ........................................................................................................... 1 ..
24 580046654 Tube ........................................................................................................... 1 ..
25 900003231 Clamp ......................................................................................................... 1 ..
26 580070000 Bracket ....................................................................................................... 1 ..
27 580042354 Hose ........................................................................................................... 1 ..
28 580050410 Retainer (Three Wire Clip) ......................................................................... 1 ..
29 511405800 Clamp (Worm Screw) ................................................................................. 4 ..
30 580046629 Hose ........................................................................................................... 1 ..
31 580043696 Elbow (3/8 90 degree Elbow) ..................................................................... 1 ..
32 580042867 Fitting ......................................................................................................... 1 ..
33 580039900 Capscrew ................................................................................................... 5 ..
34 580065981 Adapter ....................................................................................................... 1 1
35 580072047 Screw ......................................................................................................... 1 ..
ASSEMBLED ENGINE
GM 4.3L GASOLINE AND LPG – SHEET 2 OF 3
KEY:
A: Gasoline
B: LPG
QTY
ITEM PART NO. DESCRIPTION A B
a 501884908 Fitting ......................................................................................................... 1 ..
FOOTNOTES:
a Not Illustrated d S/N C878V01564E →
b → S/N C878V01563E e S/N C878V01684E →
c → S/N C878V01683E
NOTES
ASSEMBLED ENGINE
GM 4.3L GASOLINE AND LPG – SHEET 3 OF 3
FOOTNOTES:
a Gasoline Engine d → S/N C878V01683E
b LPG Engine e S/N C878V01564E →
c → S/N C878V01563E f S/N C878V01684E →
CYLINDER HEAD
GM 4.3L, GASOLINE AND LPG
FOOTNOTES:
a → S/N C878V01563E c S/N C878V01564E →
b → S/N C878V01683E d S/N C878V01684E →
CYLINDER BLOCK
GM 4.3L, GASOLINE AND LPG
FOOTNOTES:
a → S/N C878V01563E c S/N C878V01564E →
b → S/N C878V01683E d S/N C878V01684E →
FOOTNOTES:
a → S/N C878V01563E e S/N C878V01564E →
b → S/N C878V01563E (LPG) f S/N C878V01564E → (LPG)
c → S/N C878V01683E g S/N C878V01684E →
d → S/N C878V01683E (Gasoline) h S/N C878V01684E → (Gasoline)
NOTES
FOOTNOTES:
a Quanity is listed for both heads f S/N C878V01564E →
b → S/N C878V01563E g S/N C878V01564E → (LPG)
c → S/N C878V01563E (LPG) h S/N C878V01684E →
d → S/N C878V01683E i S/N C878V01684E → (Gasoline)
e → S/N C878V01683E (Gasoline)
NOTES
OIL PUMP
GM 4.3L, GASOLINE AND LPG
FOOTNOTES:
a → S/N C878V01563E c S/N C878V01564E →
b → S/N C878V01683E d S/N C878V01684E →
NOTES
FOOTNOTES:
a Use sealant 580078442
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Not Illustrated
NOTES
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Lower b Upper
NOTES
3 EXHAUST SYSTEM
CONTENTS
SECTION 3
EXHAUST SYSTEM
DESCRIPTION PAGE
EXHAUST SYSTEM
CUMMINS 4.5L DIESEL ............................................................................................................................. 3-2
GM 4.3L, GASOLINE AND LPG ................................................................................................................. 3-4
EXHAUST SYSTEM
CUMMINS 4.5L DIESEL
KEY:
A: with Catalytic Converter
B: without Catalytic Converter
QTY
ITEM PART NO. DESCRIPTION A B
1 580066347 Tail Pipe ..................................................................................................... 1 1
2 916522400 Cover .......................................................................................................... 1 1
3 580007621 Clamp ......................................................................................................... 4 4
4 580067786 Exhaust Pipe .............................................................................................. 1 1
5 b 580076420 Muffler ........................................................................................................ .. 1
5 580076421 Muffler ........................................................................................................ .. 1
5 580066449 Catalytic Converter (2-Way Catalytic) ........................................................ 1 ..
6 580056381 Locknut ....................................................................................................... 6 6
7 504226242 Washer ....................................................................................................... 2 2
8 580081092 Isolator ....................................................................................................... 2 2
9 580030968 Capscrew ................................................................................................... 2 2
10 501614100 Clamp ......................................................................................................... 1 1
11 580026621 Nut .............................................................................................................. 2 2
12 580049231 Capscrew ................................................................................................... 2 2
13 580084757 Hanger ....................................................................................................... 1 1
14 580084585 Exhaust Pipe .............................................................................................. 1 1
15 580056209 Gasket ........................................................................................................ 1 1
16 580030970 Capscrew ................................................................................................... 3 3
17 580088536 Exhaust Pipe .............................................................................................. 1 1
a 580085394 Stud ............................................................................................................ 4 4
FOOTNOTES:
a Not Illustrated b UL Application DS
EXHAUST SYSTEM
GM 4.3L, GASOLINE AND LPG
KEY:
A: with Catalytic Converter
B: without Catalytic Converter
QTY
ITEM PART NO. DESCRIPTION A B
1 580066347 Tail Pipe ..................................................................................................... 1 1
2 916522400 Cover .......................................................................................................... 1 1
3 580007621 Clamp ......................................................................................................... 2 2
4 580030968 Capscrew ................................................................................................... 2 2
5 580037329 Washer ....................................................................................................... 4 4
6 580037328 Mount ......................................................................................................... 2 2
7 580077713 Spacer ........................................................................................................ 2 2
8 580077759 Bracket ....................................................................................................... 1 ..
9 580027572 Nut .............................................................................................................. 6 4
10 504226242 Washer ....................................................................................................... 2 2
11 580056381 Locknut ....................................................................................................... 2 2
12 580081560 Exhaust Pipe .............................................................................................. 1 ..
13 580039610 Gasket ........................................................................................................ 2 2
14 580054719 Gasket ........................................................................................................ 1 ..
15 580081559 Exhaust Pipe .............................................................................................. 1 1
15 580088894 Exhaust Pipe (Alternate Part) ..................................................................... 1 1
16 449021006 Washer ....................................................................................................... 6 6
17 580054687 Locknut ....................................................................................................... 6 6
18 580054724 Stud ............................................................................................................ 6 6
19 580054716 Gasket ........................................................................................................ 2 2
20 580066348 Exhaust Pipe .............................................................................................. 1 1
21 580052855 Catalytic Converter (LPG) .......................................................................... 1 ..
21 580083309 Catalytic Converter (Gasoline) ................................................................... 1 ..
22 580039566 Washer ....................................................................................................... 1 2
23 580054717 Gasket ........................................................................................................ 1 ..
24 449022017 Lockwasher ................................................................................................ 2 ..
25 580020060 Nut .............................................................................................................. 2 ..
26 580074438 Exhaust Pipe .............................................................................................. 1 ..
26 580066347 Tail Pipe ..................................................................................................... .. 1
27 580063288 Muffler (Crimped) ....................................................................................... 1 1
27 a 580054021 Muffler (Welded) ......................................................................................... 1 1
28 580030970 Capscrew ................................................................................................... 3 3
FOOTNOTES:
a Optional
NOTES
4 COOLING SYSTEM
CONTENTS
SECTION 4
COOLING SYSTEM
DESCRIPTION PAGE
COOLING SYSTEM
GM 4.3L GASOLINE AND LPG - CUMMINS 4.5L DIESEL (→ S/N C878V01610E) ................................. 4-2
GM 4.3L LPG AND GASOLINE - CUMMINS 4.5L DIESEL (S/N C878V01611E →) ................................. 4-4
COOLING SYSTEM
GM 4.3L GASOLINE AND LPG – CUMMINS 4.5L DIESEL (→ S/N C878V01610E)
FOOTNOTES:
a Cummins 4.5L Diesel c without Low Coolant Sensor
b GM 4.3L Gasoline and LPG
COOLING SYSTEM
GM 4.3L LPG AND GASOLINE – CUMMINS 4.5L DIESEL (S/N C878V01611E →)
FOOTNOTES:
a Cummins 4.5L Diesel c Without Low Coolant Sensor
b GM 4.3L Gasoline and LPG
NOTES
5 FUEL SYSTEM
CONTENTS
SECTION 5
FUEL SYSTEM
DESCRIPTION PAGE
AIR INTAKE
GM 4.3L, GASOLINE AND LPG (→ S/N C878V01854F)
AIR INTAKE
GM 4.3L GASOLINE AND LPG (S/N C878V01855F →)
FOOTNOTES:
a PENDING PER ECN 13628104 →
AIR INTAKE
CUMMINS 4.5L DIESEL
FOOTNOTES:
a PENDING PER ECN 13628104 →
FOOTNOTES:
a Not Illustrated c S/N C878V01739F →
b → S/N C878V01738F
NOTES
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a → 3/2008 b 3/2008 →
FOOTNOTES:
a Left Rail Only c Right Rail Only
b Not Illustrated
LPG REGULATOR
GM 4.3L LPG
FOOTNOTES:
a Not Illustrated
FUEL SYSTEM
CUMMINS 4.5L DIESEL
FOOTNOTES:
a Not Illustrated b UL Type DS
FOOTNOTES:
a → PENDING PER ECN 105549 b PENDING PER ECN 105549 →
FOOTNOTES:
a For Use With Foot Directional Control Pedal Only b For Use With Standard Pedal Only
NOTES
6 ELECTRICAL SYSTEM
CONTENTS
SECTION 6
ELECTRICAL SYSTEM
DESCRIPTION PAGE
SECTION 6
ELECTRICAL SYSTEM
DESCRIPTION PAGE
NOTES
ELECTRICAL SYSTEM
RIGHT HAND CHASSIS – GM 4.3L GASOLINE AND LPG
FOOTNOTES:
a Not Illustrated d S/N C878V01564E → LPG
b → S/N C878V01563E LPG e S/N C878V01684E → Gas
c → S/N C878V01683E Gas
ELECTRICAL SYSTEM
RIGHT HAND CHASSIS – CUMMINS 4.5L DIESEL
COWL ELECTRICAL
ELECTRIC HYDRAULIC
KEY:
A: With Return to Set Tilt
B: Without Return to Set Tilt
QTY
ITEM PART NO. DESCRIPTION A B
1 580051810 Wire Harness (Cowl with Foot Directional Control, Diesel) (FP19000
[Page 6-100]).............................................................................................. 1 ..
1 580068402 Wire Harness (Cowl with Forward/Reverse Lever) (Cowl with Forward/
Reverse Lever, Diesel) (FP19001 [Page 6-104])...................................... .. 1
1 f 580082486 Wire Harness (Cowl with Foot Directional Control, Gasoline and LPG)
(FP18967 [Page 6-92]).............................................................................. 1 ..
1 f 580082487 Wire Harness (Cowl with Forward/Reverse Lever) (Cowl with Forward/
Reverse Lever, Gasoline and LPG) (FP18968 [Page 6-96]).................... .. 1
2 580047200 Screw ......................................................................................................... 2 2
3 580062311 Bracket ....................................................................................................... 1 1
4 580037180 Capscrew ................................................................................................... 2 2
5 580038826 Bracket ....................................................................................................... 1 1
6 a 580038751 Wire Harness (Electronic Control Valve) (FP18970 [Page 6-110])........... 1 1
6 c 580040090 Wire Harness (Electronic Control Valve) (FP18969 [Page 6-108])........... 1 1
7 g 580049608 Vehicle System Manager (VSM) -8525419 ................................................ 1 1
7 e 580049609 Vehicle System Manager (VSM) -8525420 ................................................ 1 1
7 d 580049610 Vehicle System Manager (VSM) -8525421 ................................................ 1 1
8 580026812 Clip ............................................................................................................. 3 1
9 580056613 Fastener ..................................................................................................... 3 1
10 580056614 Bracket ....................................................................................................... 1 1
11 580030968 Capscrew ................................................................................................... 3 3
12 580037180 Capscrew ................................................................................................... 2 2
b 580050194 Connector ................................................................................................... 1 1
FOOTNOTES:
a Four Function e With Electronic Hydraulics and Overhead Guard
b Not Illustrated f With Hydraulic Pump Solenoid
c Three Function g Without Electronic Hydraulics
d With Electronic Hydraulics and Cab
FOOTNOTES:
a Remove Panels From Overlay as Required For c PENDING PER ECN 105334 →
Truck Configuration.
b → PENDING PER ECN 105334
NOTES
ENGINE ELECTRICAL
GM 4.3L GASOLINE AND LPG
KEY:
A: Gasoline
B: LPG
QTY
ITEM PART NO. DESCRIPTION A B
1 580037160 Sensor (Air Flow Restriction) ..................................................................... 1 1
2 580051800 Nut .............................................................................................................. 3 3
3 580039438 Capscrew ................................................................................................... 4 4
4 580078811 Bracket Wldmt ............................................................................................ 1 1
5 580049231 Capscrew ................................................................................................... 3 3
6 580026621 Nut .............................................................................................................. 6 6
7 580048273 Oxygen Sensor (With Wire Harness) ......................................................... 2 2
8 505970526 Nut .............................................................................................................. 1 1
9 580078572 Wire Harness (LH Chassis) (FP18962 [Page 6-72])................................. 1 ..
9 580078573 Wire Harness (LH Chassis) (FP18963 [Page 6-74])................................. .. 1
10 580049559 Clamp (Swivel) ........................................................................................... 1 1
11 580041557 Clamp ......................................................................................................... 1 1
12 937100904 Nut .............................................................................................................. 1 1
13 940600908 Washer ....................................................................................................... 3 3
14 580027573 Nut (Flange) ............................................................................................... 1 1
15 580047714 Capscrew ................................................................................................... 4 4
16 580072127 Nut .............................................................................................................. 2 2
17 580006579 Bolt ............................................................................................................. 2 2
17 580087935 Bolt (Alternate Part) .................................................................................... 2 2
18 580074751 Starter (FP20718 [Page 6-16]).................................................................. 1 1
19 580074788 Bracket ....................................................................................................... 1 1
20 580045558 Clip ............................................................................................................. 3 3
21 580032023 Bracket ....................................................................................................... 1 ..
22 580083531 Battery Cable (Positive) (FP18944 [Page 6-14])....................................... 1 1
23 580083532 Battery Cable (Negative) (FP18944 [Page 6-14])..................................... 1 1
24 580037180 Capscrew ................................................................................................... 2 2
25 580077308 Battery Cable (Negative) ............................................................................ 1 1
25 580006553 E-Ring .................................................................................................... 2 2
25 580050293 E-Ring .................................................................................................... 1 1
BATTERY CABLES
GM 4.3L GASOLINE AND LPG
STARTER
GM 4.3L (GS AND LPS) (PENDING PER ECN 105844 →)
ENGINE ELECTRICAL
CUMMINS 4.5L DIESEL
BATTERY CABLES
CUMMINS 4.5L DIESEL
LIGHTS
STOP, TAIL, TURN, BACKUP, AND STROBE
FOOTNOTES:
a Not Illustrated c → PENDING PER ECN 105217
b → 6/2007 d PENDING PER ECN 105217 →
FOOTNOTES:
a Alternate Part c GM 4.3L Gasoline and LPG
b Cummins 4.5L Diesel
NOTES
MAST ELECTRICAL
ITEM PART NO. DESCRIPTION QTY
1 580082318 Bracket ................................................................................................................ 1
2 580058270 Capscrew ............................................................................................................ 1
3 580077708 Bracket ................................................................................................................ 1
4 580044862 Insert ................................................................................................................... 1
5 580077709 Sensor (Mast Position) ....................................................................................... 1
6 580047034 Capscrew ............................................................................................................ 2
7 449015112 Locknut ............................................................................................................... 2
8 580072635 Capscrew ............................................................................................................ 1
9 580058190 Nut ...................................................................................................................... 1
NOTES
FOOTNOTES:
a Kit Includes: 1 Interlock Rocker (must be used in d Kit Includes: 1 Momentary Switch, 1 Lockwasher,
combination with a Momentary Interlock Switch), 1 1 Gasket, 1 Nut (parts are NSS)
Gasket, 4 Screws (parts are NSS) e Module must be replaced with 580089966 Module
b Kit Includes: 1 Mini-Lever Plug, 1 Gasket (parts are
NSS)
c Kit Includes: 1 Momentary Interlock Switch Plug, 1
Gasket (parts are NSS)
FOOTNOTES:
a Kit Includes: 1 Interlock Mini-Lever (must be used c Kit Includes: 1 Momentary Switch, 1 Lockwasher,
in combination with a Momentary Interlock Switch), 1 Gasket, 1 Nut (parts are NSS)
1 Gasket, 4 Screws (parts are NSS) d Kit Includes: 1 Plain Mini-Lever, 1 Gasket, 4
b Kit Includes: 1 Momentary Switch Hole Plug, 1 Screws (parts are NSS)
Gasket (parts are NSS)
FOOTNOTES:
a Kit Includes: 1 Interlock Rocker (must be used in c Kit Includes: 1 Momentary Interlock Switch Plug, 1
combination with a Momentary Interlock Switch), 1 Gasket (parts are NSS)
Gasket, 4 Screws (parts are NSS) d Kit Includes: 1 Momentary Switch, 1 Lockwasher,
b Kit Includes: 1 Mini-Lever Plug, 1 Gasket (parts are 1 Gasket, 1 Nut (parts are NSS)
NSS)
NOTES
FOOTNOTES:
a Kit Includes: 1 Interlock Mini-Lever (must be used c Kit Includes: 1 Momentary Switch, 1 Lockwasher,
in combination with a Momentary Interlock Switch), 1 Gasket, 1 Nut (parts are NSS)
1 Gasket, 4 Screws (parts are NSS)
b Kit Includes: 1 Momentary Switch Hole Plug, 1
Gasket (parts are NSS)
WIRE HARNESS
RIGHT HAND CHASSIS – GM 4.3L GASOLINE AND LPG (→ S/N C878V01563E LPG)
(→ S/N C878V01683E GAS)
WIRE HARNESS
RIGHT HAND CHASSIS – GM 4.3L GASOLINE AND LPG (→ S/N C878V01563E LPG)
(→ S/N C878V01683E GAS)
WIRE HARNESS
RIGHT HAND CHASSIS – GM 4.3L GASOLINE AND LPG (→ S/N C878V01563E LPG)
(→ S/N C878V01683E GAS)
WIRE HARNESS
RIGHT HAND CHASSIS – GM 4.3L GASOLINE AND LPG (→ S/N C878V01563E LPG)
(→ S/N C878V01683E GAS)
NOTES
WIRE HARNESS
RIGHT HAND CHASSIS – GM 4.3L GASOLINE AND LPG (S/N C878V01564E → LPG)
(S/N C878V01684E → GAS)
WIRE HARNESS
RIGHT HAND CHASSIS – GM 4.3L GASOLINE AND LPG (S/N C878V01564E → LPG)
(S/N C878V01684E → GAS)
WIRE HARNESS
RIGHT HAND CHASSIS – GM 4.3L GASOLINE AND LPG (S/N C878V01564E → LPG)
(S/N C878V01684E → GAS)
WIRE HARNESS
RIGHT HAND CHASSIS – GM 4.3L GASOLINE AND LPG (S/N C878V01564E → LPG)
(S/N C878V01684E → GAS)
NOTES
WIRE HARNESS
RIGHT HAND CHASSIS – CUMMINS 4.5L DIESEL
WIRE HARNESS
RIGHT HAND CHASSIS – CUMMINS 4.5L DIESEL
WIRE HARNESS
RIGHT HAND CHASSIS – CUMMINS 4.5L DIESEL
WIRE HARNESS
RIGHT HAND CHASSIS – CUMMINS 4.5L DIESEL
NOTES
WIRE HARNESS
LEFT HAND CHASSIS – GM 4.3L GASOLINE
WIRE HARNESS
LEFT HAND CHASSIS – GM 4.3L LPG
WIRE HARESS
ENGINE – GM 4.3L GASOLINE (→ S/N C878V01683E)
WIRE HARNESS
ENGINE – GM 4.3L GASOLINE (S/N C878V01684E →)
WIRE HARNESS
ENGINE – GM 4.3L GASOLINE (S/N C878V01684E →)
NOTES
WIRE HARNESS
ENGINE – GM 4.3L LPG (→ S/N C878V01563E)
WIRE HARNESS
ENGINE – GM 4.3L LPG (S/N C878V01564E →)
WIRE HARNESS
ENGINE – GM 4.3L LPG (S/N C878V01564E →)
NOTES
WIRE HARNESS
ENGINE – CUMMINS 4.5L DIESEL
WIRE HARNESS
ENGINE – CUMMINS 4.5L DIESEL
NOTES
WIRE HARNESS
COWL WITH FOOT DIRECTIONAL CONTROL PEDAL – GM 4.3L GASOLINE AND LPG
WIRE HARNESS
COWL WITH FOOT DIRECTIONAL CONTROL PEDAL – GM 4.3L GASOLINE AND LPG
NOTES
WIRE HARNESS
COWL WITH FORWARD/REVERSE LEVER – GM 4.3L GASOLINE AND LPG
WIRE HARNESS
COWL WITH FORWARD/REVERSE LEVER – GM 4.3L GASOLINE AND LPG
NOTES
WIRE HARNESS
COWL WITH FOOT DIRECTIONAL CONTROL PEDAL – CUMMINS 4.5L DIESEL
WIRE HARNESS
COWL WITH FOOT DIRECTIONAL CONTROL PEDAL – CUMMINS 4.5L DIESEL
NOTES
WIRE HARNESS
COWL WITH FORWARD/REVERSE LEVER – CUMMINS 4.5L DIESEL
WIRE HARNESS
COWL WITH FORWARD/REVERSE LEVER – CUMMINS 4.5L DIESEL
NOTES
WIRE HARNESS
ELECTRONIC CONTROL VALVE – THREE FUNCTION
WIRE HARNESS
ELECTRONIC CONTROL VALVE – FOUR FUNCTION
WIRE HARNESS
REAR CHASSIS
WIRE HARNESS
TRANSMISSION – TWO SPEED
FOOTNOTES:
a Not Illustrated
WIRE HARNESS
TRANSMISSION – THREE SPEED
WIRE HARNESS
TRANSMISSION – THREE SPEED
NOTES
WIRE HARNESS
SEALED ALTERNATOR – CUMMINS 4.5L DIESEL
WIRE HARNESS
LIGHTS WITH OVERHEAD GUARD
WIRE HARNESS
LIGHTS (6/2007 →)
FOOTNOTES:
a → PENDING PER ECN 105217 b PENDING PER ECN 105217 →
7 TRANSMISSION
CONTENTS
SECTION 7
TRANSMISSION
DESCRIPTION PAGE
TRANSMISSION MOUNT
ITEM PART NO. DESCRIPTION QTY
1 449001023 Capscrew ............................................................................................................ 1
2 449022013 Lockwasher ......................................................................................................... 1
3 580063482 Washer ............................................................................................................... 1
4 580063480 Crossmember ..................................................................................................... 1
5 580063478 Housing (Bushing) .............................................................................................. 1
6 502566903 Washer ............................................................................................................... 6
7 502565901 Capscrew ............................................................................................................ 2
8 311323023 Capscrew ............................................................................................................ 8
9 580069314 Bracket (Isolator) ................................................................................................ 1
10 580063481 Pin ....................................................................................................................... 1
11 a 580068347 Transmission Assy (Three Speed) ..................................................................... 1
11 c 580085901 Transmission Assy (Three Speed) ..................................................................... 1
11 b 580068348 Transmission Assy (Two Speed) ........................................................................ 1
11 d 580085902 Transmission Assy (Two Speed) ........................................................................ 1
12 580063477 Bushing ............................................................................................................... 1
13 580049879 Washer ............................................................................................................... 4
14 580051384 Nut (Flange) ........................................................................................................ 2
FOOTNOTES:
a → S/N C878V01747F INC. 01761-01764 c S/N C878V01748F → EXC. 01761-01764
b → S/N C878V01777F INC. 01857-01859 d S/N C878V01778F → EXC. 01857-01859
TORQUE CONVERTER
GM 4.3L GASOLINE AND LPG
FOOTNOTES:
a → S/N C878V01747F INC. 01761-01764 e S/N C878V01748F → EXC. 01761-01764
b → S/N C878V01777F INC. 01857-01859, f S/N C878V01778F → EXC. 01857-01859,
01863-01864, 01867-01868, 01873, 0001 01863-01864, 01867-01868, 01873, 0001
c → S/N C878V01777F INC. 01857-01859, g S/N C878V01778F → EXC. 01857-01859,
01863-01864, 01867-01868, 01873, 0018 01863-01864, 01867-01868, 01873, 0018
d → S/N C878V01777F INC. 01857-01859, h S/N C878V01778F → EXC. 01857-01859,
01863-01864, 01867-01868, 01873, 0187 01863-01864, 01867-01868, 01873, 0187
TORQUE CONVERTER
CUMMINS 4.5L DIESEL
FOOTNOTES:
a → S/N C878V01747F INC. 01761-01764 e S/N C878V01748F → EXC. 01761-01764
b → S/N C878V01777F INC. 01857-01859, f S/N C878V01778F → EXC. 01857-01859,
01863-01864, 01867-01868, 01873, 0001 01863-01864, 01867-01868, 01873, 0001
c → S/N C878V01777F INC. 01857-01859, g S/N C878V01778F → EXC. 01857-01859,
01863-01864, 01867-01868, 01873, 0018 01863-01864, 01867-01868, 01873, 0018
d → S/N C878V01777F INC. 01857-01859, h S/N C878V01778F → EXC. 01857-01859,
01863-01864, 01867-01868, 01873, 0187 01863-01864, 01867-01868, 01873, 0187
TRANSMISSION COOLING
WITH EXTERNAL OIL COOLER
FOOTNOTES:
a → S/N C878V01520E b S/N C878V01521E →
TRANSMISSION ASSEMBLY
THREE SPEED – SHEET 1 OF 2
FOOTNOTES:
a Cummins Engines-Service with 580085901 and d → S/N C878V01777F INC. 01857-01859,
Converter 580081764 plus CDF file 01863-01864, 01867-01868, 01873,
b GM Engines- Service with 580085901 and 01878-01881, 01885, 01889, 01891, 01894
Converter 580081763 plus CDF file e S/N C878V01748F → EXC. 01761-01764
c → S/N C878V01747F INC. 01761-01764 f S/N C878V01778F → EXC. 01857-01859,
01863-01864, 01867-01868, 01873,
01878-01881, 01885, 01889, 01891, 01894
NOTES
TRANSMISSION ASSEMBLY
THREE SPEED – SHEET 2 OF 2
FOOTNOTES:
a Cummins Engines-Service with 580085901 and c → S/N C878V01748F INC. 01761-01764
Converter 580081764 plus CDF file d → S/N C878V01777F INC. 01857-01859,
b GM Engines- Service with 580085901 and 01863-01864, 01867-01868, 01873,
Converter 580081763 plus CDF file 01878-01881, 01885, 01889, 01891, 01894
CONTROL VALVE
THREE SPEED TRANSMISSION
TRANSMISSION ASSEMBLY
TWO SPEED – SHEET 1 OF 2
FOOTNOTES:
a Cummins Engines-Service with 580085902 and d → S/N C878V01747F INC. 01761-01764
Converter 580081764 plus CDF file e S/N C878V01520E ↔ S/N C878V01748F INC.
b GM Engines- Service with 580085902 and 01761-01764
Converter 580081763 plus CDF file f S/N C878V01748F → EXC. 01761-01764
c → S/N C878V01519E
NOTES
TRANSMISSION ASSEMBLY
TWO SPEED – SHEET 2 OF 2
FOOTNOTES:
a Cummins Engines-Service with 580085902 and d → S/N C878V01747F INC. 01761-01764
Converter 580081764 plus CDF file e S/N C878C01520E ↔ S/N C878C01747E INC.
b GM Engines- Service with 580085902 and 01761-01764
Converter 580081763 plus CDF file f S/N C878V01748F → EXC. 01761-01764
c → S/N C878V01519E
REVERSE CLUTCH
TWO SPEED TRANSMISSION
FOOTNOTES:
a → S/N C878V01747F INC. 01761-01764 b S/N C878V01748F → EXC. 01761-01764
NOTES
CONTROL VALVE
TWO SPEED TRANSMISSION (→ S/N C878V01747F INC. 01761-01764)
CONTROL VALVE
TWO SPEED TRANSMISSION (→ S/N C878V01747F INC. 01761-01764)
NOTES
CONTROL VALVE
TWO SPEED TRANSMISSION (S/N C878V01748F → EXC. 01761-01764)
NOTES
PUMP DRIVE
ITEM PART NO. DESCRIPTION QTY
1 ac 580080600 Drive Gear .......................................................................................................... 1
1 df 580089184 Drive Gear .......................................................................................................... 1
2 580080604 Capscrew ............................................................................................................ 1
3 580070516 Lockwasher ......................................................................................................... 1
4 580080603 Support ............................................................................................................... 1
5 580080605 Pin ....................................................................................................................... 1
6 580080601 Ball Bearing ........................................................................................................ 1
7 580083472 Retaining Ring .................................................................................................... 1
8 580080598 Screw .................................................................................................................. 1
9 580080599 Lockwasher ......................................................................................................... 1
10 580080597 Support ............................................................................................................... 1
11 580080596 Pin ....................................................................................................................... 1
12 580080736 Snap Ring ........................................................................................................... 1
13 580080735 Bearing ............................................................................................................... 1
14 ab 580080595 Gear (Pump Drive) .............................................................................................. 1
14 de 580089183 Idler Gear (Pump Drive) ...................................................................................... 1
FOOTNOTES:
a → S/N C878V01747F INC. 01761-01764 d S/N C878V01748F → EXC. 01761-01764
b → S/N C878V01777F INC. 01857-01859, e S/N C878V01778F → EXC. 01857-01859,
01863-01864, 01867-01868, 01873, 0018 01863-01864, 01867-01868, 01873, 0018
c → S/N C878V01777F INC. 01857-01859, f S/N C878V01778F → EXC. 01857-01859,
01863-01864, 01867-01868, 01873, 0187 01863-01864, 01867-01868, 01873, 0187
NOTES
8 DRIVE AXLE
CONTENTS
SECTION 8
DRIVE AXLE
DESCRIPTION PAGE
KEY:
A: 8.25 x 15 Pneumatic
B: 8.25 x 15 Solid Pneumatic
QTY
ITEM PART NO. DESCRIPTION A B
1 580050050 Tire (Monarch) ............................................................................................ .. 4
1 580081172 Tire (Monarch) ............................................................................................ .. 4
1 580050050 Tire (Monarch)(Alternate Part) ................................................................... .. 4
1 580050049 Tire (Trell) ................................................................................................... 4 ..
1 580015806 Tire (Radial) ............................................................................................... 4 ..
1 a 580014869 Tubeless Bead Seal ............................................................................... 1 1
1 a 580014987 Tubeless Bead Seal Valve ..................................................................... 1 1
2 580078075 Wheel Assy ................................................................................................ 4 4
FOOTNOTES:
a Radial Tires Only
NOTES
FOOTNOTES:
a Cummins 4.5L Diesel d with Two and Three Speed Transmissions
b Used with Bias Ply Tires e with Two Speed Transmissions
c Used with Radial Tires
DIFFERENTIAL
ITEM PART NO. DESCRIPTION QTY
580064079 Drive Axle (14.8 Overall Ratio) ........................................................................... 1
580064080 Drive Axle (15.4 Overall Ratio) ........................................................................... 1
580076228 Pinion ............................................................................................................. 1
1 580076223 Differential Carrier ...................................................................................... 1
2 580076224 Washer ....................................................................................................... 2
3 580076225 Gear ........................................................................................................... 2
4 580076227 Washer ....................................................................................................... 4
5 580076228 Pinion ......................................................................................................... 4
6 580076226 Pin .............................................................................................................. 2
7 580076230 Bolt ............................................................................................................. 15
8 580069903 Bolt ................................................................................................................. 2
9 580076219 Nut .................................................................................................................. 2
10 580076220 Seal ................................................................................................................ 2
11 580086333 Snap Ring ....................................................................................................... 2
12 580076218 O-Ring ............................................................................................................ 2
13 580076221 Bearing ........................................................................................................... 2
14 580076222 Bolt ................................................................................................................. 2
15 580076217 Gear and Pinion (14.8 overall Ratio) .............................................................. 1
15 580076404 Gear and Pinion (15.4 Overall Ratio) ............................................................. 1
16 580076216 Bearing ........................................................................................................... 1
17 580081758 Kit-Shim .......................................................................................................... 1
18 580076211 Shim (0.1 mm) ................................................................................................ 1
18 580076212 Shim (0.2 mm) ................................................................................................ 1
18 580076213 Shim (0.5 mm) ................................................................................................ 1
18 580076214 Shim (0.15 mm) .............................................................................................. 1
19 580076208 Spacer ............................................................................................................ 1
20 580069883 Bearing ........................................................................................................... 1
21 580076207 Seal ................................................................................................................ 1
22 580076206 Cover Plate ..................................................................................................... 1
23 580076204 Flange ............................................................................................................ 1
24 580076205 O-Ring ............................................................................................................ 1
25 580076203 Nut .................................................................................................................. 1
NOTES
9 STEERING SYSTEM
CONTENTS
SECTION 9
STEERING SYSTEM
DESCRIPTION PAGE
FOOTNOTES:
a → 1/2007 b 2/2007 →
FOOTNOTES:
a For Vehicles With Diesel Engines Only
NOTES
STEER AXLE
ITEM PART NO. DESCRIPTION QTY
580081635 Steering Axle Assy .............................................................................................. 1
1 072387302 Bearing Cup ................................................................................................... 2
2 072387301 Bearing Cone ................................................................................................. 2
3 504224231 Wear Sleeve ................................................................................................... 2
4 504224298 Seal ................................................................................................................ 2
5 580011846 Spindle (RH) ................................................................................................... 1
6 580007166 Steering Axle (Frame) .................................................................................... 1
7 504224242 Seal ................................................................................................................ 2
8 520045589 Seal ................................................................................................................ 2
9 504225236 O-Ring ............................................................................................................ 2
10 065001000 Bearing Cone ................................................................................................. 2
11 504224222 Shim (0.005 in.) .............................................................................................. 3
12 504224232 Shim (0.007 in.) .............................................................................................. 3
13 504224292 Shim (0.020 in.) .............................................................................................. 2
14 580050203 Shim (0.002 in.) .............................................................................................. 2
15 580007182 Bearing Cap (Assembly) ................................................................................ 2
15 580007183 Bearing Cap ............................................................................................... 1
15 065000900 Bearing Cup ............................................................................................... 1
16 449021006 Washer ........................................................................................................... 2
17 580049010 Capscrew ....................................................................................................... 2
18 015631500 Grease Fitting ................................................................................................. 2
19 931014904 Capscrew ....................................................................................................... 6
20 015918200 Snap Ring ....................................................................................................... 8
21 580052359 Pin .................................................................................................................. 2
22 580052360 Pin .................................................................................................................. 2
23 580091329 Seal ................................................................................................................ 8
24 580052282 Tie Rod (Assembly) ........................................................................................ 1
24 580011850 Tie Rod ....................................................................................................... 1
25 580052264 Spherical Roller Bearing ............................................................................ 1
26 015631500 Grease Fitting ............................................................................................. 2
27 502565901 Capscrew ....................................................................................................... 8
28 449022041 Lockwasher .................................................................................................... 8
29 580064660 Steering Cylinder (FP18908 [Page 9-9])....................................................... 1
30 580003485 Bushing .......................................................................................................... 2
31 580003484 Shim (0.040 in.) .............................................................................................. AR
32 580003483 Shim (0.110 in.) .............................................................................................. AR
33 580003486 Flange ............................................................................................................ 2
34 580003482 Sealing Ring ................................................................................................... 2
35 580082310 Wheel Hub ...................................................................................................... 2
36 580002014 Wheel Stud ..................................................................................................... 12
37 502175921 Bearing Cup ................................................................................................... 2
38 053239100 Bearing Cup ................................................................................................... 2
39 580003603 Wear Sleeve ................................................................................................... 2
40 015418400 Cotter Pin ....................................................................................................... 2
41 504227283 Cap ................................................................................................................. 2
42 504240211 Wheel Nut ....................................................................................................... 2
43 580007181 Washer ........................................................................................................... 2
44 502175920 Bearing Cone ................................................................................................. 2
45 060733800 Bearing Cone ................................................................................................. 2
46 580003602 Seal ................................................................................................................ 2
47 580011849 Spindle (LH) ................................................................................................... 1
STEER AXLE
ITEM PART NO. DESCRIPTION QTY
48 504224266 Plug ................................................................................................................ 2
49 022784400 Grease Fitting ................................................................................................. 2
STEERING LINES
ITEM PART NO. DESCRIPTION QTY
1 580019866 Fitting .................................................................................................................. 2
1 580063949 O-Ring ............................................................................................................ 1
1 052645200 O-Ring ............................................................................................................ 1
2 580047714 Capscrew ............................................................................................................ 7
3 580026621 Nut ...................................................................................................................... 7
4 580045558 Clip ...................................................................................................................... 4
5 a 580075225 Hose Assy ........................................................................................................... 1
5 bc 580087742 Hose Assy ........................................................................................................... 1
5 d 580088711 Hose Assy ........................................................................................................... 1
6 580020430 Fitting .................................................................................................................. 1
6 580063949 O-Ring ............................................................................................................ 1
6 052645300 O-Ring ............................................................................................................ 1
7 580039350 Fitting .................................................................................................................. 1
7 580063949 O-Ring ............................................................................................................ 1
7 052645300 O-Ring ............................................................................................................ 1
8 a 580075226 Hose Assy ........................................................................................................... 1
8 cd 580087741 Hose Assy ........................................................................................................... 1
8 d 580088712 Hose Assy ........................................................................................................... 1
9 580049814 Clip ...................................................................................................................... 3
FOOTNOTES:
a → PENDING PER ECN 105356 c PENDING PER ECN 105356 →
b → PENDING PER ECN 105432 d PENDING PER ECN 105432 →
FOOTNOTES:
a → 9/2007 b 9/2007 →
KEY:
A: 8.25 x 15-14 PR
B: 8.25 x 15 Solid Pneumatic
C: 8.25 R15 Radial
QTY
ITEM PART NO. DESCRIPTION A B C
1 a 580050050 Tire (Monarch) ................................................................................... .. 2 ..
1 b 580081172 Tire (Monarch) ................................................................................... .. 2 ..
1 580050050 Tire (Monarch)(Alternate Part) .......................................................... .. 2 ..
1 580050049 Tire (Trell) .......................................................................................... 2 .. ..
2 580014962 Pneumatic Tire .................................................................................. .. .. 2
2 580015806 Tire ................................................................................................ .. .. 1
2 580014869 Tubeless Bead Seal ...................................................................... .. .. 1
2 580014987 Tubeless Bead Seal Valve ............................................................ .. .. 1
3 580078076 Wheel Assy ....................................................................................... 2 2 2
4 580003941 Wheel Nut .......................................................................................... 12 12 12
FOOTNOTES:
a Soft Ride b Standard Hardness
10 BRAKE SYSTEM
CONTENTS
SECTION 10
BRAKE SYSTEM
DESCRIPTION PAGE
FOOTNOTES:
a Not Illustrated
NOTES
FOOTNOTES:
a Not Illustrated
NOTES
PARK BRAKE
ITEM PART NO. DESCRIPTION QTY
580080971 Parking Brake (without Cab) ............................................................................... 1
580080972 Parking Brake (with Cab) .................................................................................... 1
1 580081500 Parking Brake Lever (with Cab) ..................................................................... 1
1 580081499 Parking Brake Lever (without Cab) ................................................................ 1
1 580084626 Grip ............................................................................................................ 1
2 580026812 Clip ................................................................................................................. 1
3 580050676 Clip (Key Hole) ............................................................................................... 1
4 580044785 Sensor (Brake Position) (Brake Position) ....................................................... 1
5 940600906 Washer ........................................................................................................... 2
6 580047034 Capscrew ....................................................................................................... 2
7 580083236 Clamp ................................................................................................................. 2
8 449001204 Capscrew ............................................................................................................ 2
9 580056624 Pin (Rod End) ..................................................................................................... 2
10 580000868 Lockring .............................................................................................................. 2
11 580049231 Capscrew ............................................................................................................ 4
12 580081697 Bracket ................................................................................................................ 1
13 580063366 Bracket ................................................................................................................ 1
14 449015135 Nut ...................................................................................................................... 2
15 580068098 Parking Brake Cable (RH) .................................................................................. 1
16 580068097 Parking Brake Cable (LH) ................................................................................... 1
17 580037180 Capscrew ............................................................................................................ 4
11 HYDRAULIC SYSTEM
CONTENTS
SECTION 11
HYDRAULIC SYSTEM
DESCRIPTION PAGE
FOOTNOTES:
a Cummins 4.5L Diesel Only e Not Illustrated
b GDP135VX f → PENDING PER ECN 104853
c GM 4.3L Gasoline and LPG Only g PENDING PER ECN 104853 →
d GP/GLP135-155VX and GDP135VX
NOTES
GEAR PUMP
(→ S/N C878V01509E)
GEAR PUMP
(S/N C878V01593E →)
HAND LEVERS
THREE FUNCTION – WITH DETENTED LEVERS
FOOTNOTES:
a → PENDING PER ECN 104512 c PENDING PER ECN 104512 →
b → PENDING PER ECN 10498402 d PENDING PER ECN 10498402 →
HAND LEVERS
THREE FUNCTION – WITHOUT DETENTED LEVERS
FOOTNOTES:
a → PENDING PER ECN 104512 c PENDING PER ECN 104512 →
b → PENDING PER ECN 10498402 d PENDING PER ECN 10498402 →
HAND LEVERS
FOUR FUNCTION – WITH DETENTED LEVERS
FOOTNOTES:
a → PENDING PER ECN 104512 c PENDING PER ECN 104512 →
b → PENDING PER ECN 10498402 d PENDING PER ECN 10498402 →
HAND LEVERS
FOUR FUNCTION – WITHOUT DETENTED LEVERS
FOOTNOTES:
a → PENDING PER ECN 104512 d PENDING PER ECN 104512 →
b → PENDING PER ECN 10498402 e PENDING PER ECN 10498402 →
c → PENDING PER ECN 104998402
FOOTNOTES:
a → 9/2007 c 9/2007 →
b → PENDING PER ECN 104512 d PENDING PER ECN 104512 →
FOOTNOTES:
a → 9/2007 c 9/2007 →
b → PENDING PER ECN 104512 d PENDING PER ECN 104512 →
NOTES
FOOTNOTES:
a → PENDING PER ECN 104512 b PENDING PER ECN 104512 →
NOTES
FOOTNOTES:
a Not Illustrated c 9/2007 →
b → 9/2007
FOOTNOTES:
a Not Illustrated c 9/2007 →
b → 9/2007
FOOTNOTES:
a Four Function Only b Three Function Only
TILT SECTION
ELECTRONIC CONTROL VALVE – THREE AND FOUR FUNCTION
FOOTNOTES:
a Four Function Only b Three Function Only
FOOTNOTES:
a Four Function Only b Three Function Only
FOOTNOTES:
a Not Illustrated
OUTLET SECTION
ELECTRONIC CONTROL VALVE – THREE AND FOUR FUNCTION
FOOTNOTES:
a 5° Forward/10° Back b 5° Forward/6° Back
TILT CYLINDERS
KEY:
A: 5 Degrees Forward/6 Degrees Back
B: 5 Degrees Forward/10 Degrees Back
QTY
ITEM PART NO. DESCRIPTION A B
580074282 Tilt Cylinder (LH) ........................................................................................ 1 ..
580074283 Tilt Cylinder (LH) ........................................................................................ .. 1
580066764 Tilt Cylinder (RH) ........................................................................................ 1 ..
580066765 Tilt Cylinder (RH) ........................................................................................ .. 1
1 520045448 Rod Wiper .............................................................................................. 1 1
2 580006745 End Plug ................................................................................................ 1 1
3 580022493 Rod Seal ................................................................................................ 1 1
4 580006739 Back-Up Ring ......................................................................................... 1 1
5 501949902 O-Ring ................................................................................................... 1 1
6 524240806 Cylinder Rod .......................................................................................... 1 ..
6 524240830 Cylinder Rod .......................................................................................... .. 1
7 580006743 O-Ring ................................................................................................... 1 1
8 506304101 Spacer ................................................................................................... 1 ..
9 504305710 Piston Seal ............................................................................................. 1 1
10 580006744 Wear Ring .............................................................................................. 1 1
11 580006742 Piston ..................................................................................................... 1 1
12 502637904 Locknut .................................................................................................. 1 1
13 580082894 Tube Wldmt-Cylinder (RH) .................................................................... 1 ..
13 580074280 Tube Wldmt-Cylinder (LH) ..................................................................... 1 ..
13 580074281 Tube Wldmt-Cylinder (LH) ..................................................................... .. 1
13 580082895 Tube Wldmt-Cylinder (RH) .................................................................... .. 1
580023428 Kit-Seal ....................................................................................................... 1 1
TILT HYDRAULICS
ITEM PART NO. DESCRIPTION QTY
1 580019865 Fitting .................................................................................................................. 4
1 504155200 O-Ring ............................................................................................................ 1
1 052645200 O-Ring ............................................................................................................ 1
2 580075491 Hose Assy ........................................................................................................... 1
3 580026621 Nut ...................................................................................................................... 2
4 580073148 Hose Clamp (Dual Hose) .................................................................................... 2
5 580058269 Capscrew ............................................................................................................ 2
6 580020430 Fitting .................................................................................................................. 6
6 580063949 O-Ring ............................................................................................................ 1
6 052645300 O-Ring ............................................................................................................ 1
7 580080018 Fitting .................................................................................................................. 1
8 900011244 Clamp ................................................................................................................. 2
9 580079375 Hose ................................................................................................................... 1
10 580077924 Fitting .................................................................................................................. 1
10 052645300 O-Ring ............................................................................................................ 1
11 580019810 Fitting .................................................................................................................. 1
11 504155200 O-Ring ............................................................................................................ 1
11 052645300 O-Ring ............................................................................................................ 1
12 580075468 Hose Assy ........................................................................................................... 1
13 580020576 Fitting .................................................................................................................. 1
13 580063949 O-Ring ............................................................................................................ 1
13 052645300 O-Ring ............................................................................................................ 1
14 580047714 Capscrew ............................................................................................................ 2
15 580077546 Valve Block ......................................................................................................... 1
15 580077546 Valve Block ..................................................................................................... 1
15 580077543 Hydraulic Control Valve .................................................................................. 1
16 580075490 Hose Assy ........................................................................................................... 1
17 580075490 Hose Assy ........................................................................................................... 1
18 580075487 Hose Assy ........................................................................................................... 1
19 580075492 Hose Assy ........................................................................................................... 1
HYDRAULIC FILTER
ITEM PART NO. DESCRIPTION QTY
1 580067372 Cap Assembly ................................................................................................ 1
1 ..... O-Ring ........................................................................................................ 1
1 ..... Spring ......................................................................................................... 1
2 580067374 Bowl ................................................................................................................ 1
3 580067377 Hydraulic Filter ............................................................................................... 1
3 ..... O-Ring ........................................................................................................ 1
4 a 580049602 Pressure Switch .................................................................................................. 1
580070562 Kit-O-Ring ........................................................................................................... 1
FOOTNOTES:
a With Electronic Monitoring Package
FOOTNOTES:
a Used for mast removal
FOOTNOTES:
a → PENDING PER ECN 104512 b PENDING PER ECN 104512 →
NOTES
SECTION 12
MAST-TWO STAGE LIMITED FREE-LIFT
DESCRIPTION PAGE
CARRIAGE
PIN TYPE - TWO STAGE LIMITED FREE-LIFT ......................................................................................... 12-12
INNER MAST
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 12-4
MAIN LIFT
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 12-6
MAIN LIFT CYLINDER
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 12-10
OUTER MAST
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 12-2
OUTER MAST
TWO STAGE LIMITED FREE-LIFT
A613
FOOTNOTES:
a Refer to Table
INNER MAST
TWO STAGE LIMITED FREE-LIFT
A613
FOOTNOTES:
a Letter on Inside Face b Refer to Table
MAIN LIFT
TWO STAGE LIMITED FREE-LIFT
A613
FOOTNOTES:
a alternate part b Refer to Table
NOTES
FOOTNOTES:
a Not Illustrated c Used with 5940 mm Lift Height
b Refer to Table
CARRIAGE
PIN TYPE – TWO STAGE LIMITED FREE-LIFT
FOOTNOTES:
a Letter on Inside Face b Optional
NOTES
SECTION 13
MAST-THREE STAGE FULL FREE-LIFT
DESCRIPTION PAGE
CARRIAGE
PIN TYPE - THREE STAGE FULL FREE-LIFT .......................................................................................... 13-20
FREE-LIFT
THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-16
FREE-LIFT CYLINDER
THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-18
INNER MAST
THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-6
INTERMEDIATE MAST
THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-4
MAIN LIFT
THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-8
MAIN LIFT CYLINDERS
THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-12
OUTER MAST
THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-2
OUTER MAST
THREE STAGE FULL FREE-LIFT
A614
FOOTNOTES:
a Refer to Table
INTERMEDIATE MAST
THREE STAGE FULL FREE-LIFT
A614
FOOTNOTES:
a Refer to Table
INNER MAST
THREE STAGE FULL FREE-LIFT
A614
FOOTNOTES:
a Refer to Table
MAIN LIFT
THREE STAGE FULL FREE-LIFT
A614
MAIN LIFT
THREE STAGE FULL FREE-LIFT
FOOTNOTES:
a A614-4640 d alternate part
b A614-5540 e Refer to Table
c A614-6140
NOTES
RIGHT HAND
FOOTNOTES:
a Refer to Table
NOTES
FREE-LIFT
THREE STAGE FULL FREE-LIFT
A614
FOOTNOTES:
a Refer to Table
FREE-LIFT CYLINDER
THREE STAGE FULL FREE-LIFT
A614
FOOTNOTES:
a Refer to Table
CARRIAGE
PIN TYPE – THREE STAGE FULL FREE-LIFT
FOOTNOTES:
a Letter on Inside Face b Optional
NOTES
SECTION 14
ATTACHMENTS AND HEADER HOSE GROUP
DESCRIPTION PAGE
CARRIAGE
TWO STAGE LIMITED FREE-LIFT – HOOK TYPE
FOOTNOTES:
a Letter on Inside Face b with Attachments
CARRIAGE
THREE STAGE FULL FREE-LIFT) – HOOK TYPE
FOOTNOTES:
a Letter on Inside Face b with Attachments
KEY:
A: Three function
B: Four Function
QTY
ITEM PART NO. DESCRIPTION A B
a. . . . . Mast Assy ................................................................................................... 1 1
1 520045244 Stubshaft ................................................................................................ 1 2
2 580029125 Hose Sheave ......................................................................................... 1 2
3 520045187 Bushing ............................................................................................. 1 2
4 580055650 Nut ......................................................................................................... 2 4
5 580006903 Hose Clamp ........................................................................................... 1 2
6 580055731 Capscrew ............................................................................................... 2 4
7 505965599 Clamp .................................................................................................... 2 4
8 580012772 Hose Clamp ........................................................................................... 2 4
9 580039425 Fitting ..................................................................................................... 2 4
10 b 580020430 Fitting ..................................................................................................... 2 2
10 052645300 O-Ring ............................................................................................... 1 1
10 580063949 O-Ring ............................................................................................... 1 1
11 b 580071068 Drain Valve ............................................................................................ 1 1
12 b 052643300 Fitting ..................................................................................................... 1 1
12 052645300 O-Ring ............................................................................................... 1 1
13 b 518803619 Fitting ..................................................................................................... 2 2
14 b 052645300 O-Ring ................................................................................................... 1 1
15 b 518802601 Quick Disconnect Fitting ........................................................................ 2 2
16 580069454 Fitting ..................................................................................................... 2 2
16 580063949 O-Ring ............................................................................................... 1 1
17 580020987 Fitting ..................................................................................................... 4 6
17 580063949 O-Ring ............................................................................................... 1 1
18 580076912 Bracket ................................................................................................... 1 2
19 580078959 Tube Assy .............................................................................................. .. 1
20 580078960 Tube Assy .............................................................................................. .. 1
21 a. . . . . Hose Assy .............................................................................................. 2 4
22 580071041 Capscrew ............................................................................................... 2 4
23 580064308 Bracket (RH) .......................................................................................... 1 1
23 580064307 Bracket (LH) ........................................................................................... .. 1
24 580055652 Nut ......................................................................................................... 2 4
25 580055746 Capscrew ............................................................................................... 1 2
26 580056007 Washer .................................................................................................. 1 2
27 580078958 Tube Assy .............................................................................................. 1 ..
FOOTNOTES:
a Refer to Table b With Quick Discconnect Fittings
NOTES
KEY:
A: Three Function
B: Four Function
QTY
ITEM PART NO. DESCRIPTION A B
1 580056001 Nut .............................................................................................................. .. 2
2 580006335 Mounting Plate ........................................................................................... .. 1
3 580061562 Capscrew ................................................................................................... .. 2
4 520045265 Hose Reel .................................................................................................. .. 1
4 520045333 Kit-Seal .................................................................................................. .. 1
5 052643300 Fitting ......................................................................................................... .. 2
5 052645300 O-Ring ................................................................................................... .. 1
6 505965599 Clamp ......................................................................................................... AR AR
7 580027355 Hose Clamp ............................................................................................... .. 2
8 b. . . . . Hose Assy .................................................................................................. .. 2
9 b. . . . . Hose Assy .................................................................................................. .. 2
10 580020430 Fitting ......................................................................................................... .. 2
10 052645300 O-Ring ................................................................................................... .. 1
10 580063949 O-Ring ................................................................................................... .. 1
11 580069679 Bracket (Optional) ...................................................................................... .. 1
12 580055632 Washer ....................................................................................................... 2 5
13 520045263 Strain Relief ................................................................................................ .. 1
14 580020987 Fitting ......................................................................................................... .. 2
14 580063949 O-Ring ................................................................................................... .. 1
15 520045264 Bracket ....................................................................................................... .. 1
16 580061717 Capscrew ................................................................................................... .. 2
17 580019814 Fitting ......................................................................................................... 4 4
17 052645400 O-Ring ................................................................................................... 1 1
17 580063949 O-Ring ................................................................................................... 1 1
18 580077936 Tube Assy .................................................................................................. 1 1
19 580078962 Tube Assy .................................................................................................. 1 1
20 580039425 Fitting ......................................................................................................... 2 4
21 c 580020430 Fitting ......................................................................................................... .. 2
21 052645300 O-Ring ................................................................................................... 1 1
21 580063949 O-Ring ................................................................................................... 1 1
FOOTNOTES:
a Not Illustrated c With Quick Disconnect Fittings
b Refer to Table
NOTES
FOOTNOTES:
a Three Stage Full Free-Lift b Two Stage Limited Free-Lift
SIDE-SHIFT ASSEMBLY
ITEM PART NO. DESCRIPTION QTY
580084297 Side-Shift Carriage ............................................................................................. 1
1 580084024 Grease Fitting ................................................................................................. 4
2 580084025 Bearing ........................................................................................................... 2
3 580084026 Bracket ........................................................................................................... 1
4 580084032 Cylinder Assy (FP19114 [Page 14-23])......................................................... 1
5 580084027 Fitting .............................................................................................................. 2
5 ..... O-Ring ........................................................................................................ 1
6 580084031 Pin .................................................................................................................. 1
7 580084030 Cotter Pin ....................................................................................................... 2
8 580084039 Thrust Washer (Restrictor) ............................................................................. 1
9 580084036 Bearing (Lower) .............................................................................................. 3
10 580084029 Nut .................................................................................................................. 4
11 580084037 Hook ............................................................................................................... 2
12 580084035 Capscrew ....................................................................................................... 4
13 061278300 Washer ........................................................................................................... 4
14 580084038 Pin .................................................................................................................. 1
15 ..... Faceplate ........................................................................................................ 1
580084040 Kit-Service ...................................................................................................... 1
NOTES
15 OPTIONS
CONTENTS
SECTION 15
OPTIONS
DESCRIPTION PAGE
NOTES
BACK-UP ALARM
ITEM PART NO. DESCRIPTION QTY
1 580045132 Back-Up Alarm (82-102 dbA) .............................................................................. 1
2 580056613 Fastener .............................................................................................................. 1
3 580026812 Clip ...................................................................................................................... 1
4 580044859 Insert ................................................................................................................... 2
5 580039438 Capscrew ............................................................................................................ 2
ACCUMULATOR
ITEM PART NO. DESCRIPTION QTY
1 580081340 Accumulator ........................................................................................................ 1
2 580066235 Clamp ................................................................................................................. 1
3 580081339 Bracket ................................................................................................................ 1
4 203083100 Capscrew ............................................................................................................ 2
5 580080976 Fitting .................................................................................................................. 1
5 052645700 O-Ring ............................................................................................................ 1
5 580029083 O-Ring ............................................................................................................ 1
6 580080267 Hose ................................................................................................................... 1
7 580019899 Fitting .................................................................................................................. 1
7 580029083 O-Ring ............................................................................................................ 2
8 580083669 Clamp ................................................................................................................. 2
FOOTNOTES:
a Not Shown
LIFTING EYE
ITEM PART NO. DESCRIPTION QTY
1 580078642 Eyebolt ................................................................................................................ 1
2 580015437 Anchor ................................................................................................................ 1
3 937300930 Nut ...................................................................................................................... 1
4 015421700 Cotter Pin ............................................................................................................ 1
5 580060025 Nut ...................................................................................................................... 1
NOTES
SECTION 16
FIELD CONVERSION KITS
DESCRIPTION PAGE
FOOTNOTES:
a Used On Mast A613
b Used On mast A613, Attachment 100D-PBS, 140D-PBS
c Used On Mast A613, Attachment 100D-RRB, 120D-RRB
d Used On Mast A613, Attachment 100E-BDS
e Used On Mast A613, Attachment 150D-BDS
f Used On Mast A613, Attachment 150D-BSS
g Used On Mast A613, Attachment 150D-RRB
h Used On mast A614, Attachment 100D-PBS, 140D-PBS
i Used On Mast A614, Attachment 100D-RRB, 120D-RRB
j Used On Mast A614, Attachment 100E-BDS
k Used On Mast A614, Attachment 150D-BDS
l Used On Mast A614, Attachment 150D-BSS
m Used On Mast A614, Attachment 150D-RRB
FOOTNOTES:
a This kit requires software that must be dealer installed. Dealer needs to obtain a new Configuration Data File
(CDF) from Aftermarket Services. The CDF should be ordered from the Software Resources page of AXCESS
Online. See Service Gram LD00018.
FOOTNOTES:
a This kit requires software that must be dealer installed. Dealer needs to obtain a new Configuration Data File
(CDF) from Aftermarket Services. The CDF should be ordered from the Software Resources page of AXCESS
Online. See Service Gram LD00018.
FOOTNOTES:
a This kit requires software that must be dealer installed. Dealer needs to obtain a new Configuration Data File
(CDF) from Aftermarket Services. The CDF should be ordered from the Software Resources page of AXCESS
Online. See Service Gram LD00018.
FOOTNOTES:
a → PENDING PER ECN 10451202
b PENDING PER ECN 10451202 →
c PENDING PER ECN 10498401 →
d PENDING PER ECN 10498402 →
FOOTNOTES:
a This kit requires software that must be dealer installed. Dealer needs to obtain a new Configuration Data File
(CDF) from Aftermarket Services. The CDF should be ordered from the Software Resources page of AXCESS
Online. See Service Gram LD00018.
NOTES
17 NUMERICAL INDEX
NUMERICAL INDEX
SECTION 17
NUMERICAL INDEX
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
SECTION 18
USER SUPPORT INFORMATION
DESCRIPTION PAGE
Your investment in a Yale Industrial Truck is important to you and to your Yale Dealer. You measure the return on
that investment through the performance of these trucks and the drivers who operate and the mechanics who service
them safely and efficiency. The following information is intended to help you to achieve your investments objectives:
SERVICE PARTS ORDERING INSTRUCTIONS operators manual is missing from any Yale Industrial
Truck, it should be replaced. Replacement copies are
HOW TO ORDER SERVICE PARTS available for a nominal fee from your Yale Dealer.
In order to prevent delay, too much communication and OPERATOR TRAINING
to have your orders filled correctly, quickly, and at the
least possible cost, the following is the correct procedure The Yale "Basic Operator Training" program helps
to use to order replacement parts. industrial truck users increase their materials handling
production and safety through correct lift truck operation,
WHEN ORDERING PARTS training, and motivation. The Yale program is based
upon real life experience – not theoretical concepts. We
Contact your authorized Yale Industrial Truck Dealer
developed a "complete" program that is totally self-
giving them the following information:
contained – incorporating the most modern instructional
1. Your Purchase order number. techniques including elements of self-study, audio-visual
support (both video and slides), and classroom study.
2. Complete addresses for sending the invoice and
parts. SERVICE TRAINING COURSE
3. Tell us how you want your parts sent. If we do not Operators and Yale dealer service technicians can
get this information, we will send the parts using the improve their technical ability for maintaining and
lowest priced method. repairing Yale Industrial Trucks, which decreases repair
time and cost, by taking Yale Service Training courses.
4. Correct part number(s) and description(s). Use your Different types of mechanical, electric, and electronic
parts manual as a reference. subjects are available. Courses can be held at customer
or Dealer locations in addition to regularly scheduled
5. Model and serial number of the truck. courses which are held at Yale Corporate Headquarters
in Greenville, NC.
TECHNICAL SERVICE PUBLICATIONS
SERVICE TRAINING MATERIALS
Technical literature, with detailed information, is
available at a nominal fee to assist users to effectively Your own service training can be supported through a
maintain Yale Industrial Trucks in a safe, useful complete line of Yale Service Training materials. An
condition. Part Manuals with complete replacement parts Index is available from your Yale Dealer which lists
identification, Service Maintenance Manuals which textbooks, audio-visual programs and films. These
provide service and overhaul procedures and additional materials will provide your training staff with everything
copies of the Operating Manual can be obtained from necessary for training your group.
your Yale Industrial Truck Dealer.
For additional information or assistance in obtaining
To provide instructions for safely operating and servicing these user support publications and programs, contact:
Yale Industrial Trucks, each truck is equipped with an
operators manual. It describes various operating Yale Materials Handling Corporation
techniques and safety warnings to the operator. It 1400 Sullivan Drive
contains a guide to safe maintenance practices and Caller No. 12011
recommended schedules for maintenance. if the Greenville, NC 27834-2011