SPARE PARTS MANUAL

MODELS 20 & 44

AISLE-MASTER LTD
CLONTIBRET
CO MONAGHAN
IRELAND

TEL + 353 47 80400

FAX + 353 47 80402
Email: info@aisle-master.com
Website: www.aisle-master.com

Date : Serial Number :

 AISLE-MASTER

SECTION No. CONTENTS

1 MAIN CHASSIS ASSEMBLY
2 MAST CARRIER ASSEMBLY
2A PIPE CLAMP STABILISER ASSEMBLY
3 MAIN FRONT AXLE ASSEMBLY
4 ROLL CAGE ASSEMBLY
5 ENGINE ASSEMBLY
5A ACCELERATOR PEDAL ASSEMBLY
5B AIR FILTER ASSEMBLY
5C ENGINE MOUNTING ASSEMBLY
5D ENGINE AIRBOX INTAKE ASSEMBLY
5E CARBURETOR & FUEL CUT-OFF ASSEMBLY
5F CARBURETOR ASSEMBLY
5G FUEL CUT -OFF ASSEMBLY
5H EXHAUST CATALYST SECTION ASSEMBLY
6 HYDRAULIC TANK ASSEMBLY
7 LEFT & RIGHT HAND DOOR ASSEMB LY
8 REAR GRILL ASSEMBLY
9 BATTERY STAND ASSEMBLY
10 FOOT PLATE ASSEMBLY
11 SEAT & ENGINE COVER ASSEMBLY
12 MAIN PIPE ASSEMBLY
12A GEAR PUMP ASSEMBLY

12B AISLE-MASTER VALVE CHEST ASSEMBLY

12C RETURN FILTER ASSEMBLY
12D DRIVE PUMP FEED / SUPPLY
12E DRIVE PUMP ASSEMBLY
12F REAR MANIFOLD BLOCK ASSEMBLY

i
 AISLE-MASTER

SECTION No. CONTENTS

12G SUCTION FILTER ASSEMBLY
12H FRONT WHEEL HYDRAULICS
12I FRONT MANIFOLD BLOCK
12J REAR WHEEL HYDRAULICS
12K BRAKE VALVE ASSEMBLY
12L SIDE-SHIFT HYDRAULICS
12M STEERING HYDRAULICS
12N STEERING MOTOR ASSEMBLY
12P STEERING VALVE ASSEMBLY
12Q LIFT CYLINDER HYDRAULICS
12R TILT CYLINDER HYDRAULICS
12S BRAKE / INCHING PEDAL HYDRAULICS
12T BRAKE / INCHING PEDAL ENCLOSURE
13 STEERING COVER ASSEMBLY
14 TILT CYLINDER ASSEMBLY
14A STEERING CYLINDER ASSEMBLY
14B MAST FREE-LIFT CYLINDER ASSEMBLY
14C MAST OUTER LIFT CYLINDER ASSEMBLY
15 GAS BOTTLE HOLDER ASSEMBLY
15A GAS LINE TEE CONNECTION ASSEMBLY
16 HYDRAULICS CONTRO L MOUNT ASSEMBLY
17 MAIN LOOM

17A CHASSIS LOOM ASSEMBLY

17B DASH ELECTRICAL ASSEMBLY
17C LOAD MONITOR LOOMS
17D LIGHTS & FLASHING BEACON LOOMS
17E BATTERY & ENGINE EARTH LOOMS

ii
 AISLE-MASTER

SECTION No. CONTENTS

17F SEAT SWITCH LOOM
17G STEERING COLUMN ASSEMBLY

17H STEERING BLOCK

17I COMMANDER KIT ASSEMBLY
17J HORN DEVICE ASSEMBLY
17K REVERSING BLEEPER ASSEMBLY
18 4.7M MAST ASSEMBLY (MK1)

18A 4.7M MAST OUTER SECTION ASSEMBLY (MK1)

18B 4.7M MAST MIDDLE SECTION ASSEMBLY (MK1)
18C 4.7M MAST INNER SECTION ASSEMBLY (MK1)
18D CHAIN HEAD ASSEMBLY
18E MAST SIDE SHIFT ASSEMBLY
18F 4.7M MAST ASSEMBLY (MK 2)
18G 4.7M MAST OUTER SECTION ASSEMBLY (MK 2)
18H 7M MAST ASSEMBLY (HIGH LIFT)
18I 7M MAST OUTER SECTION ASSEMBLY (HL)
18J 7M MAST MIDDLE SECTION ASSEMBLY (HL)
18K 7M MAST INNER SECTION ASSEMBLY (HL)
19 INDEX

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 AISLE-MASTER

SECTION 1

MAIN CHASSIS ASSEMBLY

 AISLE-MASTER

MAIN CHASSIS (HIGH LIFT)

ASSEMBLY
 AISLE-MASTER

SECTION 2

MAST CARRIER ASSEMBLY

 AISLE-MASTER

MAST CARRIER (HIGH LIFT)

ASSEMBLY
 AISLE-MASTER

SECTION 3

MAIN FRONT AXLE ASSEMBLY

 AISLE-MASTER

SECTION 4

ROLL CAGE ASSEMBLY

 AISLE-MASTER

SECTION 5

ENGINE ASSEMBLY
ALSO:
ALSO:
 AISLE-MASTER

SECTION 6

HYDRAULIC TANK ASSEMBLY

 AISLE-MASTER

SECTION 7

LEFT & RIGHT HAND DOOR

ASSEMBLY
 NOTE: FOR SPARE PARTS
SIDE DOORS 3 & 14 MUST BE SUPPLIED WITH TWO PULL HANDLES 2 & FITTINGS 4 5 6
 NOTE: FOR SPARE PARTS
SIDE DOORS 2 & 10 MUST BE SUPPLIED WITH TWO FLUSH HANDLES 19
 AISLE-MASTER

SECTION 8

REAR GRILL ASSEMBLY

 AISLE-MASTER

SECTION 9

BATTERY STAND ASSEMBLY

 AISLE-MASTER

SECTION 10

FOOT PLATE ASSEMBLY

 AISLE-MASTER

SECTION 11

SEAT & ENGINE COVER

ASSEMBLY
 AISLE-MASTER

SECTION 12

HYDRAULIC PIPE LAYOUTS

& COMPONENTS
 ULICS
IF T HYDRA
H
SIDE-S ST
TO MA
 T
M AS
O
ST
LIC
R AU
D
T HY
LI F
 AISLE-MASTER

SECTION 13

STEERING COVER ASSEMBLY

 AISLE-MASTER

STEERING COVER (HIGH LIFT)

ASSEMBLY
 AISLE-MASTER

SECTION 14

TILT / STEERING /MAST

CYLINDERS ASSEMBLIES
 AISLE-MASTER

TILT CYLINDER (HIGH LIFT)

ASSEMBLY
 AISLE-MASTER

SECTION 15

GAS BOTTLE HOLDER

ATTACHMENTS
 AISLE-MASTER

SECTION 16

HYDRAULICS CONTROL
MOUNT ASSEMBLY
 AISLE-MASTER

SECTION 17

(1.) ELECTRICAL LOOMS &

ATTACHMENTS

(2.) STEERING COLUMN &

ATTACHMENTS
 RELAY PURPOSE
1 STARTER (NEUTRAL)
2 FORWARD MOTION
3 REVERSE MOTION
4 BRAKES
5 WORKLIGHTS
6 ALARM / REVERSING BLEEPER
7 SEAT SWITCH

RELAY 6
RELAY 1
RELAY
RELAY 3
RELAY 2
RELAY 5

RELAY 7

SEAT SWITCH LOOM MAIN LOOM

 I NE
N G
E
 AISLE-MASTER

SECTION 18

MAST ASSEMBLY
 AISLE-MASTER

MAST (HIGH LIFT) ASSEMBLY

 Index
A
Accelerator cable, 5A
Accelerator pedal, 5A
Arm rest, 16
B
Ballast step, 1
Battery bracket, 9
Battery stand, 9
Battery, 9
Bell housing, 5
Brake / Inching pedal, 12T
Brake / Inching spring, 12T
Brake BVS spool, 12K
Brake solenoid, 12K
Brake Valve, 12K
C
Carburetor & Fuel Cut-Off assembly, 5E
Carburetor assembly, 5F
Chain head assembly, 18D
Chassis, 1
Check straps, 7
Commander kit, 17I
Crail nut (C-track nut), 1
D
Dash, 17G
Drive pump feed / supply, 12D
Drive Pump Manifold Block, 12F
Drive pump purge valve, 12E
Drive pump, 12E
E
Engine airbox intake, 5D
Engine cover, 11
Engine flywheel, 5
Engine mounting brackets, 5
Engine mounting, 5C
Engine, 5
Exhaust catalyst section assembly, 5H
Exhaust upright pipe, 4
F
Fan guard, 5
Filter - Air, 5B
Filter - Return, 12C
Filter - Strainer, 6
Filter - Suction, 12G
Flashing beacon, 4
Foot plate, 10
Forward / Reverse control lever, 16
Front axle pivot trust washers, 3
Front axle radial spherical plain bearings, 3
Front axle, 3
Front wheel hydraulics, 12H
Front wheels, 3
Fuel Cut-Off assembly, 5G
Fuse box, 17G
Fuses, 17G
G
Gas bottle coupling, 15
Gas bottle holder, 15
Gas Filter, 16
Gas line tee connection, 15, 15A
Gas Strut cylinder (for positioning of engine cover), 4
Gear pump side adaptor, 12A
Gear pump, 12A
H
Horn button switch, 16
Horn device, 17J
Hydraulic tank inspection cap, 6
Hydraulic tank oil level gauge, 6
Hydraulic tank, 6
Hydraulics control mount, 16
Hydraulics controls cover, 16
Hydraulics decal plate, 16
I
Ignition key, 17G
Ignition switch, 17G
Instrument gauge, 17G
J
K
L
Lift cylinder hydraulics, 12Q
Lights switch button, 17G
Lights, 4
Load monitor display unit, 4
Load monitor sensor, 2
Loom - Battery & engine earth, 17E
Loom - Chassis, 17A
Loom - Dash, 17B
Loom - Flashing beacon & lights, 17D
Loom - Load monitor, 17C
Loom - Main, 17
Loom - Seat switch, 17F
M
Main Fuse 50A, 9
Main pipe hydraulics, 12
Manifold block - front hose lock, 12I
Manifold block - front, 12I
Manifold block - rear, 12F
Mast (4.7m) assembly (MK1), 18
Mast (4.7m) assembly (MK2), 18F
Mast (4.7m) inner section assembly (MK1), 18C
Mast (4.7m) middle section assembly (MK1), 18B
Mast (4.7m) outer section assembly (MK1), 18A
Mast (4.7m) outer section assembly (MK2), 18G
Mast (7m) assembly (high lift), 18H
Mast (7m) inner section assembly (MK1), 18K
Mast (7m) middle section assembly (MK1), 18J
Mast (7m) outer section assembly (HL), 18I
Mast carriage bearing housing lower, 2
Mast carriage bearing housing top, 2
Mast carriage, 2
Mast free-lift cylinder assembly, 14B
Mast Mirror, 18A
Mast outer lift cylinder assembly, 14C
Mirror (5" convex), 4
N
O
Oil cooler, 5
Oil Tray, 5D
Oxygen sensor, 5H
P
Park brake switch, 17G
Pipe clamp stabiliser, 2A
Pressure Switch, 11
PSI clamp 1 1/4", 12
PSI clamp 3/4", 12D
Q
R
Radiator fan guard, 5
Radiator mounting (bobbins rubber mountings), 6
Radiator mounting (Bottom stabiliser rubber mountings), 5
Radiator, 5
Ratchet (for gas bottle), 15
Rear grill, 8
Rear wheel hydraulics, 12J
Rear wheels, 1
Relay, 17B
Relief valve - lift (Valve bank), 12B
Relief valve - Main (Valve bank), 12B
Reversing bleeper, 17K
Roll cage Mirror, 4
Roll cage, 4
S
Seat, 11
Side doors, 7
Side-Shift assembly, 18E
Side-shift hydraulics, 12L
Slew ring, 2
Steering area cover, 13
Steering chain, 2
Steering column, 17G, 17H
Steering cylinder, 14A
Steering hydraulics, 12M
Steering motor, 12N
Steering valve, 12P
Steering wheel, 17G
T
Tilt cylinder hydraulics, 12R
Tilt cylinders (High Lift), 14D
Tilt cylinders, 14
Tray (for main chassis), 1
U
V
Valve chest, 12B
W
Wheel motor cover, 1
Wheel motor front, 3
Wheel motor rear, 1
Wheel nuts, 1, 3
Wheels - Front, 3
Wheels - Rear, 1