Professional Documents
Culture Documents
H30FT
(F001)
S/N F001V04869M
This truck may contain certain non-production and/or special content. Every effort has been made
to reflect that in this manual, but the user is well advised to refer to the special content information
that pertains to this specific serial number truck. If so equipped, the special content information
will be located in the last chapter of this manual.
SECTIONS
1 FRAME
2 ENGINE ASSEMBLY
3 FUEL SYSTEM
4 ELECTRICAL SYSTEM
5 TRANSMISSION
6 DRIVE AXLE
7 STEERING SYSTEM
8 BRAKE SYSTEM
9 HYDRAULIC SYSTEM
13 OPTIONS
15 NUMERICAL INDEX
This Parts Manual is divided into 15 major sections which are listed above. Quick reference to these sections can
be made by placing the right thumb on the tab of the desired section, bending the book back and thumbing the pages
to the corresponding tab.
UNIT CODE F001
03/2014 NORTH AMERICA
TABLE OF CONTENTS
DESCRIPTION PAGE
A
ADD ON OPTIONS
ADD ON TELEMETRY KITS ........................................................................................................................... 14-13
AIR INTAKE SYSTEM
AIR FILTER ASSEMBLY - LPG, GASOLINE, AND DIESEL ...................................................................... 3-70
MAZDA 2.0L, GASOLINE - 2005 AND 2006 EMISSION COMPLIANT ENGINES (→ S/N F001V02238E)
.................................................................................................................................................................... 3-4
MAZDA 2.0L, GASOLINE - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →) ............... 3-24
MAZDA 2.0L, LPG - 2005 AND 2006 EMISSION COMPLIANT ENGINES (→ S/N F001V02238E) ......... 3-8
MAZDA 2.0L, LPG - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →) ........................... 3-32
PRE-CLEANER AND DUCT ....................................................................................................................... 3-71
YANMAR DIESEL (→ 12/2007) ................................................................................................................. 3-66
YANMAR DIESEL (1/2008 →) ................................................................................................................... 3-68
ALTERNATOR AND MOUNTING
YANMAR DIESEL ....................................................................................................................................... 4-77
ARMREST ASSEMBLY
MINI-LEVER MODULES - SEMI-SUSPENSION SEAT WITH HIP RESTRAINTS (S/N F001V03522H →)
.................................................................................................................................................................... 1-50
MINI-LEVER MODULES - FULL SUSPENSION SEAT (S/N F001V03522H →) ....................................... 1-52
ASSEMBLED ENGINE
MAZDA 2.0L, GASOLINE AND LPG - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →)
.................................................................................................................................................................... 2-58
AUDIBLE ALARM KITS ................................................................................................................................... 14-4
AUXILIARY SECTION, ONE AND TWO
MANUAL CONTROL VALVE - THREE AND FOUR FUNCTION (4/2014 →) ........................................... 9-48
AUXILIARY SECTIONS, ONE AND TWO
MANUAL CONTROL VALVE - THREE AND FOUR FUNCTION (→ S/N F001V02621E) ........................ 9-44
MANUAL CONTROL VALVE - THREE AND FOUR FUNCTION (S/N F001V02564E ↔ 4/2014) ............ 9-46
AUXILIARY TUBE EXTENSION KIT
AUXILIARY TUBE EXTENSIONS
TWO STAGE FULL FREE-LIFT AND THREE STAGE FULL FREE-LIFT (→ 4/2011) .............................. 13-30
TWO STAGE FULL FREE-LIFT AND THREE STAGE FULL FREE-LIFT (4/2011 →) .............................. 13-32
TWO-STAGE LIMITED FREE-LIFT ............................................................................................................ 13-28
B
BACK-UP ALARM ........................................................................................................................................... 13-6
BRAKE ASSEMBLY ........................................................................................................................................ 8-14
BRAKE LINKAGE
DUAL PEDAL (→ S/N F001V03571H) ....................................................................................................... 8-6
DUAL PEDAL (S/N F001V03572H →) ....................................................................................................... 8-10
SINGLE PEDAL (→ S/N F001V03571H) ................................................................................................... 8-2
SINGLE PEDAL (S/N F001V03572H →) ................................................................................................... 8-4
C
CAMSHAFT AND DRIVE GEAR
YANMAR 2.6L DIESEL ............................................................................................................................... 2-106
CAMSHAFT AND VALVES
MAZDA 2.0L, GASOLINE AND LPG - 2005 AND 2006 EMISSION COMPLIANT
ENGINES (→ S/N F001V02238E) ............................................................................................................. 2-48
DESCRIPTION PAGE
MAZDA 2.0L, GASOLINE AND LPG - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →)
.................................................................................................................................................................... 2-62
CARBURETOR
MAZDA 2.0L, LPG - 2005 AND 2006 EMISSION COMPLIANT ENGINES (→ S/N F001V02238E) ......... 2-50
MAZDA 2.0L, LPG - 2005 AND 2006 EMISSION COMPLIANT ENGINES (→ S/N F001V02238E) ......... 3-18
CARRIAGE
THREE STAGE FULL FREE-LIFT (→ 4/2011) .......................................................................................... 12-24
THREE STAGE FULL FREE-LIFT (4/2011 →) .......................................................................................... 12-26
TWO STAGE FULL FREE-LIFT (→ 4/2011) .............................................................................................. 11-24
TWO STAGE FULL FREE-LIFT (4/2011 →) .............................................................................................. 11-26
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 10-16
CHARGE PUMP ASSEMBLY ......................................................................................................................... 5-67
CONTROL VALVE
TRANSMISSION (→ 9/2007) ..................................................................................................................... 5-64
CONTROL VALVE ASSEMBLY
9/2007 → .................................................................................................................................................... 5-66
ELECTRONIC CONTROL - THREE AND FOUR FUNCTION (→ S/N F001V02519E) ............................. 9-52
MANUAL CONTROL - THREE AND FOUR FUNCTION (→ 4/2014) ........................................................ 9-34
MANUAL CONTROL - THREE AND FOUR FUNCTION (4/2014 →) ........................................................ 9-36
CONTROL VALVE LOCKOUT GROUP
MANUAL CONTROL VALVE ...................................................................................................................... 9-30
CONVERSION KIT
COOLING SYSTEM
GASOLINE - MAZDA 2.0L (→ S/N F001V02162D) ................................................................................... 2-8
GASOLINE (MAZDA 2.0L) (S/N F001V02163D ↔ S/N F001V02239E) .................................................... 2-14
LPG - MAZDA 2.0L (→ S/N F001V02162D) .............................................................................................. 2-10
LPG (MAZDA 2.0L) (S/N F001V02163D ↔ S/N F001V02238E) ............................................................... 2-12
MAZDA 2.0L, GASOLINE AND LPG - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →)
.................................................................................................................................................................... 2-16
YANMAR 2.6L - DIESEL (S/N F001V02163D →) ...................................................................................... 2-88
YANMAR 2.6L DIESEL (→ S/N F001V02163D) ........................................................................................ 2-86
COUNTERWEIGHT
→ 4/2007 .................................................................................................................................................... 1-3
4/2007 → .................................................................................................................................................... 1-4
COUNTERWEIGHT EXHAUST
MAZDA 2.0L GASOLINE AND LPG - WITH CATALYTIC CONVERTER (→ S/N F001V02238E) ............ 2-18
WITH PURIFIER - YANMAR 2.6L DIESEL ................................................................................................. 2-90
COWL ELECTRICAL
ELECTRO-HYDRAULICS ........................................................................................................................... 4-36
MANUAL HYDRAULIC - WITH OPERATOR PRESENCE SYSTEM ......................................................... 4-38
COWL MOUNTING ......................................................................................................................................... 1-66
CRANKSHAFT AND PISTONS
MAZDA 2.0L, GASOLINE AND LPG - 2005 AND 2006 EMISSION COMPLIANT
ENGINES (→ S/N F001V02238E) ............................................................................................................. 2-36
MAZDA 2.0L, GASOLINE AND LPG - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →)
.................................................................................................................................................................... 2-64
YANMAR 2.6L DIESEL ............................................................................................................................... 2-108
DESCRIPTION PAGE
CYLINDER BLOCK
MAZDA 2.0L, GASOLINE AND LPG - 2005 AND 2006 EMISSION COMPLIANT
ENGINES (→ S/N F001V02238E) ............................................................................................................. 2-32
MAZDA 2.0L, GASOLINE AND LPG - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →)
.................................................................................................................................................................... 2-66
YANMAR 2.6L DIESEL ............................................................................................................................... 2-110
CYLINDER HEAD
MAZDA 2.0L, GASOLINE AND LPG - 2005 AND 2006 EMISSION COMPLIANT
ENGINES (→ S/N F001V02238E) ............................................................................................................. 2-34
YANMAR 2.6L DIESEL ............................................................................................................................... 2-102
CYLINDER HEAD AND COVER
MAZDA 2.0L, GASOLINE AND LPG - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239V →)
.................................................................................................................................................................... 2-60
D
DELAY VALVE
MAZDA 2.0L, LPG - 2005 AND 2006 EMISSION COMPLIANT
ENGINES (S/N F001V02035D ↔ S/N F001V02238E) .............................................................................. 2-56
MAZDA 2.0L, LPG - 2005 AND 2006 EMISSION COMPLIANT
ENGINES (S/N F001V02035D ↔ S/N F001V02238E) .............................................................................. 3-22
DIRECTIONAL CONTROL KITS ..................................................................................................................... 14-2
DISTRIBUTOR
MAZDA 2.0L - 2005 AND 2006 EMISSION COMPLIANT ENGINES (→ S/N F001V02238E) .................. 4-76
DRIVE AXLE
SHEET 1 OF 3 ............................................................................................................................................ 6-4
SHEET 2 OF 3 ............................................................................................................................................ 6-6
SHEET 3 OF 3 ............................................................................................................................................ 6-8
DRIVE AXLE AND ATTACHING PARTS ........................................................................................................ 6-2
DRIVE TIRES AND WHEELS
PNEUMATIC - TRELLEBORG .................................................................................................................... 6-12
PNEUMATIC RADIAL ................................................................................................................................. 6-10
PNEUMATIC SOLID - MONARCH .............................................................................................................. 6-11
DUAL MIRRORS
WITH CAB ................................................................................................................................................... 13-9
E
E-HYDRAULIC CONTROL CONVERSION KITS
ELECTRICAL SYSTEM
RH CHASSIS .............................................................................................................................................. 4-4
RH CHASSIS - WITH SEAT BELT SEQUENCE MODULE ........................................................................ 4-8
ELECTRONIC CONTROL LEVERS
MINI-LEVER MODULE (FOUR FUNCTION) - DATE CODE 0725 THRU 0743 ......................................... 4-56
MINI-LEVER MODULE (FOUR FUNCTION) - DATE CODE 0744 ............................................................. 4-62
MINI-LEVER MODULES - DATE CODE 0724 ............................................................................................ 4-52
MINI-LEVER MODULES (THREE FUNCTION) - DATE CODE 0725 THRU 0743 ..................................... 4-54
MINI-LEVER MODULES (THREE FUNCTION) - DATE CODE 0744 ......................................................... 4-58
ELECTRONIC LEVER LABELS
AUXILIARY DUAL FUNCTION ................................................................................................................... 1-84
AUXILIARY SINGLE FUNCTION ................................................................................................................ 1-82
DESCRIPTION PAGE
ELECTRONIC PRESSURE REGULATOR ASSEMBLY
MAZDA 2.0L AND 2.2L LPG (2/2008 ↔ 2/2012) ....................................................................................... 3-46
MAZDA 2.0L AND 2.2L LPG (2/2013 →) ................................................................................................... 3-48
MAZDA 2.0L, LPG - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E ↔ 2/2008) ............... 3-44
ELECTRONIC PRESSURE REGULATOR KIT
MAZDA 2.0L, LPG - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →) ........................... 3-50
ELECTRONIC THROTTLE LINKAGE
YANMAR DIESEL (→ S/N F001V03643H) ................................................................................................ 3-84
YANMAR DIESEL (S/N F001V04644H →) ................................................................................................ 3-86
EMISSION CONTROL SYSTEM
MAZDA 2.0L, GASOLINE - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →) ............... 2-76
MAZDA 2.0L, LPG - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →) ........................... 2-78
EMISSIONS LINES
MAZDA 2.0L, GASOLINE - 2005 AND 2006 EMISSION COMPLIANT ENGINES (→ S/N F001V02238E)
.................................................................................................................................................................... 2-54
MAZDA 2.0L, GASOLINE - 2005 AND 2006 EMISSION COMPLIANT ENGINES (→ S/N F001V02238E)
.................................................................................................................................................................... 3-20
ENGINE CONTROL MODULE
MAZDA 2.0L, GASOLINE - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →) ............... 4-44
MAZDA 2.0L, LPG - 2007-2010 EMISSION COMPLIANT ENGINES (S/N F001V02239E →) ................. 4-45
ENGINE COOLING
MAZDA 2.0L, GASOLINE AND LPG - 2005 AND 2006 EMISSION COMPLIANT
ENGINES (→ S/N F001V02238E) ............................................................................................................. 2-38
MAZDA 2.0L, GASOLINE AND LPG - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →)
.................................................................................................................................................................... 2-74
ENGINE ELECTRICAL COMPONENTS
MAZDA 2.0L AND 2.2L, GASOLINE AND LPG - 2005 AND 2006 EMISSION COMPLIANT
ENGINES (→ S/N F001V02238E) ............................................................................................................. 4-14
MAZDA 2.0L, GASOLINE AND LPG - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →)
.................................................................................................................................................................... 4-18
ENGINE ELECTRICAL SYSTEM
MAZDA 2.0L, GASOLINE - 2005 AND 2006 EMISSION COMPLIANT ENGINES (→ S/N F001V02238E)
.................................................................................................................................................................... 4-24
MAZDA 2.0L, GASOLINE AND LPG - 2007-2010 EMISSION COMPLIANT
ENGINES (S/N F001V02239E →) ............................................................................................................. 4-28
MAZDA 2.0L, LPG - 2005 AND 2006 EMISSION COMPLIANT ENGINES (→ S/N F001V02238E) ......... 4-20
YANMAR DIESEL ....................................................................................................................................... 4-48
ENGINE FUEL SYSTEM
MAZDA 2.0L, GASOLINE AND LPG - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →)
.................................................................................................................................................................... 2-84
ENGINE FUEL SYSTEM AND EMISSIONS CONTROL
MAZDA 2.0L, LPG - 2005 AND 2006 EMISSION COMPLIANT ENGINES (→ S/N F001V02238E) ......... 2-44
MAZDA 2.0L, LPG - 2005 AND 2006 EMISSION COMPLIANT ENGINES (→ S/N F001V02238E) ......... 3-16
ENGINE FUEL SYSTEM AND INTAKE MANIFOLD
MAZDA 2.0L, GASOLINE - 2005 AND 2006 EMISSION COMPLIANT ENGINES (→ S/N F001V02238E)
.................................................................................................................................................................... 2-42
MAZDA 2.0L, GASOLINE - 2005 AND 2006 EMISSION COMPLIANT ENGINES (→ S/N F001V02238E)
.................................................................................................................................................................... 3-14
ENGINE MOUNTING ...................................................................................................................................... 2-4
DESCRIPTION PAGE
ENGINE SAFETY ELECTRICAL
MAZDA 2.0L ................................................................................................................................................ 4-32
EXHAUST MANIFOLD
MAZDA 2.0L, GASOLINE AND LPG - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →)
.................................................................................................................................................................... 2-72
EXHAUST WITH CATALYTIC CONVERTER
COUNTERWEIGHT AND OVERHEAD - MAZDA 2.0L, GASOLINE AND LPG, 2007 EMISSION
COMPLIANT ENGINES (S/N F001V02239E →) ....................................................................................... 2-22
F
FAN ASSEMBLY ............................................................................................................................................. 2-6
FENDER EXTENSIONS AND MUD GUARDS ............................................................................................... 1-68
FIRE EXTINGUISHER .................................................................................................................................... 13-10
FLOORPLATES AND COVERS
→ S/N F001V02859F EXC. 02851 ............................................................................................................. 1-54
S/N F001V02860F ↔ S/N F001V03334G INC. 02851 .............................................................................. 1-58
S/N F001V03335G → ................................................................................................................................ 1-62
FLYWHEEL AND HOUSING
MAZDA 2.0L (→ S/N F001V02037D) ......................................................................................................... 2-26
MAZDA 2.0L (S/N F001V02038D →) ......................................................................................................... 2-28
YANMAR 2.6L DIESEL ............................................................................................................................... 2-96
FORK ASSEMBLY KITS ................................................................................................................................. 14-13
FORK POSITIONER ASSEMBLY ................................................................................................................... 13-26
FORKS ............................................................................................................................................................ 1-72
OPTIONAL .................................................................................................................................................. 1-73
FORWARD CLUTCH
INPUT - SINGLE SPEED (→ S/N F001V02229E) ..................................................................................... 5-52
FORWARD CLUTCH (INPUT)
SINGLE SPEED (→ S/N F001V02230E) ................................................................................................... 5-54
SINGLE SPEED (S/N T141M001501 →) (S/N T148M001501 →) ............................................................ 5-56
FREE-LIFT
THREE STAGE FULL FREE-LIFT - 8520000 SERIES ............................................................................... 12-18
THREE STAGE FULL FREE-LIFT - 8800000 SERIES ............................................................................... 12-20
TWO STAGE FULL FREE-LIFT - 8520000 SERIES .................................................................................. 11-14
TWO STAGE FULL FREE-LIFT - 8800000 SERIES .................................................................................. 11-18
FREE-LIFT CYLINDER
THREE STAGE FULL FREE-LIFT .............................................................................................................. 12-22
TWO STAGE FULL FREE-LIFT .................................................................................................................. 11-22
FUEL FILTER
YANMAR DIESEL ....................................................................................................................................... 3-74
FUEL INJECTION
YANMAR DIESEL ....................................................................................................................................... 3-76
FUEL PUMP AND SENDER
MAZDA 2.0L, GASOLINE - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →) ............... 3-28
FUEL SUPPLY SYSTEM
MAZDA 2.0L, GASOLINE - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →) ............... 3-26
MAZDA 2.0L, LPG - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →) ........................... 3-34
FUEL SYSTEM
MAZDA 2.0L, GASOLINE - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →) ............... 3-30
DESCRIPTION PAGE
MAZDA 2.0L, GASOLINE AND LPG - 2005 AND 2006 EMISSION COMPLIANT
ENGINES (→ S/N F001V02238E) ............................................................................................................. 3-6
MAZDA 2.0L, LPG - 2005 AND 2006 EMISSION COMPLIANT ENGINES (→ S/N F001V02238E) ......... 3-10
MAZDA 2.0L, LPG - 2007-2010 EMISSION COMPLIANT ENGINES (S/N F001V02239E →) ................. 3-36
YANMAR DIESEL ....................................................................................................................................... 3-72
FUEL SYSTEM HOSES AND ATTACHING PARTS
MAZDA 2.0L AND 2.2L LPG - 2007-2010 EMISSION COMPLIANT ENGINES (S/N F001V02239E →)
.................................................................................................................................................................... 3-38
FUEL SYSTEM SENSORS
MAZDA 2.0L, LPG - 2007-2010 EMISSION COMPLIANT ENGINES (S/N F001V02239E →) ................. 4-47
FUEL, SYSTEM SENSORS
MAZDA 2.0L, GASOLINE - 2007-2010 EMISSION COMPLIANT ENGINES (S/N F001V02239E →) ...... 4-46
FULL SUSPENSION SEAT
MANUAL AND ELECTRO-HYDRAULIC — SWIVEL AND NON SWIVEL - SHEET 1 OF
4 (S/N F001V03522H →) ........................................................................................................................... 1-40
RECLINER AND DAMPER KITS - SHEET 3 OF 4 (S/N F001V03522H →) .............................................. 1-44
SERVICE KITS FOR NON SWIVEL AND SWIVEL - SHEET 2 OF 4 (S/N F001V03522H →) .................. 1-42
WITH AND WITHOUT ELECTRONIC CONTROLS (S/N F001V01401 ↔ S/N F001V01501) .................. 1-30
WITH AND WITHOUT ELECTRONIC CONTROLS (S/N F001V01501 ↔ S/N F001V01792D) ................ 1-32
WITH LIMITED BACK TILT (S/N F001V01793D ↔ S/N F001V03521H) .................................................. 1-34
FULL SUSPENSION SEAT ATTACHING PARTS
NOT INCLUDED WITH SEAT - SHEET 4 OF 4 WITH MANUAL HYDRAULICS (S/N F001V03522H →)
.................................................................................................................................................................... 1-46
NOT INCLUDED WITH SEAT - SHEET 4 OF 4 WITH ELECTRO-HYDRAULICS (S/N F001V03522H →)
.................................................................................................................................................................... 1-48
FULL SUSPENSION SWIVEL SEAT
WITH AND WITHOUT ELECTRONIC CONTROLS (→ S/N F001V01807D) ............................................ 1-36
WITH LIMITED BACK TILT (S/N F001V01808D ↔ S/N F001V03521H) .................................................. 1-38
G
GEAR HOUSING
YANMAR 2.6L DIESEL ............................................................................................................................... 2-98
GEAR PUMP ASSEMBLY
CHAIN DRIVE OPTION .............................................................................................................................. 9-12
GEAR DRIVE OPTION ............................................................................................................................... 9-10
H
HAND LEVERS
FOUR FUNCTION - WITHOUT DETENTED LEVERS ............................................................................... 9-24
FOUR FUNCTION - WITH DETENTED LEVERS ....................................................................................... 9-26
THREE FUNCTION - WITHOUT DETENTED LEVERS ............................................................................. 9-20
THREE FUNCTION - WITH DETENTED LEVERS ..................................................................................... 9-22
HEADER HOSE
THREE STAGE FULL FREE-LIFT - 8520000 SERIES (S/N B555V06632G →) ....................................... 12-32
THREE STAGE FULL FREE-LIFT - 8800000 SERIES ............................................................................... 12-36
THREE STAGE FULL FREE-LIFT - 8520000 SERIES (→ S/N B555V06631G) ....................................... 12-28
TWO STAGE FULL FREE- LIFT (10/2012 →) ........................................................................................... 11-40
DESCRIPTION PAGE
HEADER HOSE CONVERSION KITS
HEADER HOSES
TWO STAGE FULL FREE- LIFT (9/2009 ↔ 4/2011) ................................................................................. 11-32
TWO STAGE FULL FREE- LIFT (3/2011 ↔ 10/2012) ............................................................................... 11-36
TWO STAGE FULL FREE-LIFT (→ 9/2008) .............................................................................................. 11-28
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 10-18
HOOD
→ S/N F001V03576H ................................................................................................................................. 1-8
S/N F001V03577H ↔ S/N F001V03688H ................................................................................................. 1-10
S/N F001V03689H → ................................................................................................................................. 1-12
HYDRAULIC CONTROL VALVE
ELECTRO HYDRAULIC POPPET VALVE - HOIST AND LOWER ............................................................ 9-62
ELECTRONIC CONTROL - THREE AND FOUR FUNCTION (S/N F001V02519E ↔ 7/2009) ................. 9-56
ELECTRONIC CONTROL - THREE AND FOUR FUNCTION (7/2009 →) ................................................ 9-58
ELECTRONIC VALVE AUXILIARY ONE SECTION - THREE AND FOUR FUNCTION ............................ 9-66
ELECTRONIC VALVE AUXILIARY TWO SECTION - FOUR FUNCTION ................................................. 9-68
ELECTRONIC VALVE OUTLET SECTION - THREE AND FOUR FUNCTION (→ 7/2009) ...................... 9-70
ELECTRONIC VALVE OUTLET SECTION (7/2009 →) ............................................................................ 9-72
ELECTRONIC VALVE TILT SECTION - THREE AND FOUR FUNCTION ................................................ 9-64
HYDRAULIC CONTROLS
HYDRAULIC FILTER
→ S/N F001V03498G ................................................................................................................................ 9-13
S/N F001V03499G → ................................................................................................................................ 9-14
HYDRAULIC SUPPLY AND RETURN
WITH ALUMINUM TRANSMISSION - WITH GEAR DRIVE ....................................................................... 9-6
WITH ALUMINUM TRANSMISSION - WITH CHAIN DRIVE ...................................................................... 9-8
WITH IRON TRANSMISSION ..................................................................................................................... 9-4
I
IMPACT SENSOR ........................................................................................................................................... 4-10
INNER MAST
THREE STAGE FULL FREE-LIFT .............................................................................................................. 12-8
TWO STAGE FULL FREE-LIFT .................................................................................................................. 11-6
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 10-6
INSTRUMENT CLUSTER ............................................................................................................................... 4-51
INTAKE AND EXHAUST MANIFOLD
YANMAR 2.6L DIESEL ............................................................................................................................... 2-94
INTAKE AND EXHAUST MANIFOLDS
MAZDA 2.0L, GASOLINE AND LPG - 2005 AND 2006 EMISSION COMPLIANT
ENGINES (→ S/N F001V02238E) ............................................................................................................. 2-30
INTAKE MANIFOLD
MAZDA 2.0L, GASOLINE - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →) ............... 2-80
MAZDA 2.0L, LPG - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →) ........................... 2-82
INTEGRAL SIDE-SHIFT
FORK POSITIONER - TWO STAGE LIMITED FREE-LIFT ........................................................................ 13-22
FORK POSITIONER - THREE STAGE FULL FREE-LIFT .......................................................................... 13-24
INTEGRAL SIDE-SHIFT CARRIAGE
TWO AND THREE STAGE FULL FREE-LIFT ............................................................................................ 13-14
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 13-12
DESCRIPTION PAGE
INTEGRAL SIDE-SHIFT CYLINDER .............................................................................................................. 13-17
INTEGRAL SIDE-SHIFT HYDRAULIC HOSES
TWO AND THREE STAGE FULL FREE-LIFT (→ 4/2011) ........................................................................ 13-19
TWO AND THREE STAGE FULL FREE-LIFT (4/2011 →) ........................................................................ 13-20
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 13-18
INTERMEDIATE MAST
THREE STAGE FULL FREE-LIFT .............................................................................................................. 12-6
L
LABELS
EXTERIOR .................................................................................................................................................. 1-76
HYDRAULIC CONTROL LABELS - CONTROL LEVER ............................................................................. 1-86
INTERIOR ................................................................................................................................................... 1-78
LIGHT OPTIONS ............................................................................................................................................. 14-4
LOAD BACKREST EXTENSION ..................................................................................................................... 1-70
LOAD WEIGH ELECTRICAL .......................................................................................................................... 4-74
LPG TANK BRACKET
SWING OUT (→ S/N F001V02748E) ......................................................................................................... 3-52
SWING OUT (S/N F001V02749E →) ......................................................................................................... 3-54
SWING OUT, DROP DOWN (S/N F001V02749E →) ................................................................................ 3-62
SWING OUT/DROP DOWN (→ S/N F001V02748E) ................................................................................. 3-58
LUBRICATION SYSTEM
YANMAR 2.6L DIESEL ............................................................................................................................... 2-114
M
MAIN LIFT
THREE STAGE FULL FREE-LIFT .............................................................................................................. 12-10
TWO STAGE FULL FREE-LIFT .................................................................................................................. 11-8
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 10-8
MAIN LIFT CYLINDER
LEFT HAND - TWO STAGE LIMITED FREE-LIFT ..................................................................................... 10-14
LEFT HAND - TWO STAGE FULL FREE-LIFT ........................................................................................... 11-12
RIGHT HAND - TWO STAGE LIMITED FREE-LIFT ................................................................................... 10-12
RIGHT HAND - TWO STAGE FULL FREE-LIFT ........................................................................................ 11-10
THREE STAGE FULL FREE-LIFT - RIGHT HAND .................................................................................... 12-14
THREE STAGE FULL FREE-LIFT - LEFT HAND ....................................................................................... 12-16
MANUAL VALVE ANTI STALL GROUP
4/2014 → .................................................................................................................................................... 9-32
MAST ELECTRICAL
TILT SENSOR ............................................................................................................................................. 4-72
MAST INSTALLATION .................................................................................................................................... 9-74
MASTER CYLINDER ...................................................................................................................................... 8-12
MINI LEVER MODULE LABELS
HYDRAULIC CONTROL FUNCTIONS ....................................................................................................... 1-80
MINI-LEVER CONTROLS
WITH ARMREST - THREE FUNCTION (S/N F001V03522H →) .............................................................. 4-64
WITH ARMREST - FOUR FUNCTION (S/N F001V03522H →) ................................................................ 4-66
MIRRORS ........................................................................................................................................................ 13-8
MISCELLANEOUS KITS ................................................................................................................................. 14-5
DESCRIPTION PAGE
MIXER AND THROTTLE BODY ASSEMBLY
MAZDA 2.0L AND 2.2L LPG - 2007 EMISSION COMPLIANT ENGINES (2/2008 →) .............................. 3-42
MAZDA 2.0L, LPG - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E ↔ 2/2008) ............... 3-40
MONOTROL PEDAL ASSEMBLY
→ S/N F001V04303K ................................................................................................................................. 3-96
N
NON SUSPENSION SEAT
WITHOUT ELECTRONIC CONTROLS (S/N F001V01401 ↔ S/N F001V01501) ..................................... 1-14
WITHOUT ELECTRONIC CONTROLS (S/N F001V01501 ↔ S/N F001V03521H) ................................... 1-16
WITHOUT ELECTRONIC CONTROLS (S/N F001V03522H →) ............................................................... 1-18
WITHOUT ELECTRONIC CONTROLS - OPTIONAL ................................................................................. 1-20
O
OIL PAN
YANMAR 2.6L DIESEL ............................................................................................................................... 2-100
OIL PUMP AND FILTER
MAZDA 2.0L, GASOLINE AND LPG - 2005 AND 2006 EMISSION COMPLIANT
ENGINES (→ S/N F001V02238E) ............................................................................................................. 2-52
MAZDA 2.0L, GASOLINE AND LPG - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →)
.................................................................................................................................................................... 2-70
OUTER MAST
THREE STAGE FULL FREE-LIFT (→ S/N B555V13829L) ....................................................................... 12-2
THREE STAGE FULL FREE-LIFT (S/N B555V13830L →) ....................................................................... 12-4
TWO STAGE FULL FREE-LIFT (→ S/N B559V02695L) ........................................................................... 11-2
TWO STAGE FULL FREE-LIFT (S/N B559V02696L →) ........................................................................... 11-4
TWO STAGE LIMITED FREE-LIFT (→ S/N B551V03957L) ...................................................................... 10-2
TWO STAGE LIMITED FREE-LIFT (S/N B551V03958L →) ...................................................................... 10-4
OUTLET SECTION
MANUAL CONTROL VALVE - THREE AND FOUR FUNCTION ............................................................... 9-50
OVERHEAD EXHAUST
MAZDA 2.0L GASOLINE AND LPG - WITH CATALYTIC CONVERTER (→ S/N F001V02238E) ............ 2-20
WITHOUT PURIFIER - YANMAR 2.6L DIESEL ......................................................................................... 2-92
OVERHEAD GUARD ...................................................................................................................................... 1-6
P
PARK BRAKE
→ S/N F001V03571H ................................................................................................................................. 8-18
S/N F001V03572H → ................................................................................................................................. 8-20
POWER DISTRIBUTION MODULE
→ S/N F001V02055D ................................................................................................................................. 4-40
S/N F001V02056D → ................................................................................................................................. 4-42
R
REMOTE KEY SWITCH .................................................................................................................................. 4-12
RETURN TO SET TILT KITS .......................................................................................................................... 14-2
REVERSE CLUTCH
COUNTER - SINGLE SPEED (→ S/N F001V02229E) .............................................................................. 5-58
REVERSE CLUTCH (COUNTER)
SINGLE SPEED (→ S/N F001V02230E) ................................................................................................... 5-60
DESCRIPTION PAGE
SINGLE SPEED (S/N T141M001501 →) (S/N T148M001501 →) ............................................................ 5-62
S
SEAT CONVERSION KITS ............................................................................................................................. 14-5
SEMI SUSPENSION SEAT
WITH AND WITHOUT ELECTRONIC CONTROLS (S/N F001V01501 ↔ S/N F001V03040F) ................ 1-24
SEMI-SUSPENSION SEAT
WITH AND WITHOUT ELECTRONIC CONTROLS (S/N F001V01401 ↔ S/N F001V01501) .................. 1-22
WITH AND WITHOUT ELECTRONIC CONTROLS (S/N F001V03040F ↔ S/N F001V03521H) .............. 1-26
WITH AND WITHOUT ELECTRONIC CONTROLS (S/N F001V03522H →) ............................................ 1-28
STATOR SUPPORT HOUSING ...................................................................................................................... 5-50
STEER TIRES AND WHEELS ........................................................................................................................ 7-16
STEERING AXLE ............................................................................................................................................ 7-12
STEERING COLUMN AND ATTACHING PARTS
DIESEL ........................................................................................................................................................ 7-5
GASOLINE AND LPG ................................................................................................................................. 7-4
STEERING COLUMN ASSEMBLY ................................................................................................................. 7-6
ISOLATED, DIESEL .................................................................................................................................... 7-8
STEERING CONTROL UNIT .......................................................................................................................... 7-10
STEERING CYLINDER ................................................................................................................................... 7-14
STEERING SYSTEM ...................................................................................................................................... 7-2
STROBE LIGHT
→ S/N F001V02545E ................................................................................................................................. 13-2
LED (S/N F001V02546E →) ...................................................................................................................... 13-4
T
THROTTLE BODY AND ATTACHING PARTS
MAZDA 2.0L, GASOLINE - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →) ............... 3-31
THROTTLE CABLE
MECHANICAL THROTTLE - DIESEL (→ 10/2013) ................................................................................... 3-80
MECHANICAL THROTTLE - YANMAR DIESEL (10/2013 →) .................................................................. 3-82
THROTTLE CABLE LINKAGE
YANMAR DIESEL ....................................................................................................................................... 3-78
THROTTLE LINKAGE
GASOLINE .................................................................................................................................................. 3-88
LPG ............................................................................................................................................................. 3-91
THROTTLE PEDAL AND ATTACHING PARTS
MONOTROL PEDAL (LPG) (→ S/N F001V04303K) ................................................................................. 3-94
THROTTLE PEDAL ASSEMBLY AND ATTACHING PARTS
MONOTROL (S/N F001V04304K →) ......................................................................................................... 3-98
STANDARD PEDAL .................................................................................................................................... 3-92
TILT CYLINDERS
LEFT HAND ................................................................................................................................................ 9-78
RIGHT HAND .............................................................................................................................................. 9-76
TILT/HOIST AND AUXILIARY HOSES ........................................................................................................... 9-16
TIMING GEAR AND OIL PAN
MAZDA 2.0L, GASOLINE AND LPG - 2005 AND 2006 EMISSION COMPLIANT
ENGINES (→ S/N F001V02238E) ............................................................................................................. 2-46
DESCRIPTION PAGE
TIMING GEAR COVER AND OIL PAN
MAZDA 2.0L, GASOLINE AND LPG - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →)
.................................................................................................................................................................... 2-68
TORQUE CONVERTER .................................................................................................................................. 5-7
TORQUE CONVERTER HOUSING AND ATTACHING PARTS
SINGLE SPEED (S/N T141M001501 →) ................................................................................................... 5-40
SINGLE SPEED - ALUMINUM CHAIN DRIVE (2/2011 →) ....................................................................... 5-46
TRANSMISSION
SINGLE SPEED - SHEET 1 OF 2 (→ S/N F001V01948D EXC. 1930-1936, 1938-1942, 1944-1946) ..... 5-18
SINGLE SPEED - SHEET 2 OF 2 (→ S/N F001V01948D EXC. 1930-1936, 1938-1942, 1944-1946) ..... 5-22
SINGLE SPEED - SHEET 1 OF
2 (S/N F001V01949D ↔ S/N F001V02229E INC. 1930-1936, 1938-1942, 1944-1946) ........................... 5-24
SINGLE SPEED - SHEET 2 OF
2 (S/N F001V01949D ↔ S/N F001V02229E INC. 1930-1936, 1938-1942, 1944-1946) ........................... 5-28
SINGLE SPEED - SHEET 1 OF 2 (S/N T133M0001501 → (DRY BRAKE)) (S/N F001V02230E →) ...... 5-30
SINGLE SPEED - SHEET 2 OF 2 (S/N T133M0001501 → (DRY BRAKE)) (S/N F001V02230E →) ...... 5-32
TRANSMISSION COOLING
MAZDA 2.0L (→ S/N F001V03310F) ......................................................................................................... 5-8
MAZDA 2.0L (S/N F001V03311F →) ......................................................................................................... 5-10
YANMAR DIESEL (→ S/N F001V03310F) ................................................................................................ 5-12
YANMAR DIESEL (S/N F001V03311F →) ................................................................................................ 5-14
YANMAR DIESEL (2/2011 →) ................................................................................................................... 5-16
TRANSMISSION ELECTRICAL SYSTEM ...................................................................................................... 4-70
TRANSMISSION HOUSING AND ASSEMBLY
SINGLE SPEED (S/N T141M001501 →) ................................................................................................... 5-36
SINGLE SPEED - ALUMINUM CHAIN DRIVE (2/2011 →) ....................................................................... 5-42
TRANSMISSION MOUNT
→ 9/2009 (T117M, T133M) ........................................................................................................................ 5-2
S/N T141M001501 → ................................................................................................................................. 5-4
SINGLE SPEED - ALUMINUM CHAIN DRIVE (2/2011 →) ....................................................................... 5-6
V
VALVE ASSEMBLY, LIFT AND LOWER
ELECTRONIC CONTROL VALVE - THREE AND FOUR FUNCTION (→ S/N F001V02519E) ................ 9-54
ELECTRONIC VALVE INLET SECTION - THREE AND FOUR FUNCTION .............................................. 9-60
VALVE ASSEMBLY, LIFT AND TILT
MANUAL CONTROL VALVE - THREE AND FOUR FUNCTION (→ S/N F001V02621E) ........................ 9-38
MANUAL CONTROL VALVE - THREE AND FOUR FUNCTION (S/N F001V02622E ↔ 4/2014) ............ 9-40
MANUAL CONTROL VALVE - THREE AND FOUR FUNCTION (4/2014 →) ........................................... 9-42
W
WATER PUMP
YANMAR 2.6L DIESEL ............................................................................................................................... 2-112
WEATHER PROTECTION .............................................................................................................................. 1-88
WEATHER PROTECTION KITS ..................................................................................................................... 14-5
WIDE TIRE CONVERSION ............................................................................................................................. 14-2
WIRE HARNESS
ALTERNATOR ............................................................................................................................................ 4-232
BACK-UP ALARM ....................................................................................................................................... 13-11
DESCRIPTION PAGE
COWL WITH FORWARD/REVERSE - MANUAL WITH OPERATOR PRESENCE (→ S/N F001V03571H)
.................................................................................................................................................................... 4-222
COWL WITH FORWARD/REVERSE LEVER (→ S/N F001V03571H) ...................................................... 4-214
COWL WITH FORWARD/REVERSE LEVER - WITHOUT RETURN TO SET TILT (S/N F001V03572H →)
.................................................................................................................................................................... 4-218
COWL WITH FORWARD/REVERSE LEVER - WITH HYDRAULIC PUMP
SOLENOID (S/N F001V03572H →) ........................................................................................................... 4-226
COWL WITH MONOTROL PEDAL (→ S/N F001V03572H) ...................................................................... 4-198
COWL WITH MONOTROL PEDAL - WITH RETURN TO SET TILT (S/N F001V03572H →) ................... 4-202
COWL WITH MONOTROL PEDAL - WITH HYDRAULIC PUMP SOLENOID (→ S/N F001V03571H) .... 4-206
COWL WITH MONOTROL PEDAL - WITH HYDRAULIC PUMP SOLENOID (S/N F001V03572H →) .... 4-210
ELECTRONIC CONTROL VALVE - 3 FUNCTION ..................................................................................... 4-234
ELECTRONIC CONTROL VALVE - 4 FUNCTION ..................................................................................... 4-236
GASOLINE ENGINE - MAZDA 2.0L (→ S/N F001V02037D) .................................................................... 4-160
GASOLINE ENGINE - MAZDA 2.0L (S/N F001V02038D ↔ S/N F001V02238E) ..................................... 4-164
LIGHTS (→ S/N F001V02042D) ................................................................................................................ 4-244
LIGHTS (S/N F001V02043D →) ................................................................................................................ 4-246
LIGHTS (6/2007 →) ................................................................................................................................... 4-248
LPG ENGINE - MAZDA 2.0L (→ S/N F001V02037D) ............................................................................... 4-174
LPG ENGINE - MAZDA 2.0L (S/N F001V02038D ↔ S/N F001V02238E) ................................................ 4-176
RH CHASSIS - MAZDA 2.0L (→ 2/2006) ................................................................................................... 4-78
RH CHASSIS - MAZDA LPG 2.0L (→ S/N F001V02037D) ....................................................................... 4-82
RH CHASSIS - MAZDA 2.0L (S/N F001V02038D ↔ S/N F001V02238E) ................................................ 4-88
RH CHASSIS - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E ↔ S/N F001V03139F)
.................................................................................................................................................................... 4-94
RH CHASSIS - MAZDA, WITH ANTI-STALL (S/N F001V03140F →) ....................................................... 4-100
RH CHASSIS - MAZDA (S/N F001V03622H →) ....................................................................................... 4-106
RH CHASSIS - MAZDA-WITHOUT SEAT BELT SEQUENCE MODULE (1/2013 →) ............................... 4-112
RH CHASSIS - MAZDA-WITH SEAT BELT SEQUENCE MODULE .......................................................... 4-118
RH CHASSIS - YANMAR DIESEL (→ 2/2006) .......................................................................................... 4-124
RH CHASSIS - YANMAR DIESEL (→ S/N F001V02036D) ....................................................................... 4-128
RH CHASSIS - YANMAR DIESEL (S/N F001V02037D →) ....................................................................... 4-134
RH CHASSIS - YANMAR DIESEL (S/N F001V03622H →) ....................................................................... 4-140
RH CHASSIS - YANMAR-WITHOUT SEAT BELT SEQUENCE MODULE (1/2013 →) ............................ 4-146
RH CHASSIS - YANMAR-WITH SEAT BELT SEQUENCE MODULE ....................................................... 4-152
SEALED ALTERNATOR - MAZDA 2.0L (S/N F001V02239E →) .............................................................. 4-230
SEAT JUMPER (S/N F001V03522H →) .................................................................................................... 4-158
TRANSMISSION - SINGLE SPEED (→ S/N F001V02037D) .................................................................... 4-238
TRANSMISSION - SINGLE SPEED (S/N F001V02038D ↔ 9/2009) ........................................................ 4-240
TRANSMISSION - SINGLE SPEED (10/2009 →) ..................................................................................... 4-242
YANMAR DIESEL (→ S/N F001V02037D) ................................................................................................ 4-190
YANMAR DIESEL (S/N F001V02038D →) ................................................................................................ 4-194
WIRE HARNESS (ENGINE)
MAZDA 2.0L AND 2.2L LPG - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239V →) ........... 4-178
MAZDA 2.0L AND 2.2L LPG - 2010 SERIES .............................................................................................. 4-184
MAZDA 2.0L, GASOLINE - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →) ............... 4-168
WORK, REAR DRIVE, AND BRAKE/TAIL LIGHTS ........................................................................................ 4-68
Listed below are abbreviations used in parts manuals to denote the following expressions:
spacer
TERM DEFINITION TERM DEFINITION
Amp Amperes FRE Freezer Environment
AR As Required in. inches
BDI Battery Discharge Indicators LPG Liquefied Petroleum Gas
BWI Brush Wear Indicator MAP Manifold Absolute Pressure
CE Communicator End mm millimeters
CRE Corrosive Environment MSTS Microprocessor Spark Timing System
D/B Date Break NPT National Pipe Threads
dbA Decibel "A" Scale O/S Oversize
DE Drive End PTO Power Take Off
ECH Empty Container Handler RPM Revolutions per Minute
ECH-3 Empty Container Handler - 3 High S/N Serial Number
Stacking TMM Truck Management Module
ECH-4 Empty Container Handler - 4 High UL Type D Diesel-Powered Safety Rating
Stacking
UL Type DS Diesel-Powered Safety Rating
ECH-5 Empty Container Handler - 5 High
Stacking UL Type E Battery-Powered Safety Rating
This parts manual describes and illustrates assemblies, The different constructions are indicated by keys and
subassemblies, and detail parts needed for service footnotes. The callouts correspond to descriptions
replacement. found on the next page.
This manual contains serial number specific parts NOTE: This lift truck may contain special content. Every
information. Every effort has been made to provide you effort has been made to reflect that information in this
a manual that reflects your fork lift truck as it was manual. The user is advised to refer to the special
manufactured. The serial number for your truck is content information that pertains to this specific serial
shown on the front cover of this manual. number truck.
Parts that are specific to your truck are identified in If your truck contains special content a Special Parts
bold lettering in the parts list. Parts that are not specific Information section is included as the last section of this
are in gray lettering. Entire figures that are not manual. Use the section table of contents to locate. This
applicable to your truck are completely grayed out, section contains parts lists and drawings for the special
these are also shown as grayed items in the Table of content added to the lift truck.
Contents. If an entire section was not applicable to your
truck it was not included in this publication. When possible a SPI icon ( ) will be placed in the parts
list denoting that the part number has been replaced by
Please note that it is possible that not all items specific a special equipment design part number. Please refer
to your truck will be shown in bold lettering. In this case to the SPI section for information on these parts. The
refer to the grayed items and the illustration for proper SPI icon in a table of contents is a quick reference
parts ordering. If a part still cannot be identified, please showing which figures are part of the SPI section.
consult your local dealer for Hyster lift trucks.
(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 Hyster lift trucks.
Parts referred to in this book as right or left hand parts are in accordance with the illustration above.
(1) and (2) The first letter and number indicates the mast unit code.
(3) The second letter indicates the plant of manufacture.
(4) The four or five digit number indicates the production sequence number of the mast.
(5) Carriage travel in millimeters stamped just below the serial number.
Mast Group identification consists of mast unit code (1) and (2) plus carriage travel (5).
For pending production sequence numbers contact your local dealer for Hyster lift trucks.
(1) and (2) The first letter and three numbers indicate the attachment unit code.
(3) The second letter indicates the plant of manufacture.
(4) The four or five digit number indicates the production sequence number.
For pending production sequence numbers contact your local dealer for Hyster lift trucks.
Side-shift carriages and attachments have nameplates. Use the serial number found on the nameplate to identify
the attachment.
Always refer to the group, serial, or part number when ordering service parts.
Modifications of attachments and side-shift carriages by SPED (Special Products Engineering Department) are
identified by a model prefix code beginning with the letter "S". Contact your dealer for Hyster lift trucks for information
on these assemblies.
PUBLICATIONS
Every new lift truck is provided with an OPERATING MANUALS with complete replacement part
MANUAL. This manual has information that the identification, are available at a nominal fee from your
operator must know for inspection and operation of the Hyster dealer to assist users in effectively maintaining
lift truck. Hyster 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
1 FRAME
UNIT CODE F001
03/2014 NORTH AMERICA
SECTION 1
FRAME
DESCRIPTION PAGE
ARMREST ASSEMBLY
MINI-LEVER MODULES - SEMI-SUSPENSION SEAT WITH HIP RESTRAINTS (S/N F001V03522H →)
.................................................................................................................................................................... 1-50
MINI-LEVER MODULES - FULL SUSPENSION SEAT (S/N F001V03522H →) ....................................... 1-52
COUNTERWEIGHT
→ 4/2007 .................................................................................................................................................... 1-3
4/2007 → .................................................................................................................................................... 1-4
COWL MOUNTING ......................................................................................................................................... 1-66
ELECTRONIC LEVER LABELS
AUXILIARY DUAL FUNCTION ................................................................................................................... 1-84
AUXILIARY SINGLE FUNCTION ................................................................................................................ 1-82
FENDER EXTENSIONS AND MUD GUARDS ............................................................................................... 1-68
FLOORPLATES AND COVERS
→ S/N F001V02859F EXC. 02851 ............................................................................................................. 1-54
S/N F001V02860F ↔ S/N F001V03334G INC. 02851 .............................................................................. 1-58
S/N F001V03335G → ................................................................................................................................ 1-62
FORKS ............................................................................................................................................................ 1-72
OPTIONAL .................................................................................................................................................. 1-73
FULL SUSPENSION SEAT
MANUAL AND ELECTRO-HYDRAULIC — SWIVEL AND NON SWIVEL - SHEET 1 OF
4 (S/N F001V03522H →) ........................................................................................................................... 1-40
RECLINER AND DAMPER KITS - SHEET 3 OF 4 (S/N F001V03522H →) .............................................. 1-44
SERVICE KITS FOR NON SWIVEL AND SWIVEL - SHEET 2 OF 4 (S/N F001V03522H →) .................. 1-42
WITH AND WITHOUT ELECTRONIC CONTROLS (S/N F001V01401 ↔ S/N F001V01501) .................. 1-30
WITH AND WITHOUT ELECTRONIC CONTROLS (S/N F001V01501 ↔ S/N F001V01792D) ................ 1-32
WITH LIMITED BACK TILT (S/N F001V01793D ↔ S/N F001V03521H) .................................................. 1-34
FULL SUSPENSION SEAT ATTACHING PARTS
NOT INCLUDED WITH SEAT - SHEET 4 OF 4 WITH MANUAL HYDRAULICS (S/N F001V03522H →)
.................................................................................................................................................................... 1-46
NOT INCLUDED WITH SEAT - SHEET 4 OF 4 WITH ELECTRO-HYDRAULICS (S/N F001V03522H →)
.................................................................................................................................................................... 1-48
FULL SUSPENSION SWIVEL SEAT
WITH AND WITHOUT ELECTRONIC CONTROLS (→ S/N F001V01807D) ............................................ 1-36
WITH LIMITED BACK TILT (S/N F001V01808D ↔ S/N F001V03521H) .................................................. 1-38
HOOD
→ S/N F001V03576H ................................................................................................................................. 1-8
S/N F001V03577H ↔ S/N F001V03688H ................................................................................................. 1-10
S/N F001V03689H → ................................................................................................................................. 1-12
LABELS
EXTERIOR .................................................................................................................................................. 1-76
HYDRAULIC CONTROL LABELS - CONTROL LEVER ............................................................................. 1-86
INTERIOR ................................................................................................................................................... 1-78
LOAD BACKREST EXTENSION ..................................................................................................................... 1-70
MINI LEVER MODULE LABELS
HYDRAULIC CONTROL FUNCTIONS ....................................................................................................... 1-80
NON SUSPENSION SEAT
WITHOUT ELECTRONIC CONTROLS (S/N F001V01401 ↔ S/N F001V01501) ..................................... 1-14
WITHOUT ELECTRONIC CONTROLS (S/N F001V01501 ↔ S/N F001V03521H) ................................... 1-16
WITHOUT ELECTRONIC CONTROLS (S/N F001V03522H →) ............................................................... 1-18
©2014 HYSTER COMPANY See Service Manual 1-1
for service procedures.
UNIT CODE F001
NORTH AMERICA 03/2014
SECTION 1
FRAME
DESCRIPTION PAGE
FOOTNOTES:
a → 4/2014
NOTES
OVERHEAD GUARD
ITEM PART NO. DESCRIPTION QTY
1 b 1599203
4051143 Overhead Guard (Standard) ............................................................................. 1
1 a 1599209
4051144 Overhead Guard (Optional) ................................................................................ 1
2 4035130 Capscrew ........................................................................................................... 2
3 1370949
1528888 Nut (Shoulder) ................................................................................................... 2
4 1536813 Handle (Grab) .................................................................................................... 1
5 1583611 Capscrew ........................................................................................................... 2
6 1531557 Insert .................................................................................................................. 4
7 1558219 Grommet ............................................................................................................ 2
8 1560671 Grommet ............................................................................................................ 1
9 1494888 Plug .................................................................................................................... 4
10 1599415 Plug .................................................................................................................... 1
11 1586495 Capscrew ........................................................................................................... 2
12 1531558 Insert .................................................................................................................. 2
13 1598220 Grommet ............................................................................................................ 1
14 1527395 Grommet ............................................................................................................. 1
14 362255 Grommet (Alternate Part) ................................................................................. 1
15 1500912 Clip ..................................................................................................................... 1
16 1582464 Fastener ............................................................................................................. 1
17 2070223 Handle (Assembly) (Optional) ......................................................................... 1
17 2069454 Handle ........................................................................................................... 1
17 1566726 Push Button Switch (Horn) .......................................................................... 1
17 1493465 Connector (2 Pin) ......................................................................................... 1
17 1330414 Connector (Secondary Lock) ...................................................................... 1
17 1330437 Terminal (Pin) ............................................................................................... 2
18 1527888 Capscrew ........................................................................................................... 6
18 1566853 Capscrew (Optional) ......................................................................................... 6
FOOTNOTES:
a 82 in. Overhead Guard b 85 in. Overhead Guard
HOOD
(→ S/N F001V03576H)
HOOD
(S/N F001V03577H ↔ S/N F001V03688H)
FOOTNOTES:
a With lift and latch option
HOOD
(S/N F001V03689H →)
FOOTNOTES:
a With Lift and Latch Option b Without Lift and Latch Option
FOOTNOTES:
a Not Illustrated d S/N F001V02932F ↔ S/N F001V03341G
b → S/N F001V02931F e S/N F001V02932F →
c → S/N F001V03341G INC. 03353 f S/N F001V03342G → EXC. 03353
FOOTNOTES:
a Not Illustrated
SEMI-SUSPENSION SEAT
WITH AND WITHOUT ELECTRONIC CONTROLS (S/N F001V01401 ↔ S/N F001V01501)
KEY:
A: Without Arm Controls
B: With Arm Controls
QTY
ITEM PART NO. DESCRIPTION A B
1 1585989 Seat-Semi Suspension (Vinyl) ................................................................... 1 ..
1 1585990 Seat-Semi Suspension (Cloth) ................................................................... 1 ..
1 1585981 Seat-Semi Suspension (Vinyl) ................................................................... .. 1
1 1585982 Seat-Semi Suspension (Cloth) ................................................................... .. 1
2 1362058 Kit-Manual Holder .................................................................................. 1 1
3 1382111 Seat Cushion (Back Cushion) (Vinyl) .................................................... 1 1
3 1382113 Seat Cushion (Back Cushion) (Cloth) .................................................... 1 1
4 1563224 Hip Restraint (LH) .................................................................................. 1 1
4 1563225 Hip Restraint (RH) ................................................................................. 1 ..
5 1470158 Kit-Seat Belt ........................................................................................... 1 1
6 1382112 Seat Cushion (Vinyl) .............................................................................. .. 1
6 1382114 Seat Cushion (Cloth) ............................................................................. .. 1
7 1483023 Guide ..................................................................................................... 1 1
8 1563227 Knob ...................................................................................................... 1 1
9 1459173 Kit-Seat Rail ........................................................................................... 1 1
10 2075428 Wire Harness (With Electronic Controls) ............................................... .. 1
10 2089673 Wire Harness (With Hip Restraints) ....................................................... 1 ..
11 191941 Nut .............................................................................................................. 4 4
a 1563211 Knob (Electronic Control Arm) ................................................................... .. 1
a 1362049 Kit-Shock Absorber .................................................................................... 1 1
a 1563215 Sensor (Operator Presence) ...................................................................... 1 1
a 1563210 Cap (Electronic Control Arm) ..................................................................... .. 1
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Not Illustrated c → S/N F001V03048F
b → S/N F001V01954D INC. 01996, 01998, 02000, d S/N F001V01955D → EXC. 01996, 01998, 02000,
02002, 02005, 02010 02002, 02005, 02010
SEMI-SUSPENSION SEAT
WITH AND WITHOUT ELECTRONIC CONTROLS (S/N F001V03040F ↔ S/N F001V03521H)
KEY:
A: With Hip Restraints
B: With Electronic Control Arm
QTY
ITEM PART NO. DESCRIPTION A B
e 2102126 Seat-Semi Suspension (Vinyl) ................................................................... 1 ..
g 2103364 Seat-Semi Suspension (Vinyl) ................................................................... 1 ..
e 2102127 Seat-Semi Suspension (Cloth) ................................................................... 1 ..
g 2103365 Seat-Semi Suspension (Cloth) ................................................................... 1 ..
d 2102128 Seat-Semi Suspension (Vinyl) ................................................................... .. 1
g 2103366 Seat-Semi Suspension (Vinyl) ................................................................... .. 1
f 2102129 Seat-Semi Suspension (Cloth) ................................................................... .. 1
g 2103367 Seat-Semi Suspension (Cloth) ................................................................... .. 1
1 1382111 Seat Cushion (Back Cushion) (Vinyl) .................................................... 1 1
1 1382113 Seat Cushion (Back Cushion) (Cloth) .................................................... 1 1
2 1563224 Hip Restraint (LH) .................................................................................. 1 1
2 1563225 Hip Restraint (RH) ................................................................................. 1 ..
3 1598504 Kit-Seat Belt (Black) ............................................................................... 1 1
3 1636120 Kit-Red Seat Belt ................................................................................... 1 1
4 1382112 Seat Cushion (Vinyl) .............................................................................. 1 1
4 1382114 Seat Cushion (Cloth) ............................................................................. 1 1
4 c 1563215 Sensor (Operator Presence) .................................................................. 1 1
4 g 1709876 Sensor (Operator Presence) .................................................................. 1 1
ag 4002682 Bracket (Operator Presence Sensor) .................................................... 1 1
5 b 1483023 Guide ..................................................................................................... 1 1
6 1563227 Knob ...................................................................................................... 1 1
7 1690995 Kit-Seat Rail ........................................................................................... 1 ..
8 302400 Nut ......................................................................................................... 4 4
8 a 1677286 Stud ....................................................................................................... 4 4
9 1362058 Kit-Manual Holder .................................................................................. 1 1
10 1591652 Wire Harness ......................................................................................... 1 ..
10 1654891 Wire Harness ......................................................................................... .. 1
11 1500901 Clip ............................................................................................................. 1 1
12 296149 Capscrew ................................................................................................... 1 1
13 1500912 Clip ............................................................................................................. 1 1
14 1537551 Nut (Clip) .................................................................................................... 1 1
a 1362049 Kit-Shock Absorber .................................................................................... 1 1
a 1647532 Foam for Right hand Forearm Cushion/Rest ............................................. .. 1
a 1563211 Knob (Electronic Control Arm) ................................................................... .. 1
FOOTNOTES:
a Not Illustrated e S/N F001V03047F ↔ S/N F001V03342G
b Not used with 2102126 f S/N F001V03054F ↔ S/N F001V03342G
c → S/N F001V03342G g S/N F001V03343F →
d S/N F001V03041F ↔ S/N F001V03342G
SEMI-SUSPENSION SEAT
WITH AND WITHOUT ELECTRONIC CONTROLS (S/N F001V03522H →)
KEY:
A: With Hip Restraints
B: With Electronic Control Arm
QTY
ITEM PART NO. DESCRIPTION A B
4601836 Seat-Semi Suspension (Vinyl) ................................................................... 1 ..
4601837 Seat-Semi Suspension (Cloth) ................................................................... 1 ..
4005807 Seat-Semi Suspension (Vinyl) ................................................................... .. 1
4005808 Seat-Semi Suspension (Cloth) ................................................................... .. 1
1 a 1382111 Seat Cushion (Back Cushion) (Vinyl) .................................................... 1 1
1 a 1382113 Seat Cushion (Back Cushion) (Cloth) .................................................... 1 1
2 a 1382112 Seat Cushion (Vinyl) .............................................................................. 1 1
2 a 1382114 Seat Cushion (Cloth) ............................................................................. 1 1
3 a 1709876 Sensor (Operator Presence) .................................................................. 1 1
4 a 4002682 Bracket (Operator Presence Sensor) .................................................... 1 1
5 a 1563227 Knob ...................................................................................................... 1 1
6 a 1690995 Kit-Seat Rail ........................................................................................... 1 1
7 a 4013095 Wire Harness ......................................................................................... 1 1
8 a 1563224 Hip Restraint (LH) .................................................................................. 1 1
9 a 1563225 Hip Restraint (RH) ................................................................................. 1 ..
9 ..... Armrest w/Electro Hydraulic Mini Levers ................................................... .. 1
9 4005010 Armrest (Slider for Mini Lever) (RH) (FFigure 1-25)............................. .. 1
10 1677286 Stud ............................................................................................................ 4 4
11 313828 Nut .............................................................................................................. 4 4
12 2107969 Cover (Seat-Side Electrical) ....................................................................... 1 1
13 296357 Washer ....................................................................................................... 2 2
14 1694830 Capscrew ................................................................................................... 2 2
15 1598504 Kit-Seat Belt (Black) ................................................................................... 1 1
15 1636120 Kit-Red Seat Belt ........................................................................................ 1 1
16 4008420 Cover Plate ................................................................................................ 1 1
17 1581852 Washer ....................................................................................................... 4 5
18 221533 Capscrew ................................................................................................... 2 1
18 221530 Capscrew (RH) ........................................................................................... .. 1
19 19901 Roll Pin ....................................................................................................... 1 1
20 ..... Capscrew ................................................................................................... 8 8
b 221353 Locknut (For Use with Item 18) .................................................................. .. 1
ab 1362049 Kit-Shock Absorber .................................................................................... 1 1
ab 1362058 Kit-Manual Holder ...................................................................................... 1 1
ab 4041515 Seat Pan .................................................................................................... 1 1
FOOTNOTES:
a Included With Seat b Not Illustrated
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Not Illustrated c S/N F001V01955D →
b S/N F001V01808D ↔ S/N F001V01954D
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Included with seat b Not Illustrated
FOOTNOTES:
a Included with Seat b Included with Seat and Non Swivel/Swivel Sets
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Not Illustrated
ARMREST ASSEMBLY
MINI-LEVER MODULES – SEMI-SUSPENSION SEAT WITH HIP RESTRAINTS (S/N F001V03522H →)
ARMREST ASSEMBLY
MINI-LEVER MODULES – FULL SUSPENSION SEAT (S/N F001V03522H →)
FOOTNOTES:
a Gasoline c LPG
b Gasoline and Diesel
NOTES
FOOTNOTES:
a Gasoline d → S/N F001V03033F
b Gasoline and Diesel e S/N F001V03034F →
c LPG
NOTES
FOOTNOTES:
a Not Illustrated d → S/N F001V03357G
b Not required with fender extension e 1/2013 →
c → 1/2013 f S/N F001V03358G →
NOTES
COWL MOUNTING
ITEM PART NO. DESCRIPTION QTY
1 1583611 Capscrew ........................................................................................................... 2
2 a 1566545 Cowl .................................................................................................................... 1
2 b 1686708 Cowl .................................................................................................................... 1
2 c 1704990 Cowl ................................................................................................................... 1
3 1530243 Insert .................................................................................................................. 2
4 1640776 Insert .................................................................................................................. 7
4 1581567 Nut (Optional) .................................................................................................... 7
4 320160 Washer (Optional) ............................................................................................... 7
5 1605990 Capscrew ............................................................................................................ 7
FOOTNOTES:
a → S/N F001V03055F c 5/2010 →
b S/N F001V03056F ↔ 5/2010
KEY:
A: 100 mm x 40 mm (4 in. x 1.5 in.) Standard Taper
B: 100 mm x 40 mm (4 in. x 1.5 in.) Full Bottom Taper
NOTE: This parts list contains multiple truck configurations, refer to the KEY to choose the correct QTY column
for your truck.
QTY
ITEM PART NO. DESCRIPTION A B
1 384211 Fork (36 in.) ................................................................................................ 2 ..
1 384213 Fork (42 in.) ................................................................................................ 2 ..
1 384214 Fork (48 in.) ................................................................................................ 2 ..
1 384215 Fork (54 in.) ............................................................................................... 2 ..
1 384216 Fork (60 in.) ................................................................................................ 2 ..
1 1338076 Fork (36 in.) ................................................................................................ .. 2
1 1338077 Fork (42 in.) ................................................................................................ .. 2
1 1338078 Fork (48 in.) ................................................................................................ .. 2
2 1523732 Knob .......................................................................................................... 1 1
3 1477167 Wedge Band .............................................................................................. 1 1
4 1477166 Washer ....................................................................................................... 1 1
5 1500782 Spring ........................................................................................................ 1 1
6 1523733 Pin .............................................................................................................. 1 1
1523734 Pin (Not Illustrated) .................................................................................. 1 1
1523735 Kit-Latch (Includes Items 2-7) .................................................................... 2 2
KEY:
A: 100 mm x 40 mm Standard Taper
B: 100 mm x 40 mm Full Bottom Taper
QTY
ITEM PART NO. DESCRIPTION A B
1 1378786 Fork (36 in.) ................................................................................................ 2 ..
1 1378788 Fork (42 in.) ................................................................................................ 2 ..
1 1378789 Fork (48 in.) ................................................................................................ 2 ..
1 1378790 Fork (54 in.) ................................................................................................ 2 ..
1 1378791 Fork (60 in.) ................................................................................................ 2 ..
1 1378798 Fork (36 in.) ................................................................................................ .. 2
1 1378799 Fork (42 in.) ................................................................................................ .. 2
1 1378800 Fork (48 in.) ................................................................................................ .. 2
1 4083370 Fork (36 in.) ................................................................................................ 2 ..
1 4083372 Fork (42 in.) ................................................................................................ 2 ..
1 4083373 Fork (48 in.) ................................................................................................ 2 ..
1 4083374 Fork (54 in.) ................................................................................................ 2 ..
1 4083375 Fork (60 in.) ................................................................................................ 2 ..
1 4083383 Fork (36 in.) ................................................................................................ .. 2
1 4083384 Fork (42 in.) ................................................................................................ .. 2
1 4083385 Fork (48 in.) ................................................................................................ .. 2
2 302450 Roll Pin ....................................................................................................... 1 1
2 4083647 Pin .............................................................................................................. 1 1
3 1378763 Latch .......................................................................................................... 1 1
3 4083646 Lever .......................................................................................................... 1 1
4 1378762 Spring ......................................................................................................... 1 1
4 4083648 Spring ......................................................................................................... 1 1
5 1378760 Pin .............................................................................................................. 1 1
5 4083649 Pin .............................................................................................................. 1 1
KEY:
A: 100 mm x 40 mm Standard Taper
B: 100 mm x 40 mm Full Bottom Taper
QTY
ITEM PART NO. DESCRIPTION A B
1378765 Kit-Latch (Class II) (Includes Items 2-5) ..................................................... 2 2
4083888 Kit Fork Latch Mechanism (Class 2A) (Includes Items 2-5) ....................... 2 2
NOTES
LABELS
EXTERIOR
FOOTNOTES:
a Contact Your Local Hyster Dealer d → S/N F001V03055F
b Diesel Only e S/N F001V03056F →
c LPG Only
LABELS
INTERIOR
FOOTNOTES:
a Contact Your Local Hyster Dealer b Electric Transmission
LABELS
HYDRAULIC CONTROL LABELS – CONTROL LEVER
WEATHER PROTECTION
ITEM PART NO. DESCRIPTION QTY
1 1616510 Kit-Front Screen W Wiper ................................................................................... 1
1 1616514 Frame ............................................................................................................. 1
2 1616543 Glass .............................................................................................................. 1
3 1616549 Reservoir ........................................................................................................ 1
4 2043353 Switch (Wipers,Top And Rear) ....................................................................... 1
5 1558219 Grommet ........................................................................................................ 1
6 1616550 Seal ................................................................................................................ 2
7 1616554 Seal ..................................................................................................................... 1
8 1616548 Bracket ................................................................................................................ 4
9 1583611 Capscrew ............................................................................................................ 4
10 1624529 Foam ................................................................................................................... 12
11 1616552 Bracket (Light) .................................................................................................... 2
12 1616518 Panel ................................................................................................................... 1
12 1616520 Frame ............................................................................................................. 1
12 1531557 Insert .............................................................................................................. 4
13 1616540 Glass .............................................................................................................. 1
14 1616541 Seal ................................................................................................................ 1
15 1616551 Seal ................................................................................................................ 1
16 1616546 Bracket ................................................................................................................ 4
17 1583611 Capscrew ............................................................................................................ 4
18 1598294 Wiper Motor ........................................................................................................ 1
18 1645315 Kit-Front Wiper Motor Mounting ..................................................................... 1
19 1598298 Wiper Arm ........................................................................................................... 1
20 1598299 Wiper Blade ........................................................................................................ 1
1616556 Wire Harness (Front Screen) (Not Illustrated) .................................................... 1
NOTES
2 ENGINE ASSEMBLY
UNIT CODE F001
03/2014 NORTH AMERICA
SECTION 2
ENGINE ASSEMBLY
DESCRIPTION PAGE
ASSEMBLED ENGINE
MAZDA 2.0L, GASOLINE AND LPG - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →)
.................................................................................................................................................................... 2-58
CAMSHAFT AND DRIVE GEAR
YANMAR 2.6L DIESEL ............................................................................................................................... 2-106
CAMSHAFT AND VALVES
MAZDA 2.0L, GASOLINE AND LPG - 2005 AND 2006 EMISSION COMPLIANT
ENGINES (→ S/N F001V02238E) ............................................................................................................. 2-48
MAZDA 2.0L, GASOLINE AND LPG - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →)
.................................................................................................................................................................... 2-62
CARBURETOR
MAZDA 2.0L, LPG - 2005 AND 2006 EMISSION COMPLIANT ENGINES (→ S/N F001V02238E) ......... 2-50
COOLING SYSTEM
GASOLINE - MAZDA 2.0L (→ S/N F001V02162D) ................................................................................... 2-8
GASOLINE (MAZDA 2.0L) (S/N F001V02163D ↔ S/N F001V02239E) .................................................... 2-14
LPG - MAZDA 2.0L (→ S/N F001V02162D) .............................................................................................. 2-10
LPG (MAZDA 2.0L) (S/N F001V02163D ↔ S/N F001V02238E) ............................................................... 2-12
MAZDA 2.0L, GASOLINE AND LPG - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →)
.................................................................................................................................................................... 2-16
YANMAR 2.6L - DIESEL (S/N F001V02163D →) ...................................................................................... 2-88
YANMAR 2.6L DIESEL (→ S/N F001V02163D) ........................................................................................ 2-86
COUNTERWEIGHT EXHAUST
MAZDA 2.0L GASOLINE AND LPG - WITH CATALYTIC CONVERTER (→ S/N F001V02238E) ............ 2-18
WITH PURIFIER - YANMAR 2.6L DIESEL ................................................................................................. 2-90
CRANKSHAFT AND PISTONS
MAZDA 2.0L, GASOLINE AND LPG - 2005 AND 2006 EMISSION COMPLIANT
ENGINES (→ S/N F001V02238E) ............................................................................................................. 2-36
MAZDA 2.0L, GASOLINE AND LPG - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →)
.................................................................................................................................................................... 2-64
YANMAR 2.6L DIESEL ............................................................................................................................... 2-108
CYLINDER BLOCK
MAZDA 2.0L, GASOLINE AND LPG - 2005 AND 2006 EMISSION COMPLIANT
ENGINES (→ S/N F001V02238E) ............................................................................................................. 2-32
MAZDA 2.0L, GASOLINE AND LPG - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →)
.................................................................................................................................................................... 2-66
YANMAR 2.6L DIESEL ............................................................................................................................... 2-110
CYLINDER HEAD
MAZDA 2.0L, GASOLINE AND LPG - 2005 AND 2006 EMISSION COMPLIANT
ENGINES (→ S/N F001V02238E) ............................................................................................................. 2-34
YANMAR 2.6L DIESEL ............................................................................................................................... 2-102
CYLINDER HEAD AND COVER
MAZDA 2.0L, GASOLINE AND LPG - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239V →)
.................................................................................................................................................................... 2-60
DELAY VALVE
MAZDA 2.0L, LPG - 2005 AND 2006 EMISSION COMPLIANT
ENGINES (S/N F001V02035D ↔ S/N F001V02238E) .............................................................................. 2-56
EMISSION CONTROL SYSTEM
MAZDA 2.0L, GASOLINE - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →) ............... 2-76
MAZDA 2.0L, LPG - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →) ........................... 2-78
©2014 HYSTER COMPANY See Service Manual 2-1
for service procedures.
UNIT CODE F001
NORTH AMERICA 03/2014
SECTION 2
ENGINE ASSEMBLY
DESCRIPTION PAGE
EMISSIONS LINES
MAZDA 2.0L, GASOLINE - 2005 AND 2006 EMISSION COMPLIANT ENGINES (→ S/N F001V02238E)
.................................................................................................................................................................... 2-54
ENGINE COOLING
MAZDA 2.0L, GASOLINE AND LPG - 2005 AND 2006 EMISSION COMPLIANT
ENGINES (→ S/N F001V02238E) ............................................................................................................. 2-38
MAZDA 2.0L, GASOLINE AND LPG - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →)
.................................................................................................................................................................... 2-74
ENGINE FUEL SYSTEM
MAZDA 2.0L, GASOLINE AND LPG - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →)
.................................................................................................................................................................... 2-84
ENGINE FUEL SYSTEM AND EMISSIONS CONTROL
MAZDA 2.0L, LPG - 2005 AND 2006 EMISSION COMPLIANT ENGINES (→ S/N F001V02238E) ......... 2-44
ENGINE FUEL SYSTEM AND INTAKE MANIFOLD
MAZDA 2.0L, GASOLINE - 2005 AND 2006 EMISSION COMPLIANT ENGINES (→ S/N F001V02238E)
.................................................................................................................................................................... 2-42
ENGINE MOUNTING ...................................................................................................................................... 2-4
EXHAUST MANIFOLD
MAZDA 2.0L, GASOLINE AND LPG - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →)
.................................................................................................................................................................... 2-72
EXHAUST WITH CATALYTIC CONVERTER
COUNTERWEIGHT AND OVERHEAD - MAZDA 2.0L, GASOLINE AND LPG, 2007 EMISSION
COMPLIANT ENGINES (S/N F001V02239E →) ....................................................................................... 2-22
FAN ASSEMBLY ............................................................................................................................................. 2-6
FLYWHEEL AND HOUSING
MAZDA 2.0L (→ S/N F001V02037D) ......................................................................................................... 2-26
MAZDA 2.0L (S/N F001V02038D →) ......................................................................................................... 2-28
YANMAR 2.6L DIESEL ............................................................................................................................... 2-96
GEAR HOUSING
YANMAR 2.6L DIESEL ............................................................................................................................... 2-98
INTAKE AND EXHAUST MANIFOLD
YANMAR 2.6L DIESEL ............................................................................................................................... 2-94
INTAKE AND EXHAUST MANIFOLDS
MAZDA 2.0L, GASOLINE AND LPG - 2005 AND 2006 EMISSION COMPLIANT
ENGINES (→ S/N F001V02238E) ............................................................................................................. 2-30
INTAKE MANIFOLD
MAZDA 2.0L, GASOLINE - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →) ............... 2-80
MAZDA 2.0L, LPG - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →) ........................... 2-82
LUBRICATION SYSTEM
YANMAR 2.6L DIESEL ............................................................................................................................... 2-114
OIL PAN
YANMAR 2.6L DIESEL ............................................................................................................................... 2-100
OIL PUMP AND FILTER
MAZDA 2.0L, GASOLINE AND LPG - 2005 AND 2006 EMISSION COMPLIANT
ENGINES (→ S/N F001V02238E) ............................................................................................................. 2-52
MAZDA 2.0L, GASOLINE AND LPG - 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →)
.................................................................................................................................................................... 2-70
OVERHEAD EXHAUST
MAZDA 2.0L GASOLINE AND LPG - WITH CATALYTIC CONVERTER (→ S/N F001V02238E) ............ 2-20
2-2 See Service Manual ©2014 HYSTER COMPANY
for service procedures.
UNIT CODE F001
03/2014 NORTH AMERICA
SECTION 2
ENGINE ASSEMBLY
DESCRIPTION PAGE
ENGINE MOUNTING
KEY:
A: Mazda Engine
B: Yanmar Diesel Engine
NOTE: This parts list contains multiple truck configurations, refer to the KEY to choose the correct QTY column
for your truck.
QTY
ITEM PART NO. DESCRIPTION A B
1 1557478 Mount (RH) ................................................................................................ 1 ..
1 1557479 Mount (LH) ................................................................................................ 1 ..
2 1557767 Mount ......................................................................................................... .. 2
3 293698 Capscrew .................................................................................................. 2 2
4 1504075 Washer ...................................................................................................... 2 2
5 1557737 Washer ...................................................................................................... 4 4
6 2069951 Isolator ...................................................................................................... 4 4
7 1565453 Nut (Flange) .............................................................................................. 2 2
8 1565150 Bolt (Flange) ............................................................................................. 8 8
KEY:
A: Mazda Engine
B: Yanmar Diesel Engine
NOTE: This parts list contains multiple truck configurations, refer to the KEY to choose the correct QTY column
for your truck.
QTY
ITEM PART NO. DESCRIPTION A B
1 1375642 Fan ............................................................................................................. 1 1
2 1528140 Spacer ....................................................................................................... 1 ..
2 1377781 Spacer ........................................................................................................ .. 1
3 293619 Capscrew .................................................................................................. 4 4
4 296418 Washer ...................................................................................................... 4 4
NOTES
COOLING SYSTEM
GASOLINE – MAZDA 2.0L (→ S/N F001V02162D)
KEY:
A: Serpentine Radiator
B: Square Wave Radiator
QTY
ITEM PART NO. DESCRIPTION A B
1 1534355 Bracket (Top) ............................................................................................. 1 ..
1 1534356 Bracket (Top) ............................................................................................. .. 1
2 1530243 Insert .......................................................................................................... 4 4
3 1583611 Capscrew ................................................................................................... 4 4
4 1352140 Radiator Cap .............................................................................................. 1 1
5 1529787 Isolator ....................................................................................................... 4 4
6 2060012 Radiator ...................................................................................................... 1 ..
6 1528595 Fitting (Drain) ......................................................................................... 1 ..
6 2060015 Radiator ...................................................................................................... .. 1
6 1597795
1569080 Screw ..................................................................................................... 4 4
7 1527982 Hose Clamp ............................................................................................... 4 4
8 2073405 Hose (Upper) .............................................................................................. 1 1
9 2073351 Hose ........................................................................................................... 1 1
10 369804 Clamp ......................................................................................................... 1 1
11 1501999 Hose Clamp ............................................................................................... 1 1
12 1580433 Tube ........................................................................................................... 1 1
13 1581392 Shroud ........................................................................................................ 1 ..
13 1581391 Shroud ........................................................................................................ .. 1
14 1535257 Nut .............................................................................................................. 2 2
15 320154 Washer ....................................................................................................... 2 2
16 302023 Screw ......................................................................................................... 2 2
17 1329271 Clip ............................................................................................................. 2 2
18 2059211 Radiator Hose (Lower) ............................................................................... 1 1
19 1531404 Sensor (Low Coolant Level) (Optional) ...................................................... 1 1
19 14385 Fitting (Optional) ......................................................................................... 1 1
19 246108 Sealant ....................................................................................................... AR AR
20 1329240 Hose ........................................................................................................... 1 1
21 1480237 Nut .............................................................................................................. 1 1
22 369815 Clamp ......................................................................................................... 2 2
23 1347026 Reservoir .................................................................................................... 1 1
24 1531167 Bracket ....................................................................................................... 1 1
25 1527879 Capscrew ................................................................................................... 2 2
26 345455 Outlet Assembly ......................................................................................... 1 1
26 339735
1663877 Hose ...................................................................................................... 1 1
26 345453 Outlet (Reservoir) .................................................................................. 1 1
26 345454 Cap ........................................................................................................ 1 1
26 336550 Bushing .................................................................................................. 1 1
COOLING SYSTEM
LPG – MAZDA 2.0L (→ S/N F001V02162D)
KEY:
A: Serpentine Radiator
B: Square Wave Radiator
QTY
ITEM PART NO. DESCRIPTION A B
1 1534355 Bracket (Top) ............................................................................................. 1 ..
1 1534356 Bracket (Top) ............................................................................................. .. 1
2 1530243 Insert .......................................................................................................... 4 4
3 1583611 Capscrew ................................................................................................... 4 4
4 1352140 Radiator Cap .............................................................................................. 1 1
5 1529787 Isolator ....................................................................................................... 4 4
6 2060012 Radiator ...................................................................................................... 1 ..
6 1528595 Fitting (Drain) ......................................................................................... 1 ..
6 2060015 Radiator ...................................................................................................... .. 1
6 1597795
1569080 Screw ..................................................................................................... 4 4
7 1527982 Hose Clamp ............................................................................................... 3 3
8 2058863 Radiator Hose (Upper) ............................................................................... 1 1
9 1501999 Hose Clamp ............................................................................................... 1 1
10 1581392 Shroud ........................................................................................................ 1 ..
10 1581391 Shroud ........................................................................................................ .. 1
11 1535257 Nut .............................................................................................................. 2 2
12 320154 Washer ....................................................................................................... 2 2
13 302023 Screw ......................................................................................................... 2 2
14 1329271 Clip ............................................................................................................. 2 2
15 2059211 Radiator Hose (Lower) ............................................................................... 1 1
16 1531404 Sensor (Low Coolant Level) (Optional) ...................................................... 1 1
16 14385 Fitting (Optional) ......................................................................................... 1 1
16 246108 Sealant ....................................................................................................... AR AR
17 1329240 Hose ........................................................................................................... 1 1
18 1480237 Nut .............................................................................................................. 1 1
19 369815 Clamp ......................................................................................................... 2 2
20 1347026 Reservoir .................................................................................................... 1 1
21 1531167 Bracket ....................................................................................................... 1 1
22 1527879 Capscrew ................................................................................................... 2 2
23 345455 Outlet Assembly ......................................................................................... 1 1
23 339735
1663877 Hose ...................................................................................................... 1 1
23 345453 Outlet (Reservoir) .................................................................................. 1 1
23 345454 Cap ........................................................................................................ 1 1
23 336550 Bushing .................................................................................................. 1 1
COOLING SYSTEM
LPG (MAZDA 2.0L) (S/N F001V02163D ↔ S/N F001V02238E)
KEY:
A: Serpentine Radiator
B: Square Wave Radiator
NOTE: This parts list contains multiple truck configurations, refer to the KEY to choose the correct QTY column
for your truck.
QTY
ITEM PART NO. DESCRIPTION A B
1 1534355 Bracket (Top) ............................................................................................ 1 ..
1 1534356 Bracket (Top) ............................................................................................. .. 1
2 1530243 Insert ......................................................................................................... 4 4
3 1583611 Capscrew .................................................................................................. 4 4
4 1352140 Radiator Cap ............................................................................................. 1 1
5 1529787 Isolator ...................................................................................................... 4 4
6 2060012 Radiator ..................................................................................................... 1 ..
6 1528595 Fitting (Drain) ......................................................................................... 1 ..
6 2060015 Radiator ...................................................................................................... .. 1
6 1597795
1569080 Screw ..................................................................................................... 4 4
7 369804 Clamp ........................................................................................................ 4 4
8 2058863 Radiator Hose (Upper) ............................................................................. 1 1
9 2059211 Radiator Hose (Lower) ............................................................................. 1 1
10 1581392 Shroud ....................................................................................................... 1 ..
10 1581391 Shroud ........................................................................................................ .. 1
11 1535257 Nut ............................................................................................................. 2 2
12 320154 Washer ...................................................................................................... 2 2
13 302023 Screw ......................................................................................................... 2 2
14 1329271 Clip ............................................................................................................ 2 2
15 345455 Outlet Assembly ....................................................................................... 1 1
15 339735
1663877 Hose ...................................................................................................... 1 1
15 345453 Outlet (Reservoir) ................................................................................ 1 1
15 345454 Cap ........................................................................................................ 1 1
15 336550 Bushing ................................................................................................ 1 1
16 1531404 Sensor (Low Coolant Level) (Optional) .................................................. 1 1
16 14385 Fitting (Optional) ......................................................................................... 1 1
16 246108 Sealant ....................................................................................................... AR AR
17 1329240 Hose .......................................................................................................... 1 1
18 1480237 Nut ............................................................................................................. 1 1
19 369815 Clamp ........................................................................................................ 2 2
20 1633307 Reservoir ................................................................................................... 1 1
COOLING SYSTEM
GASOLINE (MAZDA 2.0L) (S/N F001V02163D ↔ S/N F001V02239E)
KEY:
A: Serpentine Radiator
B: Square Wave Radiator
QTY
ITEM PART NO. DESCRIPTION A B
1 1534355 Bracket (Top) ............................................................................................. 1 ..
1 1534356 Bracket (Top) ............................................................................................. .. 1
2 1530243 Insert .......................................................................................................... 4 4
3 1583611 Capscrew ................................................................................................... 4 4
4 1352140 Radiator Cap .............................................................................................. 1 1
5 1529787 Isolator ....................................................................................................... 4 4
6 2060012 Radiator ...................................................................................................... 1 ..
6 1528595 Fitting (Drain) ......................................................................................... 1 ..
6 2060015 Radiator ...................................................................................................... .. 1
6 1597795
1569080 Screw ..................................................................................................... 4 4
7 369804 Clamp ......................................................................................................... 4 4
8 2073405 Hose (Upper) .............................................................................................. 1 1
9 2073351 Hose ........................................................................................................... 1 1
10 2059211 Radiator Hose (Lower) ............................................................................... 1 1
11 1527876 Capscrew ................................................................................................... 1 1
12 1580433 Tube ........................................................................................................... 1 1
13 1581392 Shroud ........................................................................................................ 1 ..
13 1581391 Shroud ........................................................................................................ .. 1
14 1535257 Nut .............................................................................................................. 2 2
15 320154 Washer ....................................................................................................... 2 2
16 302023 Screw ......................................................................................................... 2 2
17 1329271 Clip ............................................................................................................. 2 2
18 345455 Outlet Assembly ......................................................................................... 1 1
18 339735
1663877 Hose ...................................................................................................... 1 1
18 345453 Outlet (Reservoir) .................................................................................. 1 1
18 345454 Cap ........................................................................................................ 1 1
18 336550 Bushing .................................................................................................. 1 1
19 1531404 Sensor (Low Coolant Level) (Optional) ...................................................... 1 1
19 14385 Fitting (Optional) ......................................................................................... 1 1
19 246108 Sealant ....................................................................................................... AR AR
20 1329240 Hose ........................................................................................................... 1 1
21 1480237 Nut .............................................................................................................. 1 1
22 369815 Clamp ......................................................................................................... 2 2
23 1633307 Reservoir .................................................................................................... 1 1
COOLING SYSTEM
MAZDA 2.0L, GASOLINE AND LPG – 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →)
KEY:
A: Serpentine Radiator
B: Square Wave Radiator
NOTE: This parts list contains multiple truck configurations, refer to the KEY to choose the correct QTY column
for your truck.
QTY
ITEM PART NO. DESCRIPTION A B
1 1534868 Bracket (Top) ............................................................................................. 1 ..
1 1609615 Bracket (Top) ............................................................................................. .. 1
2 1530243 Insert ......................................................................................................... 4 4
3 1583611 Capscrew .................................................................................................. 4 4
4 1352140 Radiator Cap ............................................................................................. 1 1
5 1529787 Isolator ...................................................................................................... 4 4
6 2060012 Radiator ..................................................................................................... 1 ..
6 4606169 Fitting .................................................................................................... 2 ..
6 252729 O-Ring .............................................................................................. 1 ..
6 1546684 O-Ring .............................................................................................. 1 ..
6 1528495 Drain Plug ............................................................................................. 1 ..
6 2060015 Radiator ...................................................................................................... .. 1
6 1597795
1569080 Screw ..................................................................................................... 4 4
6 4606424 Radiator (Alternate Part) ............................................................................ .. 1
6 4038264 Drain Valve ............................................................................................ .. 1
6 4038266 Bolt ......................................................................................................... .. 8
7 369804 Clamp ........................................................................................................ 4 4
8 2092218 Hose (Gasoline) ......................................................................................... 1 1
8 2058863 Radiator Hose (LPG) ................................................................................ 1 1
9 1329240 Hose .......................................................................................................... 1 1
10 369815 Clamp ........................................................................................................ 1 1
11 1633307 Reservoir ................................................................................................... 1 1
12 345455 Outlet Assembly ....................................................................................... 1 1
12 339735
1663877 Hose ...................................................................................................... 1 1
12 345454 Cap ........................................................................................................ 1 1
12 336550 Bushing ................................................................................................ 1 1
13 1581392 Shroud ....................................................................................................... 1 ..
13 1581391 Shroud ........................................................................................................ .. 1
14 1535257 Nut ............................................................................................................. 2 2
15 320154 Washer ...................................................................................................... 2 2
16 302023 Screw ......................................................................................................... 2 2
17 1329271 Clip ............................................................................................................ 2 2
18 2059211 Radiator Hose (Lower) ............................................................................. 1 1
19 1531404 Sensor (Low Coolant Level) (Optional) .................................................. 1 1
19 14385 Fitting (Optional) ......................................................................................... 1 1
19 246108 Sealant ....................................................................................................... AR AR
COUNTERWEIGHT EXHAUST
MAZDA 2.0L GASOLINE AND LPG – WITH CATALYTIC CONVERTER (→ S/N F001V02238E)
OVERHEAD EXHAUST
MAZDA 2.0L GASOLINE AND LPG – WITH CATALYTIC CONVERTER (→ S/N F001V02238E)
FOOTNOTES:
a → S/N F001V03526G
b S/N F001V03527G →
NOTES
CYLINDER BLOCK
MAZDA 2.0L, GASOLINE AND LPG – 2005 AND 2006 EMISSION COMPLIANT ENGINES
(→ S/N F001V02238E)
CYLINDER HEAD
MAZDA 2.0L, GASOLINE AND LPG – 2005 AND 2006 EMISSION COMPLIANT ENGINES
(→ S/N F001V02238E)
FOOTNOTES:
a Black b Red/Brown
FOOTNOTES:
a 0.25 mm c 0.75 mm
b 0.50 mm d Standard
ENGINE COOLING
MAZDA 2.0L, GASOLINE AND LPG – 2005 AND 2006 EMISSION COMPLIANT ENGINES
(→ S/N F001V02238E)
ENGINE COOLING
MAZDA 2.0L, GASOLINE AND LPG – 2005 AND 2006 EMISSION COMPLIANT ENGINES
(→ S/N F001V02238E)
NOTES
FOOTNOTES:
a Cut To Length
CARBURETOR
MAZDA 2.0L, LPG – 2005 AND 2006 EMISSION COMPLIANT ENGINES (→ S/N F001V02238E)
EMISSIONS LINES
MAZDA 2.0L, GASOLINE – 2005 AND 2006 EMISSION COMPLIANT ENGINES (→ S/N F001V02238E)
DELAY VALVE
MAZDA 2.0L, LPG – 2005 AND 2006 EMISSION COMPLIANT ENGINES
(S/N F001V02035D ↔ S/N F001V02238E)
NOTES
FOOTNOTES:
a Black b Red/Brown
CYLINDER BLOCK
MAZDA 2.0L, GASOLINE AND LPG – 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →)
FOOTNOTES:
a Not Illustrated
NOTES
ENGINE COOLING
MAZDA 2.0L, GASOLINE AND LPG – 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →)
FOOTNOTES:
a → S/N F001V02970F b S/N F001V02971F →
NOTES
INTAKE MANIFOLD
MAZDA 2.0L, GASOLINE – 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →)
INTAKE MANIFOLD
MAZDA 2.0L, LPG – 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E →)
FOOTNOTES:
a → S/N F001V02970F b S/N F001V02971F →
COOLING SYSTEM
YANMAR 2.6L DIESEL (→ S/N F001V02163D)
COOLING SYSTEM
YANMAR 2.6L – DIESEL (S/N F001V02163D →)
COUNTERWEIGHT EXHAUST
WITH PURIFIER – YANMAR 2.6L DIESEL
FOOTNOTES:
a → S/N F001V03526G b S/N F001V03527G →
OVERHEAD EXHAUST
WITHOUT PURIFIER – YANMAR 2.6L DIESEL
FOOTNOTES:
a → S/N F001V03526G b S/N F001V03527G →
FOOTNOTES:
a → S/N F001V03006F b S/N F001V03007F →
FOOTNOTES:
a → 9/2009 c 10/2009 →
b → S/N F001V02229E d S/N F001V02230E →
GEAR HOUSING
YANMAR 2.6L DIESEL
FOOTNOTES:
a → S/N F001V03006F b S/N F001V03007F →
OIL PAN
YANMAR 2.6L DIESEL
FOOTNOTES:
a → S/N F001V03006F b S/N F001V03007F →
CYLINDER HEAD
YANMAR 2.6L DIESEL
CYLINDER HEAD
YANMAR 2.6L DIESEL
1599898 Kit-Gasket (2.6L Engine Complete) (Includes Items 2, 7, 9, 19-20, 42-43) ........ 1
FOOTNOTES:
a → S/N F001V03006F b S/N F001V03007F →
NOTES
FOOTNOTES:
a → S/N F001V03006F b S/N F001V03007F →
FOOTNOTES:
a → 9/2009 c 10/2009 →
b → S/N F001V03006F d S/N F001V03007F →
CYLINDER BLOCK
YANMAR 2.6L DIESEL
FOOTNOTES:
a → S/N F001V03006F b S/N F001V03007F →
FOOTNOTES:
a → S/N F001V03006F b S/N F001V03007F →
NOTES
LUBRICATION SYSTEM
YANMAR 2.6L DIESEL
FOOTNOTES:
a → S/N F001V03006F b S/N F001V03007F →
NOTES
3 FUEL SYSTEM
UNIT CODE F001
03/2014 NORTH AMERICA
SECTION 3
FUEL SYSTEM
DESCRIPTION PAGE
SECTION 3
FUEL SYSTEM
DESCRIPTION PAGE
NOTES
FUEL SYSTEM
MAZDA 2.0L, GASOLINE AND LPG – 2005 AND 2006 EMISSION COMPLIANT ENGINES
(→ S/N F001V02238E)
FOOTNOTES:
a Optional GS
FUEL SYSTEM
MAZDA 2.0L, LPG – 2005 AND 2006 EMISSION COMPLIANT ENGINES (→ S/N F001V02238E)
FUEL SYSTEM
MAZDA 2.0L, LPG – 2005 AND 2006 EMISSION COMPLIANT ENGINES (→ S/N F001V02238E)
NOTES
FOOTNOTES:
a Cut To Length
CARBURETOR
MAZDA 2.0L, LPG – 2005 AND 2006 EMISSION COMPLIANT ENGINES (→ S/N F001V02238E)
EMISSIONS LINES
MAZDA 2.0L, GASOLINE – 2005 AND 2006 EMISSION COMPLIANT ENGINES (→ S/N F001V02238E)
DELAY VALVE
MAZDA 2.0L, LPG – 2005 AND 2006 EMISSION COMPLIANT ENGINES
(S/N F001V02035D ↔ S/N F001V02238E)
FOOTNOTES:
a → 10/2010 b 10/2010 →
FOOTNOTES:
a For use only on systems with low fuel sensor. d → S/N F001V03153F
b For use only on systems without low fuel sensor. e S/N F001V03154F →
c Not Illustrated
NOTES
FOOTNOTES:
a Not Shown c → S/N F001V02970F
b Used between hoses 1650786 and 1650784 d S/N F001V02971F →
NOTES
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Not Illustrated c 12/2012 →
b → 12/2012
NOTES
FOOTNOTES:
a → S/N F001V02108D b S/N F001V02109D →
NOTES
FOOTNOTES:
a Not Illustrated e 1/2013 →
b → 1/2013 f 12/2012 →
c → 12/2012 g S/N F001V03358G →
d → S/N F001V03357G
NOTES
FOOTNOTES:
a → S/N F001V01716D b S/N F001V01717D →
FOOTNOTES:
a → S/N F001V02871F d S/N F001V02901F →
b → S/N F001V03034F e S/N F001V03035F →
c S/N F001V02872F ↔ 10/2010 f 10/2010 →
KEY:
A: LPG
B: GAS
C: Diesel
QTY
ITEM PART NO. DESCRIPTION A B C
d 2055193
4611248 Air Filter ............................................................................................ 1 .. ..
2060843
4611249 Air Filter ............................................................................................. .. 1 ..
a 1501855 Air Filter (FFigure 3-30).................................................................... .. .. 1
b 2105338 Air Filter ............................................................................................. .. .. 1
d 4612945 Air Filter ......................................................................................... .. .. 1
1 374923 Valve ............................................................................................. 1 1 1
2 1559419 Guide (With O-Ring) .................................................................... 1 1 ..
2 1574260 Liner (With O-Ring) ....................................................................... .. .. 1
3 1559418 Filter Element .............................................................................. 1 1 ..
3 1574111 Filter Element ................................................................................ .. .. 1
4 1559420 Cover ............................................................................................ 1 1 ..
4 a 1574131 Cover ............................................................................................. .. .. 1
4 c 1687933 Cover ............................................................................................. .. .. 1
5 141331 Cap ............................................................................................... 1 1 1
6 d 4030497 Connector (Pipe Nipple) ............................................................. 1 .. 1
FOOTNOTES:
a → S/N F001V02871F c S/N F001V02872F →
b S/N F001V02872F ↔ 10/2010 d 10/2010 →
FOOTNOTES:
a Not Illustrated c S/N F001V03288F →
b → S/N F001V03287F
FUEL SYSTEM
YANMAR DIESEL
FOOTNOTES:
a DS Models Only b Standard Models Only
FUEL FILTER
YANMAR DIESEL
FOOTNOTES:
a → S/N F001V03006F b S/N F001V03007F →
FUEL INJECTION
YANMAR DIESEL
FOOTNOTES:
a → S/N F001V03006F b S/N F001V03007F →
NOTES
FOOTNOTES:
a → S/N F001V03341G b S/N F001V03342G →
THROTTLE LINKAGE
GASOLINE
FOOTNOTES:
a With Basic Power Shift Transmission d → S/N F001V02218E
b With Electronic Control Transmission e S/N F001V01535C ↔ S/N F001V02219E
c → S/N F001V01534C f S/N F001V02219E →
FOOTNOTES:
a → S/N F001V01534C d S/N F001V02219E ↔ S/N F001V04303K
b → S/N F001V02218E e S/N F001V02219E →
c S/N F001V01535C ↔ S/N F001V02218E f S/N F001V04304K →
FOOTNOTES:
a → S/N F001V01535C c S/N F001V01535C ↔ S/N F001V02218E
b → S/N F001V02218E d S/N F001V02219E →
NOTES
4 ELECTRICAL SYSTEM
UNIT CODE F001
03/2014 NORTH AMERICA
SECTION 4
ELECTRICAL SYSTEM
DESCRIPTION PAGE
SECTION 4
ELECTRICAL SYSTEM
DESCRIPTION PAGE
SECTION 4
ELECTRICAL SYSTEM
DESCRIPTION PAGE
ELECTRICAL SYSTEM
RH CHASSIS
FOOTNOTES:
a Not Illustrated
b → 8/2006
c → S/N F001V02021D
d → S/N F001V02037D
e → S/N F001V02055D
f → S/N F001V02163D
g 8/2006 ↔ S/N F001V02162D
h S/N F001V02022D →
i S/N F001V02038D →
j S/N F001V02056D →
k S/N F001V02163D →
l S/N F001V02164D →
m S/N F001V03622H →
NOTES
ELECTRICAL SYSTEM
RH CHASSIS – WITH SEAT BELT SEQUENCE MODULE
FOOTNOTES:
a Not Illustrated
IMPACT SENSOR
ITEM PART NO. DESCRIPTION QTY
1 1535166 Bracket ................................................................................................................ 1
2 1500912 Clip ...................................................................................................................... 2
3 1582464 Fastener .............................................................................................................. 2
3 2100710 Fastener (Alternate Part) .................................................................................... 1
4 2079281 Wire Harness (Impact Sensor) ........................................................................... 1
5 1489655 Connector (4 Way) ......................................................................................... 1
6 1330416 Connector ....................................................................................................... 1
7 1330437 Terminal (Pin) ................................................................................................. 4
8 1489656 Connector (4-Way) ......................................................................................... 2
9 1489657 Connector ....................................................................................................... 2
10 1330438 Terminal (Socket) ........................................................................................... 8
11 1561759 Clamp (Swivel) .................................................................................................... 2
12 1542439 Clamp (Swivel) .................................................................................................... 2
13 1502055 Clamp (Swivel) .................................................................................................... 1
14 1527879 Capscrew ............................................................................................................ 2
14 287851 Capscrew (Alternate Part) .................................................................................. 2
14 320157 Washer (Alternate Part) ...................................................................................... 2
15 2079843 Sensor (Impact) .................................................................................................. 1
16 1489655 Connector (4 Way) ......................................................................................... 1
17 1330416 Connector ....................................................................................................... 1
18 1330433 Terminal ......................................................................................................... 4
19 1502053 Clamp (Swivel) .................................................................................................... 1
FOOTNOTES:
a → S/N F001V02396E b S/N F001V02397E →
NOTES
FOOTNOTES:
a Gasoline c Not Used On This Application
b LPG
NOTES
FOOTNOTES:
a → 8/2006 b 8/2006 →
NOTES
FOOTNOTES:
a Not Illustrated c 8/2006 →
b → 8/2006
NOTES
FOOTNOTES:
a Not Illustrated
NOTES
FOOTNOTES:
a → S/N F001V02077D c S/N F001V02078D →
b → S/N F001V02162D d S/N F001V02163D →
NOTES
COWL ELECTRICAL
ELECTRO-HYDRAULICS
KEY:
A: With Monotrol Pedal
B: With Forward/Reverse Mini-Lever
QTY
ITEM PART NO. DESCRIPTION A B
1 2070269 Wire Harness (Cowl) (FFigure 4-58)......................................................... 1 ..
1 f 2098011 Wire Harness (Cowl) (FFigure 4-58)......................................................... 1 ..
1 g 4603283 Wire Harness (Cowl) (2010 Series) (FFigure 4-59).................................. 1 ..
1 e 2084829 Wire Harness (Cowl) (FFigure 4-62)......................................................... .. 1
1 def 2098012 Wire Harness (Cowl) (FFigure 4-62)......................................................... .. 1
1 deg 4603280 Wire Harness (Cowl) (2010 Series) (FFigure 4-63).................................. .. 1
2 1600190 Bracket ....................................................................................................... 1 1
2 2111004 Bracket (Left Hand) (Alternate Part) ........................................................... 1 1
2 2111005 Bracket (Right Hand) (Alternate Part) ........................................................ 1 1
3 1554902 Screw ......................................................................................................... 2 2
4 1529366 Capscrew ................................................................................................... 2 2
5 1531975 Bracket ....................................................................................................... 1 1
6 1500912 Clip ............................................................................................................. 3 3
7 1582464 Fastener ..................................................................................................... 3 3
8 1582465 Bracket ....................................................................................................... 1 1
9 1510115 Capscrew ................................................................................................... 3 3
10 2068343 Vehicle System Manager (VSM) (w/ Electro-Hydraulics) ........................... 1 1
11 a 2058909 Wire Harness (Control Valve) (FFigure 4-69)........................................... 1 1
11 c 2060198 Wire Harness (Control Valve) (FFigure 4-68)........................................... 1 1
b 1563841 Dust Cap (12 Pin) ....................................................................................... 1 1
FOOTNOTES:
a Four Function e Without Return To Set Tilt
b Not Illustrated f → S/N F001V03571H
c Three Function g S/N F001V03572H →
d With Hydraulic Pump Solenoid
COWL ELECTRICAL
MANUAL HYDRAULIC – WITH OPERATOR PRESENCE SYSTEM
KEY:
A: With Monotrol Pedal
B: With Forward/Reverse Lever
QTY
ITEM PART NO. DESCRIPTION A B
1 a 2104701 Wire Harness (Cowl) (FFigure 4-60)......................................................... 1 ..
1 b 4603281 Wire Harness (Cowl) (2010 Series) (FFigure 4-61).................................. 1 ..
1 a 2104702 Wire Harness (Cowl) (FFigure 4-64)......................................................... .. 1
1 b 4603282 Wire Harness (Cowl) (2010 Series) (FFigure 4-65).................................. .. 1
2 1529366 Capscrew ................................................................................................... 2 2
3 1600190 Bracket ....................................................................................................... 1 1
3 2111004 Bracket (Left Hand) (Alternate Part) ........................................................... 1 1
3 2111005 Bracket (Right Hand) (Alternate Part) ........................................................ 1 1
4 1500912 Clip ............................................................................................................. 4 ..
4 1500912 Clip ............................................................................................................. .. 3
4 1582464 Fastener ..................................................................................................... 4 ..
4 1582464 Fastener ..................................................................................................... .. 3
5 2068342 Vehicle System Manager (VSM) (w/ Manual Hydraulics) .......................... 1 1
6 1582465 Bracket ....................................................................................................... 1 1
7 1510115 Capscrew ................................................................................................... 3 3
8 1528482 Capscrew ................................................................................................... 1 1
8 1398062 Nut (Fold Over) .......................................................................................... 1 1
9 1686719 Bracket ....................................................................................................... 1 1
10 1562088 Clip ............................................................................................................. 2 2
FOOTNOTES:
a → S/N F001V03571H b S/N F001V03572H →
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Not Illustrated d S/N F001V02030D ↔ S/N F001V02958F
b Remove Panels From Overlay as Required For e S/N F001V02959F ↔ S/N F001V03540H
Truck Configuration. f S/N F001V03541H →
c → S/N F001V02029D
FOOTNOTES:
a Kit Includes: 1 Interlock Rocker (must be used in c Kit Includes: 1 Momentary Interlock Switch Plug, 1
combination with a Momentary Interlock Switch), 1 Gasket (parts are NSS)
Gasket, 4 Screws (parts are NSS) d Kit Includes: 1 Momentary Switch, 1 Lockwasher,
b Kit Includes: 1 Mini-Lever Plug, 1 Gasket (parts are 1 Gasket, 1 Nut (parts are NSS)
NSS)
FOOTNOTES:
a Kit Includes: 1 Interlock Mini-Lever (must be used c Kit Includes: 1 Momentary Switch, 1 Lockwasher,
in combination with a Momentary Interlock Switch), 1 Gasket, 1 Nut (parts are NSS)
1 Gasket, 4 Screws (parts are NSS) d Kit Includes: 1 Plain Mini-Lever, 1 Gasket, 4
b Kit Includes: 1 Momentary Switch Hole Plug, 1 Screws (parts are NSS)
Gasket (parts are NSS)
FOOTNOTES:
a Kit Includes: 1 Interlock Rocker (must be used in c Kit Includes: 1 Momentary Interlock Switch Plug, 1
combination with a Momentary Interlock Switch), 1 Gasket (parts are NSS)
Gasket, 4 Screws (parts are NSS) d Kit Includes: 1 Momentary Switch, 1 Lockwasher,
b Kit Includes: 1 Mini-Lever Plug, 1 Gasket (parts are 1 Gasket, 1 Nut (parts are NSS)
NSS)
NOTES
FOOTNOTES:
a Kit Includes: 1 Interlock Mini-Lever (must be used c Kit Includes: 1 Momentary Switch, 1 Lockwasher,
in combination with a Momentary Interlock Switch), 1 Gasket, 1 Nut (parts are NSS)
1 Gasket, 4 Screws (parts are NSS)
b Kit Includes: 1 Momentary Switch Hole Plug, 1
Gasket (parts are NSS)
MINI-LEVER CONTROLS
WITH ARMREST – THREE FUNCTION (S/N F001V03522H →)
KEY:
A: Without Directional Control Switch
B: With Directional Control Switch
QTY
ITEM PART NO. DESCRIPTION A B
1 4601093 Mini-Lever Assembly .................................................................................. 1 ..
1 d 4601265 Mini-Lever Assembly .................................................................................. 1 ..
1 b 4601097 Mini-Lever Assembly .................................................................................. 1 ..
1 c 4601099 Mini-Lever Assembly .................................................................................. 1 ..
1 4601101 Mini-Lever Assembly .................................................................................. .. 1
1 d 4601103 Mini-Lever Assembly .................................................................................. .. 1
1 b 4601105 Mini-Lever Assembly .................................................................................. .. 1
1 c 4601107 Mini-Lever Assembly .................................................................................. .. 1
2 ..... Lever Position 1 ..................................................................................... 1 1
2 2110791 Lever (Single Function) ..................................................................... 1 1
3 ..... Lever Position 2 ..................................................................................... 1 1
3 2110791 Lever (Single Function) ..................................................................... 1 1
3 b 2110793 Lever (With Override) ........................................................................ 1 1
4 ..... Lever Position 3 ..................................................................................... 1 1
4 2110791 Lever (Single Function) ..................................................................... 1 1
4 d 2110792 Lever (Clamping) ............................................................................... 1 1
5 2108249 Plug ........................................................................................................ 1 1
6 2111799 Armrest (Without Push Buttons) ............................................................ 1 1
6 bd 4603439 Armrest (With Push Buttons) ................................................................. 1 1
7 2111769 Cushion (Armrest) .................................................................................. 1 1
8 1709587 Nut ......................................................................................................... 5 5
9 1698449 Capscrew ............................................................................................... 6 6
10 4605336 Wire Harness ......................................................................................... 1 1
11 ad 1704528 Push Button (Position 3) ........................................................................ 1 1
11 ac 1704528 Push Button (Position 2 and 3) .............................................................. 2 2
11 ab 1704528 Push Button (Position 2) ............................................................................ 1 1
12 d 1705359 Cover (Push Button) .............................................................................. 1 1
12 c 1705359 Cover (Push Button) .............................................................................. 1 1
13 1704529 Wire Harness (Forward/Reverse Switch in the MLM) (Push
Buttons) ................................................................................................. 1 1
14 2111802
4605337 Printed Circuit Board .............................................................................. 1 1
15 2111800 Cover (Bottom Armrest) ......................................................................... 1 1
16 4601120 Plug ........................................................................................................ 1 1
17 2111770 Horn Button ............................................................................................ 1 1
18 2110943 Switch (Directional Control) ................................................................... .. 1
19 2110942 Plug (Directional Control Switch) ........................................................... 1 ..
20 1698449 Capscrew ................................................................................................... 8 8
FOOTNOTES:
a Not all Lift Trucks may have all the switches and c Three Function Clamp with Return to Set Tilt
buttons shown. d With Clamping
b Return to Set Tilt
MINI-LEVER CONTROLS
WITH ARMREST – FOUR FUNCTION (S/N F001V03522H →)
KEY:
A: Without Directional Control Switch
B: With Directional Control Switch
QTY
ITEM PART NO. DESCRIPTION A B
1 4601094 Mini-Lever Assembly .................................................................................. 1 ..
1 b 4601096 Mini-Lever Assembly .................................................................................. 1 ..
1 d 4601098 Mini-Lever Assembly .................................................................................. 1 ..
1 c 4601100 Mini-Lever Assembly .................................................................................. 1 ..
1 4601102 Mini-Lever Assembly .................................................................................. .. 1
1 b 4601104 Mini-Lever Assembly .................................................................................. .. 1
1 d 4601106 Mini-Lever Assembly .................................................................................. .. 1
1 c 4601108 Mini-Lever Assembly .................................................................................. .. 1
2 ..... Lever Position 1 ..................................................................................... 1 1
2 2110791 Lever (Single Function) ..................................................................... 1 1
3 ..... Lever Position 2 ..................................................................................... 1 1
3 2110791 Lever (Single Function) ..................................................................... 1 1
3 c 2110793 Lever (With Override) ........................................................................ 1 1
4 ..... Lever Position 3 ..................................................................................... 1 1
4 2110791 Lever (Single Function) ..................................................................... 1 1
5 ..... Lever Position 4 ..................................................................................... 1 1
5 2110791 Lever (Single Function) ..................................................................... 1 1
5 bc 2110792 Lever (Clamping) ............................................................................... 1 1
6 2111799 Armrest (Without Push Buttons) ............................................................ 1 1
6 bcd 4603439 Armrest (With Push Buttons) ................................................................. 1 1
7 2111769 Cushion (Armrest) .................................................................................. 1 1
8 1709587 Nut ......................................................................................................... 5 5
9 1698449 Capscrew ............................................................................................... 6 6
10 4605336 Wire Harness ......................................................................................... 1 1
11 ab 1704528 Push Button ........................................................................................... 1 1
11 ac 1704528 Push Button ........................................................................................... 2 2
12 b 1705359 Cover (Push Button) .............................................................................. 2 2
12 c 1705359 Cover (Push Button) .............................................................................. 1 1
13 1704529 Wire Harness (Forward/Reverse Switch in the MLM) (Push
Buttons) ................................................................................................. 1 1
14 2111802
4605337 Printed Circuit Board .............................................................................. 1 1
15 2111800 Cover (Bottom Armrest) ......................................................................... 1 1
16 4601120 Plug ........................................................................................................ 1 1
17 2111770 Horn Button ............................................................................................ 1 1
18 2110943 Switch (Directional Control) ................................................................... .. 1
19 2110942 Plug (Directional Control Switch) ........................................................... 1 ..
20 1698449 Capscrew ................................................................................................... 8 8
FOOTNOTES:
a Not all Lift Trucks may have all the switches and c With Clamping and Return to Set Tilt
buttons shown. d With Return to Set Tilt
b With Clamping
FOOTNOTES:
a Optional e S/N F001V02043D ↔ 6/2007
b → 4/2007 f S/N F001V02043D →
c → S/N F001V02042D g 4/2007 →
d → S/N F001V02545E h 6/2007 →
FOOTNOTES:
a → 8/2006 d 8/2006 ↔ S/N F001V02230E
b → 9/2005 e 9/2005 ↔ 8/2006
c → S/N F001V02229E f 8/2006 →
NOTES
WIRE HARNESS
RH CHASSIS – MAZDA 2.0L (→ 2/2006)
WIRE HARNESS
RH CHASSIS – MAZDA 2.0L (→ 2/2006)
WIRE HARNESS
RH CHASSIS – MAZDA 2.0L (→ 2/2006)
WIRE HARNESS
RH CHASSIS – MAZDA LPG 2.0L (→ S/N F001V02037D)
WIRE HARNESS
RH CHASSIS – MAZDA LPG 2.0L (→ S/N F001V02037D)
WIRE HARNESS
RH CHASSIS – MAZDA LPG 2.0L (→ S/N F001V02037D)
WIRE HARNESS
RH CHASSIS – MAZDA LPG 2.0L (→ S/N F001V02037D)
NOTES
WIRE HARNESS
RH CHASSIS – MAZDA 2.0L (S/N F001V02038D ↔ S/N F001V02238E)
WIRE HARNESS
RH CHASSIS – MAZDA 2.0L (S/N F001V02038D ↔ S/N F001V02238E)
WIRE HARNESS
RH CHASSIS – MAZDA 2.0L (S/N F001V02038D ↔ S/N F001V02238E)
WIRE HARNESS
RH CHASSIS – MAZDA 2.0L (S/N F001V02038D ↔ S/N F001V02238E)
NOTES
WIRE HARNESS
RH CHASSIS – 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E ↔ S/N F001V03139F)
WIRE HARNESS
RH CHASSIS – 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E ↔ S/N F001V03139F)
WIRE HARNESS
RH CHASSIS – 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E ↔ S/N F001V03139F)
WIRE HARNESS
RH CHASSIS – 2007 EMISSION COMPLIANT ENGINES (S/N F001V02239E ↔ S/N F001V03139F)
NOTES
WIRE HARNESS
RH CHASSIS – MAZDA, WITH ANTI-STALL (S/N F001V03140F →)
WIRE HARNESS
RH CHASSIS – MAZDA, WITH ANTI-STALL (S/N F001V03140F →)
WIRE HARNESS
RH CHASSIS – MAZDA, WITH ANTI-STALL (S/N F001V03140F →)
WIRE HARNESS
RH CHASSIS – MAZDA, WITH ANTI-STALL (S/N F001V03140F →)
NOTES
WIRE HARNESS
RH CHASSIS – MAZDA (S/N F001V03622H →)
WIRE HARNESS
RH CHASSIS – MAZDA (S/N F001V03622H →)
WIRE HARNESS
RH CHASSIS – MAZDA (S/N F001V03622H →)
WIRE HARNESS
RH CHASSIS – MAZDA (S/N F001V03622H →)
WIRE HARNESS
RH CHASSIS – MAZDA (S/N F001V03622H →)
WIRE HARNESS
RH CHASSIS – MAZDA-WITHOUT SEAT BELT SEQUENCE MODULE (1/2013 →)
WIRE HARNESS
RH CHASSIS – MAZDA-WITHOUT SEAT BELT SEQUENCE MODULE (1/2013 →)
WIRE HARNESS
RH CHASSIS – MAZDA-WITHOUT SEAT BELT SEQUENCE MODULE (1/2013 →)
WIRE HARNESS
RH CHASSIS – MAZDA-WITHOUT SEAT BELT SEQUENCE MODULE (1/2013 →)
WIRE HARNESS
RH CHASSIS – MAZDA-WITHOUT SEAT BELT SEQUENCE MODULE (1/2013 →)
WIRE HARNESS
RH CHASSIS – MAZDA-WITH SEAT BELT SEQUENCE MODULE
WIRE HARNESS
RH CHASSIS – MAZDA-WITH SEAT BELT SEQUENCE MODULE
WIRE HARNESS
RH CHASSIS – MAZDA-WITH SEAT BELT SEQUENCE MODULE
WIRE HARNESS
RH CHASSIS – MAZDA-WITH SEAT BELT SEQUENCE MODULE
WIRE HARNESS
RH CHASSIS – MAZDA-WITH SEAT BELT SEQUENCE MODULE
WIRE HARNESS
RH CHASSIS – YANMAR DIESEL (→ 2/2006)
WIRE HARNESS
RH CHASSIS – YANMAR DIESEL (→ 2/2006)
WIRE HARNESS
RH CHASSIS – YANMAR DIESEL (→ 2/2006)
WIRE HARNESS
RH CHASSIS – YANMAR DIESEL (→ S/N F001V02036D)
WIRE HARNESS
RH CHASSIS – YANMAR DIESEL (→ S/N F001V02036D)
WIRE HARNESS
RH CHASSIS – YANMAR DIESEL (→ S/N F001V02036D)
WIRE HARNESS
RH CHASSIS – YANMAR DIESEL (→ S/N F001V02036D)
NOTES
WIRE HARNESS
RH CHASSIS – YANMAR DIESEL (S/N F001V02037D →)
WIRE HARNESS
RH CHASSIS – YANMAR DIESEL (S/N F001V02037D →)
WIRE HARNESS
RH CHASSIS – YANMAR DIESEL (S/N F001V02037D →)
WIRE HARNESS
RH CHASSIS – YANMAR DIESEL (S/N F001V02037D →)
NOTES
WIRE HARNESS
RH CHASSIS – YANMAR DIESEL (S/N F001V03622H →)
WIRE HARNESS
RH CHASSIS – YANMAR DIESEL (S/N F001V03622H →)
WIRE HARNESS
RH CHASSIS – YANMAR DIESEL (S/N F001V03622H →)
WIRE HARNESS
RH CHASSIS – YANMAR DIESEL (S/N F001V03622H →)
NOTES
WIRE HARNESS
RH CHASSIS – YANMAR-WITHOUT SEAT BELT SEQUENCE MODULE (1/2013 →)
WIRE HARNESS
RH CHASSIS – YANMAR-WITHOUT SEAT BELT SEQUENCE MODULE (1/2013 →)
WIRE HARNESS
RH CHASSIS – YANMAR-WITHOUT SEAT BELT SEQUENCE MODULE (1/2013 →)
WIRE HARNESS
RH CHASSIS – YANMAR-WITHOUT SEAT BELT SEQUENCE MODULE (1/2013 →)
NOTES
WIRE HARNESS
RH CHASSIS – YANMAR-WITH SEAT BELT SEQUENCE MODULE
WIRE HARNESS
RH CHASSIS – YANMAR-WITH SEAT BELT SEQUENCE MODULE
WIRE HARNESS
RH CHASSIS – YANMAR-WITH SEAT BELT SEQUENCE MODULE
WIRE HARNESS
RH CHASSIS – YANMAR-WITH SEAT BELT SEQUENCE MODULE
WIRE HARNESS
RH CHASSIS – YANMAR-WITH SEAT BELT SEQUENCE MODULE
WIRE HARNESS
SEAT JUMPER (S/N F001V03522H →)
WIRE HARNESS
GASOLINE ENGINE – MAZDA 2.0L (→ S/N F001V02037D)
WIRE HARNESS
GASOLINE ENGINE – MAZDA 2.0L (→ S/N F001V02037D)
NOTES
WIRE HARNESS
GASOLINE ENGINE – MAZDA 2.0L (S/N F001V02038D ↔ S/N F001V02238E)
WIRE HARNESS
GASOLINE ENGINE – MAZDA 2.0L (S/N F001V02038D ↔ S/N F001V02238E)
NOTES
NOTES
WIRE HARNESS
LPG ENGINE – MAZDA 2.0L (→ S/N F001V02037D)
WIRE HARNESS
LPG ENGINE – MAZDA 2.0L (S/N F001V02038D ↔ S/N F001V02238E)
FOOTNOTES:
a Service with Kit 1705191 c Service with Kit 1705193
b Service with Kit 1705192 d Service with Kit 1705194
NOTES
FOOTNOTES:
a Used with Harness 4601366 b Used with Harness 4605854
NOTES
WIRE HARNESS
YANMAR DIESEL (→ S/N F001V02037D)
WIRE HARNESS
YANMAR DIESEL (→ S/N F001V02037D)
NOTES
WIRE HARNESS
YANMAR DIESEL (S/N F001V02038D →)
WIRE HARNESS
YANMAR DIESEL (S/N F001V02038D →)
NOTES
WIRE HARNESS
COWL WITH MONOTROL PEDAL (→ S/N F001V03572H)
WIRE HARNESS
COWL WITH MONOTROL PEDAL (→ S/N F001V03572H)
FOOTNOTES:
a With 2070269 b With 2098011
NOTES
WIRE HARNESS
COWL WITH MONOTROL PEDAL – WITH RETURN TO SET TILT (S/N F001V03572H →)
WIRE HARNESS
COWL WITH MONOTROL PEDAL – WITH RETURN TO SET TILT (S/N F001V03572H →)
NOTES
WIRE HARNESS
COWL WITH MONOTROL PEDAL – WITH HYDRAULIC PUMP SOLENOID (→ S/N F001V03571H)
WIRE HARNESS
COWL WITH MONOTROL PEDAL – WITH HYDRAULIC PUMP SOLENOID (→ S/N F001V03571H)
NOTES
WIRE HARNESS
COWL WITH MONOTROL PEDAL – WITH HYDRAULIC PUMP SOLENOID (S/N F001V03572H →)
WIRE HARNESS
COWL WITH MONOTROL PEDAL – WITH HYDRAULIC PUMP SOLENOID (S/N F001V03572H →)
NOTES
WIRE HARNESS
COWL WITH FORWARD/REVERSE LEVER (→ S/N F001V03571H)
WIRE HARNESS
COWL WITH FORWARD/REVERSE LEVER (→ S/N F001V03571H)
FOOTNOTES:
a With 2084829 b With 2098012
NOTES
WIRE HARNESS
COWL WITH FORWARD/REVERSE LEVER – WITHOUT RETURN TO SET TILT (S/N F001V03572H →)
WIRE HARNESS
COWL WITH FORWARD/REVERSE LEVER – WITHOUT RETURN TO SET TILT (S/N F001V03572H →)
NOTES
WIRE HARNESS
COWL WITH FORWARD/REVERSE – MANUAL WITH OPERATOR PRESENCE (→ S/N F001V03571H)
WIRE HARNESS
COWL WITH FORWARD/REVERSE – MANUAL WITH OPERATOR PRESENCE (→ S/N F001V03571H)
NOTES
WIRE HARNESS
COWL WITH FORWARD/REVERSE LEVER – WITH HYDRAULIC PUMP SOLENOID (S/N F001V03572H →)
WIRE HARNESS
COWL WITH FORWARD/REVERSE LEVER – WITH HYDRAULIC PUMP SOLENOID (S/N F001V03572H →)
NOTES
WIRE HARNESS
SEALED ALTERNATOR – MAZDA 2.0L (S/N F001V02239E →)
NOTES
WIRE HARNESS
ELECTRONIC CONTROL VALVE – 3 FUNCTION
WIRE HARNESS
ELECTRONIC CONTROL VALVE – 4 FUNCTION
WIRE HARNESS
TRANSMISSION – SINGLE SPEED (→ S/N F001V02037D)
FOOTNOTES:
a → 9/2005 b 9/2005 →
WIRE HARNESS
TRANSMISSION – SINGLE SPEED (S/N F001V02038D ↔ 9/2009)
WIRE HARNESS
TRANSMISSION – SINGLE SPEED (10/2009 →)
WIRE HARNESS
LIGHTS (→ S/N F001V02042D)
WIRE HARNESS
LIGHTS (S/N F001V02043D →)
WIRE HARNESS
LIGHTS (6/2007 →)
NOTES
5 TRANSMISSION
UNIT CODE F001
03/2014 NORTH AMERICA
SECTION 5
TRANSMISSION
DESCRIPTION PAGE
FOOTNOTES:
a → S/N F001V01948D EXC. 1930-1936, c S/N F001V02230E ↔ S/N F001V03310F
1938-1942, 1944-1946 d S/N F001V03311F →
b S/N F001V01949D ↔ S/N F001V02229E INC.
1930-1936, 1938-1942, 1944-1946
NOTES
TRANSMISSION MOUNT
(S/N T141M001501 →)
FOOTNOTES:
a → PENDING PER ECN 15417601 b PENDING PER ECN 15417601 →
KEY:
A: For Use With Mazda Engine
B: For Use With Yanmar Diesel Engine
NOTE: This parts list contains multiple truck configurations, refer to the KEY to choose the correct QTY column
for your truck.
QTY
ITEM PART NO. DESCRIPTION A B
1 1553122 Torque Converter ..................................................................................... 1 ..
1 1553123 Torque Converter ....................................................................................... .. 1
2 296420 Washer ...................................................................................................... 4 4
3 1541921 Capscrew .................................................................................................. 4 4
FOOTNOTES:
a Supplied with Serpentine Radiator Only c S/N F001V02230E →
b → S/N F001V02229E
NOTES
TRANSMISSION COOLING
MAZDA 2.0L (S/N F001V03311F →)
KEY:
A: With Square Radiator
B: With Serpentine Radiator
NOTE: This parts list contains multiple truck configurations, refer to the KEY to choose the correct QTY column
for your truck.
QTY
ITEM PART NO. DESCRIPTION A B
1 1565127 Fitting ......................................................................................................... 1 ..
2 2109875 Tube Assy ................................................................................................. 2 2
3 2110023 Hose ........................................................................................................... 1 ..
3 2109871 Hose ........................................................................................................... .. 1
4 a 2110024 Hose ........................................................................................................... 1 1
4 b 2109692 Hose .......................................................................................................... .. 1
4 b 2111886 Hose ........................................................................................................... 1 ..
5 1562648 Clip ............................................................................................................ 2 2
6 1527879 Capscrew .................................................................................................. 2 2
7 1480237 Nut ............................................................................................................. 2 2
8 222512 Fitting ........................................................................................................ 1 1
8 16485 O-Ring ................................................................................................... 1 1
9 1691916 Fitting ........................................................................................................ .. 1
9 1673198 Fitting ......................................................................................................... 1 ..
9 222493 Fitting ..................................................................................................... 1 ..
9 16484 O-Ring ................................................................................................... 1 ..
10 130845 Clamp ........................................................................................................ 4 4
11 a 1691525 Adapter ....................................................................................................... 1 1
12 1486749 Fitting ........................................................................................................ 1 1
FOOTNOTES:
a → 9/2009 b 9/2009 →
TRANSMISSION COOLING
YANMAR DIESEL (→ S/N F001V03310F)
FOOTNOTES:
a → S/N F001V02229E b S/N F001V02230E →
TRANSMISSION COOLING
YANMAR DIESEL (S/N F001V03311F →)
TRANSMISSION COOLING
YANMAR DIESEL (2/2011 →)
TRANSMISSION
SINGLE SPEED – SHEET 1 OF 2 (→ S/N F001V01948D EXC. 1930-1936, 1938-1942, 1944-1946)
TRANSMISSION
SINGLE SPEED – SHEET 1 OF 2 (→ S/N F001V01948D EXC. 1930-1936, 1938-1942, 1944-1946)
NOTES
TRANSMISSION
SINGLE SPEED – SHEET 2 OF 2 (→ S/N F001V01948D EXC. 1930-1936, 1938-1942, 1944-1946)
TRANSMISSION
SINGLE SPEED – SHEET 1 OF 2
(S/N F001V01949D ↔ S/N F001V02229E INC. 1930-1936, 1938-1942, 1944-1946)
TRANSMISSION
SINGLE SPEED – SHEET 1 OF 2
(S/N F001V01949D ↔ S/N F001V02229E INC. 1930-1936, 1938-1942, 1944-1946)
NOTES
TRANSMISSION
SINGLE SPEED – SHEET 2 OF 2
(S/N F001V01949D ↔ S/N F001V02229E INC. 1930-1936, 1938-1942, 1944-1946)
TRANSMISSION
SINGLE SPEED – SHEET 1 OF 2 (S/N T133M0001501 → (DRY BRAKE)) (S/N F001V02230E →)
FOOTNOTES:
a → S/N F001V03310F b S/N F001V03311F →
TRANSMISSION
SINGLE SPEED – SHEET 2 OF 2 (S/N T133M0001501 → (DRY BRAKE)) (S/N F001V02230E →)
TRANSMISSION
SINGLE SPEED – SHEET 2 OF 2 (S/N T133M0001501 → (DRY BRAKE)) (S/N F001V02230E →)
FOOTNOTES:
a Not used on dry brake application. c S/N F001V03311F →
b → S/N F001V03310F
NOTES
FOOTNOTES:
a Not Illustrated c PENDING PER ECN 15417601 →
b → PENDING PER ECN 15417601
NOTES
FOOTNOTES:
a → PENDING PER ECN 15417601 b PENDING PER ECN 15417601 →
FOOTNOTES:
a → PENDING PER ECN 15417601 b PENDING PER ECN 15417601 →
NOTES
FOOTNOTES:
a → 4/2014 c 4/2014 →
b → PENDING PER ECN 15417601 d PENDING PER ECN 15417601 →
NOTES
FORWARD CLUTCH
INPUT – SINGLE SPEED (→ S/N F001V02229E)
REVERSE CLUTCH
COUNTER – SINGLE SPEED (→ S/N F001V02229E)
CONTROL VALVE
TRANSMISSION (→ 9/2007)
FOOTNOTES:
a → S/N F001V01856D b S/N F001V01857D →
NOTES
6 DRIVE AXLE
UNIT CODE F001
03/2014 NORTH AMERICA
SECTION 6
DRIVE AXLE
DESCRIPTION PAGE
DRIVE AXLE
SHEET 1 OF 3 ............................................................................................................................................ 6-4
SHEET 2 OF 3 ............................................................................................................................................ 6-6
SHEET 3 OF 3 ............................................................................................................................................ 6-8
DRIVE AXLE AND ATTACHING PARTS ........................................................................................................ 6-2
DRIVE TIRES AND WHEELS
PNEUMATIC - TRELLEBORG .................................................................................................................... 6-12
PNEUMATIC RADIAL ................................................................................................................................. 6-10
PNEUMATIC SOLID - MONARCH .............................................................................................................. 6-11
DRIVE AXLE
SHEET 1 OF 3
DRIVE AXLE
SHEET 2 OF 3
DRIVE AXLE
SHEET 3 OF 3
KEY:
A: Narrow Tread
B: Intermediate Tread
C: Wide Tread
QTY
ITEM PART NO. DESCRIPTION A B C
..... Tire and Wheel Assembly ............................................................... 2 2 2
1 1471832 Pneumatic Tire (6.5 R10 Pneu Radial) (Michelin XZM) ................ 1 1 1
1 1358178 Pneumatic Tire (Michelin XZM 6.50 R10) ................................. 1 1 1
1 1462616 Tubeless Bead Seal .................................................................. 1 1 1
1 1471922 Tubeless Bead Seal Valve ........................................................ 1 1 1
2 2067040 Rim (Narrow Tread) ..................................................................... 1 .. ..
2 2067042 Rim (Intermediate Tread) .............................................................. .. 1 ..
2 2067043 Rim (Wide Tread) .......................................................................... .. .. 1
3 323599 Wheel Side Ring ...................................................................... 1 1 1
4 323598 Wheel Lock Ring ..................................................................... 1 1 1
KEY:
A: Narrow Tread
B: Intermediate Tread
C: Wide Tread
QTY
ITEM PART NO. DESCRIPTION A B C
1603471 Wheel And Tire (Non-Marking) .......................................................... 2 .. ..
1603473 Wheel And Tire (CB/WH) (Non-Marking) .......................................... .. 2 ..
1603475 Wheel And Tire (CB/WH) (Non-Marking) .......................................... .. .. 2
1 1544234 Solid Pneumatic Tire (6.50x10/5.0) ............................................ 1 1 1
1 1603490 Tire (Non-Marking 6.50x10/5.0) .................................................... 1 1 1
2 2067040 Rim ............................................................................................... 1 .. ..
2 2067042 Rim ................................................................................................ .. 1 ..
2 2067043 Rim ................................................................................................ .. .. 1
3 323599 Wheel Side Ring ...................................................................... 1 1 1
4 323598 Wheel Lock Ring ..................................................................... 1 1 1
FOOTNOTES:
a Not included in wheel and tire assembly
NOTES
7 STEERING SYSTEM
UNIT CODE F001
03/2014 NORTH AMERICA
SECTION 7
STEERING SYSTEM
DESCRIPTION PAGE
STEERING SYSTEM
ITEM PART NO. DESCRIPTION QTY
1 a 2092645 Hose Assy ........................................................................................................... 1
1 b 2103674 Hose Assy ........................................................................................................... 1
2 a 2092644 Hose Assy ........................................................................................................... 1
2 b 2103675 Hose Assy ........................................................................................................... 1
3 a 1516201 Fitting .................................................................................................................. 1
3 b 4022958 Fitting .................................................................................................................. 2
4 a 1486742 Fitting .................................................................................................................. 1
5 1486740 Fitting .................................................................................................................. 2
6 1544157 Clip ...................................................................................................................... 5
7 1480237 Nut ...................................................................................................................... 5
8 a 1613324 Capscrew ............................................................................................................ 5
8 b 1527879 Capscrew ............................................................................................................ 5
9 1534420 Steering Axle (Assembly) (FFigure 7-7)............................................................ 1
10 a 1360386 Clamp (Double Hose) ......................................................................................... 1
10 b 1707283 Hose Clamp ........................................................................................................ 1
11 a 1645074 Plate .................................................................................................................... 1
12 313805 Nut ...................................................................................................................... 2
13 a 287816 Capscrew ............................................................................................................ 2
13 b 287844 Capscrew ............................................................................................................ 1
FOOTNOTES:
a → S/N F001V03260F b S/N F001V03261F →
FOOTNOTES:
a → S/N F001V02188E c S/N F001V03845J →
b S/N F001V02189E ↔ S/N F001V03844J
FOOTNOTES:
a → S/N F001V03846J c S/N F001V03847J ↔ S/N F001V04135K
b → S/N F001V04135K d S/N F001V04136K →
STEERING AXLE
ITEM PART NO. DESCRIPTION QTY
1 1524921 Steering Axle ..................................................................................................... 1
2 58903 Snap Ring .......................................................................................................... 8
3 1568271 Pin ...................................................................................................................... 4
4 300752 Spherical Washer .............................................................................................. 8
5 300751 Bushing ............................................................................................................. 4
6 39352 O-Ring ................................................................................................................ 2
7 300767 Spacer ................................................................................................................ 2
8 264973 Seal .................................................................................................................... 2
9 1502277 King Pin ............................................................................................................. 2
10 1524916 Spindle (LH) ....................................................................................................... 1
11 226986 Pin ...................................................................................................................... 2
12 13957 Grease Fitting .................................................................................................... 6
13 1375472 Tapered Roller Bearing .................................................................................... 2
14 1531171 Tapered Roller Bearing .................................................................................... 2
15 1536250 Washer ............................................................................................................... 2
16 249289 Nut ...................................................................................................................... 4
17 2021800 Cap ..................................................................................................................... 2
18 15245 Cotter Pin ........................................................................................................... 4
19 1525238 Hub ..................................................................................................................... 2
20 1502276 Wheel Stud .................................................................................................... 6
21 2021898 Seal .................................................................................................................... 2
22 300766 Sleeve ................................................................................................................ 2
23 a 1524923 Tie Rod ............................................................................................................... 2
23 b 4028349 Tie Rod ............................................................................................................... 2
24 98525 Oil Seal ............................................................................................................... 2
25 156195 Bearing Cone .................................................................................................... 4
25 156194 Bearing Cup ...................................................................................................... 4
26 2055917 Steering Cylinder (FFigure 7-8)...................................................................... 1
27 1524914 Spindle (RH) ...................................................................................................... 1
28 293686 Capscrew ........................................................................................................... 4
29 1517836 Wheel Nut .......................................................................................................... 12
30 1586013 Capscrew ........................................................................................................... 4
31 1388838 Rubber Mount ................................................................................................... 1
32 2060696 Rubber Mount ................................................................................................... 2
33 2021900 Cover .................................................................................................................. 2
FOOTNOTES:
a → 3/2011 b 4/2011 →
NOTES
NOTES
8 BRAKE SYSTEM
UNIT CODE F001
03/2014 NORTH AMERICA
SECTION 8
BRAKE SYSTEM
DESCRIPTION PAGE
BRAKE LINKAGE
SINGLE PEDAL (→ S/N F001V03571H)
FOOTNOTES:
a Not Illustrated c 5/2010 →
b → 5/2010
BRAKE LINKAGE
SINGLE PEDAL (S/N F001V03572H →)
FOOTNOTES:
a Not Illustrated
BRAKE LINKAGE
DUAL PEDAL (→ S/N F001V03571H)
BRAKE LINKAGE
DUAL PEDAL (→ S/N F001V03571H)
FOOTNOTES:
a → 5/2010 b 5/2010 →
NOTES
BRAKE LINKAGE
DUAL PEDAL (S/N F001V03572H →)
FOOTNOTES:
a Not Illustrated
NOTES
BRAKE ASSEMBLY
KEY:
A: Left Hand
B: Right Hand
NOTE: This parts list contains multiple truck configurations, refer to the KEY to choose the correct QTY column
for your truck.
QTY
ITEM PART NO. DESCRIPTION A B
1552768 Brake Assembly (LH) (With Cable) ......................................................... 1 ..
1552769 Brake Assembly (RH) (With Cable) ......................................................... .. 1
1593917 Brake Assembly (LH) (Without Cable) ............................................... 1 ..
1593918 Brake Assembly (RH) (Without Cable) ............................................... .. 1
1 2026773 Backplate ......................................................................................... .. 1
1 2026774 Backplate ......................................................................................... 1 ..
2 ..... Brake Shoe ....................................................................................... 2 2
3 2026776 Bolt ................................................................................................... 2 2
4 ..... Adjuster Assembly .......................................................................... .. 1
4 ..... Adjuster Assembly .......................................................................... 1 ..
5 ..... Spring (Adjuster) ............................................................................. 1 1
6 2026777 Lever (RH) ......................................................................................... .. 1
6 2026778 Lever (LH) ......................................................................................... 1 ..
7 ..... Pin ..................................................................................................... 1 1
8 2026780 Strut .................................................................................................. 1 1
9 2026781 Retaining Ring ................................................................................. 2 2
10 2026782 Spring ............................................................................................... 2 2
11 ..... Spring (Shoe Hold Down) ............................................................... 2 2
12 ..... Washer ............................................................................................. 2 2
13 ..... Washer (Lower) ............................................................................... 1 1
14 ..... Pin ..................................................................................................... 2 2
15 1593919 Wear Plate ........................................................................................ 1 1
16 1367855 Plug ................................................................................................... 1 1
17 ..... Lever ................................................................................................. .. 1
17 ..... Lever ................................................................................................. 1 ..
18 ..... Stop (Lever) ..................................................................................... 1 1
19 ..... Spring ............................................................................................... 1 1
20 2026783 Spring ............................................................................................... 1 1
21 2026775 Wheel Cylinder ................................................................................ 1 1
22 2045884 Piston Rod ................................................................................... 2 2
23 ..... Piston ........................................................................................... 2 2
24 ..... Cup ............................................................................................... 2 2
25 ..... Spring ........................................................................................... 1 1
26 ..... Boot .............................................................................................. 2 2
27 1367871 Cup ............................................................................................... 1 1
28 1367870 Bleeder Screw ............................................................................. 1 1
29 1552770 Parking Brake Cable (LH) .................................................................... 1 ..
29 1552771 Parking Brake Cable (RH) ................................................................... .. 1
2026787 Kit-Brake Shoe (Includes Items 2, 7, 9) ..................................................... 1 1
2026784 Kit-Adjuster (LH) (Includes Items 4-5, 17-19) ......................................... 1 ..
2026785 Kit-Adjuster (RH) (Includes Items 4-5, 17-19) ........................................ .. 1
2026786 Kit-Hold Down (Includes Items 11-14) .................................................... 1 1
1367876 Kit-Repair Wheel Cylinder (Includes Items 23-26) ................................ 1 1
BRAKE ASSEMBLY
KEY:
A: Left Hand
B: Right Hand
NOTE: This parts list contains multiple truck configurations, refer to the KEY to choose the correct QTY column
for your truck.
QTY
ITEM PART NO. DESCRIPTION A B
2040957 Kit-Repair Wheel Cylinder (Includes Items 24, 26) ................................ 1 1
NOTES
PARK BRAKE
(→ S/N F001V03571H)
PARK BRAKE
(S/N F001V03572H →)
FOOTNOTES:
a Not Illustrated c S/N F001V04065K →
b → S/N F001V04063K
NOTES
9 HYDRAULIC SYSTEM
UNIT CODE F001
03/2014 NORTH AMERICA
SECTION 9
HYDRAULIC SYSTEM
DESCRIPTION PAGE
SECTION 9
HYDRAULIC SYSTEM
DESCRIPTION PAGE
MANUAL CONTROL VALVE - THREE AND FOUR FUNCTION (S/N F001V02622E ↔ 4/2014) ............ 9-40
MANUAL CONTROL VALVE - THREE AND FOUR FUNCTION (4/2014 →) ........................................... 9-42
NOTES
FOOTNOTES:
a → S/N F001V02229E d S/N F001V02230E →
b → S/N F001V03029F e S/N F001V03030F →
c → S/N F001V03498G
FOOTNOTES:
a With Quick-lok Option
KEY:
A: Mazda
B: Yanmar
NOTE: This parts list contains multiple truck configurations, refer to the KEY to choose the correct QTY column
for your truck.
QTY
ITEM PART NO. DESCRIPTION A B
2067800 Gear Pump ................................................................................................ 1 ..
2067802 Gear Pump ................................................................................................. .. 1
1 ..... Snap Ring ............................................................................................. 1 1
2 ..... Oil Seal .................................................................................................. 1 1
3 1581536 Flange ................................................................................................... 1 1
4 ..... Seal Plate and Back-Up Ring .............................................................. 2 2
5 1578673 Side Plate .............................................................................................. 2 2
6 1581537 Gear Set ................................................................................................ 1 ..
6 1581534 Gear Set ................................................................................................ .. 1
7 ..... Gear Plate ............................................................................................. 1 1
8 1581535 Cover ..................................................................................................... 1 1
9 1578671 Screw .................................................................................................... 4 ..
9 1578693 Screw ..................................................................................................... .. 4
1578672 Dowel (Not Illustrated) ......................................................................... 4 4
1465140 Kit-Seal (Includes Items 1-2, 4) ............................................................. 1 1
HYDRAULIC FILTER
(S/N F001V03499G →)
FOOTNOTES:
a → 9/2009 d 10/2009 →
b → S/N F001V02620E e 10/2013 →
c 10/2009 ↔ 10/2013 f S/N F001V02621E →
NOTES
HAND LEVERS
THREE FUNCTION – WITHOUT DETENTED LEVERS
FOOTNOTES:
a → S/N F001V02621E d S/N F001V02881F →
b S/N F001V02622E ↔ S/N F001V02880F e 4/2014 →
c S/N F001V02881F ↔ 4/2014
HAND LEVERS
THREE FUNCTION – WITH DETENTED LEVERS
FOOTNOTES:
a → S/N F001V02620E d S/N F001V03456G ↔ 4/2014
b → S/N F001V02880F e S/N F001V02881F → EXC. 02884
c S/N F001V02621E ↔ S/N F001V03464G f 4/2014 →
HAND LEVERS
FOUR FUNCTION – WITHOUT DETENTED LEVERS
FOOTNOTES:
a → S/N F001V02620E f S/N F001V03442G ↔ 4/2014
b → S/N F001V02621E g S/N F001V02881F →
c → S/N F001V02880F h S/N F001V02881F → EXC. 02884
d S/N F001V02621E ↔ S/N F001V02088F i 4/2014 →
e S/N F001V02622E ↔ S/N F001V03441G
HAND LEVERS
FOUR FUNCTION – WITH DETENTED LEVERS
FOOTNOTES:
a → S/N F001V02620E
b → S/N F001V02621E
c → S/N F001V02880F
d S/N F001V02621E ↔ S/N F001V02088F
e S/N F001V02621E ↔ S/N F001V03441G
f S/N F001V03442G ↔ 4/2014
g S/N F001V02881F → EXC. 02884
h 4/2014 →
NOTES
NOTES
FOOTNOTES:
a → S/N F001V02621E e S/N F001V03442G →
b → S/N F001V02622E f S/N F001V03465G →
c S/N F001V02622E ↔ S/N F001V03441G g S/N F001V02622E →
d S/N F001V02623E ↔ S/N F001V03464G
NOTES
FOOTNOTES:
a Not Illustrated c 4/2014 →
b → 4/2014
FOOTNOTES:
a → 6/2009 b 7/2009 →
FOOTNOTES:
a → 7/2009 b 7/2009 →
FOOTNOTES:
a → 7/2009 b 7/2009 →
FOOTNOTES:
a → 7/2009 b 7/2009 →
FOOTNOTES:
a Not Illustrated c 4/2014 →
b → 4/2014
MAST INSTALLATION
ITEM PART NO. DESCRIPTION QTY
1 1363260 Rod End ............................................................................................................. 2
1 1363260 Rod End (Alternate Part) .................................................................................. 1
2 1581848 Nut ...................................................................................................................... 2
3 1581852 Washer ............................................................................................................... 2
4 1597381 Capscrew ........................................................................................................... 2
5 1502819 Pin ...................................................................................................................... 2
6 296422 Washer ............................................................................................................... 4
7 1503858 Capscrew ........................................................................................................... 4
8 1533494 Pin Anchor ......................................................................................................... 4
9 1586013 Capscrew ........................................................................................................... 4
10 16041 Grease Fitting .................................................................................................... 2
11 1536805 Pin (Mast Pivot) ................................................................................................. 2
TILT CYLINDERS
RIGHT HAND
TILT CYLINDERS
LEFT HAND
NOTES
SECTION 10
MAST-TWO STAGE LIMITED FREE-LIFT
DESCRIPTION PAGE
CARRIAGE
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 10-16
HEADER HOSES
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 10-18
INNER MAST
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 10-6
MAIN LIFT
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 10-8
MAIN LIFT CYLINDER
LEFT HAND - TWO STAGE LIMITED FREE-LIFT ..................................................................................... 10-14
RIGHT HAND - TWO STAGE LIMITED FREE-LIFT ................................................................................... 10-12
OUTER MAST
TWO STAGE LIMITED FREE-LIFT (→ S/N B551V03957L) ...................................................................... 10-2
TWO STAGE LIMITED FREE-LIFT (S/N B551V03958L →) ...................................................................... 10-4
OUTER MAST
TWO STAGE LIMITED FREE-LIFT (→ S/N B551V03957L)
B551
FOOTNOTES:
a Refer to Table
OUTER MAST
TWO STAGE LIMITED FREE-LIFT (S/N B551V03958L →)
B551
FOOTNOTES:
a Refer to Table b Replace with larger depending on wear
INNER MAST
TWO STAGE LIMITED FREE-LIFT
B551
FOOTNOTES:
a Refer to Table b Replace with larger depending on wear
MAIN LIFT
TWO STAGE LIMITED FREE-LIFT
B551
MAIN LIFT
TWO STAGE LIMITED FREE-LIFT
FOOTNOTES:
a Refer to Table
NOTES
FOOTNOTES:
a Refer to Table
FOOTNOTES:
a Refer to Table
CARRIAGE
TWO STAGE LIMITED FREE-LIFT
FOOTNOTES:
a Replace with larger depending on wear
HEADER HOSES
TWO STAGE LIMITED FREE-LIFT
B551
KEY:
A: Three Functions
B: Four Functions
QTY
ITEM PART NO. DESCRIPTION A B
1 a. . . . . Hose Assy .................................................................................................. 2 4
2 1581582 Capscrew ................................................................................................... 4 8
3 1345348 Clamp ......................................................................................................... 2 4
4 1581566 Nut .............................................................................................................. 6 6
5 1345412 Bracket (RH) .............................................................................................. 1 1
5 1345413 Bracket (LH) ............................................................................................... .. 1
6 1477996 Hose Clamp ............................................................................................... 2 4
7 1481229 Clamp ......................................................................................................... 2 8
8 1360386 Clamp (Double Hose) ................................................................................. 1 2
9 1581842 Capscrew ................................................................................................... 2 4
10 1581565 Nut .............................................................................................................. 2 4
11 1610939 Bracket ....................................................................................................... 1 2
11 b 4052268 Bracket ....................................................................................................... 1 2
12 1581836 Capscrew ................................................................................................... 2 4
13 1581830 Capscrew ................................................................................................... 1 2
14 1581564 Lockwasher ................................................................................................ 1 2
15 c 1360548 Stubshaft .................................................................................................... 1 2
15 d 4051751 Stubshaft .................................................................................................... 1 2
16 c 1494017 Hose Sheave .............................................................................................. 1 2
16 d 4041194 Hose Sheave .............................................................................................. 1 2
17 c 1360549 Spacer ........................................................................................................ 1 2
17 d 4064560 Spacer ........................................................................................................ 1 2
18 1345190 Washer ....................................................................................................... 3 6
FOOTNOTES:
a Refer to Table c → 1/2013
b Used with lift height 2092mm only d 1/2013 →
NOTES
SECTION 11
MAST-TWO STAGE FULL FREE-LIFT
DESCRIPTION PAGE
CARRIAGE
TWO STAGE FULL FREE-LIFT (→ 4/2011) .............................................................................................. 11-24
TWO STAGE FULL FREE-LIFT (4/2011 →) .............................................................................................. 11-26
FREE-LIFT
TWO STAGE FULL FREE-LIFT - 8520000 SERIES .................................................................................. 11-14
TWO STAGE FULL FREE-LIFT - 8800000 SERIES .................................................................................. 11-18
FREE-LIFT CYLINDER
TWO STAGE FULL FREE-LIFT .................................................................................................................. 11-22
HEADER HOSE
TWO STAGE FULL FREE- LIFT (10/2012 →) ........................................................................................... 11-40
HEADER HOSES
TWO STAGE FULL FREE- LIFT (9/2009 ↔ 4/2011) ................................................................................. 11-32
TWO STAGE FULL FREE- LIFT (3/2011 ↔ 10/2012) ............................................................................... 11-36
TWO STAGE FULL FREE-LIFT (→ 9/2008) .............................................................................................. 11-28
INNER MAST
TWO STAGE FULL FREE-LIFT .................................................................................................................. 11-6
MAIN LIFT
TWO STAGE FULL FREE-LIFT .................................................................................................................. 11-8
MAIN LIFT CYLINDER
LEFT HAND - TWO STAGE FULL FREE-LIFT ........................................................................................... 11-12
RIGHT HAND - TWO STAGE FULL FREE-LIFT ........................................................................................ 11-10
OUTER MAST
TWO STAGE FULL FREE-LIFT (→ S/N B559V02695L) ........................................................................... 11-2
TWO STAGE FULL FREE-LIFT (S/N B559V02696L →) ........................................................................... 11-4
OUTER MAST
TWO STAGE FULL FREE-LIFT (→ S/N B559V02695L)
8520000 SERIES
8800000 SERIES
FOOTNOTES:
a Refer to Table b Replace with larger depending on wear
OUTER MAST
TWO STAGE FULL FREE-LIFT (S/N B559V02696L →)
8800000 SERIES
FOOTNOTES:
a Refer to Table b Replace with larger depending on wear
INNER MAST
TWO STAGE FULL FREE-LIFT
8520000 SERIES
8800000 SERIES
FOOTNOTES:
a Refer to Table
MAIN LIFT
TWO STAGE FULL FREE-LIFT
FOOTNOTES:
a Refer to Table c B559V01969 →
b → B559V01968
FOOTNOTES:
a Refer to Table c S/N B559V01969 →
b → S/N B559V01968
FREE-LIFT
TWO STAGE FULL FREE-LIFT – 8520000 SERIES
B559
FOOTNOTES:
a Refer to Table
NOTES
FREE-LIFT
TWO STAGE FULL FREE-LIFT – 8800000 SERIES
B559
FREE-LIFT
TWO STAGE FULL FREE-LIFT – 8800000 SERIES
FOOTNOTES:
a Refer to Table
NOTES
FREE-LIFT CYLINDER
TWO STAGE FULL FREE-LIFT
8520000/8800000 SERIES
FOOTNOTES:
a Refer to Table
CARRIAGE
TWO STAGE FULL FREE-LIFT (→ 4/2011)
CARRIAGE
TWO STAGE FULL FREE-LIFT (4/2011 →)
FOOTNOTES:
a Replace with larger depending on wear
HEADER HOSES
TWO STAGE FULL FREE-LIFT (→ 9/2008)
B559
KEY:
A: Three Function
B: Four Function
QTY
ITEM PART NO. DESCRIPTION A B
1 1481229 Clamp ......................................................................................................... 2 2
2 a. . . . . Hydraulic Tube ........................................................................................... 1 1
3 a. . . . . Hydraulic Tube ........................................................................................... 1 1
4 1360386 Clamp (Double Hose) ................................................................................. 3 6
5 1581842 Capscrew ................................................................................................... 2 ..
6 1617658 Clamp ......................................................................................................... 2 2
7 b 1676088
1481252 Bracket (LH) ............................................................................................... 1 1
7 c 1676087
1481253 Bracket (RH) .............................................................................................. 1 1
8 1581849 Nut .............................................................................................................. 1 1
9 1581592 Capscrew (Lower) ...................................................................................... 1 2
10 1581564 Lockwasher ................................................................................................ 1 2
11 1581560 Washer ....................................................................................................... 2 4
12 1481255 Stubshaft .................................................................................................... 1 2
13 1581559 Washer ....................................................................................................... .. 1
14 1550020 Spacer ........................................................................................................ .. 1
15 1617657 Clamp ......................................................................................................... 2 4
16 1477996 Hose Clamp ............................................................................................... 2 4
17 1581741 Capscrew ................................................................................................... 2 4
18 1581565 Nut .............................................................................................................. 4 8
19 1606855 Spacer ........................................................................................................ 2 2
20 1605688 Hose Guide ................................................................................................ 1 1
21 1345423 Clamp ......................................................................................................... 1 1
22 1360508 Clamp ......................................................................................................... 1 1
23 1581582 Capscrew ................................................................................................... 1 2
24 1481765 Clamp ......................................................................................................... 1 1
HEADER HOSES
TWO STAGE FULL FREE-LIFT (→ 9/2008)
KEY:
A: Three Function
B: Four Function
QTY
ITEM PART NO. DESCRIPTION A B
25 1581566 Nut .............................................................................................................. 1 2
26 1481766 Clamp ......................................................................................................... .. 1
27 1529015 Cap ............................................................................................................. 2 4
28 137852 Strap Clamp ............................................................................................... 1 2
29 a. . . . . Hose Guide ................................................................................................ 1 1
30 1581830 Capscrew (Upper RH) ................................................................................ 1 ..
30 1597560 Capscrew (Upper LH) ................................................................................ .. 1
31 b 1676088
1481252 Bracket (LH) ............................................................................................... .. 1
31 c 1676088
1481252 Bracket (LH) (Alternate Part) ...................................................................... .. 1
32 1481249 Hose Sheave .............................................................................................. 1 2
32 1353521 Bushing .................................................................................................. 1 1
33 a. . . . . Header Hose .............................................................................................. .. 1
34 a. . . . . Header Hose .............................................................................................. .. 1
35 a. . . . . Header Hose .............................................................................................. 1 1
36 a. . . . . Header Hose .............................................................................................. 1 1
37 1481248 Hose Sheave .............................................................................................. 1 2
37 1353521 Bushing .................................................................................................. 1 1
38 1581843 Capscrew ................................................................................................... .. 2
39 1360507 Clamp (Not Illustrated) ............................................................................... 6 6
40 1617658 Clamp (Not Illustrated) ............................................................................... 1 1
FOOTNOTES:
a Refer to Table c 5/2008 →
b → 5/2008
NOTES
HEADER HOSES
TWO STAGE FULL FREE- LIFT (9/2009 ↔ 4/2011)
B559
KEY:
A: 3 Function
B: 4 Function
QTY
ITEM PART NO. DESCRIPTION A B
1 1360507 Clamp ......................................................................................................... 6 6
2 1606855 Spacer ........................................................................................................ 2 2
3 a. . . . . Hydraulic Tube ........................................................................................... 1 1
4 a. . . . . Hydraulic Tube ........................................................................................... 1 1
5 893834 Header Hose (Bracket) .............................................................................. 1 2
6 1345190 Washer ....................................................................................................... 1 2
7 1581564 Lockwasher ................................................................................................ 1 2
8 1494017 Hose Sheave .............................................................................................. 1 2
9 1353521 Bushing .................................................................................................. 1 2
10 1360549 Spacer ........................................................................................................ 1 2
11 1360547 Stubshaft .................................................................................................... 1 2
12 1581830 Capscrew ................................................................................................... 1 2
13 1581741 Capscrew ................................................................................................... 4 8
14 1360386 Clamp (Double Hose) ................................................................................. 3 6
15 1610914 Bracket ....................................................................................................... 1 1
16 a. . . . . Hose Guide ................................................................................................ 1 1
17 1617658 Clamp ......................................................................................................... 1 1
18 1360508 Clamp ......................................................................................................... 1 1
19 1345423 Clamp ......................................................................................................... 1 1
20 137852 Strap Clamp ............................................................................................... 1 2
21 1529015 Cap ............................................................................................................. 2 4
22 1581566 Nut .............................................................................................................. 2 4
23 1643405 Hose Clamp ............................................................................................... 1 2
24 1581581 Capscrew ................................................................................................... 2 4
25 1477996 Hose Clamp ............................................................................................... .. 2
26 1481229 Clamp ......................................................................................................... 2 5
27 a. . . . . Hose Guide ................................................................................................ 1 1
28 1581842 Capscrew ................................................................................................... 2 ..
HEADER HOSES
TWO STAGE FULL FREE- LIFT (9/2009 ↔ 4/2011)
KEY:
A: 3 Function
B: 4 Function
QTY
ITEM PART NO. DESCRIPTION A B
28 1581843 Capscrew ................................................................................................... .. 2
29 a. . . . . Header Hose .............................................................................................. 2 2
30 a. . . . . Header Hose .............................................................................................. .. 2
FOOTNOTES:
a Refer to Table
NOTES
HEADER HOSES
TWO STAGE FULL FREE- LIFT (3/2011 ↔ 10/2012)
B559
KEY:
A: 3 Function
B: 4 Function
QTY
ITEM PART NO. DESCRIPTION A B
1 1360507 Clamp ......................................................................................................... 6 6
2 1606855 Spacer ........................................................................................................ 2 2
3 a. . . . . Hydraulic Tube ........................................................................................... 1 1
4 a. . . . . Hydraulic Tube ........................................................................................... 1 1
5 a. . . . . Hose Assy .................................................................................................. .. 2
6 1598303 Washer ....................................................................................................... 1 2
7 1581564 Lockwasher ................................................................................................ 1 2
8 1494017 Hose Sheave .............................................................................................. 1 2
9 b. . . . . Bushing .................................................................................................. 1 2
10 4020913 Spacer ........................................................................................................ 1 2
11 4020969 Stubshaft .................................................................................................... 1 2
12 1581828 Capscrew ................................................................................................... 1 2
13 1581741 Capscrew ................................................................................................... 4 8
14 1360386 Clamp (Double Hose) ................................................................................. 3 6
15 1610914 Bracket ....................................................................................................... 1 1
16 a. . . . . Hose Guide ................................................................................................ 1 1
17 1617658 Clamp ......................................................................................................... 1 1
18 1360508 Clamp ......................................................................................................... 1 1
19 1345423 Clamp ......................................................................................................... 1 1
20 137852 Strap Clamp ............................................................................................... 1 2
21 a. . . . . Hose Assy .................................................................................................. 2 2
22 1529015 Cap ............................................................................................................. 2 4
23 4008020 Clamp ......................................................................................................... 1 2
24 1597448 Capscrew ................................................................................................... 2 4
25 1477996 Hose Clamp ............................................................................................... .. 2
26 1481229 Clamp ......................................................................................................... 2 4
27 a. . . . . Hose Guide ................................................................................................ 1 1
28 1581842 Capscrew ................................................................................................... 2 ..
HEADER HOSES
TWO STAGE FULL FREE- LIFT (3/2011 ↔ 10/2012)
KEY:
A: 3 Function
B: 4 Function
QTY
ITEM PART NO. DESCRIPTION A B
28 1581843 Capscrew ................................................................................................... .. 2
FOOTNOTES:
a Refer to Table b → 1/2013
NOTES
HEADER HOSE
TWO STAGE FULL FREE- LIFT (10/2012 →)
B559
KEY:
A: 3 Function
B: 4 Function
QTY
ITEM PART NO. DESCRIPTION A B
1 a. . . . . Hose Guide ................................................................................................ 1 1
2 a. . . . . Hose Guide ................................................................................................ 1 1
3 a. . . . . Hydraulic Tube ........................................................................................... 1 1
4 a. . . . . Hydraulic Tube ........................................................................................... 1 1
5 a. . . . . Hose Assy .................................................................................................. .. 2
6 1598303 Washer ....................................................................................................... 1 2
7 4041194 Hose Sheave .............................................................................................. 1 2
8 4057500 Stubshaft .................................................................................................... 1 2
9 1360549 Spacer ........................................................................................................ 1 2
10 1345190 Washer ....................................................................................................... 1 2
11 4020923 Capscrew ................................................................................................... .. 1
12 4020913 Spacer ........................................................................................................ 1 2
13 1581566 Nut .............................................................................................................. 1 1
14 1360386 Clamp (Double Hose) ................................................................................. 3 6
15 4008020 Clamp ......................................................................................................... 1 2
16 1606855 Spacer ........................................................................................................ 2 2
17 1529015 Cap ............................................................................................................. 2 4
18 1597448 Capscrew ................................................................................................... 2 4
19 137852 Strap Clamp ............................................................................................... 1 2
20 1360508 Clamp ......................................................................................................... 1 1
21 a. . . . . Hose Assy .................................................................................................. 2 2
22 1617658 Clamp ......................................................................................................... 1 1
23 1581741 Capscrew ................................................................................................... 2 4
24 1345423 Clamp ......................................................................................................... 1 1
25 1581834 Capscrew ................................................................................................... 2 4
26 1581565 Nut .............................................................................................................. 2 4
27 1481229 Clamp ......................................................................................................... 3 6
28 1477996 Hose Clamp ............................................................................................... 2 4
HEADER HOSE
TWO STAGE FULL FREE- LIFT (10/2012 →)
KEY:
A: 3 Function
B: 4 Function
QTY
ITEM PART NO. DESCRIPTION A B
29 1360507 Clamp ......................................................................................................... 4 4
30 1581564 Lockwasher ................................................................................................ 1 2
31 893834 Header Hose (Bracket) .............................................................................. 1 2
32 1581828 Capscrew ................................................................................................... 1 2
33 1581843 Capscrew ................................................................................................... .. 2
FOOTNOTES:
a Refer to Table
SECTION 12
MAST-THREE STAGE FULL FREE-LIFT
DESCRIPTION PAGE
CARRIAGE
THREE STAGE FULL FREE-LIFT (→ 4/2011) .......................................................................................... 12-24
THREE STAGE FULL FREE-LIFT (4/2011 →) .......................................................................................... 12-26
FREE-LIFT
THREE STAGE FULL FREE-LIFT - 8520000 SERIES ............................................................................... 12-18
THREE STAGE FULL FREE-LIFT - 8800000 SERIES ............................................................................... 12-20
FREE-LIFT CYLINDER
THREE STAGE FULL FREE-LIFT .............................................................................................................. 12-22
HEADER HOSE
THREE STAGE FULL FREE-LIFT - 8520000 SERIES (S/N B555V06632G →) ....................................... 12-32
THREE STAGE FULL FREE-LIFT - 8800000 SERIES ............................................................................... 12-36
THREE STAGE FULL FREE-LIFT - 8520000 SERIES (→ S/N B555V06631G) ....................................... 12-28
INNER MAST
THREE STAGE FULL FREE-LIFT .............................................................................................................. 12-8
INTERMEDIATE MAST
THREE STAGE FULL FREE-LIFT .............................................................................................................. 12-6
MAIN LIFT
THREE STAGE FULL FREE-LIFT .............................................................................................................. 12-10
MAIN LIFT CYLINDER
THREE STAGE FULL FREE-LIFT - RIGHT HAND .................................................................................... 12-14
THREE STAGE FULL FREE-LIFT - LEFT HAND ....................................................................................... 12-16
OUTER MAST
THREE STAGE FULL FREE-LIFT (→ S/N B555V13829L) ....................................................................... 12-2
THREE STAGE FULL FREE-LIFT (S/N B555V13830L →) ....................................................................... 12-4
OUTER MAST
THREE STAGE FULL FREE-LIFT (→ S/N B555V13829L)
8520000 SERIES
8800000 SERIES
FOOTNOTES:
a Refer to Table
OUTER MAST
THREE STAGE FULL FREE-LIFT (S/N B555V13830L →)
8800000 SERIES
FOOTNOTES:
a Refer to Table b Replace with larger depending on wear
INTERMEDIATE MAST
THREE STAGE FULL FREE-LIFT
8520000 SERIES
8800000 SERIES
FOOTNOTES:
a Refer to Table
INNER MAST
THREE STAGE FULL FREE-LIFT
8520000 SERIES
8800000 SERIES
FOOTNOTES:
a Refer to Table
MAIN LIFT
THREE STAGE FULL FREE-LIFT
B555
MAIN LIFT
THREE STAGE FULL FREE-LIFT
FOOTNOTES:
a Refer to Table
NOTES
FOOTNOTES:
a Refer to Table
FOOTNOTES:
a Refer to Table
FREE-LIFT
THREE STAGE FULL FREE-LIFT – 8520000 SERIES
B555
FOOTNOTES:
a Refer to Table
FREE-LIFT
THREE STAGE FULL FREE-LIFT – 8800000 SERIES
B555
FOOTNOTES:
a Refer to Table
FREE-LIFT CYLINDER
THREE STAGE FULL FREE-LIFT
B555
FOOTNOTES:
a Refer to Table
CARRIAGE
THREE STAGE FULL FREE-LIFT (→ 4/2011)
CARRIAGE
THREE STAGE FULL FREE-LIFT (4/2011 →)
FOOTNOTES:
a Replace with larger depending on wear
HEADER HOSE
THREE STAGE FULL FREE-LIFT – 8520000 SERIES (→ S/N B555V06631G)
B555
KEY:
A: Three Function
B: Four Function
NOTE: This parts list contains multiple truck configurations, refer to the KEY to choose the correct QTY column
for your truck.
QTY
ITEM PART NO. DESCRIPTION A B
1 1360549 Spacer ........................................................................................................ 1 2
2 1345190 Washer ....................................................................................................... 1 2
3 1581830 Capscrew ................................................................................................... 2 2
4 1550020 Spacer ........................................................................................................ .. 1
5 1598303 Washer ...................................................................................................... .. 1
6 1481255 Stubshaft .................................................................................................... 1 2
7 1676088
1481252 Bracket (LH) ............................................................................................... 1 1
7 c 1676087
1481253 Bracket (RH) (Alternate Part) ..................................................................... 1 1
8 1581849 Nut ............................................................................................................. 2 4
9 1581564 Lockwasher .............................................................................................. 1 2
10 1581592 Capscrew ................................................................................................... 1 2
11 1581560 Washer ....................................................................................................... 2 4
12 1477996 Hose Clamp .............................................................................................. 3 6
13 1617657 Clamp ........................................................................................................ 3 6
14 a. . . . . Hose Assy .................................................................................................. 1 2
15 a. . . . . Hose Assy .................................................................................................. 1 2
16 1360507 Clamp ......................................................................................................... 2 2
17 1610914 Bracket ....................................................................................................... 1 1
18 1581841 Capscrew ................................................................................................... 2 4
19 1360386 Clamp (Double Hose) ............................................................................... 2 4
20 1581842 Capscrew .................................................................................................. 2 4
21 1597565 Capscrew .................................................................................................. 1 2
22 1363253 Bracket ...................................................................................................... 1 2
23 1348247 Hose Guide ............................................................................................... 1 1
24 1581558 Washer ...................................................................................................... 2 4
25 1581567 Nut ............................................................................................................. 1 2
26 1348246 Hose Guide ................................................................................................ .. 1
27 1581566 Nut ............................................................................................................. 3 6
28 1481765 Clamp ......................................................................................................... 1 1
29 1481766 Clamp ......................................................................................................... .. 1
HEADER HOSE
THREE STAGE FULL FREE-LIFT – 8520000 SERIES (→ S/N B555V06631G)
KEY:
A: Three Function
B: Four Function
NOTE: This parts list contains multiple truck configurations, refer to the KEY to choose the correct QTY column
for your truck.
QTY
ITEM PART NO. DESCRIPTION A B
30 1581582 Capscrew ................................................................................................... 1 2
31 1529015 Cap ............................................................................................................ 2 4
32 1481249 Hose Sheave .............................................................................................. 1 2
32 1353521 Bushing ................................................................................................ 1 1
33 b 1676088
1481252 Bracket (LH) ............................................................................................... .. 1
33 c 1676088
1481252 Bracket (LH) (Alternate Part) ...................................................................... .. 1
34 1581559 Washer ....................................................................................................... 1 2
35 1381598 Bracket ...................................................................................................... 1 1
35 1381599 Bracket ....................................................................................................... .. 1
36 1581836 Capscrew .................................................................................................. 2 4
37 1381642 Stubshaft .................................................................................................... 1 1
37 1381641 Stubshaft .................................................................................................... .. 1
38 1494017 Hose Sheave ............................................................................................. 1 2
39 1481248 Hose Sheave .............................................................................................. 1 2
39 1353521 Bushing ................................................................................................ 1 1
40 1597560 Capscrew ................................................................................................... 1 1
FOOTNOTES:
a Refer to Table c 5/2008 →
b → 5/2008
NOTES
HEADER HOSE
THREE STAGE FULL FREE-LIFT – 8520000 SERIES (S/N B555V06632G →)
B555
KEY:
A: 3 Function
B: 4 Function
QTY
ITEM PART NO. DESCRIPTION A B
1 b 1481229 Clamp ......................................................................................................... 2 4
2 1477996 Hose Clamp ............................................................................................... 2 4
3 1381599 Bracket (LH) ............................................................................................... .. 1
4 1360386 Clamp (Double Hose) ................................................................................. 2 4
5 1581853 Washer ....................................................................................................... 1 2
6 b 1494017 Hose Sheave .............................................................................................. 1 2
7 1581849 Nut .............................................................................................................. 2 4
8 1381641 Stubshaft (LH) ............................................................................................ .. 1
9 4041194 Hose Sheave .............................................................................................. 1 2
10 1360549 Spacer ........................................................................................................ 1 2
11 1345190 Washer ....................................................................................................... 1 2
12 1581830 Capscrew ................................................................................................... 2 4
13 1581842 Capscrew ................................................................................................... 2 4
14 1581565 Nut .............................................................................................................. 1 2
15 b 1581834 Capscrew ................................................................................................... 2 4
16 1581836 Capscrew ................................................................................................... 2 4
17 1381598 Bracket (RH) .............................................................................................. 1 1
18 1581566 Nut .............................................................................................................. 3 6
19 a. . . . . Hose Assy .................................................................................................. 2 4
20 b 1581828 Capscrew ................................................................................................... 1 2
21 c 4057500 Stubshaft .................................................................................................... 1 2
21 b 4020969 Stubshaft .................................................................................................... 1 2
22 1597565 Capscrew ................................................................................................... 1 2
23 1581558 Washer ....................................................................................................... 2 4
24 1363253 Bracket ....................................................................................................... 1 2
25 1348247 Hose Guide (RH) ........................................................................................ 1 1
25 1348246 Hose Guide (LH) ........................................................................................ .. 1
26 1581567 Nut .............................................................................................................. 1 2
27 1529015 Cap ............................................................................................................. 2 4
28 1597448 Capscrew ................................................................................................... 2 4
29 b 1643405 Hose Clamp ............................................................................................... 1 2
29 c 4008020 Clamp ......................................................................................................... 1 2
30 b 1581564 Lockwasher ................................................................................................ 1 2
31 1381642 Stubshaft .................................................................................................... 1 1
32 1581853 Washer ....................................................................................................... 1 2
FOOTNOTES:
a Refer to Table c 10/2012 →
b → 10/2012
NOTES
HEADER HOSE
THREE STAGE FULL FREE-LIFT – 8800000 SERIES
B555
KEY:
A: 3 Function
B: 4 Function
NOTE: This parts list contains multiple truck configurations, refer to the KEY to choose the correct QTY column
for your truck.
QTY
ITEM PART NO. DESCRIPTION A B
1 b 1481229 Clamp ........................................................................................................ 2 4
2 1477996 Hose Clamp .............................................................................................. 2 4
3 1381599 Bracket (LH) ............................................................................................... .. 1
4 1360386 Clamp (Double Hose) ............................................................................... 2 4
5 1581853 Washer ....................................................................................................... 1 2
6 b 1494017 Hose Sheave ............................................................................................. 1 2
7 1581849 Nut ............................................................................................................. 2 4
8 1381641 Stubshaft (LH) ............................................................................................ .. 1
9 4041194 Hose Sheave ............................................................................................. 1 2
10 1360549 Spacer ........................................................................................................ 1 2
11 1345190 Washer ....................................................................................................... 1 2
12 1581830 Capscrew ................................................................................................... 2 4
13 1581842 Capscrew .................................................................................................. 2 4
14 1581565 Nut ............................................................................................................. 1 2
15 b 1581834 Capscrew ................................................................................................... 2 4
16 1581836 Capscrew .................................................................................................. 2 4
17 1381598 Bracket (RH) ............................................................................................. 1 1
18 1581566 Nut ............................................................................................................. 3 6
19 a. . . . . Hose Assy ................................................................................................. 2 4
20 b 1581828 Capscrew .................................................................................................. 1 2
21 c 4057500 Stubshaft ................................................................................................... 1 2
21 b 4020969 Stubshaft .................................................................................................... 1 2
22 1597565 Capscrew .................................................................................................. 1 2
23 1581558 Washer ...................................................................................................... 2 4
24 1363253 Bracket ...................................................................................................... 1 2
25 1348247 Hose Guide (RH) ....................................................................................... 1 1
25 1348246 Hose Guide (LH) ........................................................................................ .. 1
26 1581567 Nut ............................................................................................................. 1 2
27 1529015 Cap ............................................................................................................ 2 4
28 1597448 Capscrew .................................................................................................. 2 4
29 b 1643405 Hose Clamp ............................................................................................... 1 2
29 c 4008020 Clamp ........................................................................................................ 1 2
30 b 1581564 Lockwasher .............................................................................................. 1 2
HEADER HOSE
THREE STAGE FULL FREE-LIFT – 8800000 SERIES
KEY:
A: 3 Function
B: 4 Function
NOTE: This parts list contains multiple truck configurations, refer to the KEY to choose the correct QTY column
for your truck.
QTY
ITEM PART NO. DESCRIPTION A B
31 1381642 Stubshaft .................................................................................................... 1 1
32 1581853 Washer ....................................................................................................... 1 2
FOOTNOTES:
a Refer to Table c 10/2012 →
b → 10/2012
13 OPTIONS
UNIT CODE F001
03/2014 NORTH AMERICA
SECTION 13
OPTIONS
DESCRIPTION PAGE
STROBE LIGHT
(→ S/N F001V02545E)
NOTES
BACK-UP ALARM
ITEM PART NO. DESCRIPTION QTY
1 2064929 Back-Up Alarm (82-102 dbA) ........................................................................... 1
2 1585235 Bracket ............................................................................................................... 1
3 1350215 Nut ...................................................................................................................... 2
4 1527877 Capscrew ........................................................................................................... 2
5 1480237 Nut ...................................................................................................................... 1
6 1547756 Washer ............................................................................................................... 1
7 1500912 Clip ..................................................................................................................... 1
8 1543982 Capscrew ........................................................................................................... 1
9 1344124 Fastener .............................................................................................................. 1
10 a 2070771 Wire Harness (Back-Up Alarm) .......................................................................... 1
10 b 2078882 Wire Harness (Back-Up Alarm) (FFigure 13-7).............................................. 1
FOOTNOTES:
a → S/N F001V01720D b S/N F001V01721D →
FOOTNOTES:
a → S/N F001V01720D b S/N F001V01721D →
FOOTNOTES:
a Not Illustrated c Replace with larger depending on wear
b Optional
FOOTNOTES:
a Not Illustrated c Replace with larger depending on wear
b Optional
FOOTNOTES:
a → 3/2011 b 3/2011 →
NOTES
INTEGRAL SIDE-SHIFT
FORK POSITIONER – TWO STAGE LIMITED FREE-LIFT
INTEGRAL SIDE-SHIFT
FORK POSITIONER – THREE STAGE FULL FREE-LIFT
FOOTNOTES:
a With ISS Carriage b With Standard Carriage
FOOTNOTES:
a Integral Side-Shift e → 4/2009
b Not Illustrated f → 9/2008
c Quick Disconnect Option g 4/2009 →
d Standard Carriage h 9/2008 →
FOOTNOTES:
a Integral Side-Shift Carriage d Standard Carriage
b Not Illustrated e → 10/2011
c Quick Disconnect Option f 10/2011 →
NOTES
SECTION 14
FIELD CONVERSION KITS
DESCRIPTION PAGE
ADD ON OPTIONS
FORK POSITIONER ................................................................................................................................... 14-13
ADD ON TELEMETRY KITS ........................................................................................................................... 14-13
AUDIBLE ALARM KITS ................................................................................................................................... 14-4
AUXILIARY TUBE EXTENSION KIT
TWO AND THREE STAGE FULL FREE-LIFT ............................................................................................ 14-12
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 14-12
CONVERSION KIT
SINGLE TO DUAL PEDAL .......................................................................................................................... 14-2
DIRECTIONAL CONTROL KITS ..................................................................................................................... 14-2
E-HYDRAULIC CONTROL CONVERSION KITS
→ S/N F001V03521H (MINI LEVERS WITHOUT ARMREST (DATE CODE 724-744) ............................. 14-3
→ 6/2009 S/N F001V03522H → (MINI LEVER WITH ARMREST) ........................................................... 14-3
FORK ASSEMBLY KITS ................................................................................................................................. 14-13
HEADER HOSE CONVERSION KITS
THREE STAGE FULL FREE-LIFT - 8800000 SERIES MAST .................................................................... 14-12
THREE STAGE FULL FREE-LIFT (→ S/N B555V06631G) ...................................................................... 14-10
THREE STAGE FULL FREE-LIFT - 8520000 SERIES MAST (S/N B555V06632G →) ............................ 14-11
TWO STAGE FULL FREE-LIFT (→ 5/2009) .............................................................................................. 14-8
TWO STAGE FULL FREE-LIFT (5/2009 →) .............................................................................................. 14-9
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 14-7
HYDRAULIC CONTROLS
MANUAL HYDRAULICS ............................................................................................................................. 14-2
LIGHT OPTIONS ............................................................................................................................................. 14-4
MISCELLANEOUS KITS ................................................................................................................................. 14-5
RETURN TO SET TILT KITS .......................................................................................................................... 14-2
SEAT CONVERSION KITS ............................................................................................................................. 14-5
WEATHER PROTECTION KITS ..................................................................................................................... 14-5
WIDE TIRE CONVERSION ............................................................................................................................. 14-2
CONVERSION KIT
SINGLE TO DUAL PEDAL
FOOTNOTES:
a 5/2010 →
FOOTNOTES:
a Requires software that must be dealer installed
b → S/N F001V01807D
c S/N F001V01807D →
HYDRAULIC CONTROLS
MANUAL HYDRAULICS
HYDRAULIC CONTROLS
MANUAL HYDRAULICS
(CONTINUED)
FOOTNOTES:
a → S/N F001V02620E
b → S/N F001V02880F INC. 02884
c S/N F001V02621E ↔ S/N F001V02880F INC. 02884
d S/N F001V02881F → EXC. 02884
FOOTNOTES:
a Kit requires Software that must be Dealer installed.
FOOTNOTES:
LIGHT OPTIONS
MISCELLANEOUS KITS
FOOTNOTES:
a Kit requires Software that must be Dealer installed.
ADD ON OPTIONS
FORK POSITIONER
NOTES
15 NUMERICAL INDEX
UNIT CODE F001
03/2014 NORTH AMERICA
SECTION 15
NUMERICAL INDEX
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM