MP16E, MP18E, MP20E, MP22E (A428) Parts Manual: Yale Europe Materials Handling Limited

PARTS MANUAL
MP16E, MP18E, MP20E, MP22E

(A428)
Yale Europe Materials Handling Limited 550112521

Centennial House, Building 4.5 ©Yale Corp.
Frimley Business Park 02/2016
Frimley, Surry GU16 7SG, United Kingdom
SECTIONS
1 FRAME/DRIVE UNIT
2 ELECTRICAL SYSTEM
3 STEER HANDLE/BRAKE SYSTEM
4 HYDRAULIC SYSTEM
5 LIFT LINKAGE
6 ACCESSORIES
7 NUMERICAL INDEX
8 USER SUPPORT INFORMATION
This Parts Manual is divided into 8 major sections which are listed above. Quick reference to these sections can be
made by placing the right thumb on the tab of the desired section, bending the book back and thumbing the pages
to the corresponding tab.
GENERAL INFORMATION
TABLE OF CONTENTS
DESCRIPTION PAGE
A
AUDIBLE ALARM
OPTION ....................................................................................................................................................... 2-14
B
BATTERY SIDE ROLLER ASSEMBLY
OPTION ....................................................................................................................................................... 6-3
BATTERY STOP - SIDE REMOVAL
OPTION ....................................................................................................................................................... 2-10
BATTERY TRAY
SIDE BATTERY EXTRACTION - 218 MM AND 290 MM BATTERY BOX ................................................. 1-6
VERTICAL BATTERY EXTRACTION - 156 MM BATTERY BOX ............................................................... 1-4
VERTICAL BATTERY EXTRACTION - 218 MM AND 290 MM BATTERY BOX ........................................ 1-5
C
CASTER WHEEL ASSEMBLY ........................................................................................................................ 1-14
CASTER WHEELS .......................................................................................................................................... 1-12
CONTACTOR .................................................................................................................................................. 2-33
COVERS ......................................................................................................................................................... 1-3
CYLINDER ASSEMBLY .................................................................................................................................. 4-6
D
DRIVE TIRE AND STATIC STRAP ................................................................................................................. 1-7
E
ELECTRICAL SYSTEM
WITH HOURMETER ................................................................................................................................... 2-6
WITH KEYPAD ............................................................................................................................................ 2-2
ENTRY BLADES ............................................................................................................................................. 1-10
EXTENSION BATTERY CABLE
OPTION ....................................................................................................................................................... 6-2
H
HYDRAULIC POWER UNIT ASSEMBLY ....................................................................................................... 4-4
HYDRAULIC SYSTEM .................................................................................................................................... 4-2
L
LABEL
OPTION - ONLY FOR SUNLIGHT BATTERY ............................................................................................ 1-20
LABELS ........................................................................................................................................................... 1-22
TILLER HANDLE ......................................................................................................................................... 3-6
LIFT LINKAGE ................................................................................................................................................. 5-2
LOAD BACKREST
SIDE BATTERY EXTRACTION VERSION - OPTION ................................................................................ 1-18
VERTICAL BATTERY EXTRACTION VERSION - OPTION ....................................................................... 1-16
LOAD WHEEL
SEALED BEARING ..................................................................................................................................... 1-8
TANDEM - OPTION .................................................................................................................................... 1-9
A428 ©2015 Yale Europe Materials Handling Limited i

GENERAL INFORMATION
TABLE OF CONTENTS (continued)
DESCRIPTION PAGE
M
MASTER DRIVE UNIT ASSEMBLY ................................................................................................................ 1-2
O
ON-BOARD BATTERY CHARGER ................................................................................................................. 2-8
S
SPEED REDUCTION STEERING
OPTION (→ S/N A428T01776N EXC. 01737-01739, 01745-01747, 01749-01750, 01758, 01760) ......... 2-12
OPTION (S/N A428T01656N → EXC. 01657-01685, 01690-01692, 01694-01703, 01709-01716,
01719-01726, 01728-01734, 01740-01744, 01762-01776) ....................................................................... 2-13
T
TELEMETRY
OPTION ....................................................................................................................................................... 2-16
TELEMETRY LABEL
OPTION ....................................................................................................................................................... 2-18
TILLER HANDLE AND MOUNTING WELDMENT .......................................................................................... 3-2
TILLER HEAD ASSEMBLY ............................................................................................................................. 3-4
W
WIRE HARNESS
KEYPAD JUMPER ...................................................................................................................................... 2-25
MAIN - KEYPAD OPTION ........................................................................................................................... 2-26
MAIN - HOURMETER OPTION .................................................................................................................. 2-30
OPTION HARNESS .................................................................................................................................... 2-24
TELEMETRY OPTION ................................................................................................................................ 2-20
TILLER ........................................................................................................................................................ 2-23
ii ©2015 Yale Europe Materials Handling Limited A428

GENERAL INFORMATION
ABBREVIATIONS QUICK REFERENCE SHEET
Listed below are abbreviations used in parts manuals to denote the following expressions:
spacer
TERM DEFINITION TERM DEFINITION
Amp Amperes FRE Freezer Environment
AR As Required in. inches
BDI Battery Discharge Indicators LPG Liquefied Petroleum Gas
BWI Brush Wear Indicator MAP Manifold Absolute Pressure
CE Communicator End mm millimeters
CRE Corrosive Environment MSTS Microprocessor Spark Timing System
D/B Date Break NPT National Pipe Threads
dbA Decibel "A" Scale O/S Oversize
DE Drive End PTO Power Take Off
ECH Empty Container Handler RPM Revolutions per Minute
ECH-3 Empty Container Handler - 3 High S/N Serial Number
Stacking TMM Truck Management Module
ECH-4 Empty Container Handler - 4 High UL Type D Diesel-Powered Safety Rating
Stacking
UL Type DS Diesel-Powered Safety Rating
ECH-5 Empty Container Handler - 5 High
Stacking UL Type E Battery-Powered Safety Rating
ECH-6 Empty Container Handler - 6 High UL Type EE Battery-Powered Safety Rating

Stacking UL Type ES Battery-Powered Safety Rating
ECH-7 Empty Container Handler - 7 High UL Type G Gasoline-Powered Safety Rating
Stacking UL Type GS Gasoline-Powered Safety Rating
ECM Electronic Control Module UL Type LP Gas-Powered Safety Rating
ECN Engineering Change Notice UL Type LPS LP Gas-Powered Safety Rating
EEPROM Electrically Erasable Programmable U/S Undersize
Read Only Memory
UL Underwriters Laboratory
EPA US Environmental Protection Agency
V Volts
EPROM Electrically Programmable Read Only
Memory
A428 ©2015 Yale Europe Materials Handling Limited iii

GENERAL INFORMATION
HOW TO USE THE ILLUSTRATED PARTS MANUAL
This parts manual describes and illustrates assemblies, The different constructions are indicated by keys and
subassemblies, and detail parts needed for service footnotes. The callouts correspond to descriptions
replacement. found on the next page.
iv ©2015 Yale Europe Materials Handling Limited A428

GENERAL INFORMATION
HOW TO FIND THE DESIRED PART NUMBER

WHEN THE PART NUMBER AND THE NEXT subparts of assemblies. In the example on the
HIGHER ASSEMBLY IS NOT KNOWN: previous page, BEARING CAP (Item 2) is a
1. Determine the function and application of the part subpart of the major assembly CASE.
required. Turn to the Sections Page. Choose the 9. Quantities shown are for one assembly. The
general area of reference most likely to include the quantities of the subpart BEARING CAP are
part. indicated as two and two. This means two per
2. Turn to the section you chose. Use the Section CASE assembly.
Table of Contents to determine the assembly 10. Serial number breaks identify the most current
which would normally contain the part required. parts information and are shown as follows:
Then locate the part on the assembly breakdown → S/N A810N2639
page. Indicates last serial number affected.
S/N A810N2640 →
WHEN THE PART NUMBER IS NOT KNOWN
Indicates the first serial number affected.
AND THE NEXT HIGHER ASSEMBLY IS
S/N A810N1553 ↔ S/N A810N3291
KNOWN:
Indicates a range of serial numbers affected.
3. Determine the assembly the required part is used
on. Turn to the Table of Contents (Page i). ECN numbers for pending serial numbers are
shown to allow for the inclusion of the most current
4. Locate the assembly the required part is used on
parts information and are identified as follows:
and turn to the page indicated for that assembly.
→ S/N Pending Per ECN 63243
Then locate the part on the assembly breakdown
Indicates a pending serial number for last unit
page.
affected.
WHEN THE PART NUMBER IS KNOWN: S/N Pending Per ECN 63243 →
5. Use the Numerical Index (Page 7-1) to find the Indicates a pending serial number for first unit
part number. Turn to the page listed and locate the affected.
part as indicated by the item number. Date breaks are used to indicate when a change
GENERAL: occurred but a subsequent serial number break
was not recorded. This is an arbitrary date usually
The assembly breakdowns include part numbers, based on the ECN release and are identified as
descriptions, quantities required, keys and follows:
footnotes to help in selecting correct parts. → D/B 3/00
6. Parts Supersession Information. Part numbers that Indicates that a change occurred sometime
have this history will be displayed in the parts list within that month for the item affected.
in the order that they were superseded (from oldest D/B 3/00 →
to newest). The superseded part numbers will be Indicates that a change occurred sometime
shown with a line through them. within that month for the item affected.
D/B 3/00 ↔ D/B 4/00
Five periods in the PART NO. column (. . . . .)
Indicates a range of production dates of the item
indicate that the part is either Not Serviced
affected.
Separately or there is a reference to another figure.
A figure reference is denoted by a pointing hand Contact your local dealer for Yale lift trucks for
followed by a page number in the DESCRIPTION serial number information for items with a ECN or
column (FPage 3-4) a date break.
7. Keys are used to show two or more similar
ORDERING PARTS:
assemblies, RH and LH assembly parts, etc.
Select the appropriate key, "A", "B", "C", "D", or "E" When ordering replacement parts, give the unit serial
and the corresponding quantity column to find the number, part number, name of part and quantity
required parts. Two periods in the QTY column (..) required.
indicate that the part is not used for that assembly.
8. Indented descriptions under the DESCRIPTION For any further information on parts, service, or
column are used to indicate assemblies and ordering, consult your local dealer for Yale lift trucks.
A428 ©2015 Yale Europe Materials Handling Limited v

GENERAL INFORMATION
IDENTIFICATION OF TRUCK SERIAL NUMBERS
NOTE: Serial Number breakdown is only for trucks built after 1994.
(1) and (2) The first letter and three numbers indicate the truck unit code.
(3) The second letter indicates the plant of manufacture.
(4) The four or five digit number indicates the production sequence number of the truck.
(5) The final letter indicates the year of manufacture starting with "A" in 1957, 1980, and 2003.
The letters "I", "O", and "Q" will not be used.
For pending serial numbers contact your local dealer for Yale lift trucks.
Parts referred to in this book as right or left hand parts are in accordance with the illustration above.
vi ©2015 Yale Europe Materials Handling Limited A428

GENERAL INFORMATION
PUBLICATIONS
Every new lift truck is provided with an OPERATING MANUALS with complete replacement part
MANUAL. This manual has information that the identification, are available at a nominal fee from your
operator must know for inspection and operation of the Yale dealer to assist users in effectively maintaining
lift truck. Yale lift trucks in a safe, useful condition. See the list
below for information on ordering specific publications
SERVICE MAINTENANCE MANUALS, which provide for this model lift truck.
service and overhaul procedures, and PARTS
PUBLICATION YALE PART NUMBER
Operating Manual.................................................................................................................... 550112654
Service Manual (Complete)..................................................................................................... 550127938
Parts Manual........................................................................................................................... 550112521
A428 ©2015 Yale Europe Materials Handling Limited vii

GENERAL INFORMATION
NOTES
viii ©2015 Yale Europe Materials Handling Limited A428

SECTION 1
1 FRAME/DRIVE UNIT
CONTENTS
SECTION 1
FRAME/DRIVE UNIT
DESCRIPTION PAGE
BATTERY TRAY
SIDE BATTERY EXTRACTION - 218 MM AND 290 MM BATTERY BOX ................................................. 1-6
VERTICAL BATTERY EXTRACTION - 156 MM BATTERY BOX ............................................................... 1-4
VERTICAL BATTERY EXTRACTION - 218 MM AND 290 MM BATTERY BOX ........................................ 1-5
CASTER WHEEL ASSEMBLY ........................................................................................................................ 1-14
CASTER WHEELS .......................................................................................................................................... 1-12
COVERS ......................................................................................................................................................... 1-3
DRIVE TIRE AND STATIC STRAP ................................................................................................................. 1-7
ENTRY BLADES ............................................................................................................................................. 1-10
LABEL
OPTION - ONLY FOR SUNLIGHT BATTERY ............................................................................................ 1-20
LABELS ........................................................................................................................................................... 1-22
LOAD BACKREST
SIDE BATTERY EXTRACTION VERSION - OPTION ................................................................................ 1-18
VERTICAL BATTERY EXTRACTION VERSION - OPTION ....................................................................... 1-16
LOAD WHEEL
SEALED BEARING ..................................................................................................................................... 1-8
TANDEM - OPTION .................................................................................................................................... 1-9
MASTER DRIVE UNIT ASSEMBLY ................................................................................................................ 1-2
A428 ©2015 Yale Europe Materials Handling Limited 1-1

FRAME/DRIVE UNIT
MASTER DRIVE UNIT ASSEMBLY (FIGURE 1-1)
ITEM PART NO. DESCRIPTION QTY

582029591 Master Drive Unit Assembly ............................................................................... 1
1 582049755 Brake Assy ..................................................................................................... 1
1 582015552 Brake .......................................................................................................... 1
1 582049682 Cap ............................................................................................................. 1
1 582049681 Gasket ........................................................................................................ 1
2 ..... Traction Motor Assembly ................................................................................ 1
2 582049677 Motor , Traction .......................................................................................... 1
2 582045113 Sensor , Speed .......................................................................................... 1
2 582015551 Nut .............................................................................................................. 1
3 ..... Carrier Assy .................................................................................................... 1
3 582049437 Frame ......................................................................................................... 1
3 582049438 O-Ring ........................................................................................................ 1
4 582030998 Bearing (Turntable) ........................................................................................ 1
4 582046004 Bearing ....................................................................................................... 1
4 582056459 Capscrew ................................................................................................... 24
5 582030999 Gearbox .......................................................................................................... 1
5 582056460 Snap Ring .................................................................................................. 1
5 582049680 Housing Assembly ..................................................................................... 1
5 582037756 Housing Cover ....................................................................................... 1
5 582015541 Snap Ring .............................................................................................. 1
5 582015542 O-Ring ................................................................................................... 1
5 519244834 Breather Valve ....................................................................................... 1
5 582030281 Plate ....................................................................................................... 1
6 582049754 Pinion Assembly ............................................................................................. 1
6 582037755 Pinion , Drive .............................................................................................. 1
1-2 ©2015 Yale Europe Materials Handling Limited A428

FRAME/DRIVE UNIT
COVERS (FIGURE 1-2)

1 550079667 Cover (Main) ....................................................................................................... 1
2 582046106 Stud .................................................................................................................... 2
3 519609804 Nut ...................................................................................................................... 2
4 580027573 Nut ...................................................................................................................... 5
5 258743277 Cap ..................................................................................................................... 2
6 582028147 Stud .................................................................................................................... 3
7 582015980 Cover (Center Main) ........................................................................................... 1
8 932729905 Capscrew ............................................................................................................ 1
9 582015981 Cover (Center Top) ............................................................................................. 1
10 582053119 Washer ............................................................................................................... 1

FRAME/DRIVE UNIT
BATTERY TRAY (FIGURE 1-3)

VERTICAL BATTERY EXTRACTION — 156 MM BATTERY BOX

1 582053549 Cover .................................................................................................................. 1
2 582047027 Mount (RH) ......................................................................................................... 1
3 582047026 Mount (LH) .......................................................................................................... 1
4 277458600 Guard (Cable Guide) .......................................................................................... 2
5 580003569 Washer ............................................................................................................... 4
6 932729903 Capscrew ............................................................................................................ 4
7 a 580017064 Strap ................................................................................................................... 1
8 a 277754400 Clip ...................................................................................................................... 1
FOOTNOTES:
a On-board battery charger option only

FRAME/DRIVE UNIT

VERTICAL BATTERY EXTRACTION — 218 MM AND 290 MM BATTERY BOX

1 582053547 Cover (218 mm Battery Box) .............................................................................. 1
1 582053548 Cover (290 mm Battery Box) .............................................................................. 1
2 582045569 Mount (RH) ......................................................................................................... 1
3 582045568 Mount (LH) .......................................................................................................... 1
5 580003569 Washer ............................................................................................................... 4
6 932729903 Capscrew ............................................................................................................ 4
7 a 580017064 Strap ................................................................................................................... 1
8 a 277754400 Clip ...................................................................................................................... 1
FOOTNOTES:

FRAME/DRIVE UNIT

SIDE BATTERY EXTRACTION — 218 MM AND 290 MM BATTERY BOX

1 582053547 Cover .................................................................................................................. 1
2 582046394 Battery Tray Mounting Bracket ........................................................................... 1
3 582046396 Plate .................................................................................................................... 1
4 449001410 Capscrew ............................................................................................................ 1
5 449021002 Washer ............................................................................................................... 1
7 a 580017064 Strap ................................................................................................................... 1
8 a 277754400 Clip ...................................................................................................................... 1
9 582045724 Band , Elastic ...................................................................................................... 2
10 580003569 Washer ............................................................................................................... 4
11 932729905 Capscrew ............................................................................................................ 4
12 582035083 Lanyard (290mm battery box only) ..................................................................... 1
FOOTNOTES:

FRAME/DRIVE UNIT
DRIVE TIRE AND STATIC STRAP (FIGURE 1-6)

1 582042237 Drive Wheel (250 x 75, Poly) .............................................................................. 1
1 582042238 Drive Wheel (250 x 75, Poly Wet Grip) ............................................................... 1
1 582042236 Drive Wheel (250 x 75, Vulkollan) ...................................................................... 1
2 582047188 Wheel Nut ........................................................................................................... 5
3 582038703 Static Strap ......................................................................................................... 1
4 506726507 Stud .................................................................................................................... 1
5 580058190 Nut ...................................................................................................................... 1
6 582029591 Master Drive Unit Assembly (FPage 1-2).......................................................... 1
7 582018029 Capscrew ............................................................................................................ 4

FRAME/DRIVE UNIT
LOAD WHEEL (FIGURE 1-7)

SEALED BEARING

582031798 Load Wheel Assembly (Poly) .............................................................................. 1
582031796 Load Wheel Assembly (Vulkollan) ...................................................................... 1
1 582032960 Link ................................................................................................................. 1
2 582032958 Axle ................................................................................................................ 1
3 582032968 Roller (Poly) .................................................................................................... 1
3 582032961 Roller (Vulkollan) ............................................................................................ ..
4 582032957 Pin .................................................................................................................. 1

FRAME/DRIVE UNIT
LOAD WHEEL (FIGURE 1-8)

TANDEM — OPTION
KEY:
A: Standard
B: Polyurethane
QTY
ITEM PART NO. DESCRIPTION A B
1 273011400 Bushing ...................................................................................................... 4 ..
1 582015707 Bushing ...................................................................................................... .. 4
2 580053822 Lever .......................................................................................................... 2 2
3 580064740 Washer ....................................................................................................... 4 4
4 580059462 Rocker Plate ............................................................................................... 4 4
5 272046300 Bushing ...................................................................................................... 4 ..
5 582015704 Bushing ...................................................................................................... .. 4
6 580059464 Capscrew ................................................................................................... 4 4
7 582015705 Roller .......................................................................................................... .. 4
7 580059476 Load Wheel ................................................................................................ 4 ..
8 580064749 Bushing .................................................................................................. 2 ..
9 950433907 Bearing Ball ........................................................................................... 2 ..
10 580059473 Roller ..................................................................................................... 1 ..
11 580059475 Spacer ................................................................................................... 1 ..

FRAME/DRIVE UNIT
ENTRY BLADES (FIGURE 1-9)

1 582033352 Bar , Pallet Entry Skid (Tandem Load Rollers) (Shown) ..................................... 2
1 582033351 Bar , Pallet Entry Skid (Standard Load Rollers) .................................................. 2
2 580030967 Capscrew ............................................................................................................ 4
3 580027573 Nut ...................................................................................................................... 4

FRAME/DRIVE UNIT
NOTES

FRAME/DRIVE UNIT
CASTER WHEELS (FIGURE 1-10)

FRAME/DRIVE UNIT
CASTER WHEELS
1 580027572 Nut ...................................................................................................................... 8
2 580055098 Shim .................................................................................................................... AR
3 580023593 Capscrew ............................................................................................................ 8
4 582002425 Caster Wheel Assembly (FPage 1-14).............................................................. 2

FRAME/DRIVE UNIT
CASTER WHEEL ASSEMBLY (FIGURE 1-11)

FRAME/DRIVE UNIT
CASTER WHEEL ASSEMBLY

582002425 Caster Wheel Assembly ..................................................................................... 2
1 582010616 Support ........................................................................................................... 1
2 524299833 Locknut ........................................................................................................... 1
3 582010615 Bumper Assy (Includes Spring) ...................................................................... 1
4 449001230 Screw ............................................................................................................. 1
5 582003774 Screw ............................................................................................................. 2
6 582003765 Adjuster .......................................................................................................... 2
7 582003769 Pin .................................................................................................................. 2
8 582003772 Axle Shaft ....................................................................................................... 1
9 582010614 Wheel Assy .................................................................................................... 1
10 582003775 Guard ......................................................................................................... 2
11 582003773 Axle Shaft ................................................................................................... 2
12 524149840 Wheel Assy ................................................................................................ 1
13 524149842 Tube ....................................................................................................... 1
14 524149843 Bearing .................................................................................................. 2
15 524149841 Wheel ..................................................................................................... 1

FRAME/DRIVE UNIT
LOAD BACKREST (FIGURE 1-12)

VERTICAL BATTERY EXTRACTION VERSION — OPTION

FRAME/DRIVE UNIT
LOAD BACKREST
VERTICAL BATTERY EXTRACTION VERSION – OPTION

1 582033219 Load Backrest (1800 mm) .................................................................................. 1
2 582015519 Locknut ............................................................................................................... 6
3 580037179 Capscrew ............................................................................................................ 4
4 582021567 Load Backrest Mount (RH) ................................................................................. 1
5 582021568 Load Backrest Mount (LH) .................................................................................. 1
6 582017090 Capscrew ............................................................................................................ 6
7 582057369 Mount .................................................................................................................. 4

FRAME/DRIVE UNIT
LOAD BACKREST (FIGURE 1-13)

SIDE BATTERY EXTRACTION VERSION — OPTION

FRAME/DRIVE UNIT
LOAD BACKREST
SIDE BATTERY EXTRACTION VERSION – OPTION

1 582017022 Load Backrest (1524 mm) .................................................................................. 1
2 582015519 Locknut ............................................................................................................... 8
3 582049332 Load Backrest ..................................................................................................... 1
4 580037179 Capscrew ............................................................................................................ 2
5 582057369 Mount .................................................................................................................. 2
6 582017090 Capscrew ............................................................................................................ 6
7 582034130 Spacer ................................................................................................................ 1
8 582034129 Plate .................................................................................................................... 1
9 582028413 Capscrew ............................................................................................................ 2

FRAME/DRIVE UNIT
LABEL (FIGURE 1-14)

OPTION — ONLY FOR SUNLIGHT BATTERY

550091593 Label (72,5x98mm) ............................................................................................. 2

FRAME/DRIVE UNIT
NOTES

FRAME/DRIVE UNIT
LABELS (FIGURE 1-15)

FRAME/DRIVE UNIT
LABELS
1 582015332 Label (RH Switch Functions) (FPage 3-6)......................................................... 1
2 524139322 Label (Tiller Handle Yale) (FPage 3-6).............................................................. 1
3 582020332 Label (LH Switch Functions) (FPage 3-6)......................................................... 1
4 524208881 Label (Yale) ........................................................................................................ 3
5 272213500 Label (Lifting Hook) ............................................................................................. 1
6 580064842 Safety Label ........................................................................................................ 2
7 582045464 Label (Keypad) ................................................................................................... 1
8 582045004 Label (BDI) .......................................................................................................... 1
9 524216189 Label (Warranty) (FPage 1-24).......................................................................... 1
10 582030993 Label ................................................................................................................... 1
11 ..... Nameplate .......................................................................................................... 1
12 a 580014880 Label (Snowflake) ............................................................................................... 1
FOOTNOTES:
a Cold Store option

FRAME/DRIVE UNIT
LABEL (FIGURE 1-16)

524216192 Label (Warranty) Czech ...................................................................................... 1
524216193 Label (Warranty) Danish ..................................................................................... 1
524216194 Label (Warranty) Dutch ....................................................................................... 1
524216195 Label (Warranty) Estonian .................................................................................. 1
524216196 Label (Warranty) Finnish .................................................................................... 1
524216199 Label (Warranty) Greek ...................................................................................... 1
524216200 Label (Warranty) Hungarian ............................................................................... 1
524216201 Label (Warranty) Icelandic .................................................................................. 1
524216203 Label (Warranty) Latvian .................................................................................... 1
524216204 Label (Warranty) Lithuanian ............................................................................... 1
524216205 Label (Warranty) Norwegian ............................................................................... 1
524216206 Label (Warranty) Polish ...................................................................................... 1
524216207 Label (Warranty) Portuguese .............................................................................. 1
524216191 Label (Warranty) Brazilian .................................................................................. 1
524259713 Label (Warranty) Bulgarian ................................................................................. 1
524216766 Label (Warranty) Croatian .................................................................................. 1
524216526 Label (Warranty) Turkish .................................................................................... 1
524216212 Label (Warranty) Swedish .................................................................................. 1
524216190 Label (Warranty) Slovenian ................................................................................ 1
524216210 Label (Warranty) Slovakian ................................................................................ 1
524216209 Label (Warranty) Russian ................................................................................... 1
524216208 Label (Warranty) Romanian ................................................................................ 1
550076748 Label (Warranty) (Warranty) Serbian .................................................................. 1

SECTION 2
2 ELECTRICAL SYSTEM
CONTENTS
SECTION 2
ELECTRICAL SYSTEM
DESCRIPTION PAGE
AUDIBLE ALARM
OPTION ....................................................................................................................................................... 2-14
OPTION ....................................................................................................................................................... 2-10
CONTACTOR .................................................................................................................................................. 2-33
ELECTRICAL SYSTEM
WITH HOURMETER ................................................................................................................................... 2-6
WITH KEYPAD ............................................................................................................................................ 2-2
ON-BOARD BATTERY CHARGER ................................................................................................................. 2-8
SPEED REDUCTION STEERING
OPTION (→ S/N A428T01776N EXC. 01737-01739, 01745-01747, 01749-01750, 01758, 01760) ......... 2-12
OPTION (S/N A428T01656N → EXC. 01657-01685, 01690-01692, 01694-01703, 01709-01716,
01719-01726, 01728-01734, 01740-01744, 01762-01776) ....................................................................... 2-13
TELEMETRY
OPTION ....................................................................................................................................................... 2-16
TELEMETRY LABEL
OPTION ....................................................................................................................................................... 2-18
WIRE HARNESS
KEYPAD JUMPER ...................................................................................................................................... 2-25
MAIN - KEYPAD OPTION ........................................................................................................................... 2-26
MAIN - HOURMETER OPTION .................................................................................................................. 2-30
OPTION HARNESS .................................................................................................................................... 2-24
TELEMETRY OPTION ................................................................................................................................ 2-20
TILLER ........................................................................................................................................................ 2-23

ELECTRICAL SYSTEM
ELECTRICAL SYSTEM (FIGURE 2-1)

WITH KEYPAD

ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
WITH KEYPAD

1 582042501 Battery Cable ...................................................................................................... 1
1 06205330D E-Ring ............................................................................................................ 1
1 06205330E E-Ring ............................................................................................................ 1
1 582015143 Strap Clamp ................................................................................................... 1
1 580035642 Battery Connector Housing ............................................................................ 1
1 582035136 Battery Connector .......................................................................................... 2
2 582029183 Stud .................................................................................................................... 3
3 580027573 Nut ...................................................................................................................... 5
4 582028147 Stud .................................................................................................................... 5
5 580047919 Nut ...................................................................................................................... 10
6 506726504 Stud .................................................................................................................... 6
7 582033604 Controller-Traction .............................................................................................. 1
8 582035887 Wire Harness (Main) (FPage 2-26)................................................................... 1
9 580019665 Emergency Disconnect Switch ........................................................................... 1
10 582037031 Cable .................................................................................................................. 1
11 582036781 Isolator ................................................................................................................ 1
12 449015014 Nut ...................................................................................................................... 4
13 449021001 Washer ............................................................................................................... 5
14 580096589 Fuse .................................................................................................................... 1
15 504057775 Screw .................................................................................................................. 2
16 582012416
582045353 Key Pad .............................................................................................................. 1
17 524143269 Horn .................................................................................................................... 1
18 580096845 Gauge ................................................................................................................. 1
19 504058760 Contactor (FPage 2-33)..................................................................................... 1
20 937100904 Nut ...................................................................................................................... 2
21 582045464 Label (Keypad) ................................................................................................... 1
22 582032804 Power Cable (U) ................................................................................................. 1
22 502026902 Terminal ......................................................................................................... 2
23 582032803 Power Cable (V) ................................................................................................. 1
23 502026902 Terminal ......................................................................................................... 2
24 582032800 Power Cable (W) ................................................................................................ 1
24 502026902 Terminal ......................................................................................................... 2
25 582032801 Power Cable (E-Stop) ......................................................................................... 1
25 06205330D E-Ring ............................................................................................................ 1
25 06205330E E-Ring ............................................................................................................ 1
26 582032802 Power Cable (Jumper Pump to B+) .................................................................... 1
26 010387200 Terminal ......................................................................................................... 1
26 064575700 Terminal ......................................................................................................... 1
27 580084947 Capscrew ............................................................................................................ 5
28 273059100 Plug ..................................................................................................................... 1
29 580056589 Clip ...................................................................................................................... 2
30 582033996 Control Panel ...................................................................................................... 1
31 582033994 Fuse Holder ........................................................................................................ 1
32 932728903 Capscrew ............................................................................................................ 4
33 582033999 Bracket ................................................................................................................ 1
34 582034000 Spacer ................................................................................................................ 1
35 258743277 Cap ..................................................................................................................... 3
36 580035673 Capscrew ............................................................................................................ 2
37 940004903 Washer ............................................................................................................... 2

ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
WITH KEYPAD

38 449022019 Lockwasher ......................................................................................................... 2
39 582007595 Washer ............................................................................................................... 2

ELECTRICAL SYSTEM
NOTES

ELECTRICAL SYSTEM
ELECTRICAL SYSTEM (FIGURE 2-2)

WITH HOURMETER

ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
WITH HOURMETER

1 582042501 Battery Cable ...................................................................................................... 1
1 06205330D E-Ring ............................................................................................................ 1
1 06205330E E-Ring ............................................................................................................ 1
1 582015143 Strap Clamp ................................................................................................... 1
1 582035136 Battery Connector .......................................................................................... 2
2 582029183 Stud .................................................................................................................... 3
3 580027573 Nut ...................................................................................................................... 5
4 582028147 Stud .................................................................................................................... 5
5 580047919 Nut ...................................................................................................................... 6
6 506726504 Stud .................................................................................................................... 6
7 582033604 Controller-Traction .............................................................................................. 1
8 582044985 Wire Harness (Main) (FPage 2-30)................................................................... 1
9 580019665 Emergency Disconnect Switch ........................................................................... 1
10 582037031 Cable .................................................................................................................. 1
11 582036781 Isolator ................................................................................................................ 1
12 449015014 Nut ...................................................................................................................... 4
13 449021001 Washer ............................................................................................................... 5
14 580096589 Fuse .................................................................................................................... 1
15 504057775 Screw .................................................................................................................. 2
16 582045305 Ignition Switch ..................................................................................................... 1
17 582057815 Key Set ........................................................................................................... 1
18 580096845 Gauge ................................................................................................................. 1
19 504058760 Contactor (FPage 2-33)..................................................................................... 1
20 937100904 Nut ...................................................................................................................... 2
21 582045004 Label (BDI) .......................................................................................................... 1
22 582032804 Power Cable (U) ................................................................................................. 1
22 502026902 Terminal ......................................................................................................... 2
23 582032803 Power Cable (V) ................................................................................................. 1
23 502026902 Terminal ......................................................................................................... 2
24 582032800 Power Cable (W) ................................................................................................ 1
24 502026902 Terminal ......................................................................................................... 2
25 582032801 Power Cable (E-Stop) ......................................................................................... 1
25 06205330D E-Ring ............................................................................................................ 1
25 06205330E E-Ring ............................................................................................................ 1
26 582032802 Power Cable (Jumper Pump to B+) .................................................................... 1
26 010387200 Terminal ......................................................................................................... 1
26 064575700 Terminal ......................................................................................................... 1
27 580084947 Capscrew ............................................................................................................ 5
28 273059100 Plug ..................................................................................................................... 1
29 580056589 Clip ...................................................................................................................... 2
30 258743277 Cap ..................................................................................................................... 3
31 580035673 Capscrew ............................................................................................................ 2
32 940004903 Washer ............................................................................................................... 2
33 449022019 Lockwasher ......................................................................................................... 2
34 582007595 Washer ............................................................................................................... 2
35 524143269 Horn .................................................................................................................... 1

ELECTRICAL SYSTEM
ON-BOARD BATTERY CHARGER (FIGURE 2-3)

ELECTRICAL SYSTEM
ON-BOARD BATTERY CHARGER

1 582043199 Port (AC Charge IEC) ......................................................................................... 1
2 582032808 Battery Charger (230V) (Flooded Battery) .......................................................... 1
2 582032812 Battery Charger (230V) (Lithium Ion Battery) ..................................................... 1
3 582029183 Stud .................................................................................................................... 2
4 580027573 Nut ...................................................................................................................... 2
5 582026101 Cable (SCHUKO plug) ........................................................................................ 1
6 582026102 Cable (UK plug) .................................................................................................. 1

ELECTRICAL SYSTEM
BATTERY STOP - SIDE REMOVAL (FIGURE 2-4)

OPTION

ELECTRICAL SYSTEM

OPTION

1 582049889 Handle ................................................................................................................ 1
2 582049899 Hook ................................................................................................................... 1
3 582049892 Support ............................................................................................................... 1
4 582049402 Support ............................................................................................................... 1
5 582049898 Plate .................................................................................................................... 1
6 580013990 Capscrew ............................................................................................................ 2
7 272017300 Vibration Damper ................................................................................................ 2
8 449015135 Nut ...................................................................................................................... 2
9 582050201 Roll Pin ............................................................................................................... 2
10 582049894 Pin ....................................................................................................................... 1
11 520426875 Capscrew ............................................................................................................ 1
12 582049895 Spacer ................................................................................................................ 2
13 582049890 Plate .................................................................................................................... 1
14 449021001 Washer ............................................................................................................... 1
15 449015098 Nut ...................................................................................................................... 3
16 501729904 Capscrew ............................................................................................................ 1
17 580065140 Capscrew ............................................................................................................ 1
18 582049818 Bushing ............................................................................................................... 4
19 582049893 Pin ....................................................................................................................... 1
20 582049817 Spring ................................................................................................................. 1
21 582049897 Spacer ................................................................................................................ 1
22 582049896 Spacer ................................................................................................................ 1
23 582049891 Spacer ................................................................................................................ 1

ELECTRICAL SYSTEM
SPEED REDUCTION STEERING (FIGURE 2-5)

OPTION (→ S/N A428T01776N EXC. 01737-01739, 01745-01747, 01749-01750, 01758, 01760)

1 582029282 Bracket ................................................................................................................ 1
2 580049231 Capscrew ............................................................................................................ 4
3 580027573 Nut ...................................................................................................................... 2
4 582029283 Bracket ................................................................................................................ 1
5 582032773 Speed Reduction Steering Sensor ..................................................................... 1
6 580022891 Connector ....................................................................................................... 1
7 580049231 Capscrew ............................................................................................................ 4
8 582003591 Strap Clamp (Button Head) ................................................................................ 2

ELECTRICAL SYSTEM
SPEED REDUCTION STEERING (FIGURE 2-6)

OPTION
(S/N A428T01656N → EXC. 01657-01685, 01690-01692, 01694-01703, 01709-01716, 01719-01726,
01728-01734, 01740-01744, 01762-01776)

1 582053620 Plate .................................................................................................................... 1
2 580027573 Nut ...................................................................................................................... 2
3 582053621 Bracket ................................................................................................................ 1
4 580049231 Capscrew ............................................................................................................ 2
5 582032773 Speed Reduction Steering Sensor ..................................................................... 1
6 580022891 Connector ....................................................................................................... 1
7 580046396 Clamp ................................................................................................................. 1
8 931701910 Nut ...................................................................................................................... 1

ELECTRICAL SYSTEM
AUDIBLE ALARM (FIGURE 2-7)

OPTION

1 580045132 Back-Up Alarm (82-102 dbA) .............................................................................. 1
2 582032752 Bracket ................................................................................................................ 1
3 580039438 Capscrew ............................................................................................................ 2
4 580047919 Nut ...................................................................................................................... 2

ELECTRICAL SYSTEM
NOTES

ELECTRICAL SYSTEM
TELEMETRY (FIGURE 2-8)

OPTION

ELECTRICAL SYSTEM
TELEMETRY
OPTION
KEY:
A: LEVEL 1: Monitoring
B: LEVEL 2: Access
C: LEVEL 3: Verification
QTY
ITEM PART NO. DESCRIPTION A B C
1 582028147 Stud ................................................................................................... 4 4 4
2 580013990 Capscrew .......................................................................................... 4 4 4
3 582053325 Bracket .............................................................................................. 1 1 1
4 582020730 Control Module (FM1 Cell 3G Extended Voltage) ............................. 1 1 1
4 582020701
582020715 Control Module (FM1 WiFi Extended Voltage) .................................. 1 1 1
5 580027573 Nut ..................................................................................................... 1 1 1
6 580038834 Capscrew .......................................................................................... 1 1 1
7 580017064 Strap .................................................................................................. 2 2 2
8 277754400 Clip .................................................................................................... 2 2 2
9 582020792
582020794 Antenna (GSM) ................................................................................. 1 1 1
9 582020793 Antenna (Wifi) .................................................................................... 1 1 1
10 580041805 Capscrew .......................................................................................... .. 2 2
11 580093223 Buzzer Assembly ............................................................................... .. 1 1
11 580056006 Connector (2 Pin) .......................................................................... .. 1 1
11 580056004 Connector (Secondary Lock) ........................................................ .. 1 1
11 580039516 Terminal ........................................................................................ .. 1 1
12 580044946 Nut ..................................................................................................... .. 4 4
13 582053278 Support .............................................................................................. .. 1 1
14 580092732 Capscrew .......................................................................................... .. 4 4
15 582025995 Label (ID Card Reader) ..................................................................... .. 1 1
16 582053709 Support .............................................................................................. .. 1 1
17 932726902 Capscrew .......................................................................................... .. 2 2
18 582020782 Card-ID Reader (ISO-Prox) ............................................................... .. 1 1
18 582020783 Card-ID Reader (HID Standard Prox) ............................................... .. 1 1
18 582020784 Card-ID Reader (IClass/MIFARE Prox) ............................................. .. 1 1
19 518803687 Connector ...................................................................................... .. 1 1
19 505968514 Terminal (Pin) ................................................................................ .. 1 1
20 580009798 Capscrew .......................................................................................... .. .. 2
21 582053318 Bracket .............................................................................................. .. .. 1
22 580051432 Nut ..................................................................................................... .. .. 2
23 580094577 Cap .................................................................................................... .. .. 2
24 449015135 Nut ..................................................................................................... .. .. 2
25 582020706 Display (FM2) .................................................................................... .. .. 1
26 932728908 Capscrew .......................................................................................... .. .. 2
27 a 582054025 Wire Harness (Level 1) (FPage 2-20).............................................. 1 1 1
28 a 582054024 Wire Harness (Level 2) (FPage 2-20).............................................. .. 1 1
29 a 582054023 Wire Harness (Level 3) (FPage 2-20).............................................. .. .. 1
FOOTNOTES:
a NOT ILLUSTRATED

ELECTRICAL SYSTEM
TELEMETRY LABEL (FIGURE 2-9)

OPTION

550061527 Label - System activation - Type B (English) ...................................................... 1
550061528 Label - System activation - Type B (Brazilian) .................................................... 1
550061529 Label - System activation - Type B (Czech) ....................................................... 1
550061530 Label - System activation - Type B (Danish) ...................................................... 1
550061531 Label - System activation - Type B (Dutch) ........................................................ 1
550061532 Label - System activation - Type B (Finnish) ...................................................... 1
550061533 Label - System activation - Type B (French) ...................................................... 1
550061534 Label - System activation - Type B (German) ..................................................... 1
550061535 Label - System activation - Type B (Greek) ........................................................ 1
550061536 Label - System activation - Type B (Hungarian) ................................................. 1
550061537 Label - System activation - Type B (Icelandic) ................................................... 1
550061538 Label - System activation - Type B (Italian) ........................................................ 1
550061539 Label - System activation - Type B (Norwegian) ................................................ 1
550061540 Label - System activation - Type B (Polish) ........................................................ 1
550061541 Label - System activation - Type B (Portuguese) ............................................... 1
550061542 Label - System activation - Type B (Russian) ..................................................... 1
550061543 Label - System activation - Type B (Slovakian) .................................................. 1
550061544 Label - System activation - Type B (Spanish) ..................................................... 1
550061545 Label - System activation - Type B (Swedish) .................................................... 1
550061546 Label - System activation - Type B (Croatian) .................................................... 1
550061547 Label - System activation - Type B (Estonian) .................................................... 1
550061548 Label - System activation - Type B (Latvian) ...................................................... 1
550061549 Label - System activation - Type B (Lithuanian) ................................................. 1

ELECTRICAL SYSTEM

550061550 Label - System activation - Type B (Romanian) ................................................. 1
550061551 Label - System activation - Type B (Slovenian) .................................................. 1
550061552 Label - System activation - Type B (Turkish) ...................................................... 1
550061553 Label - System activation - Type B (Bulgarian) .................................................. 1
550081533 Label - System activation - Type B (Serbian) ..................................................... 1

ELECTRICAL SYSTEM
WIRE HARNESS (FIGURE 2-10)

TELEMETRY OPTION

ELECTRICAL SYSTEM
WIRE HARNESS
TELEMETRY OPTION

1 582054025 Wire Harness ...................................................................................................... 1
2 580034053 Blade Terminal ............................................................................................... 1
3 580080969 Terminal (Blade) ............................................................................................. 1
4 580034053 Blade Terminal ............................................................................................... 1
5 580080969 Terminal (Blade) ............................................................................................. 1
6 520038850 Connector ....................................................................................................... 1
6 a 505968514 Terminal (Pin) ................................................................................................. 3
6 a 580039193 Connector (Secondary Lock) .......................................................................... 1
7 504064720 Connector ....................................................................................................... 1
7 a 505968568 Terminal (Socket) ........................................................................................... 3
8 277514700 Ring Terminal ................................................................................................. 1
9 580036981 Connector ....................................................................................................... 1
9 a 580039513 Terminal ......................................................................................................... 5
9 a 580019119 Plug ................................................................................................................ 7
10 505968533 Connector ....................................................................................................... 1
10 a 505968514 Terminal (Pin) ................................................................................................. 2
11 505968501 Connector ....................................................................................................... 1
12 582054024 Wire Harness ...................................................................................................... 1
13 504064701 Connector (4 Soc) .......................................................................................... 1
14 580019245 Connector (2 Socket) ..................................................................................... 1
14 a 580039513 Terminal ......................................................................................................... 2
15 580036982 Connector ....................................................................................................... 1
15 a 580039513 Terminal ......................................................................................................... 7
15 a 580019119 Plug ................................................................................................................ 5
16 582010004 Relay (Mini Power) ......................................................................................... 1
17 580009067 Connector ....................................................................................................... 1
17 a 580091403 Terminal ......................................................................................................... 2
17 a 582000484 Terminal ......................................................................................................... 2
18 505968533 Connector ....................................................................................................... 1
18 a 505968514 Terminal (Pin) ................................................................................................. 2
19 582054023 Wire Harness ...................................................................................................... 1
20 518803687 Connector ....................................................................................................... 1
20 a 505968514 Terminal (Pin) ................................................................................................. 4
21 504064701 Connector (4 Soc) .......................................................................................... 1
21 a 505968566 Plug ................................................................................................................ 1
22 580036983 Connector ....................................................................................................... 1
22 a 580039513 Terminal ......................................................................................................... 5

ELECTRICAL SYSTEM
WIRE HARNESS
TELEMETRY OPTION

22 a 580019119 Plug ................................................................................................................ 7
FOOTNOTES:
a NOT ILLUSTRATED

ELECTRICAL SYSTEM

TILLER

582043209 Wire Harness (Tiller) ........................................................................................... 1
1 ..... Connector Assembly (CRS18 To Tiller Card) ................................................ 1
1 518445610 Connector (8 Way) ..................................................................................... 1
1 518445602 Socket ........................................................................................................ 6
2 ..... Connector Assembly (CPS06-B To Main Harness) ....................................... 1
2 580042221 Connector ................................................................................................... 1
2 580042222 Connector (Secondary Lock) ..................................................................... 1
2 580019107 Terminal (Socket) ....................................................................................... 6
2 580019119 Plug ............................................................................................................ 2

ELECTRICAL SYSTEM

OPTION HARNESS

582033692 Wire Harness (Option Harness) .......................................................................... 1
1 ..... Connector Assembly (CRP12 Option Harness) ............................................. 1
1 580042219 Connector (8 Pin) ....................................................................................... 1
1 580019353 Terminal (Pin) ............................................................................................. 6
1 580019119 Plug ............................................................................................................ 2
2 ..... Connector Assembly (CPS13 Buzzer Alarm) ................................................. 1
2 580021087 Connector (2 Way) ..................................................................................... 1
2 580062388 Terminal ..................................................................................................... 2
3 ..... Connector Assembly (CRP14 Lift Limit Sensor) ............................................ 1
3 580080890 Connector ................................................................................................... 1
3 580019353 Terminal (Pin) ............................................................................................. 3
4 ..... Connector Assembly (CRS15 Charger CAN Port) ......................................... 1
4 518445606 Connector (Socket Female) ....................................................................... 1
4 524152700 Connector Block ......................................................................................... 1
4 518445602 Socket ........................................................................................................ 3

ELECTRICAL SYSTEM

KEYPAD JUMPER

582034144 Wire Harness (Keypad Jumper) ......................................................................... 1
1 ..... Connector Assembly (CPS17 Keypad) .......................................................... 1
1 580035032 Connector (4 Way) ..................................................................................... 1
1 580062119 Receptacle Contact 20-22 AWG ................................................................ 4
1 272479200 Wire Seal .................................................................................................... 4
2 ..... Ring Terminal (TS16 B-) ................................................................................ 1
2 505975593 E-Ring ........................................................................................................ 1
3 ..... Terminal (TP14-B Key Switch) ....................................................................... 1
3 502719902 Terminal ..................................................................................................... 1
4 ..... Terminal (TP15-B Key Switch) ....................................................................... 1
4 502719902 Terminal ..................................................................................................... 1
5 ..... Ring Terminal (TS13 Main Cont) .................................................................... 1
5 520035837 E-Ring ........................................................................................................ 1

ELECTRICAL SYSTEM

MAIN — KEYPAD OPTION

ELECTRICAL SYSTEM
WIRE HARNESS
MAIN – KEYPAD OPTION

582035887 Wire Harness (Main) ........................................................................................... 1
1 ..... Connector Assembly (CPS01 Main Controller) .............................................. 1
1 520202606 Connector (35 Way) ................................................................................... 1
2 505975593 E-Ring ........................................................................................................ 1
3 ..... Spade Terminal (TS05 Key Switch) ............................................................... 1
3 580083893 E-Ring ........................................................................................................ 1
4 ..... Connector Assembly (CRS07 Battery Display) .............................................. 1
4 518445610 Connector (8 Way) ..................................................................................... 1
4 518445602 Socket ........................................................................................................ 3
4 524152702 Insulator ..................................................................................................... 1
5 ..... Connector Assembly (TS07 Main Cont. Coil +) .............................................. 1
5 504059730 Terminal ..................................................................................................... 1
6 ..... Connector Assembly (TS03 Disconnect Switch) ............................................ 1
6 504059730 Terminal ..................................................................................................... 1
7 ..... Ring Terminal (TS01 Main Cont) .................................................................... 1
7 580024033 Terminal ..................................................................................................... 1
8 ..... FU2 ................................................................................................................. 1
8 751194100 Fuse Holder ................................................................................................ 1
8 504061787 Fuse (4 Amp) ............................................................................................. 1
9 ..... Connector Assembly (TS02 Disconnect Switch) ............................................ 1
9 504059730 Terminal ..................................................................................................... 1
10 ..... Connector Assembly (TS08 Main Cont. Coil -) .............................................. 1
10 504059730 Terminal ..................................................................................................... 1
11 ..... Connector Assembly (TS10 Horn -) ............................................................... 1
11 504059730 Terminal ..................................................................................................... 1
12 ..... Connector Assembly (TS09 Horn +) .............................................................. 1
12 504059730 Terminal ..................................................................................................... 1
13 ..... Connector Assembly (CPP01-A Charger Jumper) ......................................... 1
13 518445603 Connector ................................................................................................... 1
13 518445601 Pin .............................................................................................................. 2
13 524152699 Insulator ..................................................................................................... 1
14 ..... Connector Assembly (CRS01-A Charger Interlock) ....................................... 1
14 518445604 Connector ................................................................................................... 1
14 518445602 Socket ........................................................................................................ 2
14 524152699 Insulator ..................................................................................................... 1
15 ..... Connector Assembly (TS12 Pump Coil -) ...................................................... 1
15 504059730 Terminal ..................................................................................................... 1
16 ..... Connector Assembly (TS11 Pump Coil +) ...................................................... 1
16 504059730 Terminal ..................................................................................................... 1
17 ..... Connector Assembly (CRP04-A Brake Harness) ........................................... 1
17 580056006 Connector (2 Pin) ....................................................................................... 1
17 580019353 Terminal (Pin) ............................................................................................. 2
18 ..... Connector Assembly (CPS04-B Brake Override) ........................................... 1
18 580019245 Connector (2 Socket) ................................................................................. 1
18 580019107 Terminal (Socket) ....................................................................................... 1
18 580019119 Plug ............................................................................................................ 1

ELECTRICAL SYSTEM
WIRE HARNESS
MAIN – KEYPAD OPTION

19 ..... Connector Assembly (CRP04-B Brake Override) .......................................... 1
19 580056006 Connector (2 Pin) ....................................................................................... 1
19 580019353 Terminal (Pin) ............................................................................................. 2
20 ..... Connector Assembly (CRS05 Lower Valve) .................................................. 1
20 524223411 Connector (Socket) .................................................................................... 1
21 ..... Connector Assembly (CRP06 Tiller Harness) ................................................ 1
21 580042219 Connector (8 Pin) ....................................................................................... 1
21 580019353 Terminal (Pin) ............................................................................................. 8
22 ..... Connector Assembly (CRP10 Tiller Enable) .................................................. 1
22 580080890 Connector ................................................................................................... 1
22 580019353 Terminal (Pin) ............................................................................................. 3
23 ..... Connector Assembly (CRP11 Steering Sensor) ............................................ 1
23 580080890 Connector ................................................................................................... 1
23 580019353 Terminal (Pin) ............................................................................................. 3
24 ..... Connector Assembly (CPS03 Encoder) ......................................................... 1
24 580035032 Connector (4 Way) ..................................................................................... 1
24 580040456 Wire Seal (Yellow) ...................................................................................... 4
25 ..... Connector Assembly (CPS02 Temp Sensor) ................................................. 1
25 580035031 Connector (2 Way) ..................................................................................... 1
25 580040456 Wire Seal (Yellow) ...................................................................................... 2
26 ..... Cap (CRP12-Cap Options Cap) ..................................................................... 1
26 580042219 Connector (8 Pin) ....................................................................................... 1
26 580019119 Plug ............................................................................................................ 8
27 ..... Connector Assembly (CPS12 Options) .......................................................... 1
27 580042221 Connector ................................................................................................... 1
27 580019107 Terminal (Socket) ....................................................................................... 1
28 ..... Connector Assembly (CPP08 Handset) ......................................................... 1
28 518445605 Connector (4 Way) ..................................................................................... 1
28 518445601 Pin .............................................................................................................. 4
28 524152700 Connector Block ......................................................................................... 1
29 ..... Connector Assembly (CPS09 PC Connection) .............................................. 1
29 580019139 Connector (3-Way) ..................................................................................... 1
29 580062388 Terminal ..................................................................................................... 3
29 580051704 Dust Cap (For Diagnostic Cable) ............................................................... 1
30 ..... Spade Terminal (TS04 Key Switch) ............................................................... 1
30 580083893 E-Ring ........................................................................................................ 1
31 502719902 Terminal ......................................................................................................... 1
32 317222556 Terminal ......................................................................................................... 1
33 ..... Cap (CPS11 Steer Sensor Cap) .................................................................... 1
33 580022891 Connector ................................................................................................... 1

ELECTRICAL SYSTEM
NOTES

ELECTRICAL SYSTEM

MAIN — HOURMETER OPTION

ELECTRICAL SYSTEM
WIRE HARNESS
MAIN – HOURMETER OPTION

582044985 Wire Harness (Main) ........................................................................................... 1
1 ..... Connector Assembly (CPS01 Main Controller) .............................................. 1
1 520202606 Connector (35 Way) ................................................................................... 1
1 520202604 Plug ............................................................................................................ 7
2 505975593 E-Ring ........................................................................................................ 1
3 ..... Terminal (TS15A Keyswitch) .......................................................................... 1
3 317222556 Terminal ..................................................................................................... 1
4 ..... Terminal (TS14A Keyswitch) .......................................................................... 1
4 317222556 Terminal ..................................................................................................... 1
5 ..... Connector Assembly (CRS07 Battery Display) .............................................. 1
5 518445610 Connector (8 Way) ..................................................................................... 1
5 518445602 Socket ........................................................................................................ 3
6 ..... Terminal (TS07 Main Control Coil +) .............................................................. 1
6 504059730 Terminal ..................................................................................................... 1
7 ..... Terminal (TS03 Disconnect Switch) ............................................................... 1
7 504059730 Terminal ..................................................................................................... 1
8 ..... Ring Terminal (TS01 Main Control) ................................................................ 1
8 580024033 Terminal ..................................................................................................... 1
9 ..... Fuse Holder and Fuse (FU2) .......................................................................... 1
9 751194100 Fuse Holder ................................................................................................ 1
9 504061787 Fuse (4 Amp) ............................................................................................. 1
10 ..... Terminal (TS02 Disconnect Switch) ............................................................... 1
10 504059730 Terminal ..................................................................................................... 1
11 ..... Terminal (TS08 Main Control Coil -) ............................................................... 1
11 504059730 Terminal ..................................................................................................... 1
12 ..... Terminal (TS10 Horn -) .................................................................................. 1
12 504059730 Terminal ..................................................................................................... 1
13 ..... Terminal (TS09 Horn +) .................................................................................. 1
13 504059730 Terminal ..................................................................................................... 1
14 ..... Connector Assembly (CPP01A Charger Jumper) .......................................... 1
14 518445603 Connector ................................................................................................... 1
14 518445601 Pin .............................................................................................................. 2
15 ..... Terminal (CRS01A Charger Interlock) ........................................................... 1
15 518445604 Connector ................................................................................................... 1
15 518445602 Socket ........................................................................................................ 2
16 ..... Terminal (TS12 Pump Coil -) .......................................................................... 1
16 504059730 Terminal ..................................................................................................... 1
17 ..... Terminal (TS11 Pump Coil +) ......................................................................... 1
17 504059730 Terminal ..................................................................................................... 1
18 ..... Connector Assembly (CRP04A Brake Harness) ............................................ 1
18 580056006 Connector (2 Pin) ....................................................................................... 1
19 ..... Connector Assembly (CPS04B Brake Override) ............................................ 1
19 580019245 Connector (2 Socket) ................................................................................. 1
19 580019107 Terminal (Socket) ....................................................................................... 1
19 580019119 Plug ............................................................................................................ 1
20 ..... Connector Assembly (CRP04B Brake Override) ............................................ 1

ELECTRICAL SYSTEM
WIRE HARNESS
MAIN – HOURMETER OPTION

20 580056006 Connector (2 Pin) ....................................................................................... 1
20 580019353 Terminal (Pin) ............................................................................................. 2
21 ..... Connector Assembly (CRS05 Lower Valve) .................................................. 1
21 524223411 Connector (Socket) .................................................................................... 1
22 ..... Connector Assembly (CRP06 Tiller Harness) ................................................ 1
22 580042219 Connector (8 Pin) ....................................................................................... 1
22 580019353 Terminal (Pin) ............................................................................................. 8
23 ..... Connector Assembly (CRP10 Traction Interlock) ........................................... 1
23 580080890 Connector ................................................................................................... 1
23 580019353 Terminal (Pin) ............................................................................................. 3
24 ..... Connector Assembly (CRP11 Steering Sensor) ............................................ 1
24 580080890 Connector ................................................................................................... 1
24 580019353 Terminal (Pin) ............................................................................................. 3
25 ..... Cap (CPS11 Steering Sensor Cap) ................................................................ 1
25 580022891 Connector ................................................................................................... 1
25 580019119 Plug ............................................................................................................ 3
26 ..... Connector Assembly (CPS03 Encoder) ......................................................... 1
26 580035032 Connector (4 Way) ..................................................................................... 1
26 272479200 Wire Seal .................................................................................................... 4
27 ..... Connector Assembly (CPS02 Temperature Sensor) ..................................... 1
27 580035031 Connector (2 Way) ..................................................................................... 1
27 272479200 Wire Seal .................................................................................................... 2
28 ..... Connector Assembly (CRP12 Options Cap) .................................................. 1
28 580042219 Connector (8 Pin) ....................................................................................... 1
28 580019119 Plug ............................................................................................................ 8
29 ..... Connector Assembly (CPS12 Options) .......................................................... 1
29 580042221 Connector ................................................................................................... 1
29 580019107 Terminal (Socket) ....................................................................................... 8
30 ..... Connector Assembly (CPP08 Handset) ......................................................... 1
30 518445605 Connector (4 Way) ..................................................................................... 1
30 518445601 Pin .............................................................................................................. 4
31 ..... Connector Assembly (CPS09 PC Connection) .............................................. 1
31 580019139 Connector (3-Way) ..................................................................................... 1
31 580062388 Terminal ..................................................................................................... 3

ELECTRICAL SYSTEM
CONTACTOR (FIGURE 2-16)

504058760 Contactor ............................................................................................................ 1
1 296320455 Contact (Fixed) ............................................................................................... 1
2 519739830 Screw ............................................................................................................. 2
3 519739845 Cover (Top) .................................................................................................... 1
4 504059719 Spring ............................................................................................................. 1
5 296320456 Contact (Moving) ............................................................................................ 1
6 518803660 Coil and Frame ............................................................................................... 1
7 519739834 Insulator .......................................................................................................... 1
a 580035673 Capscrew (For Mounting) ................................................................................... 2
FOOTNOTES:
a Not Illustrated

ELECTRICAL SYSTEM
NOTES

SECTION 3
3 STEER HANDLE/BRAKE SYSTEM

CONTENTS
SECTION 3
STEER HANDLE/BRAKE SYSTEM
DESCRIPTION PAGE
LABELS
TILLER HANDLE ......................................................................................................................................... 3-6
TILLER HANDLE AND MOUNTING WELDMENT .......................................................................................... 3-2
TILLER HEAD ASSEMBLY ............................................................................................................................. 3-4

TILLER HANDLE AND MOUNTING WELDMENT (FIGURE 3-1)

TILLER HANDLE AND MOUNTING WELDMENT

1 582019366 Tiller Head Assembly (FPage 3-4).................................................................... 1
2 580023593 Capscrew ............................................................................................................ 2
3 931701910 Nut ...................................................................................................................... 2
4 580000119 Plug ..................................................................................................................... 2
5 504229298 Nut ...................................................................................................................... 1
6 524141136 Ball Stud ............................................................................................................. 1
7 582031382 Cylinder Assy ...................................................................................................... 1
8 582003591 Strap Clamp (Button Head) ................................................................................ 2
9 582053464 Tiller Sensor ........................................................................................................ 1
10 582017793 Bushing ............................................................................................................... 2
11 582035668 Cover .................................................................................................................. 1
12 580083871 Capscrew ............................................................................................................ 2
13 580029990 Washer ............................................................................................................... 2
14 582023900 Shaft Assembly (Tiller Handle Pivot) .................................................................. 1
15 582014374 Capscrew ............................................................................................................ 1
16 582023892 Grommet ............................................................................................................. 1
17 449001241 Capscrew ............................................................................................................ 4
18 580055861 Nut ...................................................................................................................... 1
19 580003654 Capscrew ............................................................................................................ 1
20 582031381 Mounting Weldment ............................................................................................ 1
21 272469000 Washer ............................................................................................................... 2
22 582048717 Tiller Handle ........................................................................................................ 1
23 582048716 Vibration Damper ................................................................................................ 1
24 582047378 Bracket ................................................................................................................ 1
25 277558000 Strap Clamp ........................................................................................................ 2
26 582043209 Wire Harness (Tiller) (FPage 2-23)................................................................... 1
27 520038838 Strap Clamp ........................................................................................................ 3
28 449021001 Washer ............................................................................................................... 4

TILLER HEAD ASSEMBLY (FIGURE 3-2)

TILLER HEAD ASSEMBLY

582019366 Tiller Head Assembly .......................................................................................... 1
1 580026296 Capscrew ....................................................................................................... 2
2 940004902 Washer ........................................................................................................... 2
3 582007131 Accelerator Control Knob ............................................................................... 1
4 580012962 Bushing .......................................................................................................... 2
5 580011991 Cover (Belly Switch) ....................................................................................... 1
6 580082841 Locking Lever (Belly Spring) .......................................................................... 1
7 580038175 Spring (Cover, Belly) ...................................................................................... 1
8 580034974 Capscrew ....................................................................................................... 2
9 582019747 Plate ............................................................................................................... 1
10 582015784 Bushing .......................................................................................................... 1
11 524338448 Tiller Head Assembly (Lower Half) (Composite) ............................................ 1
12 932200901 Capscrew ....................................................................................................... 3
13 524144372 Spring ............................................................................................................. 1
14 582007134 Cover , Rear (For Push Button) ...................................................................... 1
15 524292775 Screw ............................................................................................................. 1
16 580079167 Support Clip .................................................................................................... 1
17 582015751 Printed Circuit Board ...................................................................................... 1
18 580013106 Camshaft , Direction Control .......................................................................... 1
19 582007130 Accelerator Control Knob ............................................................................... 1
20 580060389 Spring , Directional Control Return ................................................................. 1
21 524228248 Tiller Head (Upper Half) ................................................................................. 1
22 580012969 Spring (Horn/Snail) ......................................................................................... 1
23 582005203 Horn Button Cover .......................................................................................... 1
24 582007128 Push Button Switch Assembly (On-Off) ......................................................... 4
24 a 580026824 Microswitch (On-Off, Molex Connector) ..................................................... 4
24 a 582015753 Push Button Switch .................................................................................... 4
25 580012970 Spring , Directional Control Return ................................................................. 1
FOOTNOTES:
a Not Illustrated

LABELS (FIGURE 3-3)

TILLER HANDLE

1 582020332 Label (LH Switch Functions) ............................................................................... 1
2 524139322 Label (Tiller Handle Yale) ................................................................................... 1
3 582015332 Label (RH Switch Functions) .............................................................................. 1

SECTION 4
4 HYDRAULIC SYSTEM
CONTENTS
SECTION 4
HYDRAULIC SYSTEM
DESCRIPTION PAGE
CYLINDER ASSEMBLY .................................................................................................................................. 4-6

HYDRAULIC POWER UNIT ASSEMBLY ....................................................................................................... 4-4
HYDRAULIC SYSTEM .................................................................................................................................... 4-2

HYDRAULIC SYSTEM
HYDRAULIC SYSTEM (FIGURE 4-1)

1 582013368 Hydraulic Power Unit (FPage 4-4)..................................................................... 1
2 582041056
580047714 Capscrew ............................................................................................................ 2
3 582014173 Hose Assy ........................................................................................................... 1
4 316534106 Fitting .................................................................................................................. 1
5 580093279 Screw .................................................................................................................. 2
6 580056997 Cylinder Assy (FPage 4-6)................................................................................ 1
7 582002209 Spacer ................................................................................................................ 2
8 580060015 Pin ....................................................................................................................... 1

HYDRAULIC SYSTEM
NOTES

HYDRAULIC SYSTEM
HYDRAULIC POWER UNIT ASSEMBLY (FIGURE 4-2)

HYDRAULIC SYSTEM
HYDRAULIC POWER UNIT ASSEMBLY

582013368 Hydraulic Power Unit .......................................................................................... 1
1 580064007 Motor .............................................................................................................. 1
2 582015474 Nut .................................................................................................................. 1
3 580064011 Hydraulic Motor Sub Unit ............................................................................... 1
3 580064012 Kit-Seal ....................................................................................................... 1
4 582015475 Check Valve ................................................................................................... 1
5 582015477 Tool (Check Valve) ......................................................................................... 1
6 582015481 Relief Valve .................................................................................................... 1
7 582015489 Pipe ................................................................................................................ 1
7 582015490 Strainer ....................................................................................................... 1
8 582015491 Valve .............................................................................................................. 1
8 582015493 Kit-Seal Valve ............................................................................................. 1
8 582042440 Coil ............................................................................................................. 1
9 582015494 Restrictor ........................................................................................................ 1
10 582015478 Tank (For Hydraulic Pump) ............................................................................ 1
11 582015479 O-Ring ........................................................................................................ 1
12 582015480 Plug (Filter) ................................................................................................. 1
13 580028972 Clamp Assembly ........................................................................................ 1
14 582015498 Fitting .............................................................................................................. 1
a 582015492 Solenoid ......................................................................................................... 1
FOOTNOTES:
a Not Illustrated

HYDRAULIC SYSTEM
CYLINDER ASSEMBLY (FIGURE 4-3)

580056997 Cylinder Assy ...................................................................................................... 1
1 582031135 Cylinder Liner ................................................................................................. 1
2 582031133 Head ............................................................................................................... 1
3 272131500 Cylinder Head ................................................................................................. 1
4 582031134 Piston ............................................................................................................. 1
5 582031132 Cylinder Rod ................................................................................................... 1
6 580060095 O-Ring ............................................................................................................ 2
7 277269200 Wiper .............................................................................................................. 1
8 580060093 Seal ................................................................................................................ 1
9 580060092 O-Ring ............................................................................................................ 1
10 580060091 O-Ring ............................................................................................................ 2
11 019327000 O-Ring ............................................................................................................ 1
582003607 Kit-Seal ............................................................................................................... 1

SECTION 5
5 LIFT LINKAGE
CONTENTS
SECTION 5
LIFT LINKAGE
DESCRIPTION PAGE
LIFT LINKAGE ................................................................................................................................................. 5-2

LIFT LINKAGE
LIFT LINKAGE (FIGURE 5-1)

LIFT LINKAGE
LIFT LINKAGE
1 582023896 Shaft (Drive Frame Pivot) ................................................................................... 2
2 582014374 Capscrew ............................................................................................................ 2
3 582023893 Rocker Arm Assembly (520 mm) ........................................................................ 1
4 582036149 Pull Rod (520 mm) .............................................................................................. 1
4 582036145 Pull Rod (582 mm) .............................................................................................. 1
4 582036148 Pull Rod (654 mm) .............................................................................................. 1
4 582036147 Pull Rod (726 mm) .............................................................................................. 1
4 582036141 Pull Rod (788 mm) .............................................................................................. 1
4 582036143 Pull Rod (860 mm) .............................................................................................. 1
4 582036146 Pull Rod (876 mm) .............................................................................................. 1
4 582036142 Pull Rod (938 mm) .............................................................................................. 1
4 582036144 Pull Rod (1010 mm) ............................................................................................ 1
4 582034096 Pull Rod (1120 mm) ............................................................................................ 1
4 582034092 Pull Rod (1182 mm) ............................................................................................ 1
4 582034093 Pull Rod (1382 mm) ............................................................................................ 1
4 582034094 Pull Rod (1254 mm) ............................................................................................ 1
4 582034091 Pull Rod (1320 mm) ............................................................................................ 1
4 582034095 Pull Rod (1454 mm) ............................................................................................ 1
5 582017793 Bushing ............................................................................................................... 6
6 582023898 Shaft (Front Fork Frame Pivot) ........................................................................... 2
7 582023897 Shaft (Pull Rod Pivot) ......................................................................................... 2
8 582007824 Capscrew ............................................................................................................ 6
9 449076005 Grease Fitting ..................................................................................................... 12
10 449034030 Roll Pin ............................................................................................................... 2
11 ..... Load Wheels (FPage 1-8, FPage 1-9)............................................................. 2
12 582023899 Shaft (Rear Fork Pivot) ....................................................................................... 2
13 580063754 Axle (Pin) ............................................................................................................ 2

LIFT LINKAGE
NOTES

SECTION 6
6 ACCESSORIES
CONTENTS
SECTION 6
ACCESSORIES
DESCRIPTION PAGE
BATTERY SIDE ROLLER ASSEMBLY

OPTION ....................................................................................................................................................... 6-3
EXTENSION BATTERY CABLE
OPTION ....................................................................................................................................................... 6-2

ACCESSORIES
EXTENSION BATTERY CABLE (FIGURE 6-1)

OPTION

1 580080014 Battery Cable ...................................................................................................... 1

ACCESSORIES
BATTERY SIDE ROLLER ASSEMBLY (FIGURE 6-2)

OPTION

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

ACCESSORIES
NOTES

SECTION 7
7 NUMERICAL INDEX
NUMERICAL INDEX
SECTION 7
NUMERICAL INDEX
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
010387200 2-3 26 449001230 1-15 4 2-31 12 518445610 2-23 1

2-7 26 449001241 3-3 17 2-31 13 2-27 4
019327000 4-6 11 449001410 1-6 4 2-31 16 2-31 5
06205330D 2-3 1 449001415 6-3 6 2-31 17 518803660 2-33 6
2-3 25 449015014 2-3 12 504061787 2-27 8 518803687 2-17 19
2-7 1 2-7 12 2-31 9 2-21 20
2-7 25 449015036 6-3 9 504064701 2-21 13 518806635 2-21 20
06205330E 2-3 1 449015098 2-11 15 2-21 21 519244834 1-2 5
2-3 25 6-3 17 504064720 2-21 7 519609804 1-3 3
2-7 1 449015135 2-11 8 504071785 6-3 8 519739830 2-33 2
2-7 25 2-17 24 504229298 3-3 5 519739834 2-33 7
064575700 2-3 26 449021001 2-3 13 505968501 2-21 11 519739845 2-33 3
2-7 26 2-7 13 505968514 2-17 19 520035837 2-25 5
258743277 1-3 5 2-11 14 2-21 6 520038838 3-3 27
2-3 35 3-3 28 2-21 10 520038850 2-21 6
2-7 30 6-3 16 2-21 18 520202601 2-27 1
272017300 2-11 7 449021002 1-6 5 2-21 20 2-31 1
272046300 1-9 5 449022019 2-4 38 505968533 2-21 10 520202604 2-31 1
272131500 4-6 3 2-7 33 2-21 18 520202606 2-27 1
272213500 1-23 5 449034030 5-3 10 505968540 2-21 10 2-31 1
272373400 6-3 10 449076005 5-3 9 2-21 18 520426875 2-11 11
272373600 6-3 12 501729904 2-11 16 505968566 2-21 21 524139322 1-23 2
272469000 3-3 21 502026902 2-3 22 505968568 2-21 7 3-6 2
272479200 2-25 1 2-3 23 2-21 11 524141136 3-3 6
2-32 26 2-3 24 2-21 13 524143269 2-3 17
2-32 27 2-7 22 2-21 21 2-7 35
273011400 1-9 1 2-7 23 505975593 2-25 2 524144372 3-5 13
273059100 2-3 28 2-7 24 2-27 2 524149840 1-15 12
2-7 28 502719902 2-25 3 2-31 2 524149841 1-15 15
273070600 6-3 4 2-25 4 506726504 2-3 6 524149842 1-15 13
277033300 6-3 5 2-28 31 2-7 6 524149843 1-15 14
277269200 4-6 7 504057775 2-3 15 506726507 1-7 4 524152699 2-27 13
277458600 1-4 4 2-7 15 518445601 2-27 13 2-27 14
1-5 4 504058760 2-3 19 2-28 28 524152700 2-24 4
1-6 6 2-7 19 2-31 14 2-28 28
277514700 2-21 8 2-33 2-32 30 524152702 2-27 4
277558000 3-3 25 504059719 2-33 4 518445602 2-23 1 524208881 1-23 4
277754400 1-4 8 504059730 2-27 5 2-24 4 524216189 1-23 9
1-5 8 2-27 6 2-27 4 524216190 1-24
1-6 8 2-27 9 2-27 14 524216191 1-24
2-17 8 2-27 10 2-31 5 524216192 1-24
296320455 2-33 1 2-27 11 2-31 15 524216193 1-24
296320456 2-33 5 2-27 12 518445603 2-27 13 524216194 1-24
316534106 4-2 4 2-27 15 2-31 14 524216195 1-24
317222556 2-28 32 2-27 16 518445604 2-27 14 524216196 1-24
2-31 3 2-31 6 2-31 15 524216199 1-24
2-31 4 2-31 7 518445605 2-28 28 524216200 1-24
449001014 6-3 15 2-31 10 2-32 30 524216201 1-24
449001023 6-3 7 2-31 11 518445606 2-24 4 524216203 1-24

NUMERICAL INDEX
NUMERICAL INDEX (continued)
524216204 1-24 1-6 10 2-32 24 580036986 2-21 9

524216205 1-24 580003654 3-3 19 580019665 2-3 9 2-21 15
524216206 1-24 580009067 2-21 17 2-7 9 2-22 22
524216207 1-24 580009798 2-17 20 580020944 2-21 13 580037179 1-17 3
524216208 1-24 580011991 3-5 5 2-21 21 1-19 4
524216209 1-24 580012962 3-5 4 580021087 2-24 2 580038175 3-5 7
524216210 1-24 580012969 3-5 22 580021088 2-21 11 580038834 2-17 6
524216212 1-24 580012970 3-5 25 2-24 2 580039193 2-21 6
524216526 1-24 580013106 3-5 18 580022891 2-12 6 580039194 2-21 7
524216766 1-24 580013990 2-11 6 2-13 6 2-28 29
524223411 2-28 20 2-17 2 2-28 33 2-32 31
2-32 21 580014880 1-23 12 2-32 25 580039438 2-14 3
524228248 3-5 21 580017064 1-4 7 580022892 2-28 33 580039513 2-21 9
524259713 1-24 1-5 7 2-32 25 2-21 14
524292775 3-5 15 1-6 7 580023194 6-3 3 2-21 15
524299833 1-15 2 2-17 7 580023593 1-13 3 2-21 22
524338448 3-5 11 580018464 6-3 14 3-3 2 580039516 2-17 11
550061527 2-18 580018467 6-3 11 580024033 2-27 7 580040456 2-28 24
550061528 2-18 580019107 2-23 2 2-31 8 2-28 25
550061529 2-18 2-27 18 580026296 3-5 1 580041805 2-17 10
550061530 2-18 2-28 27 580026824 3-5 24 580042219 2-24 1
550061531 2-18 2-31 19 580027572 1-13 1 2-28 21
550061532 2-18 2-32 29 580027573 1-3 4 2-28 26
550061533 2-18 580019119 2-21 9 1-10 3 2-32 22
550061534 2-18 2-21 15 2-3 3 2-32 28
550061535 2-18 2-22 22 2-7 3 580042220 2-24 1
550061536 2-18 2-23 2 2-9 4 2-28 21
550061537 2-18 2-24 1 2-12 3 2-32 22
550061538 2-18 2-27 18 2-13 2 2-32 28
550061539 2-18 2-28 26 2-17 5 580042221 2-23 2
550061540 2-18 2-31 19 580028972 4-5 13 2-28 27
550061541 2-18 2-32 25 580029990 3-3 13 2-32 29
550061542 2-18 2-32 28 580030967 1-10 2 580042222 2-23 2
550061543 2-18 580019139 2-28 29 580034053 2-21 2 2-28 27
550061544 2-18 2-32 31 2-21 4 2-32 29
550061545 2-18 580019245 2-21 14 580034974 3-5 8 580044946 2-17 12
550061546 2-18 2-27 18 580035031 2-28 25 580045132 2-14 1
550061547 2-18 2-31 19 2-32 27 580046396 2-13 7
550061548 2-18 580019246 2-21 14 580035032 2-25 1 580047714 4-2 2
550061549 2-18 2-27 18 2-28 24 580047919 2-3 5
550061550 2-19 2-31 19 2-32 26 2-7 5
550061551 2-19 580019353 2-24 1 580035638 6-2 1 2-14 4
550061552 2-19 2-24 3 580035642 2-3 1 580048302 6-3 13
550061553 2-19 2-27 17 2-7 1 580049231 2-12 2
550076748 1-24 2-28 19 6-2 1 2-12 7
550079667 1-3 1 2-28 21 580035673 2-3 36 2-13 4
550081533 2-19 2-28 22 2-7 31 580049393 6-3 2
550091593 1-20 2-28 23 2-33 580051432 2-17 22
580000119 3-3 4 2-32 20 580036981 2-21 9 580051704 2-28 29
580003569 1-4 5 2-32 22 580036982 2-21 15 580051801 6-3 1
1-5 5 2-32 23 580036983 2-21 22 580053822 1-9 2

NUMERICAL INDEX
580055098 1-13 2 580080891 2-24 3 5-3 2 582020794 2-17 9

580055861 3-3 18 2-28 22 582015143 2-3 1 582021567 1-17 4
580056004 2-17 11 2-28 23 2-7 1 582021568 1-17 5
2-27 17 2-32 23 582015332 1-23 1 582023892 3-3 16
2-28 19 2-32 24 3-6 3 582023893 5-3 3
2-31 18 580080969 2-21 3 582015474 4-5 2 582023894 5-3 3
2-32 20 2-21 5 582015475 4-5 4 582023895 5-3 3
580056006 2-17 11 580082841 3-5 6 582015477 4-5 5 582023896 5-3 1
2-27 17 580083871 3-3 12 582015478 4-5 10 582023897 5-3 7
2-28 19 580083893 2-27 3 582015479 4-5 11 582023898 5-3 6
2-31 18 2-28 30 582015480 4-5 12 582023899 5-3 12
2-32 20 580084947 2-3 27 582015481 4-5 6 582023900 3-3 14
580056589 2-3 29 2-7 27 582015489 4-5 7 582025995 2-17 15
2-7 29 580091403 2-21 17 582015490 4-5 7 582026101 2-9 5
580056997 4-2 6 580092732 2-17 14 582015491 4-5 8 582026102 2-9 6
4-6 580093223 2-17 11 582015492 4-5 582028147 1-3 6
580058190 1-7 5 580093279 4-2 5 582015493 4-5 8 2-3 4
580059462 1-9 4 580094577 2-17 23 582015494 4-5 9 2-7 4
580059464 1-9 6 580096589 2-3 14 582015498 4-5 14 2-17 1
580059473 1-9 10 2-7 14 582015519 1-17 2 582028413 1-19 9
580059475 1-9 11 580096845 2-3 18 1-19 2 582029183 2-3 2
580059476 1-9 7 2-7 18 582015541 1-2 5 2-7 2
580060015 4-2 8 582000484 2-21 17 582015542 1-2 5 2-9 3
580060091 4-6 10 582002209 4-2 7 582015551 1-2 2 582029282 2-12 1
580060092 4-6 9 582002425 1-13 4 582015552 1-2 1 582029283 2-12 4
580060093 4-6 8 1-15 582015704 1-9 5 582029591 1-2
580060095 4-6 6 582003591 2-12 8 582015705 1-9 7 1-7 6
580060389 3-5 20 3-3 8 582015707 1-9 1 582030281 1-2 5
580062119 2-25 1 582003607 4-6 582015751 3-5 17 582030993 1-23 10
2-28 24 582003765 1-15 6 582015753 3-5 24 582030998 1-2 4
2-28 25 582003769 1-15 7 582015784 3-5 10 582030999 1-2 5
2-32 26 582003772 1-15 8 582015980 1-3 7 582031132 4-6 5
2-32 27 582003773 1-15 11 582015981 1-3 9 582031133 4-6 2
580062388 2-24 2 582003774 1-15 5 582017022 1-19 1 582031134 4-6 4
2-28 29 582003775 1-15 10 582017090 1-17 6 582031135 4-6 1
2-32 31 582005203 3-5 23 1-19 6 582031381 3-3 20
580063754 5-3 13 582007128 3-5 24 582017793 3-3 10 582031382 3-3 7
580064007 4-5 1 582007130 3-5 19 5-3 5 582031796 1-8
580064011 4-5 3 582007131 3-5 3 582018029 1-7 7 582031798 1-8
580064012 4-5 3 582007134 3-5 14 582019366 3-3 1 582032752 2-14 2
580064740 1-9 3 582007595 2-4 39 3-5 582032773 2-12 5
580064749 1-9 8 2-7 34 582019747 3-5 9 2-13 5
580064842 1-23 6 582007824 5-3 8 582020332 1-23 3 582032800 2-3 24
580065140 2-11 17 582010004 2-21 16 3-6 1 2-7 24
580079167 3-5 16 582010614 1-15 9 582020706 2-17 25 582032801 2-3 25
580080014 6-2 1 582010615 1-15 3 582020715 2-17 4 2-7 25
580080890 2-24 3 582010616 1-15 1 582020730 2-17 4 582032802 2-3 26
2-28 22 582013368 4-2 1 582020782 2-17 18 2-7 26
2-28 23 4-5 582020783 2-17 18 582032803 2-3 23
2-32 23 582014173 4-2 3 582020784 2-17 18 2-7 23
2-32 24 582014374 3-3 15 582020793 2-17 9 582032804 2-3 22

NUMERICAL INDEX
2-7 22 582036145 5-3 4 582046396 1-6 3 582053547 1-5 1

582032808 2-9 2 582036146 5-3 4 582047026 1-4 3 1-6 1
582032812 2-9 2 582036147 5-3 4 582047027 1-4 2 582053548 1-5 1
582032957 1-8 4 582036148 5-3 4 582047188 1-7 2 582053549 1-4 1
582032958 1-8 2 582036149 5-3 4 582047378 3-3 24 582053620 2-13 1
582032960 1-8 1 582036781 2-3 11 582048716 3-3 23 582053621 2-13 3
582032961 1-8 3 2-7 11 582048717 3-3 22 582053709 2-17 16
582032968 1-8 3 582037031 2-3 10 582049332 1-19 3 582054023 2-17 29
582033219 1-17 1 2-7 10 582049402 2-11 4 2-21 19
582033351 1-10 1 582037755 1-2 6 582049437 1-2 3 582054024 2-17 28
582033352 1-10 1 582037756 1-2 5 582049438 1-2 3 2-21 12
582033604 2-3 7 582038703 1-7 3 582049677 1-2 2 582054025 2-17 27
2-7 7 582042236 1-7 1 582049680 1-2 5 2-21 1
582033692 2-24 582042237 1-7 1 582049681 1-2 1 582056459 1-2 4
582033994 2-3 31 582042238 1-7 1 582049682 1-2 1 582056460 1-2 5
582033996 2-3 30 582042440 4-5 8 582049754 1-2 6 582057369 1-17 7
582033999 2-3 33 582042501 2-3 1 582049755 1-2 1 1-19 5
582034000 2-3 34 2-7 1 582049817 2-11 20 582057815 2-7 17
582034091 5-3 4 582043199 2-9 1 582049818 2-11 18 751194100 2-27 8
582034092 5-3 4 582043209 2-23 582049889 2-11 1 2-31 9
582034093 5-3 4 3-3 26 582049890 2-11 13 931701910 2-13 8
582034094 5-3 4 582044985 2-7 8 582049891 2-11 23 3-3 3
582034095 5-3 4 2-31 582049892 2-11 3 932200901 3-5 12
582034096 5-3 4 582045004 1-23 8 582049893 2-11 19 932726902 2-17 17
582034129 1-19 8 2-7 21 582049894 2-11 10 932728903 2-3 32
582034130 1-19 7 582045113 1-2 2 582049895 2-11 12 932728908 2-17 26
582034144 2-25 582045305 2-7 16 582049896 2-11 22 932729903 1-4 6
582035083 1-6 12 582045353 2-3 16 582049897 2-11 21 1-5 6
582035136 2-3 1 582045464 1-23 7 582049898 2-11 5 932729905 1-3 8
2-7 1 2-3 21 582049899 2-11 2 1-6 11
582035668 3-3 11 582045568 1-5 3 582050201 2-11 9 937100904 2-3 20
582035887 2-3 8 582045569 1-5 2 582053119 1-3 10 2-7 20
2-27 582045724 1-6 9 582053278 2-17 13 940004902 3-5 2
582036141 5-3 4 582046004 1-2 4 582053318 2-17 21 940004903 2-3 37
582036142 5-3 4 582046106 1-3 2 582053325 2-17 3 2-7 32
582036143 5-3 4 582046394 1-6 2 582053464 3-3 9 950433907 1-9 9
582036144 5-3 4

SECTION 8
8 USER SUPPORT INFORMATION

CONTENTS
SECTION 8
USER SUPPORT INFORMATION
DESCRIPTION PAGE
SERVICE PARTS ORDERING INSTRUCTIONS ........................................................................................... 8-2

TECHNICAL SERVICE PUBLICATIONS ........................................................................................................ 8-2

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

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

Yale Europe Materials Handling Limited 550112521
Centennial House, Building 4.5 ©Yale Corp.
Frimley Business Park 02/2016
Frimley, Surry GU16 7SG, United Kingdom

MP16E, MP18E, MP20E, MP22E (A428) Parts Manual: Yale Europe Materials Handling Limited

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PARTS MANUAL

MP16E, MP18E, MP20E, MP22E

Yale Europe Materials Handling Limited 550112521

3 STEER HANDLE/BRAKE SYSTEM

8 USER SUPPORT INFORMATION

A428 ©2015 Yale Europe Materials Handling Limited i

TABLE OF CONTENTS (continued)

ii ©2015 Yale Europe Materials Handling Limited A428

ABBREVIATIONS QUICK REFERENCE SHEET

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

A428 ©2015 Yale Europe Materials Handling Limited iii

HOW TO USE THE ILLUSTRATED PARTS MANUAL

iv ©2015 Yale Europe Materials Handling Limited A428

HOW TO FIND THE DESIRED PART NUMBER

A428 ©2015 Yale Europe Materials Handling Limited v

IDENTIFICATION OF TRUCK SERIAL NUMBERS

vi ©2015 Yale Europe Materials Handling Limited A428

PUBLICATION YALE PART NUMBER

Operating Manual.................................................................................................................... 550112654

Service Manual (Complete)..................................................................................................... 550127938

Parts Manual........................................................................................................................... 550112521

A428 ©2015 Yale Europe Materials Handling Limited vii

viii ©2015 Yale Europe Materials Handling Limited A428

A428 ©2015 Yale Europe Materials Handling Limited 1-1

MASTER DRIVE UNIT ASSEMBLY (FIGURE 1-1)

ITEM PART NO. DESCRIPTION QTY

1-2 ©2015 Yale Europe Materials Handling Limited A428

COVERS (FIGURE 1-2)

ITEM PART NO. DESCRIPTION QTY

A428 ©2015 Yale Europe Materials Handling Limited 1-3

BATTERY TRAY (FIGURE 1-3)

ITEM PART NO. DESCRIPTION QTY

1-4 ©2015 Yale Europe Materials Handling Limited A428

BATTERY TRAY (FIGURE 1-4)

ITEM PART NO. DESCRIPTION QTY

A428 ©2015 Yale Europe Materials Handling Limited 1-5

BATTERY TRAY (FIGURE 1-5)

ITEM PART NO. DESCRIPTION QTY

1-6 ©2015 Yale Europe Materials Handling Limited A428

DRIVE TIRE AND STATIC STRAP (FIGURE 1-6)

ITEM PART NO. DESCRIPTION QTY

A428 ©2015 Yale Europe Materials Handling Limited 1-7

LOAD WHEEL (FIGURE 1-7)

ITEM PART NO. DESCRIPTION QTY

1-8 ©2015 Yale Europe Materials Handling Limited A428

LOAD WHEEL (FIGURE 1-8)

A428 ©2015 Yale Europe Materials Handling Limited 1-9

ENTRY BLADES (FIGURE 1-9)

ITEM PART NO. DESCRIPTION QTY

1-10 ©2015 Yale Europe Materials Handling Limited A428

A428 ©2015 Yale Europe Materials Handling Limited 1-11

CASTER WHEELS (FIGURE 1-10)

1-12 ©2015 Yale Europe Materials Handling Limited A428

A428 ©2015 Yale Europe Materials Handling Limited 1-13

CASTER WHEEL ASSEMBLY (FIGURE 1-11)

1-14 ©2015 Yale Europe Materials Handling Limited A428

CASTER WHEEL ASSEMBLY

A428 ©2015 Yale Europe Materials Handling Limited 1-15

LOAD BACKREST (FIGURE 1-12)