Yale GLP050LX, GDP50LX Parts Manual

PARTS MANUAL

GLP050LX, GDP50LX

(A974)

Yale Materials Handling Corporation

1400 Sullivan Drive Caller No. 12011 Greenville, NC 27834-2011

550013968

©Yale Corp.

01/2012

MODEL NOMENCLATURE

NOTE: This parts manual contains alternate pages for certain assemblies. The truck model code can be used to

determine many of the assemblies on your lift truck (power, tire type, mast type). The complete truck model and serial number are stamped into the nameplate. See 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

12 MAST-THREE STAGE FULL FREE-LIFT

13 OPTIONS

14 NUMERICAL INDEX

15 USER SUPPORT INFORMATION

This Parts Manual is divided into 15 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

AIR FILTER ASSEMBLY ................................................................................................................................. 5-4

AIR INTAKE SYSTEM

MAZDA 2.0L ................................................................................................................................................ 5-2

YANMAR 2.6L DIESEL ............................................................................................................................... 5-22

ALTERNATOR AND MOUNTING

YANMAR 2.6L DIESEL ............................................................................................................................... 6-31

ASSEMBLED ENGINE

MAZDA 2.0L, LPG - 2010 EMISSION COMPLIANT ENGINES .................................................................. 2-6

AUDIBLE BACKUP ALARM ............................................................................................................................ 13-3

BATTERY AND CABLES ................................................................................................................................ 6-8

BRAKE ASSEMBLY ........................................................................................................................................ 10-2

BRAKE PEDAL LINKAGE ............................................................................................................................... 10-4

CAMSHAFT AND DRIVE GEAR

YANMAR 2.6L DIESEL ............................................................................................................................... 2-40

CAMSHAFT AND VALVES

MAZDA 2.0L, GASOLINE AND LPG - 2010 EMISSION COMPLIANT ENGINES ...................................... 2-26

CARRIAGE

THREE STAGE FULL FREE-LIFT .............................................................................................................. 12-18

CENTER SECTION ......................................................................................................................................... 8-6

CHARGE PUMP .............................................................................................................................................. 7-18

COOLING SYSTEM

MAZDA 2.0L ................................................................................................................................................ 4-2

YANMAR 2.6L - DIESEL ............................................................................................................................. 4-4

COUNTER/REVERSE CLUTCH

SINGLE SPEED TRANSMISSION .............................................................................................................. 7-24

COUNTERWEIGHT ........................................................................................................................................ 1-6

COWL MOUNT ................................................................................................................................................ 1-10

CRANKSHAFT AND PISTONS

MAZDA 2.0L, LPG - 2010 EMISSION COMPLIANT ENGINES .................................................................. 2-14

YANMAR 2.6L DIESEL ............................................................................................................................... 2-42

CYLINDER BLOCK

MAZDA 2.0L LPG - 2010 EMISSION COMPLIANT ENGINES ................................................................... 2-10

YANMAR 2.6L DIESEL ............................................................................................................................... 2-44

CYLINDER HEAD

YANMAR 2.6L DIESEL ............................................................................................................................... 2-36

CYLINDER HEAD AND COVER

MAZDA 2.0L LPG - 2010 EMISSION COMPLIANT ENGINES ................................................................... 2-8

DISPLAY CLUSTER ........................................................................................................................................ 6-12

DRIVE AXLE ASSEMBLY ............................................................................................................................... 8-2

DRIVE TIRE AND WHEEL .............................................................................................................................. 8-8

A974

GENERAL INFORMATION

TABLE OF CONTENTS (continued)

DESCRIPTION PAGE

ELECTRICAL ARRANGEMENT

MAZDA ........................................................................................................................................................ 6-2

ELECTRONIC PRESSURE REGULATOR ASSEMBLY

MAZDA 2.0L LPG - 2010 EMISSION COMPLIANT ENGINES ................................................................... 5-14

ELECTRONIC PRESSURE REGULATOR KIT

(MAZDA 2.0L LPG) ..................................................................................................................................... 5-16

EMISSION CONTROL SYSTEM

MAZDA 2.0L, LPG - 2010 EMISSION COMPLIANT ENGINES .................................................................. 2-22

ENGINE CONTROL MODULE

MAZDA 2.0L LPG ........................................................................................................................................ 6-6

ENGINE COOLING SYSTEM

MAZDA 2.0L, LPG - 2010 EMISSION COMPLIANT ENGINES .................................................................. 2-20

ENGINE ELECTRICAL COMPONENTS

MAZDA 2.0L, LPG - 2010 EMISSION COMPLIANT ENGINES .................................................................. 6-4

ENGINE ELECTRICAL SYSTEM

YANMAR 2.6L DIESEL ............................................................................................................................... 6-28

ENGINE MOUNTING ...................................................................................................................................... 2-4

EXHAUST MANIFOLD

MAZDA 2.0L, LPG - 2010 EMISSION COMPLIANT ENGINES .................................................................. 2-18

EXHAUST SYSTEM

YANMAR 2.6L DIESEL ............................................................................................................................... 3-6

EXHAUST SYSTEM WITH CATALYTIC CONVERTER

MAZDA 2.0L, LPG ....................................................................................................................................... 3-2

MAZDA 2.0L, LPG - LATIN AMERICAN SERIES ....................................................................................... 3-4

FIRE EXTINGUISHER .................................................................................................................................... 13-4

FLOORPLATES AND COVERS ...................................................................................................................... 1-12

FLYWHEEL AND HOUSING

YANMAR 2.6L DIESEL ............................................................................................................................... 2-30

FLYWHEEL AND HOUSING ASSEMBLY

MAZDA 2.0L ................................................................................................................................................ 2-2

FORKS ............................................................................................................................................................ 1-2

OPTIONAL .................................................................................................................................................. 1-3

FREE LIFT CYLINDER ASSEMBLY

THREE STAGE FULL FREE LIFT .............................................................................................................. 12-16

FUEL FILTER

YANMAR 2.6L DIESEL ............................................................................................................................... 5-24

FUEL INJECTION

YANMAR 2.6L DIESEL ............................................................................................................................... 5-26

FUEL SYSTEM

MAZDA 2.0L LPG - 2010 EMISSION COMPLIANT ENGINES ................................................................... 5-8

YANMAR 2.6L DIESEL ............................................................................................................................... 5-20

FUEL SYSTEM HOSES AND ATTACHING PARTS

MAZDA 2.0L LPG - 2010 EMISSION COMPLIANT ENGINES ................................................................... 5-10

FUEL SYSTEM SENSORS

MAZDA 2.0L LPG - 2010 EMISSION COMPLIANT ENGINES ................................................................... 6-7

A974

GENERAL INFORMATION

TABLE OF CONTENTS (continued)

DESCRIPTION PAGE

FUEL TANK COVERS

LATIN AMERICAN SERIES ........................................................................................................................ 5-5

FULL SUSPENSION SEAT

MANUAL HYDRAULIC - NON-SWIVEL ...................................................................................................... 1-20

SHEET 2 OF 2 ............................................................................................................................................ 1-24

GEAR HOUSING

YANMAR 2.6L DIESEL ............................................................................................................................... 2-32

GEAR PUMP ASSEMBLY ............................................................................................................................... 11-4

HAND LEVERS

2 AND 3 FUNCTION ................................................................................................................................... 11-14

HEADER HOSE AND ATTACHING PARTS

3 FUNCTION ............................................................................................................................................... 12-20

HOOD .............................................................................................................................................................. 1-16

HYDRAULIC CONTROL VALVE

MANUAL - 3 FUNCTION ............................................................................................................................. 11-16

HYDRAULIC FILTER HOUSING ..................................................................................................................... 11-10

HYDRAULIC HOSES

STEERING .................................................................................................................................................. 11-6

HYDRAULIC SUPPLY AND RETURN ............................................................................................................ 11-2

INPUT/FORWARD CLUTCH

SINGLE SPEED TRANSMISSION .............................................................................................................. 7-22

INTAKE AND EXHAUST MANIFOLD

YANMAR 2.6L DIESEL ............................................................................................................................... 2-28

INTAKE MANIFOLD

MAZDA 2.0L, LPG - 2010 EMISSION COMPLIANT ENGINES .................................................................. 2-16

INTEGRAL SIDE-SHIFT CARRIAGE

THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-6

INTEGRAL SIDE-SHIFT CYLINDER .............................................................................................................. 13-10

INTEGRAL SIDE-SHIFT HYDRAULIC HOSES

THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-8

LABELS

SHEET 1 OF 2 ............................................................................................................................................ 1-26

SHEET 2 OF 2 ............................................................................................................................................ 1-28

LIGHTS

STOP, TAIL, TURN, BACKUP, AND STROBE - WITH OVERHEAD GUARD ........................................... 6-10

LOAD BACKREST EXTENSION ..................................................................................................................... 1-4

LPG FUEL TANK AND MOUNTING ............................................................................................................... 5-6

LUBRICATION SYSTEM

YANMAR 2.6L DIESEL ............................................................................................................................... 2-48

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iii

GENERAL INFORMATION

TABLE OF CONTENTS (continued)

DESCRIPTION PAGE

MAIN LIFT CYLINDER ASSEMBLY

THREE STAGE FULL FREE LIFT .............................................................................................................. 12-12

MAST ASSEMBLY

INNER MAST AND FREE-LIFT .................................................................................................................. 12-8

INTERMEDIATE MAST AND MAIN LIFT .................................................................................................... 12-4

OUTER MAST ............................................................................................................................................. 12-2

MIRRORS ........................................................................................................................................................ 13-2

MIXER AND THROTTLE BODY ASSEMBLY

MAZDA 2.0L - 2010 EMISSION COMPLIANT ENGINES ........................................................................... 5-12

NON SUSPENSION SEAT

WITHOUT ELECTRONIC CONTROLS ...................................................................................................... 1-18

OIL PAN

YANMAR 2.6L DIESEL ............................................................................................................................... 2-34

OIL PUMP AND FILTER

MAZDA 2.0L, LPG - 2010 EMISSION COMPLIANT ENGINES .................................................................. 2-24

OVERHEAD GUARD ...................................................................................................................................... 1-8

PARK BRAKE .................................................................................................................................................. 10-6

STATOR SUPPORT HOUSING ...................................................................................................................... 7-20

STEER TIRE AND WHEEL ............................................................................................................................. 9-12

STEERING AXLE AND ATTACHING PARTS ................................................................................................. 9-8

STEERING COLUMN ASSEMBLY ................................................................................................................. 9-4

ISOLATED, DIESEL .................................................................................................................................... 9-6

STEERING CYLINDER ................................................................................................................................... 9-10

STEERING WHEEL AND COLUMN ............................................................................................................... 9-2

THROTTLE CABLE LINKAGE

YANMAR 2.6L DIESEL ............................................................................................................................... 5-28

THROTTLE PEDAL AND ATTACHING PARTS ............................................................................................. 5-18

TILT AND AUXILIARY HOSES ....................................................................................................................... 11-8

TILT CYLINDER AND MAST INSTALLATION ................................................................................................ 11-11

TILT CYLINDER ASSEMBLY .......................................................................................................................... 11-12

TIMING GEAR COVER AND OIL PAN

MAZDA 2.0L, LPG - 2010 EMISSION COMPLIANT ENGINES .................................................................. 2-12

TORQUE CONVERTER .................................................................................................................................. 7-8

TORQUE CONVERTER HOUSING AND ATTACHING PARTS

SINGLE SPEED (→ 2/2011) ...................................................................................................................... 7-10

SINGLE SPEED, ALUMINUM CHAIN DRIVE (2/2011 →) ......................................................................... 7-14

TRANSMISSION COOLING

MAZDA 2.0L LPG ........................................................................................................................................ 7-2

YANMAR DIESEL ....................................................................................................................................... 7-4

A974

GENERAL INFORMATION

TABLE OF CONTENTS (continued)

DESCRIPTION PAGE

TRANSMISSION HOUSING AND ASSEMBLY

SINGLE SPEED (→ 2/2011) ...................................................................................................................... 7-12

SINGLE SPEED, ALUMINUM CHAIN DRIVE (2/2011 →) ......................................................................... 7-16

TRANSMISSION MOUNT

SINGLE SPEED .......................................................................................................................................... 7-6

VALVE ASSEMBLY, AUXILIARY

MANUAL CONTROL VALVE - THREE FUNCTION ................................................................................... 11-20

VALVE ASSEMBLY, LIFT AND TILT

MANUAL CONTROL VALVE - THREE FUNCTION ................................................................................... 11-18

VALVE ASSEMBLY, OUTLET SECTION

MANUAL CONTROL VALVE - THREE FUNCTION ................................................................................... 11-22

WATER PUMP

YANMAR 2.6L DIESEL ............................................................................................................................... 2-46

WIRE HARNESS

MAZDA 2.0L LPG - POWERTRAIN ............................................................................................................ 6-14

RH CHASSIS - SHEET 1 OF 2 (→ S/N A974V01949J) ............................................................................. 6-18

RH CHASSIS - SHEET 2 OF 2 (→ S/N A974V01949J) ............................................................................. 6-20

RH CHASSIS - SHEET 1 OF 2 (S/N A974V01950J →) ............................................................................. 6-22

RH CHASSIS - SHEET 2 OF 2 (S/N A974V01950J →) ............................................................................. 6-24

YANMAR 2.6L DIESEL - POWERTRAIN .................................................................................................... 6-32

YANMAR 2.6L DIESEL - FUSED ALTERNATOR ....................................................................................... 6-36

WIRE HARNESS ADAPTER

LOW FUEL PRESSURE ............................................................................................................................. 6-26

A974

GENERAL INFORMATION

ABBREVIATIONS QUICK REFERENCE SHEET

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

spacer

TERM DEFINITION

Amp Amperes

AR As Required

BDI Battery Discharge Indicators

BWI Brush Wear Indicator

CE Communicator End

CRE Corrosive Environment

D/B Date Break

dbA Decibel "A" Scale

DE Drive End

ECH Empty Container Handler

ECH-3 Empty Container Handler - 3 High

Stacking

ECH-4 Empty Container Handler - 4 High

Stacking

ECH-5 Empty Container Handler - 5 High

Stacking

ECH-6 Empty Container Handler - 6 High

Stacking

ECH-7 Empty Container Handler - 7 High

Stacking

ECM Electronic Control Module

ECN Engineering Change Notice

EEPROM Electrically Erasable Programmable

Read Only Memory

EPA US Environmental Protection Agency

EPROM Electrically Programmable Read Only

Memory

FRE Freezer Environment

in. inches

LPG Liquefied Petroleum Gas

MAP Manifold Absolute Pressure

mm millimeters

MSTS Microprocessor Spark Timing System

NPT National Pipe Threads

O/S Oversize

PTO Power Take Off

RPM Revolutions per Minute

S/N Serial Number

TMM Truck Management Module

UL Type D Diesel-Powered Safety Rating

UL Type DS Diesel-Powered Safety Rating

UL Type E Battery-Powered Safety Rating

UL Type EE Battery-Powered Safety Rating

UL Type ES Battery-Powered Safety Rating

UL Type G Gasoline-Powered Safety Rating

UL Type GS Gasoline-Powered Safety Rating

UL Type LP Gas-Powered Safety Rating

UL Type LPS LP Gas-Powered Safety Rating

U/S Undersize

UL Underwriters Laboratory

V Volts

A974

GENERAL INFORMATION

HOW TO USE THE ILLUSTRATED PARTS MANUAL

This parts manual describes and illustrates assemblies, subassemblies, and detail parts needed for service replacement.

The different constructions are indicated by keys and footnotes. The callouts correspond to descriptions found on the next page.

A974

vii

GENERAL INFORMATION

HOW TO FIND THE DESIRED PART NUMBER

WHEN THE PART NUMBER AND THE NEXT HIGHER ASSEMBLY IS NOT KNOWN:

1. Determine the function and application of the part

required. Turn to the Sections Page. Choose the general area of reference most likely to include the part.

2. Turn to the section you chose. Use the Section

Table of Contents to determine the assembly which would normally contain the part required. Then locate the part on the assembly breakdown page.

WHEN THE PART NUMBER IS NOT KNOWN AND THE NEXT HIGHER ASSEMBLY IS KNOWN:

3. Determine the assembly the required part is used

on. Turn to the Table of Contents (Page i).

4. Locate the assembly the required part is used on

and turn to the page indicated for that assembly. Then locate the part on the assembly breakdown page.

WHEN THE PART NUMBER IS KNOWN:

5. Use the Numerical Index (Page 14-1) to find the

part number. Turn to the page listed and locate the part as indicated by the item number.

GENERAL:

The assembly breakdowns include part numbers, descriptions, quantities required, keys and footnotes to help in selecting correct parts.

6. Parts Supersession Information. Part numbers that

have this history will be displayed in the parts list in the order that they were superseded (from oldest to newest). The superseded part numbers will be shown with a line through them.

Five periods in the PART NO. column (. . . . .)

indicate that the part is either Not Serviced Separately or there is a reference to another figure. A figure reference is denoted by a pointing hand followed by a parts page number in the DESCRIPTION column (F7A56)

7. Keys are used to show two or more similar

assemblies, RH and LH assembly parts, etc. Select the appropriate key, "A", "B", "C", "D", or "E" and the corresponding quantity column to find the required parts. Two periods in the QTY column (..) indicate that the part is not used for that assembly.

8. Indented descriptions under the DESCRIPTION

column are used to indicate assemblies and

subparts of assemblies. In the example on the previous page, BEARING CAP (Item 2) is a subpart of the major assembly CASE.

9. Quantities shown are for one assembly. The quantities of the subpart BEARING CAP are indicated as two and two. This means two per CASE assembly.

10. Serial number breaks identify the most current parts information and are shown as follows:

→ S/N A810N2639

Indicates last serial number affected.

S/N A810N2640 →

Indicates the first serial number affected.

S/N A810N1553 ↔ S/N A810N3291

Indicates a range of serial numbers affected.

ECN numbers for pending serial numbers are shown to allow for the inclusion of the most current parts information and are identified as follows:

→ S/N Pending Per ECN 63243

Indicates a pending serial number for last unit affected.

S/N Pending Per ECN 63243 →

Indicates a pending serial number for first unit affected.

Date breaks are used to indicate when a change occurred but a subsequent serial number break was not recorded. This is an arbitrary date usually based on the ECN release and are identified as follows:

→ D/B 3/00

Indicates that a change occurred sometime within that month for the item affected.

D/B 3/00 →

Indicates that a change occurred sometime within that month for the item affected.

D/B 3/00 ↔ D/B 4/00

Indicates a range of production dates of the item affected.

Contact your local dealer for Yale lift trucks for serial number information for items with a ECN or a date break.

ORDERING PARTS:

When ordering replacement parts, give the unit serial number, part number, name of part and quantity required.

For any further information on parts, service, or ordering, consult your local dealer for Yale lift trucks.

viii

A974

GENERAL INFORMATION

IDENTIFICATION OF TRUCK SERIAL NUMBERS

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.

A974

GENERAL INFORMATION

IDENTIFICATION OF MAST SERIAL NUMBERS

(1) and (2) The first letter and number indicates the mast unit code.

(3) The second letter indicates the plant of manufacture.

(4) The four or five digit number indicates the production sequence number of the mast.

(5) Carriage travel in millimeters stamped just below the serial number.

Mast Group identification consists of mast unit code (1) and (2) plus carriage travel (5).

For pending production sequence numbers contact your local dealer for Yale lift trucks.

LIFT EQUIPMENT IDENTIFICATION

1. Fork part number, capacity rating, plant code letter, and date of manufacture are stamped approximately six inches below the top of most forks.

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

3. The mast identification number has a unit code, a letter indicating the plant of manufacture, and a serial number. Underneath the production sequence number is a four digit number that indicates the carriage travel in millimeters.

4. Tilt and lift cylinder group numbers are stamped on the cylinder shell.

Always refer to the group, serial, or part number when ordering service parts.

Modification of masts and carriages by SPED (Special Products Engineering Department) are identified by a model prefix code beginning with the letter "S". contact your dealer for Yale lift trucks for information on these assemblies.

A974

IDENTIFICATION OF ATTACHMENT AND SIDE-

SHIFT CARRIAGE SERIAL NUMBERS

(1) and (2) The first letter and three numbers indicate the attachment unit code.

(3) The second letter indicates the plant of manufacture.

(4) The four or five digit number indicates the production sequence number.

For pending production sequence numbers contact your local dealer for Yale lift trucks.

GENERAL INFORMATION

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.

A974

GENERAL INFORMATION

PUBLICATIONS

Every new lift truck is provided with an OPERATING MANUAL. This manual has information that the operator must know for inspection and operation of the lift truck.

MANUALS with complete replacement part identification, are available at a nominal fee from your Yale dealer to assist users in effectively maintaining 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

PUBLICATION YALE PART NUMBER

Operating Manual.................................................................................................................... 550013965

Service Manual (Complete)..................................................................................................... 550013971

Parts Manual........................................................................................................................... 550013968

xii

A974

GENERAL INFORMATION

MASTER PART SHEET CROSS-REFERENCE

NOTE: Throughout this manual are references to Part Sheet Numbers. These references are usually found after

the description of a part or assembly. The Part Sheet Number is found on the upper left- or righthand corner of the parts pages.

EXAMPLE:

ITEM PART NO. DESCRIPTION QTY

31 505965530 Steering Cylinder (F6E67 [Figure 4-3]) ..............................................................

32 504224261 Pin........................................................................................................................ 4

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

PART SHEET PAGE

P21394..................................2-40

P21596..................................1-18

P21895..................................1-10

P21896....................................1-6

P21897..................................1-12

P21898....................................1-8

P21899..................................1-16

P21900..................................1-26

P21901..................................1-28

P21902....................................1-4

P21903....................................2-4

P21904....................................3-2

P21905....................................3-4

P21906....................................2-2

P21907....................................2-8

P21908..................................2-10

P21909..................................2-12

P21910..................................2-14

P21911..................................2-16

P21912..................................2-18

P21913..................................2-20

P21914..................................2-22

P21916..................................2-24

P21917....................................2-6

P21918....................................4-2

P21949....................................5-5

P21950....................................5-6

P21951....................................5-2

P21952....................................5-8

P21953..................................5-10

P21954..................................5-12

P21955..................................5-14

P21956..................................5-16

P21957....................................7-8

P21958..................................7-16

P21959..................................7-14

PART SHEET PAGE

P21960..................................7-22

P21961..................................7-24

P21962....................................7-6

P21963....................................7-2

P21976..................................11-2

P21977..................................11-6

P21978..................................11-8

P21979................................11-10

P21980................................11-11

P21981................................11-12

P21982................................11-14

P21983................................11-16

P21984................................11-18

P21985................................11-20

P21986................................11-22

P22004..................................12-2

P22005..................................12-4

P22006..................................12-8

P22007................................12-12

P22008................................12-16

P22009................................12-20

P22010..................................6-10

P22011..................................6-12

P22012....................................6-6

P22013..................................6-18

P22014..................................6-20

P22015..................................6-14

P22028....................................8-2

P22029....................................8-6

P22030....................................8-8

P22031....................................9-8

P22032....................................9-2

P22033....................................9-4

P22034..................................13-2

P22035..................................13-3

P22036..................................13-4

PART SHEET PAGE

P22041..................................5-18

P22042....................................6-2

P22043....................................6-8

P22046..................................7-10

P22050................................12-18

P22051..................................13-6

P22052..................................13-8

P22053................................13-10

P22054..................................10-2

P22055..................................10-4

P22056..................................10-6

P22060..................................9-12

P22063....................................5-4

P22063....................................1-2

P22064....................................1-3

P22064..................................9-10

P22068..................................1-20

P22075..................................6-26

P22082..................................1-24

P22083..................................11-4

P22407..................................7-12

P22408..................................7-18

P22409..................................7-20

P22411....................................6-4

P22412....................................6-7

P22717..................................2-26

P23073..................................5-20

P23189..................................2-28

P23190..................................2-30

P23191..................................2-32

P23192..................................2-34

P23193..................................2-36

P23195..................................2-42

P23196..................................2-44

P23197..................................2-46

P23198..................................2-48

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xiii

GENERAL INFORMATION

PART SHEET PAGE

P23199....................................3-6

P23200....................................4-4

P23201..................................5-22

P23202..................................5-24

P23203..................................5-26

PART SHEET PAGE

P23204..................................5-28

P23205..................................6-28

P23206..................................6-31

P23207..................................6-32

P23208..................................6-36

PART SHEET PAGE

P23209....................................7-4

P23335..................................6-22

P23336..................................6-24

P23485....................................9-6

xiv

A974

SECTION 1

1 GENERAL TRUCK

CONTENTS

SECTION 1

GENERAL TRUCK

DESCRIPTION PAGE

COUNTERWEIGHT ........................................................................................................................................ 1-6

COWL MOUNT ................................................................................................................................................ 1-10

FLOORPLATES AND COVERS ...................................................................................................................... 1-12

FORKS ............................................................................................................................................................ 1-2

OPTIONAL .................................................................................................................................................. 1-3

FULL SUSPENSION SEAT

MANUAL HYDRAULIC - NON-SWIVEL ...................................................................................................... 1-20

SHEET 2 OF 2 ............................................................................................................................................ 1-24

HOOD .............................................................................................................................................................. 1-16

LABELS

SHEET 1 OF 2 ............................................................................................................................................ 1-26

SHEET 2 OF 2 ............................................................................................................................................ 1-28

LOAD BACKREST EXTENSION ..................................................................................................................... 1-4

NON SUSPENSION SEAT

WITHOUT ELECTRONIC CONTROLS ...................................................................................................... 1-18

OVERHEAD GUARD ...................................................................................................................................... 1-8

A974

1-1

P22063 05-10

FORKS (FIGURE 1-1)

ITEM PART NO. DESCRIPTION QTY

1 504111202 Fork (42 in.) ........................................................................................................ 2

1 504111203 Fork (48 in.) ........................................................................................................ 2

2 580034999 Knob ................................................................................................................... 2

3 580035001 Pin ....................................................................................................................... 2

4 580026749 Spring ................................................................................................................. 2

5 580035000 Pin ....................................................................................................................... 2

580035002 Kit-Latch .............................................................................................................. 2

1-2

A974

FORKS (FIGURE 1-2)

OPTIONAL

05-10 P22064

ITEM PART NO. DESCRIPTION QTY

1 524199303 Fork (42 in.) ........................................................................................................ 2

2 580006844 Roll Pin ............................................................................................................... 2

3 580006843 Latch ................................................................................................................... 2

4 580006842 Spring ................................................................................................................. 2

5 580049861 Pin ....................................................................................................................... 2

580049860 Kit-Latch (Class II) .............................................................................................. 1

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P21902 04-10

LOAD BACKREST EXTENSION (FIGURE 1-3)

1-4

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04-10 P21902

LOAD BACKREST EXTENSION

KEY: A: For Use With Standard Carriage Only B: For Use With Integral Side-Shift Carriage Only

QTY

ITEM PART NO. DESCRIPTION A B

1 524310196 Load Backrest (38.5 in.) ............................................................................. 1 ..

1 524310197 Load Backrest (42 in.) ................................................................................ .. 1

2 501749901 Capscrew ................................................................................................... .. 4

2 505960578 Capscrew ................................................................................................... 4 ..

3 504233271 Washer ....................................................................................................... 4 4

4 061278200 Washer ....................................................................................................... 4 4

5 909882405 Nut .............................................................................................................. 4 4

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1-5

P21896 11-09

COUNTERWEIGHT (FIGURE 1-4)

1-6

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11-09 P21896

COUNTERWEIGHT

ITEM PART NO. DESCRIPTION QTY

1 580051185 Seal ..................................................................................................................... 1

2 550005006 Counterweight ..................................................................................................... 1

3 580080171 Tow Pin ............................................................................................................... 1

4 580002019 Washer ............................................................................................................... 1

5 955400911 Washer ............................................................................................................... 1

6 449001406 Capscrew ............................................................................................................ 1

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1-7

P21898 03-10

OVERHEAD GUARD (FIGURE 1-5)

1-8

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03-10 P21898

OVERHEAD GUARD

ITEM PART NO. DESCRIPTION QTY

1 524240422 Overhead Guard ................................................................................................. 1

2 582015340 Capscrew ............................................................................................................ 2

3 580004218

580056528 Nut (Shoulder) .................................................................................................... 2

4 580056526 Handle (Grab) ..................................................................................................... 1

5 580056815 Capscrew ............................................................................................................ 2

6 580044861 Insert ................................................................................................................... 4

7 580090887 Grommet ............................................................................................................. 2

8 524208883 Grommet ............................................................................................................. 1

9 258979300 Plug ..................................................................................................................... 4

10 524240692 Plug ..................................................................................................................... 1

11 580058212 Capscrew ............................................................................................................ 2

12 580041704 Insert ................................................................................................................... 2

13 580063390 Grommet ............................................................................................................. 1

14 500136904 Grommet ............................................................................................................. 1

15 580026812 Clip ...................................................................................................................... 1

16 580056613 Fastener .............................................................................................................. 1

17 580051747 Handle Assembly ................................................................................................ 1

17 580050959 Handle ............................................................................................................ 1

17 580058447 Push Button Switch ........................................................................................ 1

17 580022893 Connector ....................................................................................................... 1

17 505968540 Connector (Secondary Lock) .......................................................................... 1

17 505968514 Terminal (Pin) ................................................................................................. 1

18 580056667 Capscrew ............................................................................................................ 6

18 580051941 Capscrew (Optional) ........................................................................................... 6

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1-9

P21895 03-10

COWL MOUNT (FIGURE 1-6)

ITEM PART NO. DESCRIPTION QTY

1 580056815 Capscrew ............................................................................................................ 2

1 580030966 Capscrew (Optional) ........................................................................................... 2

2 550007449 Cowl .................................................................................................................... 1

3 580074879 Insert ................................................................................................................... 7

3 580055652 Nut (Optional) ..................................................................................................... 7

3 504071785 Washer (Optional) ............................................................................................... 7

4 580064483 Capscrew ............................................................................................................ 7

1-10

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