P.C. MS14-MS16 (C852) - Eng

PARTS MANUAL
MS14 MS16
MS14 MS16
(C852)
Yale Europe Materials Handling Limited 524336822

Flagship House, Reading Road North ©Yale Corp.
Fleet, Hampshire GU13 8HR United Kingdom 10/2009
Telephone; +44 (0) 1252 810 261
Telefax; +44 (0) 1252 770 702
SECTIONS
1 FRAME/DRIVE UNIT
2 ELECTRICAL SYSTEM
3 LOAD WHEEL
4 HYDRAULIC SYSTEM
5 MAST-TWO STAGE FULL FREE-LIFT
6 MAST-THREE STAGE FULL FREE-LIFT
7 OPTIONS
8 NUMERICAL INDEX
9 USER SUPPORT INFORMATION
This Parts Manual is divided into 9 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
B
BATTERY COMPARTMENT
LATERAL BATTERY REMOVAL ................................................................................................................ 1-6
BATTERY ROLLER TRUCK ........................................................................................................................... 7-2
C
COVERS AND ADHESIVE LABELS ............................................................................................................... 1-2
D
DISTRIBUTOR ................................................................................................................................................ 4-2
DRAWBAR CONTROL BOX
PROPORTIONAL SWITCH VERSION ....................................................................................................... 1-18
E
ELECTROMAGNETIC BRAKE ....................................................................................................................... 1-16
ELECTRONIC SYSTEM .................................................................................................................................. 2-2
F
FORK 2 STAGE
FFL .............................................................................................................................................................. 5-8
HI VI ............................................................................................................................................................ 5-10
FORK 3 STAGE
FFL .............................................................................................................................................................. 6-6
H
HYDRAULIC CYLINDER
2 STAGE FFL .............................................................................................................................................. 4-7
2 STAGE HI-VI ............................................................................................................................................ 4-6
3 STAGE ..................................................................................................................................................... 4-8
HYDRAULIC SYSTEM .................................................................................................................................... 4-4
L
LEXAN GUARD
2 STAGE FFL .............................................................................................................................................. 7-6
2 STAGE HI-VI ............................................................................................................................................ 7-4
3 STAGE FFL .............................................................................................................................................. 7-8
LOAD WHEELS ............................................................................................................................................... 3-2
M
MAST 2 STAGE
FFL .............................................................................................................................................................. 5-2
HI VI ............................................................................................................................................................ 5-6
MAST 3 STAGE
FFL .............................................................................................................................................................. 6-2
P
POWER CABLES DIAGRAM .......................................................................................................................... 2-4
S
SUPPORTS AND CASTER WHEELS ............................................................................................................ 1-10
C852 ©2009 Yale Europe Materials Handling Limited i

GENERAL INFORMATION
TABLE OF CONTENTS (continued)
DESCRIPTION PAGE
T
TRACTION MOTOR ........................................................................................................................................ 1-14
TRACTION UNIT ............................................................................................................................................. 1-12
W
WIRE HARNESS DIAGRAM ........................................................................................................................... 2-6
WIRE NET ....................................................................................................................................................... 5-12
ii ©2009 Yale Europe Materials Handling Limited C852

GENERAL INFORMATION
ABBREVIATIONS QUICK REFERENCE SHEET
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
ECH-6 Empty Container Handler - 6 High UL Type EE Battery-Powered Safety Rating

Stacking UL Type ES Battery-Powered Safety Rating
ECH-7 Empty Container Handler - 7 High UL Type G Gasoline-Powered Safety Rating
Stacking UL Type GS Gasoline-Powered Safety Rating
ECM Electronic Control Module UL Type LP Gas-Powered Safety Rating
ECN Engineering Change Notice UL Type LPS LP Gas-Powered Safety Rating
EEPROM Electrically Erasable Programmable U/S Undersize
Read Only Memory
UL Underwriters Laboratory
EPA US Environmental Protection Agency
V Volts
EPROM Electrically Programmable Read Only
Memory
C852 ©2009 Yale Europe Materials Handling Limited iii

GENERAL INFORMATION
HOW TO USE THE ILLUSTRATED PARTS MANUAL
This parts manual describes and illustrates assemblies, The different constructions are indicated by keys and
subassemblies, and detail parts needed for service footnotes. The callouts correspond to descriptions
replacement. found on the next page.
iv ©2009 Yale Europe Materials Handling Limited C852

GENERAL INFORMATION
HOW TO FIND THE DESIRED PART NUMBER

WHEN THE PART NUMBER AND THE NEXT previous page, BEARING CAP (Item 2) is a
HIGHER ASSEMBLY IS NOT KNOWN: subpart of the major assembly CASE.
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 8-1) to find the Date breaks are used to indicate when a change
part number. Turn to the page listed and locate the occurred but a subsequent serial number break
part as indicated by the item number. was not recorded. This is an arbitrary date usually
based on the ECN release and are identified as
GENERAL: follows:
→ D/B 3/00
The assembly breakdowns include part numbers, Indicates that a change occurred sometime
descriptions, quantities required, keys and within that month for the item affected.
footnotes to help in selecting correct parts. D/B 3/00 →
Indicates that a change occurred sometime
6. Five periods in the PART NO. column (. . . . .)
within that month for the item affected.
indicate that the part is either Not Serviced
D/B 3/00 ↔ D/B 4/00
Separately or there is a reference to another figure.
Indicates a range of production dates of the item
A figure reference is denoted by a pointing hand
affected.
followed by a page number in the DESCRIPTION
column (FPage 3-4) Contact your local dealer for Yale lift trucks for
serial number information for items with a ECN or
7. Keys are used to show two or more similar
a date break.
assemblies, RH and LH assembly parts, etc.
Select the appropriate key, "A", "B", "C", "D", or "E" ORDERING PARTS:
and the corresponding quantity column to find the
required parts. Two periods in the QTY column (..) When ordering replacement parts, give the unit serial
indicate that the part is not used for that assembly. number, part number, name of part and quantity
required.
8. Indented descriptions under the DESCRIPTION
column are used to indicate assemblies and For any further information on parts, service, or
subparts of assemblies. In the example on the ordering, consult your local dealer for Yale lift trucks.
C852 ©2009 Yale Europe Materials Handling Limited v

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.
vi ©2009 Yale Europe Materials Handling Limited C852

GENERAL INFORMATION
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
PUBLICATION YALE PART NUMBER
Operating Manual.................................................................................................................... 524301672
Service Manual (Complete)..................................................................................................... 524301698
Parts Manual........................................................................................................................... 524336822
C852 ©2009 Yale Europe Materials Handling Limited vii

GENERAL INFORMATION
NOTES
viii ©2009 Yale Europe Materials Handling Limited C852

SECTION 1
1 FRAME/DRIVE UNIT
CONTENTS
SECTION 1
FRAME/DRIVE UNIT
DESCRIPTION PAGE
BATTERY COMPARTMENT
LATERAL BATTERY REMOVAL ................................................................................................................ 1-6
COVERS AND ADHESIVE LABELS ............................................................................................................... 1-2
DRAWBAR CONTROL BOX
PROPORTIONAL SWITCH VERSION ....................................................................................................... 1-18
ELECTROMAGNETIC BRAKE ....................................................................................................................... 1-16
SUPPORTS AND CASTER WHEELS ............................................................................................................ 1-10
TRACTION MOTOR ........................................................................................................................................ 1-14
TRACTION UNIT ............................................................................................................................................. 1-12
C852 ©2009 Yale Europe Materials Handling Limited 1-1

FRAME/DRIVE UNIT
COVERS AND ADHESIVE LABELS (FIGURE 1-1)
1-2 ©2009 Yale Europe Materials Handling Limited C852

FRAME/DRIVE UNIT

FRAME/DRIVE UNIT
COVERS AND ADHESIVE LABELS

ITEM PART NO. DESCRIPTION QTY
1 272303000 Label ................................................................................................................... 2
2 272213500 Label (Lifting Hook) ............................................................................................. 1
3 524139322 Label (Yale) ........................................................................................................ 1
4 272328700 Screw .................................................................................................................. 6
5 272213200 Label ................................................................................................................... 1
6 150802070 Label (Hyster) ..................................................................................................... 2
7 580013324 Cover .................................................................................................................. 1
7 580013325 Cover .................................................................................................................. 1
8 449007018 Screw .................................................................................................................. 4
9 524141524 Cover .................................................................................................................. 1
10 580013326 Cover .................................................................................................................. 1
11 524327019 Cover .................................................................................................................. 1
12 524141523 Cover .................................................................................................................. 1
13 580093734 Clip ...................................................................................................................... 4
14 580012968 Label (LH Switch Functions) ............................................................................... 1
15 580012967 Label (RH Switch Functions) .............................................................................. 1
16 277458400 Cushion ............................................................................................................... 2
17 580012959 Spacer ................................................................................................................ 2
18 580014880 Label (Snowflake) ............................................................................................... 1
19 524216189 Label (Warranty) English .................................................................................... 1
19 524216191 Label Brazilian .................................................................................................... 1
19 524216192 Label Czech ........................................................................................................ 1
19 524216193 Label Danish ....................................................................................................... 1
19 524216194 Label Dutch ......................................................................................................... 1
19 524216195 Label Estonian .................................................................................................... 1
19 524216196 Label Finnish ...................................................................................................... 1
19 524216197 Label (Warranty) French ..................................................................................... 1
19 524216198 Label (Warranty) German ................................................................................... 1
19 524216199 Label Greek ........................................................................................................ 1
19 524216200 Label Hungarian ................................................................................................. 1
19 524216201 Label Icelandic .................................................................................................... 1
19 524216202 Label (Warranty) Italian ...................................................................................... 1
19 524216203 Label Latvian ...................................................................................................... 1
19 524216204 Label Lithuanian ................................................................................................. 1
19 524216205 Label Norwegian ................................................................................................. 1
19 524216206 Label Polish ........................................................................................................ 1
19 524216207 Label Portuguese ................................................................................................ 1
19 524216208 Label Romanian .................................................................................................. 1
19 524216209 Label Russian ..................................................................................................... 1
19 524216210 Label Slovakian .................................................................................................. 1
19 524216190 Label Slovenian .................................................................................................. 1
19 524216211 Label (Warranty) Spanish ................................................................................... 1
19 524216212 Label Swedish .................................................................................................... 1
19 524216526 Label Turkish ...................................................................................................... 1
19 524216766 Label Croatian .................................................................................................... 1
20 580053923 Instruction Label ................................................................................................. 1
21 524242350 Label ................................................................................................................... 2

FRAME/DRIVE UNIT
NOTES

FRAME/DRIVE UNIT
BATTERY COMPARTMENT (FIGURE 1-2)

LATERAL BATTERY REMOVAL

FRAME/DRIVE UNIT

FRAME/DRIVE UNIT
BATTERY COMPARTMENT
LATERAL BATTERY REMOVAL

1 272458700 Capscrew ............................................................................................................ 1
2 449021001 Washer ............................................................................................................... 2
3 524139713 Frame ................................................................................................................. 3
4 580014526 Extension Spring ................................................................................................. 1
5 449015098 Nut ...................................................................................................................... 3
6 272470200 Bumper ............................................................................................................... 1
7 015918400 Snap Ring ........................................................................................................... 6
8 272387700 Bearing ............................................................................................................... 6
9 272387100 Tube Assy ........................................................................................................... 3
10 272409600 Rod ..................................................................................................................... 3
11 272471100 Key ...................................................................................................................... 1
12 580014631 Frame ................................................................................................................. 1
13 272470200 Bumper ............................................................................................................... 1
14 580013298 Shock Absorber .................................................................................................. 2
15 580029307 Trim-Bulk (M) ...................................................................................................... 1

FRAME/DRIVE UNIT
NOTES

FRAME/DRIVE UNIT
SUPPORTS AND CASTER WHEELS (FIGURE 1-3)

FRAME/DRIVE UNIT
SUPPORTS AND CASTER WHEELS

1 580092328 Caster Wheel ...................................................................................................... 1
2 580013314 Screw .................................................................................................................. 2
3 580013312 Spacer ................................................................................................................ 1
4 580092729 Swivel Fork ......................................................................................................... 1
5 580092728 Wheel .................................................................................................................. 1
6 015120100 Ball Bearing ........................................................................................................ 2
7 580092727 Axle Shaft ........................................................................................................... 1
8 524148554 Locknut ............................................................................................................... 1
9 931015914 Capscrew ............................................................................................................ 1
10 580037730 Bushing ............................................................................................................... 2

FRAME/DRIVE UNIT
TRACTION UNIT (FIGURE 1-4)

FRAME/DRIVE UNIT
TRACTION UNIT
1 449001058 Capscrew ............................................................................................................ 5
2 449021010 Washer ............................................................................................................... 5
3 580013479 Drive Wheel 95Sh ............................................................................................... 1
3 580022041 Drive Wheel 70Sh Rubber .................................................................................. 1
3 580013477 Drive Wheel 72Sh No marking Cold Storage ..................................................... 1
3 580013478 Drive Wheel 72Sh Gripped Cold Storage ........................................................... 1
4 580014438 Seal ................................................................................................................ 1
5 501989923 Snap Ring ....................................................................................................... 1
6 501989907 Snap Ring ....................................................................................................... 1
7 580014439 Shim ............................................................................................................... 1
8 580014440 Shim ............................................................................................................... 1
9 580014441 Bearing ........................................................................................................... 2
10 580014457 Kit-Gear .......................................................................................................... 1
11 580041309 Transmission Housing .................................................................................... 1
12 272393000 Key ................................................................................................................. 1
13 273129300 Key ................................................................................................................. 2
14 272019300 Bearing ........................................................................................................... 2
15 272006900 Shim ............................................................................................................... 1
16 272040800 Spacer ............................................................................................................ 1
17 580041302 Gear ............................................................................................................... 1
18 272386700 Nut .................................................................................................................. 1
19 272090800 Screw ............................................................................................................. 2
20 580014446 Bearing ........................................................................................................... 1
21 900005220 Capscrew ....................................................................................................... 6
22 272053000 Screw .................................................................................................................. 3
23 580023467 Capscrew ............................................................................................................ 3
24 580040114 Transmission Assy .............................................................................................. 1
25 580014447 Drain Plug ....................................................................................................... 3
26 580014448 Fitting .............................................................................................................. 2
27 272013700 Gasket ............................................................................................................ 1
28 580041303 Gear ............................................................................................................... 1
29 449015014 Nut .................................................................................................................. 1
30 502566901 Washer ........................................................................................................... 1

FRAME/DRIVE UNIT
TRACTION MOTOR (FIGURE 1-5)

FRAME/DRIVE UNIT
TRACTION MOTOR
1 580090778 Electric Motor ...................................................................................................... 1
2 580094593 Terminal ......................................................................................................... 1
3 580094595 End Cover ...................................................................................................... 1
4 580014499 Bearing ........................................................................................................... 2
5 580070960 Washer ........................................................................................................... 1
6 580094601 Ring ................................................................................................................ 1
7 580094599 Wheel ............................................................................................................. 1
8 580094597 Support Plate .................................................................................................. 1
9 580094598 Spacer ............................................................................................................ 1
10 580094596 Sensor ............................................................................................................ 1
11 580094623 Oil Seal ........................................................................................................... 1
12 015915100 Snap Ring ....................................................................................................... 1
13 640046901 Snap Ring ....................................................................................................... 1
14 580094594 End Cover ...................................................................................................... 1
15 580094592 Stator .............................................................................................................. 1
16 580094600 Rotor ............................................................................................................... 1
17 901083873 Stud ................................................................................................................ 6
18 504057745 Disk ................................................................................................................ 3

FRAME/DRIVE UNIT
ELECTROMAGNETIC BRAKE (FIGURE 1-6)

FRAME/DRIVE UNIT
ELECTROMAGNETIC BRAKE
1 580081696 Brake Assy .......................................................................................................... 1
2 580011872 Capscrew ....................................................................................................... 3
3 580081695 Coil ................................................................................................................. 1
4 580035385 Coil (Hub) ....................................................................................................... 1
5 272034900 Disk ................................................................................................................ 1
6 580077043 Disk ................................................................................................................ 1
7 524148447 Band ............................................................................................................... 1
8 524213453 Dust Cap ............................................................................................................. 1

FRAME/DRIVE UNIT
DRAWBAR CONTROL BOX (FIGURE 1-7)

PROPORTIONAL SWITCH VERSION

FRAME/DRIVE UNIT
DRAWBAR CONTROL BOX

PROPORTIONAL SWITCH VERSION

1 524139010 Cover (Snail Cover) ............................................................................................ 1
2 580011989 Tiller Head (Lower) ............................................................................................. 1
3 932200907 Capscrew ............................................................................................................ 3
4 524138799 Steering .............................................................................................................. 1
5 580013298 Shock Absorber .................................................................................................. 2
6 580013129 Casting ................................................................................................................ 1
7 272106000 Screw .................................................................................................................. 1
8 580035765 Shock Absorber .................................................................................................. 1
9 272087200 Pin ....................................................................................................................... 1
10 272027800 Pin ....................................................................................................................... 2
11 272006400 Washer ............................................................................................................... 2
12 272015100 Bushing ............................................................................................................... 2
13 580013974 Sensor ................................................................................................................ 1
14 272330200 Support ............................................................................................................... 1
15 272466100 Screw .................................................................................................................. 2
16 580013482 Screw .................................................................................................................. 4
17 580026296 Capscrew ....................................................................................................... 2
18 524236628 Switch (LH) ..................................................................................................... 1
19 580012962 Bushing .......................................................................................................... 2
20 580012970 Spring gray color ............................................................................................ 1
21 524139006 Tiller (Upper) .................................................................................................. 1
22 580026824 Microswitch ..................................................................................................... 2
23 524139319 Switch Assembly ............................................................................................ 2
24 580012969 Spring ............................................................................................................. 1
25 524139009 Cover (Horn) ................................................................................................... 1
26 524148522 Switch (3-Wires) ............................................................................................. 2
27 524236627 Switch (RH) .................................................................................................... 1
28 580011991 Cover (Belly Switch) ....................................................................................... 1
29 580094457 Control Card ................................................................................................... 1
30 580013106 Camshaft ........................................................................................................ 1
31 272076200 Plug ..................................................................................................................... 1
32 940004902 Washer ........................................................................................................... 2
33 449001013 Capscrew ............................................................................................................ 2
34 449022016 Lockwasher ......................................................................................................... 2
35 449021001 Washer ............................................................................................................... 2
36 580038175 Spring ............................................................................................................. 1
37 524330473 Tiller Head .......................................................................................................... 1
38 524330466 Tiller Head .......................................................................................................... 1
39 580055434 Cover .......................................................................................................... 2
40 524149804 Button (On/Off Push Button) ...................................................................... 2
41 580055435 Cover .......................................................................................................... 2
42 580060389 Spring copper color ........................................................................................ 1

FRAME/DRIVE UNIT
NOTES

SECTION 2
2 ELECTRICAL SYSTEM
CONTENTS
SECTION 2
ELECTRICAL SYSTEM
DESCRIPTION PAGE
ELECTRONIC SYSTEM .................................................................................................................................. 2-2

POWER CABLES DIAGRAM .......................................................................................................................... 2-4
WIRE HARNESS DIAGRAM ........................................................................................................................... 2-6

ELECTRICAL SYSTEM
ELECTRONIC SYSTEM (FIGURE 2-1)

ELECTRICAL SYSTEM
ELECTRONIC SYSTEM
1 273004100 Bdi And Hourmeter ............................................................................................. 1
1 580096839 Display optional .................................................................................................. 1
2 580094362 Ignition Switch ..................................................................................................... 1
3 524327019 Cover .................................................................................................................. 1
4 580014086 Adhesive ............................................................................................................. 1
5 449021002 Washer ............................................................................................................... 7
6 520038883 Screw .................................................................................................................. 2
7 580092138 Switch ................................................................................................................. 1
8 449001412 Capscrew ............................................................................................................ 1
9 449021003 Washer ............................................................................................................... 10
10 449015135 Nut ...................................................................................................................... 7
11 580091806 Horn .................................................................................................................... 1
12 580093629 Controller ............................................................................................................ 1
13 580001407 Clamp ................................................................................................................. 2
14 505972555 Fuse (10 Amp) .................................................................................................... 4
15 506395532 Capscrew ............................................................................................................ 2
16 580063867 Support ............................................................................................................... 1
17 449015112 Locknut ............................................................................................................... 2
18 580013298 Shock Absorber .................................................................................................. 2
19 580094789 Support ............................................................................................................... 1
20 580077549 Fuse (300 Amp) .................................................................................................. 1
21 449015014 Nut ...................................................................................................................... 4
22 449021001 Washer ............................................................................................................... 6
23 505975518 Capscrew ............................................................................................................ 2
24 580060500 Isolator ................................................................................................................ 1
25 580060506 Isolator ................................................................................................................ 1
26 580093734 Clip ...................................................................................................................... 2

ELECTRICAL SYSTEM
POWER CABLES DIAGRAM (FIGURE 2-2)

ELECTRICAL SYSTEM
POWER CABLES DIAGRAM

1 580039028 Battery Connector ............................................................................................... 1
2 580039025 Battery Connector Housing ................................................................................. 1
3 580039027 Battery Cable ...................................................................................................... 1
4 580039026 Battery Cable ...................................................................................................... 1
5 580039032 Cable Assy .......................................................................................................... 1
6 580039029 Battery Connector Housing ................................................................................. 1
7 580039031 Battery Cable ...................................................................................................... 1
8 580039030 Battery Cable ...................................................................................................... 1
9 580092138 Switch ................................................................................................................. 1
10 580013300 Battery Charger .................................................................................................. 1
11 580077549 Fuse (300 Amp) .................................................................................................. 1
12 580093316 Power Cable ....................................................................................................... 1
13 580093317 Power Cable ....................................................................................................... 1
14 580093318 Power Cable ....................................................................................................... 1
15 580093320 Power Cable ....................................................................................................... 1
16 580093319 Power Cable ....................................................................................................... 1
17 580093537 Power Cable ....................................................................................................... 1
18 580093321 Power Cable ....................................................................................................... 1

ELECTRICAL SYSTEM
WIRE HARNESS DIAGRAM (FIGURE 2-3)

ELECTRICAL SYSTEM
WIRE HARNESS DIAGRAM

1 580093629 Controller ............................................................................................................ 1
2 580095362 Control Panel ...................................................................................................... 1
3 580092138 Switch ................................................................................................................. 1
4 580014683 Holder ................................................................................................................. 1
5 273004100 Bdi And Hourmeter ............................................................................................. 1
6 580091806 Horn .................................................................................................................... 1
7 580035055 Wire Harness ...................................................................................................... 1
8 580086084 Wire Harness ...................................................................................................... 1
9 580093385 Wire Harness ...................................................................................................... 1
10 505972555 Fuse (10 Amp) .................................................................................................... 4
11 580013300 Battery Charger .................................................................................................. 1
12 580091804 Relay ................................................................................................................... 1
13 580096848 Wire Harness optional ........................................................................................ 1
14 580096839 Display optional .................................................................................................. 1
15 580093654 Wire Harness ...................................................................................................... 1

ELECTRICAL SYSTEM
NOTES

SECTION 3
3 LOAD WHEEL
CONTENTS
SECTION 3
LOAD WHEEL
DESCRIPTION PAGE
LOAD WHEELS ............................................................................................................................................... 3-2

Load Wheel
LOAD WHEELS (FIGURE 3-1)

Load Wheel
LOAD WHEELS
1 580038707 Roller .................................................................................................................. 2
2 580037615 Roller .............................................................................................................. 2
3 580037672 Seal ................................................................................................................ 2
4 580038711 Roller .............................................................................................................. 1
5 015120400 Ball Bearing .................................................................................................... 2
6 580038710 Roller .............................................................................................................. 1
7 449034082 Roll Pin ........................................................................................................... 6
8 580013309 Pin ....................................................................................................................... 2
9 272008800 Grease Fitting ..................................................................................................... 2
10 580013311 Rocker Arm ......................................................................................................... 2
11 272006400 Washer ............................................................................................................... 8
12 580037625 Roller .............................................................................................................. 1
13 580038708 Roller .............................................................................................................. 1
14 580038706 Roller .................................................................................................................. 4
15 277548400 Plate .................................................................................................................... 2
16 277548500 Pin ....................................................................................................................... 4
17 273127500 Bushing ............................................................................................................... 4
18 273033400 Fitting .................................................................................................................. 4
19 580001470 Capscrew ............................................................................................................ 4
20 580037612 Roller .................................................................................................................. 4
21 277548300 Plate .................................................................................................................... 2
22 580038709 Roller .................................................................................................................. 2
23 272078800 Pin ....................................................................................................................... 4
24 449034030 Roll Pin ............................................................................................................... 2
25 580037624 Roller .................................................................................................................. 1

Load Wheel
NOTES

SECTION 4
4 HYDRAULIC SYSTEM
CONTENTS
SECTION 4
HYDRAULIC SYSTEM
DESCRIPTION PAGE
DISTRIBUTOR ................................................................................................................................................ 4-2

HYDRAULIC CYLINDER
2 STAGE FFL .............................................................................................................................................. 4-7
2 STAGE HI-VI ............................................................................................................................................ 4-6
3 STAGE ..................................................................................................................................................... 4-8
HYDRAULIC SYSTEM .................................................................................................................................... 4-4

HYDRAULIC SYSTEM
DISTRIBUTOR (FIGURE 4-1)

HYDRAULIC SYSTEM
DISTRIBUTOR
1 580014492 Pump And Motor ............................................................................................ 1
2 580014491 Brush .............................................................................................................. 4
3 272013200 Damper ............................................................................................................... 2
4 449021006 Washer ............................................................................................................... 2
5 449001023 Capscrew ............................................................................................................ 2
6 580014479 Distributor ....................................................................................................... 1
7 580014480 Relief Valve .................................................................................................... 2
8 518818830 Strainer ........................................................................................................... 1
9 580014482 Reservoir ........................................................................................................ 1
10 580027871 Tube Assy ...................................................................................................... 1
11 580027872 Hyd Oil Fill Cap .............................................................................................. 1
12 580014481 Pump .............................................................................................................. 1
13 580062569 Flow Valve ...................................................................................................... 1
14 580014489 Valve .............................................................................................................. 1
15 518818806 Valve .............................................................................................................. 1
16 580023828 Coupling ......................................................................................................... 1
17 580014493 Pump And Motor ................................................................................................. 1
18 580013988 Wire Harness ...................................................................................................... 1
19 580013474 Support ............................................................................................................... 1

HYDRAULIC SYSTEM
HYDRAULIC SYSTEM (FIGURE 4-2)

HYDRAULIC SYSTEM
HYDRAULIC SYSTEM
KEY:
A: 2 STG Hi Vi
B: 2 STG FFL
C: 3 STG FFL
QTY
ITEM PART NO. DESCRIPTION A B C
1 277263400 Fitting ................................................................................................. 2 2 3
2 277263200 Fitting ................................................................................................. 2 2 1
3 580013476 Hydraulic Tube .................................................................................. 1 1 1
4 580013345 Tube Assy ......................................................................................... 1 1 1
5 013405200 Fitting ................................................................................................. .. .. 1
6 580014635 Hydraulic Tube .................................................................................. .. .. 1
7 019899100 Fitting ................................................................................................. .. .. 2
8 580014636 Hydraulic Hose Asm h=4025mm ....................................................... .. .. 1
8 580014638 Hydraulic Hose Asm h=4325mm ....................................................... .. .. 1
8 a 580014637 Hydraulic Hose Asm h=4625mm ....................................................... .. .. 1
8 a 580018418 Hose Assy h=5395mm ...................................................................... .. .. 1
9 056731900 Sleeve ............................................................................................... .. .. 1
10 504071729 Fitting ................................................................................................. .. .. 1
11 580014632 Hydraulic Tube h=4025mm ............................................................... .. .. 1
11 580014633 Hydraulic Tube h=4325mm ............................................................... .. .. 1
11 a 580014634 Hydraulic Tube h=4625mm ............................................................... .. .. 1
11 a 580018432 Tube h=5395mm ............................................................................... .. .. 1
12 580026864 Seal ................................................................................................... .. 2 ..
13 277038600 Hose Failure Valve Body ................................................................... .. 2 ..
14 580026783 Hyd Pipe Ftg ...................................................................................... .. 2 ..
15 277406300 Fitting ................................................................................................. .. 2 ..
16 580026885 Tube Assy ......................................................................................... .. 1 ..
17 580026887 Tube Assy h=2603mm ...................................................................... .. 1 ..
17 580026888 Tube Assy h=2803mm ...................................................................... .. 1 ..
17 580026889 Tube Assy h=3003mm ...................................................................... .. 1 ..
17 580026890 Tube Assy h=3203mm ...................................................................... .. 1 ..
17 580026891 Tube Assy h=3403mm ...................................................................... .. 1 ..
17 580026892 Tube Assy h=3603mm ...................................................................... .. 1 ..
17 580026893 Tube Assy h=4003mm ...................................................................... .. 1 ..
FOOTNOTES:
a only for 1,6ton

HYDRAULIC SYSTEM
HYDRAULIC CYLINDER (FIGURE 4-3)

2 STAGE HI-VI

1 580015734 Cylinder Assy h=2830mm ................................................................................... 2
2 580016918 Kit-Seal ............................................................................................................... 1
3 580015507 Flow Valve .......................................................................................................... 2

HYDRAULIC SYSTEM

2 STAGE FFL

2 580026908 Kit-Seal ............................................................................................................... 2
4 580016919 Kit-Seal ............................................................................................................... 1
5 580015508 Flow Valve .......................................................................................................... 1
6 580015507 Flow Valve .......................................................................................................... 2

HYDRAULIC SYSTEM

3 STAGE

HYDRAULIC SYSTEM
HYDRAULIC CYLINDER
3 STAGE

1 a 580015736 Cylinder Assy h=4625mm ................................................................................... 2
2 580016918 Kit-Seal ............................................................................................................... 2
3 580016919 Kit-Seal ............................................................................................................... 1
5 580015508 Flow Valve .......................................................................................................... 1
6 580015507 Flow Valve .......................................................................................................... 2
FOOTNOTES:
a only for 1,6ton

HYDRAULIC SYSTEM
NOTES

SECTION 5
5 MAST-TWO STAGE FULL FREE-LIFT

CONTENTS
SECTION 5
MAST-TWO STAGE FULL FREE-LIFT
DESCRIPTION PAGE
FORK 2 STAGE
FFL .............................................................................................................................................................. 5-8
HI VI ............................................................................................................................................................ 5-10
MAST 2 STAGE
FFL .............................................................................................................................................................. 5-2
HI VI ............................................................................................................................................................ 5-6
WIRE NET ....................................................................................................................................................... 5-12

Mast-Two Stage Full Free-Lift
MAST 2 STAGE (FIGURE 5-1)

FFL


MAST 2 STAGE
FFL

1 580012895 Bracket (LH) ........................................................................................................ 1
2 504234265 Shim (0.508 mm) ................................................................................................ 100
3 012824300 O-Ring ................................................................................................................ 2
4 504075764 Wear Strip ........................................................................................................... 2
5 580014669 Screw .................................................................................................................. 2
6 272328600 Damper ............................................................................................................... 2
7 449021003 Washer ............................................................................................................... 2
8 449015135 Nut ...................................................................................................................... 2
9 580012894 Bracket (RH) ....................................................................................................... 1
10 449021003 Washer ............................................................................................................... 6
11 272328700 Screw .................................................................................................................. 8
12 500227904 Snap Ring ........................................................................................................... 3
13 449021042 Washer ............................................................................................................... 6
14 272010200 Seal ..................................................................................................................... 2
15 272465500 Rubber Pad ......................................................................................................... 2
16 580012892 Brace .................................................................................................................. 2
17 580012890 Bracket ................................................................................................................ 1
18 449021001 Washer ............................................................................................................... 2
19 449001013 Capscrew ............................................................................................................ 2
20 580012891 Sheave ................................................................................................................ 1
21 580012889 Bracket ................................................................................................................ 1
22 273066000 Pulley .................................................................................................................. 2
23 272065300 Washer ............................................................................................................... 5
24 015915900 Snap Ring ........................................................................................................... 2
25 580014108 Leaf Chain - Fixed Length h=2603mm ............................................................... 2
26 449025027 Cotter Pin ............................................................................................................ 8
27 272101200 Pin ....................................................................................................................... 4
28 272101300 Anchor ................................................................................................................ 4
29 449015107 Locknut ............................................................................................................... 4
30 504233232 Shim (0.508 mm) ................................................................................................ 100
31 518797634 Load Roller ......................................................................................................... 8
32 015916300 Snap Ring ........................................................................................................... 8
33 580015115 Snap Ring ........................................................................................................... 3
34 580014670 Pin ....................................................................................................................... 3
35 580040491 Capscrew ............................................................................................................ 2
36 449021019 Washer ............................................................................................................... 2

NOTES


HI VI

MAST 2 STAGE
HI VI

1 580012914 Pin ....................................................................................................................... 2
2 273066000 Pulley .................................................................................................................. 2
3 272065300 Washer ............................................................................................................... 2
4 449025027 Cotter Pin ............................................................................................................ 10
5 272101200 Pin ....................................................................................................................... 4
6 272101300 Anchor ................................................................................................................ 2
7 449015107 Locknut ............................................................................................................... 2
8 580014113 Chain h=2830mm ............................................................................................... 2
8 580014114 Chain h=3030mm ............................................................................................... 2
8 580014115 Chain h=3230mm ............................................................................................... 2
9 500227904 Snap Ring ........................................................................................................... 2
10 449021042 Washer ............................................................................................................... 2
11 580024912 Seal ..................................................................................................................... 2
12 580012892 Brace .................................................................................................................. 2
13 272465600 Wear Plate (3,05 mm) ......................................................................................... 100
13 272014200 Wear Plate (4,06 mm) ......................................................................................... 100
13 272014400 Wear Plate (5,08 mm) ......................................................................................... 100
13 272014500 Wear Plate (5,334 mm) ....................................................................................... 100
14 504235265 Capscrew ............................................................................................................ 8
15 580012896 Load Roller (Inner Mast) Ø70,1mm .................................................................... 6
15 580012912 Load Roller (Carriage) ø70,5mm ........................................................................ 6
16 015915600 Snap Ring ........................................................................................................... 6
17 272328600 Damper ............................................................................................................... 2
18 580012894 Bracket (RH) ....................................................................................................... 1
19 580012895 Bracket (LH) ........................................................................................................ 1
20 449022041 Lockwasher ......................................................................................................... 2
21 311323023 Capscrew ............................................................................................................ 2
22 015425100 Cotter Pin ............................................................................................................ 2
23 449022018 Washer ............................................................................................................... 6
24 272328700 Screw .................................................................................................................. 6
25 580014669 Screw .................................................................................................................. 2
26 449021003 Washer ............................................................................................................... 100
27 449015135 Nut ...................................................................................................................... 2
28 580014670 Pin ....................................................................................................................... 2
29 580015115 Snap Ring ........................................................................................................... 2
30 580026201 Label ................................................................................................................... 1

FORK 2 STAGE (FIGURE 5-3)

FFL

FORK 2 STAGE
FFL

1 580065150 Load Backrest ..................................................................................................... 1
2 580061459 HCE 1002 Cpscr ................................................................................................. 4
3 580013371 Nut ...................................................................................................................... 4
4 449021010 Washer ............................................................................................................... 8
5 524138883 Carriage 570x65 L=1160mm .............................................................................. 1
5 524138887 Carriage 570x55 L=1160mm .............................................................................. 1
5 524138891 Carriage 570x65 L=980 ...................................................................................... 1
6 015916300 Snap Ring ........................................................................................................... 6
7 518797634 Load Roller ......................................................................................................... 6
8 504233232 Shim (0.508 mm) ................................................................................................ 100


HI VI

FORK 2 STAGE
HI VI

1 580065150 Load Backrest ..................................................................................................... 1
2 580061459 HCE 1002 Cpscr ................................................................................................. 4
3 580013371 Nut ...................................................................................................................... 4
4 449021010 Washer ............................................................................................................... 8
5 524138882 Carriage 570x65 L=1160mm .............................................................................. 1
5 524138886 Carriage 570x55 L=1160mm .............................................................................. 1
5 524138890 Carriage 570x65 L=980 ...................................................................................... 1
6 504235265 Capscrew ............................................................................................................ 8
7 580012908 Shim (3 mm) ....................................................................................................... 2
7 580012909 Shim (4 mm) ....................................................................................................... 2
7 580012910 Shim (5 mm) ....................................................................................................... 2
7 580012911 Shim (6 mm) ....................................................................................................... 2
8 015915600 Snap Ring ........................................................................................................... 6
9 580012896 Load Roller (Inner Mast) Ø70,1mm .................................................................... 6
9 580012912 Load Roller (Carriage) Ø70,5mm ....................................................................... 6
10 449022013 Lockwasher ......................................................................................................... 2

WIRE NET (FIGURE 5-5)

WIRE NET
1 580012898 Guard h3=1275mm ............................................................................................. 1
1 580093424 Guard h3=1375mm ............................................................................................. 1
1 580012900 Guard h3=1475-1575-1775mm .......................................................................... 1
1 580012913 Guard h3=2830mm ............................................................................................. 1
1 580012897 Guard h3=3030mm ............................................................................................. 1
1 580012898 Guard h3=3230mm ............................................................................................. 1
1 580093424 Guard h3=3430mm ............................................................................................. 1
1 580012900 Guard h3=3830 ................................................................................................... 1
2 272018600 Clip ...................................................................................................................... 6
3 272342200 Nut ...................................................................................................................... 6
4 580012958 Cap ..................................................................................................................... 6

NOTES

SECTION 6
6 MAST-THREE STAGE FULL FREE-LIFT

CONTENTS
SECTION 6
MAST-THREE STAGE FULL FREE-LIFT
DESCRIPTION PAGE
FORK 3 STAGE
FFL .............................................................................................................................................................. 6-6
MAST 3 STAGE
FFL .............................................................................................................................................................. 6-2
WIRE NET ....................................................................................................................................................... 6-8

Mast-Three Stage Full Free-Lift

FFL

MAST 3 STAGE
FFL

1 580012914 Pin ....................................................................................................................... 1
2 273066000 Pulley .................................................................................................................. 4
3 272065300 Washer ............................................................................................................... 8
4 449025027 Cotter Pin ............................................................................................................ 24
5 272101200 Pin ....................................................................................................................... 8
6 272101300 Anchor ................................................................................................................ 8
7 449015107 Locknut ............................................................................................................... 8
8 580014113 Chain h=4025mm ............................................................................................... 2
8 580014114 Chain h=4325mm ............................................................................................... 2
8 a 580014115 Chain h=4625mm ............................................................................................... 2
8 a 580014116 Leaf Chain - Fixed Length h=4795mm ............................................................... 2
10 580012915 Pin ....................................................................................................................... 1
11 015425100 Cotter Pin ............................................................................................................ 2
12 449022018 Washer ............................................................................................................... 8
13 449001412 Capscrew ............................................................................................................ 8
14 504064782 Hose Sheave ...................................................................................................... 1
15 900002259 Stubshaft ............................................................................................................. 1
16 449022017 Lockwasher ......................................................................................................... 1
17 449001389 Capscrew ............................................................................................................ 1
18 500227904 Snap Ring ........................................................................................................... 3
19 449021042 Washer ............................................................................................................... 100
20 272010200 Seal ..................................................................................................................... 3
21 580012892 Brace .................................................................................................................. 2
22 272465500 Rubber Pad ......................................................................................................... 3
23 580014669 Screw .................................................................................................................. 2
24 449021003 Washer ............................................................................................................... 100
25 449015135 Nut ...................................................................................................................... 2
26 580012894 Bracket (RH) ....................................................................................................... 1
27 272328600 Damper ............................................................................................................... 2
28 580012890 Bracket ................................................................................................................ 1
29 449022016 Lockwasher ......................................................................................................... 2
30 449001415 Capscrew ............................................................................................................ 2
31 015915900 Snap Ring ........................................................................................................... 2
32 580012889 Bracket ................................................................................................................ 1
33 580012891 Sheave ................................................................................................................ 1
34 504233232 Shim (0.508 mm) ................................................................................................ 100
35 518797634 Load Roller ......................................................................................................... 8
36 015916300 Snap Ring ........................................................................................................... 8
37 580015115 Snap Ring ........................................................................................................... 3
38 580014670 Pin ....................................................................................................................... 3
39 311323023 Capscrew ............................................................................................................ 2
40 449022041 Lockwasher ......................................................................................................... 2

MAST 3 STAGE
FFL

41 504234265 Shim (0.508 mm) ................................................................................................ 100
42 504075764 Wear Strip ........................................................................................................... 4
43 012824300 O-Ring ................................................................................................................ 4
44 580012895 Bracket (LH) ........................................................................................................ 1
45 580026201 Label ................................................................................................................... 1
FOOTNOTES:
a only for 1,6ton

NOTES


FFL

FORK 3 STAGE
FFL

1 580065150 Load Backrest ..................................................................................................... 1
2 580061459 HCE 1002 Cpscr ................................................................................................. 4
3 580013371 Nut ...................................................................................................................... 4
4 449021010 Washer ............................................................................................................... 8
5 524138884 Carriage 570x65 L=1160mm .............................................................................. 1
5 524138888 Carriage 570x55 L=1160mm .............................................................................. 1
5 524138892 Carriage 570x65 L=980 ...................................................................................... 1
6 504233232 Shim (0.508 mm) ................................................................................................ 100
7 518797634 Load Roller Ø=82,3mm ...................................................................................... 4
8 015916300 Snap Ring ........................................................................................................... 4

WIRE NET (FIGURE 6-3)

WIRE NET
1 580012913 Guard h=4025mm ............................................................................................... 1
1 580012897 Guard h=4325mm ............................................................................................... 1
1 a 580012898 Guard h=4625mm ............................................................................................... 1
1 580016808 Guard h=4795mm ............................................................................................... 1
1 580018424 Guard h=5095mm ............................................................................................... 1
1 580018425 Guard h=5395mm ............................................................................................... 1
2 272018600 Clip ...................................................................................................................... 6
3 272342200 Nut ...................................................................................................................... 6
4 580012958 Cap ..................................................................................................................... 6
FOOTNOTES:
a only for 1,6ton

NOTES

SECTION 7
7 OPTIONS
CONTENTS
SECTION 7
OPTIONS
DESCRIPTION PAGE
BATTERY ROLLER TRUCK ........................................................................................................................... 7-2

LEXAN GUARD
2 STAGE FFL .............................................................................................................................................. 7-6
2 STAGE HI-VI ............................................................................................................................................ 7-4
3 STAGE FFL .............................................................................................................................................. 7-8

OPTIONS
BATTERY ROLLER TRUCK (FIGURE 7-1)

OPTIONS
BATTERY ROLLER TRUCK

1 580051801 Battery Tray ........................................................................................................ 1
2 580049393 Spacer ................................................................................................................ 4
3 580023194 Capscrew ............................................................................................................ 8
4 273070600 Roller .................................................................................................................. 8
5 277033300 Holder ................................................................................................................. 16
6 449001415 Capscrew ............................................................................................................ 16
7 449001023 Capscrew ............................................................................................................ 8
8 504071785 Washer ............................................................................................................... 10
9 449015036 Locknut ............................................................................................................... 2
10 272373400 Plate .................................................................................................................... 2
11 580018467 Screw .................................................................................................................. 4
12 272373600 Nut ...................................................................................................................... 4
13 580048302 Roller .................................................................................................................. 1
14 580018464 Plate .................................................................................................................... 1
15 449001014 Screw .................................................................................................................. 2
16 449021001 Washer ............................................................................................................... 2
17 449015098 Nut ...................................................................................................................... 2

OPTIONS
LEXAN GUARD (FIGURE 7-2)

2 STAGE HI-VI

OPTIONS
LEXAN GUARD
2 STAGE HI-VI

1 580090243 Guard h3=2765mm ............................................................................................. 1
1 580090244 Guard h3=2965mm ............................................................................................. 1
1 580090245 Guard h3=3165-3365mm ................................................................................... 1
1 580090247 Guard h3=3765mm ............................................................................................. 1
1 580090248 Guard h3=4165mm ............................................................................................. 1
2 580057830 Nut ...................................................................................................................... 2
3 580065307 Washer ............................................................................................................... 2
4 580058551 Screw .................................................................................................................. 2

OPTIONS

2 STAGE FFL

OPTIONS
LEXAN GUARD
2 STAGE FFL

1 580090243 Guard h3=2603mm ............................................................................................. 1
1 580090244 Guard h3=2803mm ............................................................................................. 1
1 580090245 Guard h3=3003-3203mm ................................................................................... 1
1 580090246 Guard h3=3403mm ............................................................................................. 1
1 580090247 Guard h3=3603mm ............................................................................................. 1
1 580090248 Guard h3=4003mm ............................................................................................. 1
2 580057830 Nut ...................................................................................................................... 2
3 580065307 Washer ............................................................................................................... 2
4 580058551 Screw .................................................................................................................. 2

OPTIONS

3 STAGE FFL

OPTIONS
LEXAN GUARD
3 STAGE FFL

1 580090243 Guard h3=4027mm ............................................................................................. 1
1 580090244 Guard h3=4327mm ............................................................................................. 1
1 a 580090245 Guard h3=4627-4797mm ................................................................................... 1
1 a 580090246 Guard h3=5097mm ............................................................................................. 1
1 a 580090247 Guard h3=5397mm ............................................................................................. 1
2 580057830 Nut ...................................................................................................................... 2
3 580065307 Washer ............................................................................................................... 2
4 580058551 Screw .................................................................................................................. 2
FOOTNOTES:
a only for 1,6t

OPTIONS
NOTES

SECTION 8
8 NUMERICAL INDEX
NUMERICAL INDEX
SECTION 8
NUMERICAL INDEX
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
012824300 5-4 3 272101300 5-4 28 311323023 5-7 21 6-3 29

6-4 43 5-7 6 6-3 39 449022017 6-3 16
013405200 4-5 5 6-3 6 449001013 1-19 33 449022018 5-7 23
015120100 1-11 6 272106000 1-19 7 5-4 19 6-3 12
015120400 3-3 5 272213200 1-4 5 449001014 7-3 15 449022041 5-7 20
015425100 5-7 22 272213500 1-4 2 449001023 4-3 5 6-3 40
6-3 11 272303000 1-4 1 7-3 7 449025027 5-4 26
015915100 1-15 12 272328600 5-4 6 449001058 1-13 1 5-7 4
015915600 5-7 16 5-7 17 449001389 6-3 17 6-3 4
5-11 8 6-3 27 449001412 2-3 8 449034030 3-3 24
015915900 5-4 24 272328700 1-4 4 6-3 13 449034082 3-3 7
6-3 31 5-4 11 449001415 6-3 30 500227904 5-4 12
015916300 5-4 32 5-7 24 7-3 6 5-7 9
5-9 6 272330200 1-19 14 449007018 1-4 8 6-3 18
6-3 36 272342200 5-13 3 449015014 1-13 29 501989907 1-13 6
6-7 8 6-9 3 2-3 21 501989923 1-13 5
015918400 1-8 7 272373400 7-3 10 449015036 7-3 9 502566901 1-13 30
019899100 4-5 7 272373600 7-3 12 449015098 1-8 5 504057745 1-15 18
056731900 4-5 9 272386700 1-13 18 7-3 17 504064782 6-3 14
150802070 1-4 6 272387100 1-8 9 449015107 5-4 29 504071729 4-5 10
272006400 1-19 11 272387700 1-8 8 5-7 7 504071785 7-3 8
3-3 11 272393000 1-13 12 6-3 7 504075764 5-4 4
272006900 1-13 15 272409600 1-8 10 449015112 2-3 17 6-4 42
272008800 3-3 9 272458700 1-8 1 449015135 2-3 10 504233232 5-4 30
272010200 5-4 14 272465500 5-4 15 5-4 8 5-9 8
6-3 20 6-3 22 5-7 27 6-3 34
272013200 4-3 3 272465600 5-7 13 6-3 25 6-7 6
272013700 1-13 27 272466100 1-19 15 449021001 1-8 2 504234265 5-4 2
272014200 5-7 13 272470200 1-8 6 1-19 35 6-4 41
272014400 5-7 13 1-8 13 2-3 22 504235265 5-7 14
272014500 5-7 13 272471100 1-8 11 5-4 18 5-11 6
272015100 1-19 12 273004100 2-3 1 7-3 16 505972555 2-3 14
272018600 5-13 2 2-7 5 449021002 2-3 5 2-7 10
6-9 2 273033400 3-3 18 449021003 2-3 9 505975518 2-3 23
272019300 1-13 14 273066000 5-4 22 5-4 7 506395532 2-3 15
272027800 1-19 10 5-7 2 5-4 10 518797634 5-4 31
272034900 1-17 5 6-3 2 5-7 26 5-9 7
272040800 1-13 16 273070600 7-3 4 6-3 24 6-3 35
272053000 1-13 22 273127500 3-3 17 449021006 4-3 4 6-7 7
272065300 5-4 23 273129300 1-13 13 449021010 1-13 2 518818806 4-3 15
5-7 3 277033300 7-3 5 5-9 4 518818830 4-3 8
6-3 3 277038600 4-5 13 5-11 4 520038883 2-3 6
272076200 1-19 31 277263200 4-5 2 6-7 4 524138799 1-19 4
272078800 3-3 23 277263400 4-5 1 449021019 5-4 36 524138882 5-11 5
272087200 1-19 9 277406300 4-5 15 449021042 5-4 13 524138883 5-9 5
272090800 1-13 19 277458400 1-4 16 5-7 10 524138884 6-7 5
272101200 5-4 27 277548300 3-3 21 6-3 19 524138886 5-11 5
5-7 5 277548400 3-3 15 449022013 5-11 10 524138887 5-9 5
6-3 5 277548500 3-3 16 449022016 1-19 34 524138888 6-7 5

NUMERICAL INDEX
NUMERICAL INDEX (continued)
524138890 5-11 5 580011872 1-17 2 580013300 2-5 10 580014479 4-3 6

524138891 5-9 5 580011989 1-19 2 2-7 11 580014480 4-3 7
524138892 6-7 5 580011991 1-19 28 580013309 3-3 8 580014481 4-3 12
524139006 1-19 21 580012889 5-4 21 580013311 3-3 10 580014482 4-3 9
524139009 1-19 25 6-3 32 580013312 1-11 3 580014489 4-3 14
524139010 1-19 1 580012890 5-4 17 580013314 1-11 2 580014491 4-3 2
524139319 1-19 23 6-3 28 580013324 1-4 7 580014492 4-3 1
524139322 1-4 3 580012891 5-4 20 580013325 1-4 7 580014493 4-3 17
524139713 1-8 3 6-3 33 580013326 1-4 10 580014499 1-15 4
524141523 1-4 12 580012892 5-4 16 580013345 4-5 4 580014526 1-8 4
524141524 1-4 9 5-7 12 580013371 5-9 3 580014631 1-8 12
524148447 1-17 7 6-3 21 5-11 3 580014632 4-5 11
524148522 1-19 26 580012894 5-4 9 6-7 3 580014633 4-5 11
524148554 1-11 8 5-7 18 580013474 4-3 19 580014634 4-5 11
524149804 1-19 40 6-3 26 580013476 4-5 3 580014635 4-5 6
524213453 1-17 8 580012895 5-4 1 580013477 1-13 3 580014636 4-5 8
524216189 1-4 19 5-7 19 580013478 1-13 3 580014637 4-5 8
524216190 1-4 19 6-4 44 580013479 1-13 3 580014638 4-5 8
524216191 1-4 19 580012896 5-7 15 580013482 1-19 16 580014669 5-4 5
524216192 1-4 19 5-11 9 580013974 1-19 13 5-7 25
524216193 1-4 19 580012897 5-13 1 580013988 4-3 18 6-3 23
524216194 1-4 19 6-9 1 580014086 2-3 4 580014670 5-4 34
524216195 1-4 19 580012898 5-13 1 580014108 5-4 25 5-7 28
524216196 1-4 19 5-13 1 6-3 9 6-3 38
524216197 1-4 19 6-9 1 580014109 5-4 25 580014683 2-7 4
524216198 1-4 19 580012900 5-13 1 6-3 9 580014880 1-4 18
524216199 1-4 19 5-13 1 580014110 5-4 25 580015115 5-4 33
524216200 1-4 19 580012908 5-11 7 6-3 9 5-7 29
524216201 1-4 19 580012909 5-11 7 580014111 5-4 25 6-3 37
524216202 1-4 19 580012910 5-11 7 6-3 9 580015507 4-6 3
524216203 1-4 19 580012911 5-11 7 580014112 5-4 25 4-7 6
524216204 1-4 19 580012912 5-7 15 6-3 9 4-9 6
524216205 1-4 19 5-11 9 580014113 5-7 8 580015508 4-7 5
524216206 1-4 19 580012913 5-13 1 6-3 8 4-9 5
524216207 1-4 19 6-9 1 580014114 5-7 8 580015693 4-7 3
524216208 1-4 19 580012914 5-7 1 6-3 8 4-9 4
524216209 1-4 19 6-3 1 580014115 5-7 8 580015694 4-7 3
524216210 1-4 19 580012915 6-3 10 6-3 8 4-9 4
524216211 1-4 19 580012958 5-13 4 580014116 5-7 8 580015696 4-7 3
524216212 1-4 19 6-9 4 6-3 8 4-9 4
524216526 1-4 19 580012959 1-4 17 580014117 5-7 8 580015697 4-7 3
524216766 1-4 19 580012962 1-19 19 6-3 8 4-9 4
524236627 1-19 27 580012967 1-4 15 580014118 5-7 8 580015698 4-7 3
524236628 1-19 18 580012968 1-4 14 580014438 1-13 4 4-9 4
524242350 1-4 21 580012969 1-19 24 580014439 1-13 7 580015734 4-6 1
524327019 1-4 11 580012970 1-19 20 580014440 1-13 8 4-9 1
2-3 3 580013106 1-19 30 580014441 1-13 9 580015735 4-6 1
524330466 1-19 38 580013129 1-19 6 580014446 1-13 20 4-9 1
524330473 1-19 37 580013298 1-8 14 580014447 1-13 25 580015736 4-6 1
580001407 2-3 13 1-19 5 580014448 1-13 26 4-9 1
580001470 3-3 19 2-3 18 580014457 1-13 10 580015737 4-6 1

NUMERICAL INDEX
580015738 4-6 1 580026902 4-7 1 7-9 2 2-5 9

580015739 4-6 1 580026903 4-7 1 580058551 7-5 4 2-7 3
580016808 6-9 1 580026904 4-7 1 7-7 4 580092328 1-11 1
580016918 4-6 2 580026905 4-7 1 7-9 4 580092727 1-11 7
4-9 2 580026906 4-7 1 580060389 1-19 42 580092728 1-11 5
580016919 4-7 4 580026907 4-7 1 580060500 2-3 24 580092729 1-11 4
4-9 3 580026908 4-7 2 580060506 2-3 25 580093316 2-5 12
580017810 4-9 1 580027871 4-3 10 580061459 5-9 2 580093317 2-5 13
580017811 4-9 1 580027872 4-3 11 5-11 2 580093318 2-5 14
580017812 4-9 1 580029307 1-8 15 6-7 2 580093319 2-5 16
580017904 4-7 3 580035055 2-7 7 580062569 4-3 13 580093320 2-5 15
580017914 4-7 3 580035385 1-17 4 580063867 2-3 16 580093321 2-5 18
4-9 4 580035765 1-19 8 580065150 5-9 1 580093385 2-7 9
580018417 4-5 8 580037612 3-3 20 5-11 1 580093424 5-13 1
580018418 4-5 8 580037615 3-3 2 6-7 1 5-13 1
580018419 4-5 8 580037624 3-3 25 580065307 7-5 3 580093537 2-5 17
580018421 6-3 8 580037625 3-3 12 7-7 3 580093629 2-3 12
580018422 5-4 25 580037672 3-3 3 7-9 3 2-7 1
6-3 9 580037730 1-11 10 580070960 1-15 5 580093654 2-7 15
580018423 5-4 25 580038175 1-19 36 580077043 1-17 6 580093734 1-4 13
580018424 6-9 1 580038706 3-3 14 580077549 2-3 20 2-3 26
580018425 6-9 1 580038707 3-3 1 2-5 11 580094362 2-3 2
580018430 4-5 11 580038708 3-3 13 580081695 1-17 3 580094457 1-19 29
580018431 4-5 11 580038709 3-3 22 580081696 1-17 1 580094592 1-15 15
580018432 4-5 11 580038710 3-3 6 580086084 2-7 8 580094593 1-15 2
580018464 7-3 14 580038711 3-3 4 580090243 7-5 1 580094594 1-15 14
580018467 7-3 11 580039025 2-5 2 7-7 1 580094595 1-15 3
580022041 1-13 3 580039026 2-5 4 7-9 1 580094596 1-15 10
580023194 7-3 3 580039027 2-5 3 580090244 7-5 1 580094597 1-15 8
580023467 1-13 23 580039028 2-5 1 7-7 1 580094598 1-15 9
580023828 4-3 16 580039029 2-5 6 7-9 1 580094599 1-15 7
580024912 5-7 11 580039030 2-5 8 580090245 7-5 1 580094600 1-15 16
580026201 5-7 30 580039031 2-5 7 7-7 1 580094601 1-15 6
6-4 45 580039032 2-5 5 7-9 1 580094623 1-15 11
580026296 1-19 17 580040114 1-13 24 580090246 7-7 1 580094789 2-3 19
580026783 4-5 14 580040491 5-4 35 7-9 1 580095362 2-7 2
580026824 1-19 22 580041302 1-13 17 580090247 7-5 1 580096839 2-3 1
580026864 4-5 12 580041303 1-13 28 7-7 1 2-7 14
580026885 4-5 16 580041309 1-13 11 7-9 1 580096848 2-7 13
580026887 4-5 17 580048302 7-3 13 580090248 7-5 1 640046901 1-15 13
580026888 4-5 17 580049393 7-3 2 7-7 1 900002259 6-3 15
580026889 4-5 17 580051801 7-3 1 580090778 1-15 1 900005220 1-13 21
580026890 4-5 17 580053923 1-4 20 580091804 2-7 12 901083873 1-15 17
580026891 4-5 17 580055434 1-19 39 580091806 2-3 11 931015914 1-11 9
580026892 4-5 17 580055435 1-19 41 2-7 6 932200907 1-19 3
580026893 4-5 17 580057830 7-5 2 580092138 2-3 7 940004902 1-19 32
580026901 4-7 1 7-7 2

NUMERICAL INDEX
NOTES

SECTION 9
9 USER SUPPORT INFORMATION

CONTENTS
SECTION 9
USER SUPPORT INFORMATION
DESCRIPTION PAGE
SERVICE PARTS ORDERING INSTRUCTIONS ........................................................................................... 9-2

TECHNICAL SERVICE PUBLICATIONS ........................................................................................................ 9-2

USER SUPPORT INFORMATION
Your investment in a Yale Industrial Truck is important to you and to your Yale Dealer. You measure the return on
that investment through the performance of these trucks and the drivers who operate and the mechanics who service
them safely and efficiency. The following information is intended to help you to achieve your investments objectives:
SERVICE PARTS ORDERING INSTRUCTIONS Technical literature, with detailed information, is

available at a nominal fee to assist users to effectively
HOW TO ORDER SERVICE PARTS maintain Yale Industrial Trucks in a safe, useful
condition. Part Manuals with complete replacement parts
In order to prevent delay, too much communication and
identification, Service Maintenance Manuals which
to have your orders filled correctly, quickly, and at the
provide service and overhaul procedures and additional
least possible cost, the following is the correct procedure
copies of the Operating Manual can be obtained from
to use to order replacement parts.
your Yale Industrial Truck Dealer.
WHEN ORDERING PARTS
To provide instructions for safely operating and servicing
Contact your authorized Yale Industrial Truck Dealer Yale Industrial Trucks, each truck is equipped with an
giving them the following information: operators manual. It describes various operating
techniques and safety warnings to the operator. It
1. Your Purchase order number. contains a guide to safe maintenance practices and
recommended schedules for maintenance. if the
2. Complete addresses for sending the invoice and operators manual is missing from any Yale Industrial
parts. Truck, it should be replaced. Replacement copies are
available for a nominal fee from your Yale Dealer.
3. Tell us how you want your parts sent. If we do not
get this information, we will send the parts using the For additional information or assistance in obtaining
lowest priced method. these user support publications see your Yale Industrial
Truck Dealer or contact:
4. Correct part number(s) and description(s). Use your
parts manual as a reference. Yale Materials Handling Corporation
Yale Europe Materials Handling Limited
5. Model and serial number of the truck.
Flagship House, Reading Road North
TECHNICAL SERVICE PUBLICATIONS Fleet, Hampshire GU138 HR United Kingdom

Yale Europe Materials Handling Limited 524336822
Flagship House, Reading Road North ©Yale Corp.
Fleet, Hampshire GU13 8HR United Kingdom 10/2009
Telephone; +44 (0) 1252 810 261
Telefax; +44 (0) 1252 770 702

P.C. MS14-MS16 (C852) - Eng

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PARTS MANUAL

Yale Europe Materials Handling Limited 524336822

5 MAST-TWO STAGE FULL FREE-LIFT

6 MAST-THREE STAGE FULL FREE-LIFT

9 USER SUPPORT INFORMATION

C852 ©2009 Yale Europe Materials Handling Limited i

TABLE OF CONTENTS (continued)

ii ©2009 Yale Europe Materials Handling Limited C852

ABBREVIATIONS QUICK REFERENCE SHEET

ECH-6 Empty Container Handler - 6 High UL Type EE Battery-Powered Safety Rating

C852 ©2009 Yale Europe Materials Handling Limited iii

HOW TO USE THE ILLUSTRATED PARTS MANUAL

iv ©2009 Yale Europe Materials Handling Limited C852

HOW TO FIND THE DESIRED PART NUMBER

C852 ©2009 Yale Europe Materials Handling Limited v

IDENTIFICATION OF TRUCK SERIAL NUMBERS

vi ©2009 Yale Europe Materials Handling Limited C852

PUBLICATION YALE PART NUMBER

Operating Manual.................................................................................................................... 524301672

Service Manual (Complete)..................................................................................................... 524301698

Parts Manual........................................................................................................................... 524336822

C852 ©2009 Yale Europe Materials Handling Limited vii

viii ©2009 Yale Europe Materials Handling Limited C852

C852 ©2009 Yale Europe Materials Handling Limited 1-1

COVERS AND ADHESIVE LABELS (FIGURE 1-1)

1-2 ©2009 Yale Europe Materials Handling Limited C852

C852 ©2009 Yale Europe Materials Handling Limited 1-3

COVERS AND ADHESIVE LABELS

1-4 ©2009 Yale Europe Materials Handling Limited C852

C852 ©2009 Yale Europe Materials Handling Limited 1-5

BATTERY COMPARTMENT (FIGURE 1-2)

1-6 ©2009 Yale Europe Materials Handling Limited C852

C852 ©2009 Yale Europe Materials Handling Limited 1-7

ITEM PART NO. DESCRIPTION QTY

1-8 ©2009 Yale Europe Materials Handling Limited C852

C852 ©2009 Yale Europe Materials Handling Limited 1-9

SUPPORTS AND CASTER WHEELS (FIGURE 1-3)

1-10 ©2009 Yale Europe Materials Handling Limited C852

SUPPORTS AND CASTER WHEELS

C852 ©2009 Yale Europe Materials Handling Limited 1-11

TRACTION UNIT (FIGURE 1-4)

1-12 ©2009 Yale Europe Materials Handling Limited C852

C852 ©2009 Yale Europe Materials Handling Limited 1-13

TRACTION MOTOR (FIGURE 1-5)

1-14 ©2009 Yale Europe Materials Handling Limited C852

C852 ©2009 Yale Europe Materials Handling Limited 1-15

ELECTROMAGNETIC BRAKE (FIGURE 1-6)

1-16 ©2009 Yale Europe Materials Handling Limited C852

C852 ©2009 Yale Europe Materials Handling Limited 1-17

DRAWBAR CONTROL BOX (FIGURE 1-7)

1-18 ©2009 Yale Europe Materials Handling Limited C852

DRAWBAR CONTROL BOX

ITEM PART NO. DESCRIPTION QTY

C852 ©2009 Yale Europe Materials Handling Limited 1-19

1-20 ©2009 Yale Europe Materials Handling Limited C852

ELECTRONIC SYSTEM .................................................................................................................................. 2-2

C852 ©2009 Yale Europe Materials Handling Limited 2-1

ELECTRONIC SYSTEM (FIGURE 2-1)

2-2 ©2009 Yale Europe Materials Handling Limited C852

C852 ©2009 Yale Europe Materials Handling Limited 2-3

POWER CABLES DIAGRAM (FIGURE 2-2)

2-4 ©2009 Yale Europe Materials Handling Limited C852

POWER CABLES DIAGRAM