Yale E108 Erc040rg Erc040zg Erc050rg Erc050zg Erc060rg Erc060zg Erc065rg Erc065zg Lift Truck Parts M

PARTS MANUAL ERC040RG, ERC040ZG, ERC050RG, ERC050ZG, ERC060RG, ERC060ZG, ERC065RG, ERC065ZG (E108)

Yale Materials Handling Corporation 1400 Sullivan Drive Caller No. 12011 Greenville, NC 27834-2011

P/N 524140148 © Yale Corp.

08/2003

MODEL NOMENCLATURE

NOTE: This parts manual contains alternate pages for certain assemblies. The truck model code can be used to determine many of the assemblies on your lift truck (power, tire type, mast type). The complete truck model and serial number are stamped into the nameplate. See Identification of Truck Serial Number on Page x for further information.

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SECTIONS

1

GENERAL TRUCK

2

ELECTRICAL SYSTEM

3

DRIVE UNIT

4

STEERING SYSTEM

5

BRAKE SYSTEM

6

HYDRAULIC SYSTEM

7

LIFTING MECHANISM

8

ATTACHMENTS AND HEADER HOSE GROUP

9

OPTIONS

10

FIELD CONVERSION KITS

11

NUMERICAL INDEX

12

USER SUPPORT INFORMATION

This Parts Manual is divided into 12 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

ALPHABETICAL INDEX DESCRIPTION

PAGE NO.

A ABBREVIATIONS QUICK REFERENCE SHEET .................................................................................................. vii ALPHABETICAL INDEX............................................................................................................................................ i B BACK-UP ALARM .............................................................................................................................................. 9-12 BATTERY CONNECTOR ................................................................................................................................... 2-43 BATTERY SLIDE AND ROLLER S/N E108V-17490Z⇒ ..................................................................................................................................... 9-20 BATTERY SLIDE AND ROLLER TRAY ⇒S/N E108V-11382 ....................................................................................................................................... 9-14 S/N E108V-11383⇔S/N E108V-17489Z ........................................................................................................ 9-16 BRAKE AND BACK-UP LIGHT ............................................................................................................................ 9-2 BRAKE PEDAL..................................................................................................................................................... 5-4 C CARRIAGE FOUR STAGE FULL FREE-LIFT .................................................................................................................... 7-84 SIX ROLLER THREE STAGE FULL FREE-LIFT .............................................................................................................. 7-42 TWO STAGE FULL FREE-LIFT .................................................................................................................. 7-64 TWO STAGE LIMITED FREE-LIFT................................................................................................................. 7-17 CONTACTOR ..................................................................................................................................................... 2-22 1A AND RB ..................................................................................................................................................... 2-18 STEERING...................................................................................................................................................... 2-20 CONTACTOR PANEL CONTACTOR HYDRAULIC ............................................................................................................................ 2-16 CONTROL ...................................................................................................................................................... 2-14 CONTROL PANEL CONTACTOR HYDRAULIC ............................................................................................................................ 2-10 TRANSISTOR HYDRAULIC ........................................................................................................................... 2-12 CONTROL PEDAL LINKAGE ............................................................................................................................. 1-22 CONTROL VALVE .............................................................................................................................................. 10-2 FOUR FUNCTION .......................................................................................................................................... 6-22 TWO AND THREE FUNCTION ...................................................................................................................... 6-18 CONTROL VALVE ATTACHING PARTS FOUR FUNCTION .......................................................................................................................................... 6-14 THREE FUNCTION ........................................................................................................................................ 6-10 TWO FUNCTION .............................................................................................................................................. 6-6 COUNTERWEIGHT ........................................................................................................................................... 1-30 COVERS ............................................................................................................................................................ 1-40 D DC CONVERTOR............................................................................................................................................... 9-25 DIRECTIONAL CONTROL PEDAL .................................................................................................................... 1-24 DOME LIGHT ..................................................................................................................................................... 9-10 DRIVE AND REAR LIGHTS ................................................................................................................................. 9-4 i

GENERAL INFORMATION

DESCRIPTION

PAGE NO. D (continued)

DRIVE UNIT ASSEMBLY ..................................................................................................................................... 3-2 DRIVE UNIT INSTALLATION EE, ES, CRE/FRE............................................................................................................................................. 3-8 DRIVE WHEEL AND TIRE ................................................................................................................................. 3-10 E ELECTRICAL ..................................................................................................................................................... 10-2 CONTACTOR HYDRAULIC .............................................................................................................................. 2-2 TRANSISTOR HYDRAULICS ........................................................................................................................... 2-6 EMERGENCY POWER/SEAT SWITCH BYPASS.............................................................................................. 9-26 F FENDER............................................................................................................................................................. 10-2 FLOOR PLATES................................................................................................................................................. 1-42 FORK ERC 040-050 RG/ZG........................................................................................................................................ 1-4 ERC 060-065 RG/ZG........................................................................................................................................ 1-6 FREE-LIFT FOUR STAGE FULL FREE-LIFT .................................................................................................................... 7-76 THREE STAGE FULL FREE-LIFT .................................................................................................................. 7-30 TWO STAGE FULL FREE-LIFT ...................................................................................................................... 7-50 FREE-LIFT CYLINDER FOUR STAGE FULL FREE-LIFT .................................................................................................................... 7-82 THREE STAGE FULL FREE-LIFT .................................................................................................................. 7-38 TWO STAGE FULL FREE-LIFT ...................................................................................................................... 7-61 FULL SUSPENSION SEAT SHEET 1 OF 2 ................................................................................................................................................ 1-18 SHEET 2 OF 2 ................................................................................................................................................ 1-20 G GEAR PUMP ...................................................................................................................................................... 4-16 OPTIONAL...................................................................................................................................................... 4-18 GENERAL TRUCK ............................................................................................................................................... 1-2 H HAND LEVER....................................................................................................................................................... 6-2 HEADER HOSE FOUR STAGE FULL FREE-LIFT ⇒S/N E108-15246 ...................................................................................................................................... 8-46 S/N E108V-15247⇒.................................................................................................................................... 8-50 THREE STAGE FULL FREE-LIFT .................................................................................................................. 8-30 TWO STAGE FULL FREE-LIFT ...................................................................................................................... 8-38 TWO STAGE LIMITED FREE-LIFT................................................................................................................. 8-24 HOOD................................................................................................................................................................. 1-34 HOSE TAKE-UP FOUR STAGE FULL FREE-LIFT .......................................................................................... 10-11 HOSE TAKE-UP THREE STAGE FULL FREE-LIFT ........................................................................................ 10-10 HOSE TAKE-UP TWO STAGE FULL FREE-LIFT .............................................................................................. 10-7 ii

GENERAL INFORMATION

DESCRIPTION

PAGE NO. H (continued)

HOSE TAKE-UP TWO STAGE LIMITED FREE-LIFT......................................................................................... 10-5 HOW TO FIND THE DESIRED PART NUMBER..................................................................................................... ix HOW TO USE THE ILLUSTRATED PARTS MANUAL ............................................................................................ ix HYDRAULIC BRAKE ASSEMBLY........................................................................................................................ 5-2 HYDRAULIC GROUP......................................................................................................................................... 6-40 HYDRAULIC MOTOR S/N E108V-16146Y⇒ For Motor 580024696, S/N E108V-16248Y⇒ For Motor 580024695 ......................... 2-40 WITH BWI ....................................................................................................................................................... 2-42 WITH OPEN CONSTRUCTION WITHOUT BWI ⇒S/N E108V-16247Y.............................................................................................................................. 2-38 WITHOUT BWI ............................................................................................................................................... 2-36 HYDRAULIC MOTOR MOUNT........................................................................................................................... 6-30 HYDRAULIC PUMP 12 CC.............................................................................................................................................................. 6-32 19 CC.............................................................................................................................................................. 6-35 19 CC SINGLE GEAR OPTIONAL .................................................................................................................................................. 6-37 LOW NOISE.................................................................................................................................................... 6-38 OPTIONAL...................................................................................................................................................... 6-34 HYDRAULIC STEERING SYSTEM.................................................................................................................... 4-20 HYDRAULIC TANK............................................................................................................................................. 6-44 I IDENTIFICATION OF ATTACHMENT AND SIDE-SHIFT CARRIAGE SERIAL NUMBERS................................... xii IDENTIFICATION OF MAST SERIAL NUMBER ..................................................................................................... xi IDENTIFICATION OF TRUCK SERIAL NUMBER.................................................................................................... x INNER MAST FOUR STAGE FULL FREE-LIFT .................................................................................................................... 7-72 THREE STAGE FULL FREE-LIFT .................................................................................................................. 7-24 TWO STAGE FULL FREE-LIFT ...................................................................................................................... 7-46 TWO STAGE LIMITED FREE-LIFT................................................................................................................... 7-6 INSTRUMENT PANEL........................................................................................................................................ 2-24 INTEGRAL SIDE-SHIFT CARRIAGE THREE AND FOUR STAGE FULL FREE-LIFT ERC 40-50 RG/ZG ...................................................................................................................................... 8-16 ERC 60-65 RG/ZG ...................................................................................................................................... 8-18 TWO STAGE FULL FREE-LIFT ERC 40-50 RG/ZG ...................................................................................................................................... 8-12 ERC 60-65 RG/ZG ...................................................................................................................................... 8-14 TWO STAGE LIMITED FREE-LIFT ERC 40-50 RG/ZG ........................................................................................................................................ 8-8 ERC 60-65 RG/ZG ...................................................................................................................................... 8-10 INTEGRAL SIDE-SHIFT CYLINDER ................................................................................................................. 8-20 INTEGRAL SIDE-SHIFT HYDRAULIC HOSES TWO STAGE LIMITED FREE-LIFT................................................................................................................. 8-22 TWO, THREE, AND FOUR STAGE FULL FREE-LIFT ................................................................................... 8-23 INTERMEDIATE MAST iii

GENERAL INFORMATION

DESCRIPTION

PAGE NO. I (continued)

THREE STAGE FULL FREE-LIFT .................................................................................................................. 7-20 INTERMEDIATE NO. 1 MAST FOUR STAGE FULL FREE-LIFT .................................................................................................................... 7-68 INTERMEDIATE NO. 2 MAST FOUR STAGE FULL FREE-LIFT .................................................................................................................... 7-70 L LABEL AND PLATE LOCATION......................................................................................................................... 1-27 LATCH KIT.......................................................................................................................................................... 1-38 LIFT TWO STAGE LIMITED FREE-LIFT................................................................................................................... 7-8 LIFT CYLINDER TWO STAGE LIMITED FREE-LIFT ERC 040-050 RG/ZG .................................................................................................................................. 7-11 ERC 060-065 RG/ZG S/N PENDING PER ECN 73680⇒.......................................................................................................... 7-15 ⇒S/N PENDING PER ECN 73680.......................................................................................................... 7-13 LOAD BACKREST ............................................................................................................................................... 1-8 M MAIN CYLINDER LEFT HAND FOUR STAGE FULL FREE-LIFT ................................................................................................................ 7-78 TWO STAGE FULL FREE-LIFT S/N PENDING PER ECN 73680⇒.......................................................................................................... 7-55 ⇒S/N PENDING PER ECN 73680.......................................................................................................... 7-53 RIGHT HAND FOUR STAGE FULL FREE-LIFT ................................................................................................................ 7-80 TWO STAGE FULL FREE-LIFT S/N PENDING PER ECN 73680⇒.......................................................................................................... 7-59 ⇒S/N PENDING PER ECN 73680.......................................................................................................... 7-57 THREE STAGE FULL FREE-LIFT .................................................................................................................. 7-34 MAIN LIFT FOUR STAGE FULL FREE-LIFT .................................................................................................................... 7-74 THREE STAGE FULL FREE-LIFT .................................................................................................................. 7-26 TWO STAGE FULL FREE-LIFT ...................................................................................................................... 7-48 MAST INSTALLATION........................................................................................................................................ 6-26 MAST TILT.......................................................................................................................................................... 10-3 MASTER CYLINDER ......................................................................................................................................... 5-18 MASTER PART SHEET CROSS-REFERENCE ................................................................................................... xiv N NON-SUSPENSION SEAT SEARS............................................................................................................................................................ 1-12 WISE............................................................................................................................................................... 1-10

iv

GENERAL INFORMATION

DESCRIPTION

PAGE NO.

O OUTER MAST FOUR STAGE FULL FREE-LIFT .................................................................................................................... 7-66 THREE STAGE FULL FREE-LIFT .................................................................................................................. 7-18 TWO STAGE FULL FREE-LIFT ...................................................................................................................... 7-44 TWO STAGE LIMITED FREE-LIFT................................................................................................................... 7-4 OVERHEAD GUARD.......................................................................................................................................... 1-32 P PARK BRAKE SEAT ACTUATED S/N PENDING PER ECN 64854⇒ ............................................................................................................. 5-16 ⇒S/N PENDING PER ECN 64854 ............................................................................................................. 5-15 PARK BRAKE LINKAGE LEVER ACTUATED ........................................................................................................................................ 5-12 SEAT ACTUATED S/N PENDING PER ECN 64854⇒ ............................................................................................................. 5-10 ⇒S/N PENDING PER ECN 64854 ............................................................................................................... 5-6 S SHIFT LEVER .................................................................................................................................................... 2-26 SIDE-SHIFT CARRIAGE ERC 040-050 RG/ZG........................................................................................................................................ 8-2 ERC 060-065 RG/ZG........................................................................................................................................ 8-4 SIDE-SHIFT CYLINDER ...................................................................................................................................... 8-6 SPOT LIGHT ........................................................................................................................................................ 9-8 STEER WHEEL AND TIRE ASSEMBLY ............................................................................................................ 4-13 STEERING AXLE ⇒S/N E108V-12739X INC. 12741, 12744, 12750, 12754, 12755, 12760, 12771, 12773, 12783 EXC. 12727-12732 ................................................................................................................................................... 4-2 S/N E108V-12740X⇒ INC. 12727-12732 EXC. 12741, 12744, 12750, 12754, 12755, 12760, 12771, 12773, 12783 .................................................................................................................................................. 4-6 STEERING CONTROL UNIT ............................................................................................................................. 4-14 STEERING CYLINDER ...................................................................................................................................... 4-19 STEERING MOTOR WITH BWI ⇒S/N E108V-17893A ................................................................................................................................. 4-26 S/N E108V-17894A⇒ ................................................................................................................................. 4-28 WITHOUT BWI ⇒S/N E108V-17893A ................................................................................................................................. 4-22 S/N E108V-17894A⇒ ................................................................................................................................. 4-24 STEERING POD ................................................................................................................................................ 4-10 STROBE LIGHT ................................................................................................................................................... 9-6 SUSPENSION SEAT GRAMMER ..................................................................................................................................................... 1-16 SEARS............................................................................................................................................................ 1-14

v

GENERAL INFORMATION

DESCRIPTION

PAGE NO.

T TILT CYLINDER ................................................................................................................................................. 6-28 TRACTION MOTOR 11 IN. WITH BWI ............................................................................................................................................ 2-32 11 IN. WITHOUT BWI..................................................................................................................................... 2-34 9 IN. WITH BWI .............................................................................................................................................. 2-28 9 IN. WITHOUT BWI....................................................................................................................................... 2-30 TRANSMISSION AND DIFFERENTIAL ............................................................................................................... 3-4 TUBE EXTENSION FOUR STAGE FULL FREE-LIFT .................................................................................................................... 8-54 TWO STAGE LIMITED FREE-LIFT................................................................................................................. 8-28 WITH ROTATOR THREE STAGE FULL FREE-LIFT .............................................................................................................. 8-36 TWO STAGE FULL FREE-LIFT .................................................................................................................. 8-44 WITHOUT ROTATOR THREE STAGE FULL FREE-LIFT .............................................................................................................. 8-34 TWO STAGE FULL FREE-LIFT .................................................................................................................. 8-42 TUBE EXTENSION FOUR STAGE FULL FREE-LIFT ....................................................................................... 10-4 TUBE EXTENSION TWO AND THREE STAGE FULL FREE-LIFT ................................................................... 10-3 TUBE EXTENSION TWO STAGE LIMITED FREE-LIFT.................................................................................... 10-3 W WIRE HARNESS CONTROL VALVE SWITCH ...........................................................................................................................

DASH ..............................................................................................................................................................

FRONT LIGHTS..............................................................................................................................................

MAIN ...............................................................................................................................................................

REAR LIGHTS ................................................................................................................................................

SWITCH..........................................................................................................................................................

TRACTION CUT-OUT ....................................................................................................................................

vi

2-48 2-44 2-45 2-46 9-13 9-23 9-24

GENERAL INFORMATION

ABBREVIATIONS QUICK REFERENCE SHEET Listed below are abbreviations used in parts manuals to denote the following expressions:

TERM

DEFINITION

TERM

DEFINITION

Amp

Amperes

MSTS

Microprocessor Spark Timing System

AR

As Required

NPT

National Pipe Threads

BDI

Battery Discharge Indicators

O/S

Oversize

BWI

Brush Wear Indicator

PTO

Power Take Off

CE

Communicator End

RPM

Revolutions per Minute

CRE

Corrosive Environment

S/N

Serial Number

D/B

Date Break

TMM

Truck Management Module

dbA

Decibel "A" Scale

UL Type D

Diesel-Powered Safety Rating

DE

Drive End

UL Type DS

Diesel-Powered Safety Rating

ECM

Electronic Control Module

UL Type E

Battery-Powered Safety Rating

ECN

Engineering Change Notice

UL Type EE

Battery-Powered Safety Rating

EEPROM

Electrically Erasable Programmable Read Only Memory

UL Type ES

Battery-Powered Safety Rating

UL Type G

Gasoline-Powered Safety Rating

EPROM

Electrically Programmable Read Only Memory

UL Type GS

Gasoline-Powered Safety Rating

FRE

Freezer Environment

UL Type LP

Gas-Powered Safety Rating

in.

inches

UL Type LPS

LP Gas-Powered Safety Rating

LPG

Liquefied Petroleum Gas

U/S

Undersize

MAP

Manifold Absolute Pressure

UL

Underwriters Laboratory

mm

millimeters

V

Volts

vii

GENERAL INFORMATION

HOW TO USE THE ILLUSTRATED PARTS MANUAL This parts manual describes and illustrates assemblies, subassemblies, and detail parts needed for service replacement.

viii

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

GENERAL INFORMATION

HOW TO FIND THE DESIRED PART NUMBER WHEN THE PART NUMBER AND THE NEXT HIGHER ASSEMBLY IS NOT KNOWN: 1. Determine the function and application of the part required. Turn to the Sections Page. Choose the general area of reference most likely to include the part.

2. Turn to the section you chose. Use the Section Table of Contents to determine the assembly which would normally contain the part required. Then locate the part on the assembly breakdown page.

WHEN THE PART NUMBER IS NOT KNOWN AND THE NEXT HIGHER ASSEMBLY IS KNOWN: 3. Determine the assembly the required part is used on. Turn to the Alphabetical Index on Page i.

4. Locate the assembly the required part is used on and turn to the page indicated for that assembly.

Then locate the part on the assembly breakdown page.

WHEN THE PART NUMBER IS KNOWN: 5. Use the Numerical Index on Page 11-1 to find the part number. Turn to the page listed and locate the part as indicated by the item number.

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

6. Five periods in the PART NO. column (. . . . .) indicate that the part is either Not Serviced Separately or there is a reference to another figure. A figure reference is denoted by a pointing hand followed by a parts page number in the DESCRIPTION column (☞7A56) 7. Keys are used to show two or more similar assemblies, RH and LH assembly parts, etc.

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

8. Indented descriptions under the DESCRIPTION column are used to indicate assemblies and subparts of assemblies. In the example on the previous page, BEARING CAP (Item 2) is a subpart of the major assembly CASE.

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

10. Serial number breaks identify the most current parts information and are shown as follows: ⇒ S/N A810N-2639 Indicates last serial number affected.

S/N A810N-2640 ⇒ Indicates the first serial number affected.

S/N A810N-1553 ⇔ S/N A810N-3291 Indicates a range of serial numbers affected.

ECN numbers for pending serial numbers are shown to allow for the inclusion of the most current parts information and are identified as follows: ⇒ S/N Pending Per ECN 63243 Indicates a pending serial number for last unit affected.

S/N Pending Per ECN 63243 ⇒ Indicates a pending serial number for first unit affected.

Date breaks are used to indicate when a change occurred but a subsequent serial number break was not recorded. This is an arbitrary date usually based on the ECN release and are identified as follows: ⇒ D/B 3/00 Indicates that a change occurred sometime within that month for the item affected.

D/B 3/00 ⇒ Indicates that a change occurred sometime within that month for the item affected.

D/B 3/00 ⇔ D/B 4/00 Indicates a range of production dates of the item affected.

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

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

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

ix

GENERAL INFORMATION

IDENTIFICATION OF TRUCK SERIAL NUMBER

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 and 1980.

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.

x

GENERAL INFORMATION

IDENTIFICATION OF MAST SERIAL NUMBER

(1) and (2)

The first letter and number indicates the mast unit code.

(3)

The second letter indicates the plant of manufacture.

(4)

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

(5)

Carriage travel in millimeters stamped just below the serial number.

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

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

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

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

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

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

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

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

GENERAL INFORMATION

IDENTIFICATION OF ATTACHMENT AND SIDE-SHIFT CARRIAGE SERIAL NUMBERS

(1) and (2)

The first letter and three numbers indicate the attachment unit code.

(3)

The second letter indicates the plant of manufacture.

(4)

The four or five digit number indicates the production sequence number.

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

Side-shift carriages and attachments have nameplates. Use the serial number found on the nameplate to identify the attachment.

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

Modifications of attachments and side-shift carriages by SPED (Special Products Engineering Department) are identified by a model prefix code beginning with the letter "S". Contact your dealer for Yale lift trucks for information on these assemblies.

xii

GENERAL INFORMATION

MASTER PART SHEET CROSS-REFERENCE NOTE: Throughout this manual are references to Part Sheet Numbers. These references are usually found after the description of a part or assembly. The Part Sheet Number is found on the upper left- or righthand corner of the parts pages.

EXAMPLE: ITEM

PART NO.

DESCRIPTION

QTY

31 32

505965530 504224261

Steering Cylinder (☞ 6E67).....................................................................................

Pin ............................................................................................................................

1 4

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

PART SHEET

PAGE NO.

P11093 ............................... 2-45 P11094 ............................... 2-46 P11095 ............................... 2-48 P11098 ............................... 2-10 P11099 ............................... 2-14 P11100 ............................... 2-16 P11101 ............................... 2-12 P11102 ............................... 2-22 P11103 ............................... 2-28 P11104 ............................... 2-30 P11105 ............................... 2-32 P11106 ............................... 2-34 P11107 ............................... 9-13 P11185 ................................. 1-2 P11186 ................................. 1-4 P11186 ................................. 1-6 P11187 ............................... 1-10 P11188 ............................... 1-12 P11189 ............................... 1-14 P11191 ............................... 1-26 P11192 ............................... 1-30 P11193 ................................. 1-8 P11194 ............................... 1-32 P11195 ............................... 1-34 P11196 ............................... 1-38 P11197 ............................... 1-40 P11198 ............................... 1-42 P11199 ............................... 2-24 P11200 ............................... 2-26 P11202 ............................... 2-18 P11203 ............................... 2-20 P11204 ............................... 2-36 P11205 ............................... 2-42 P11207 ............................... 2-43 P11209 ............................... 2-44 P11211 ................................. 3-2

PART SHEET

PAGE NO.

P11212 ................................. 3-4 P11213 ............................... 3-10 P11214 ................................. 5-2 P11215 ................................. 5-4 P11216 ................................. 5-6 P11217 ............................... 5-12 P11218 ............................... 5-15 P11219 ............................... 5-18 P11220 ................................. 4-2 P11221 ............................... 4-10 P11222 ............................... 4-13 P11223 ............................... 4-14 P11224 ............................... 4-16 P11225 ............................... 4-19 P11226 ............................... 4-20 P11227 ............................... 4-26 P11228 ............................... 4-22 P11229 ................................. 7-4 P11230 ................................. 7-6 P11231 ................................. 7-8 P11232 ............................... 7-11 P11233 ............................... 7-13 P11234 ............................... 7-17 P11235 ............................... 7-18 P11236 ............................... 7-20 P11237 ............................... 7-24 P11238 ............................... 7-26 P11239 ............................... 7-30 P11240 ............................... 7-34 P11241 ............................... 7-38 P11242 ............................... 7-42 P11243 ............................... 7-44 P11244 ............................... 7-46 P11245 ............................... 7-48 P11246 ............................... 7-50 P11247 ............................... 7-53

PART SHEET

PAGE NO.

P11248 ............................... 7-57 P11249 ............................... 7-61 P11250 ............................... 7-64 P11251 ............................... 7-66 P11252 ............................... 7-68 P11253 ............................... 7-70 P11254 ............................... 7-72 P11255 ............................... 7-74 P11256 ............................... 7-76 P11257 ............................... 7-78 P11258 ............................... 7-80 P11259 ............................... 7-82 P11260 ............................... 7-84 P11265 ................................. 6-6 P11266 ............................... 6-10 P11267 ............................... 6-14 P11268 ............................... 6-18 P11269 ............................... 6-22 P11270 ............................... 6-26 P11271 ............................... 6-28 P11272 ............................... 6-30 P11273 ............................... 6-32 P11274 ............................... 6-38 P11275 ............................... 6-35 P11276 ............................... 6-40 P11277 ............................... 6-44 P11278 ................................. 8-2 P11279 ................................. 8-4 P11280 ................................. 8-6 P11281 ............................... 8-24 P11282 ............................... 8-28 P11283 ............................... 8-30 P11284 ............................... 8-34 P11285 ............................... 8-36 P11286 ............................... 8-38 P11287 ............................... 8-42 xiii

GENERAL INFORMATION

PART SHEET

PAGE NO.

P11288 ............................... 8-44 P11289 ............................... 8-46 P11290 ............................... 8-54 P11291 ................................. 9-2 P11292 ................................. 9-4 P11293 ................................. 9-6 P11294 ............................... 9-10 P11295 ............................... 9-12 P11296 ............................... 9-14 P11297 ............................... 9-23 P11298 ............................... 9-25 P11299 ............................... 1-16 P11307 ............................... 1-22 P11308 ............................... 1-24 P11309 ................................. 2-2 P11310 ................................. 2-6

xiv

PART SHEET

PAGE NO.

P11312 ................................. 9-8 P11433 ................................. 3-8 P11467 ............................... 9-16 P12497 ................................. 8-8 P12516 ............................... 7-55 P12517 ............................... 7-59 P12518 ............................... 8-12 P12519 ............................... 8-16 P12520 ............................... 8-20 P12521 ............................... 8-22 P12522 ............................... 8-23 P12597 ............................... 6-37 P12611 ............................... 7-15 P12700 ............................... 8-10 P12701 ............................... 8-14 P12702 ............................... 8-18

PART SHEET

PAGE NO.

P12803 ............................... 1-18 P12803 ............................... 1-20 P12952 ............................... 4-18 P12954 ............................... 6-34 P12970 ............................... 8-50 P13095 ............................... 5-10 P13193 ................................. 6-2 P13199 ............................... 9-26 P13252 ............................... 2-40 P13305 ............................... 9-24 P13306 ............................... 9-20 P13350 ............................... 2-38 P13378 ................................. 4-6 P13800 ............................... 4-24 P13801 ............................... 4-28 P13802 ............................... 5-16

SECTION 1

1 GENERAL TRUCK

1

GENERAL TRUCK

CONTENTS

SECTION 1 GENERAL TRUCK DESCRIPTION

PAGE

CONTROL PEDAL LINKAGE ............................................................................................................................. 1-22 COUNTERWEIGHT ........................................................................................................................................... 1-30 COVERS ............................................................................................................................................................ 1-40 DIRECTIONAL CONTROL PEDAL .................................................................................................................... 1-24 FLOOR PLATES................................................................................................................................................. 1-42 FORK ERC 040-050 RG/ZG........................................................................................................................................ 1-4 ERC 060-065 RG/ZG........................................................................................................................................ 1-6 FULL SUSPENSION SEAT SHEET 1 OF 2 ................................................................................................................................................ 1-18 SHEET 2 OF 2 ................................................................................................................................................ 1-20 GENERAL TRUCK ............................................................................................................................................... 1-2 HOOD................................................................................................................................................................. 1-34 LABEL AND PLATE LOCATION......................................................................................................................... 1-27 LATCH KIT.......................................................................................................................................................... 1-38 LOAD BACKREST ............................................................................................................................................... 1-8 NON-SUSPENSION SEAT SEARS............................................................................................................................................................ 1-12 WISE............................................................................................................................................................... 1-10 OVERHEAD GUARD.......................................................................................................................................... 1-32 SUSPENSION SEAT GRAMMER ..................................................................................................................................................... 1-16 SEARS............................................................................................................................................................ 1-14

1-1

P11185

09-99

GENERAL TRUCK

GENERAL TRUCK

1-2

P11185

09-99

GENERAL TRUCK

ITEM

1 2 3 3 3 3 4 5 6 7 8 9 10 11

PART NO.

DESCRIPTION

.. .. .. .. .. .. .. .. .. .. .. .. .. ..

Fork (☞ P11186) .....................................................................................................

2 Load Backrest (☞ P11193) ......................................................................................

1 Mast-Two Stage Limited Free-Lift (☞ P11229, P11230) ..........................................

1 Mast-Two Stage Full Free-Lift (☞ P11243, P11244) ...............................................

1 Mast-Three Stage Full Free-Lift (☞ P11235, P11236, P11237) ..............................

1 Mast-Four Stage Full Free-Lift (☞ P11251, P11252, P11253, P11254) ..................

1 Seat (☞ P11187, P11188, P11189, P11299) ..........................................................

1 Overhead Guard (☞ P11194) ..................................................................................

1 Accelerator Pedal (☞ P11307) ................................................................................

1 Floor Plates and Cowl (☞ P11198) .........................................................................

1 Counterweight (☞ P11192) .....................................................................................

1 Steer Axle (☞ P11220) ............................................................................................

1 Drive Axle (☞ P11211) ............................................................................................

1 Label and Plate Location (☞ P11191) ..................................................................... AR

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . . .

QTY

1-3

P11186

09-99

FORK (ERC 040-050 RG/ZG)

FORKERC 040-050 RG/ZG

1-4

P11186

09-99

FORK (ERC 040-050 RG/ZG) KEY: A: ERC 040 RG/ZG (100 mm x 40 mm [4.00 in. x 1.50 in.])

B: ERC 050 RG/ZG (100 mm x 45 mm [4.00 in. x 1.75 in.])

C: ERC 050 RG/ZG (125 mm x 45 mm [5.00 in. x 1.75 in.])

ITEM

1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 3 4 5 6 7 8 9 10 11

PART NO.

d d d d d d b b b b a a a a

504111201 504111203 504111204 504110201 504110203 504110204 518648602 518648603 518649602 518649603 505861502 505861503 518647602 518647603 505850500 505854501 505852500 505853500 505851500 580034999 580035000 580026749 c 580016727 c 580016728

DESCRIPTION

A

QTY B

C

Fork (36 in.) ............................................................................................

Fork (48 in.) ............................................................................................

Fork (54 in.) ............................................................................................

Fork (36 in.) ............................................................................................

Fork (48 in.) ............................................................................................

Fork (54 in.) ............................................................................................

Fork (42 in.) ............................................................................................

Fork (48 in.) ............................................................................................

Fork (42 in.) ............................................................................................

Fork (48 in.) ............................................................................................

Fork (42 in.) ............................................................................................

Fork (48 in.) ............................................................................................

Fork (42 in.) ............................................................................................

Fork (48 in.) ............................................................................................

Lever ..................................................................................................

Pin ......................................................................................................

Washer ...............................................................................................

Spring.................................................................................................

Pin ......................................................................................................

Knob...................................................................................................

Pin ......................................................................................................

Spring.................................................................................................

Washer ...............................................................................................

Wedge ................................................................................................

2 2 2 .. .. ..

2 2 .. ..

2 2 .. ..

1 1 1 1 1 1 1 1 1 1

.. .. ..

2 2 2 .. .. .. .. .. .. .. ..

1 1 1 1 1 1 1 1 1 1

.. .. .. .. .. .. .. ..

2 2 .. ..

2 2 1 1 1 1 1 1 1 1 1 1

580035002 Latch Kit (Class II) (Includes Items 7-11) ...............................................

2

2

2

FOOTNOTES: a Polished Fork with Full Bottom Taper b Polished Fork with Full Top Taper c Refer to Latch Kit Installation Instruction. d Standard Taper

1-5

P11186

09-99

FORK (ERC 060-065 RG/ZG)

FORKERC 060-065 RG/ZG

1-6

P11186

09-99

FORK (ERC 060-065 RG/ZG) KEY: A: Standard Taper (125 mm x 45 mm [4.00 in. x 1.75 in.])

B: Polished Fork with Full Bottom Taper (125 mm x 50 mm [5.00 in. x 1.75 in.])

C: Full Top Taper (125 mm x 50 mm [5.00 in. x 1.75 in.])

ITEM

PART NO.

1 1 1 1 1 1 1 1 1 1 1 2 3 4 5 6 7 8 9 10 11

503998701 503998703 503998704 505862501 505862502 505862503 505862504 518650601 518650602 518650603 518650604 505850500 504236227 505852500 505853500 505851500 580034999 580035011 580026751 a 580016727 a 580016736

DESCRIPTION

A

QTY B

C

Fork (36 in.) ............................................................................................

Fork (48 in.) ............................................................................................

Fork (54 in.) ............................................................................................

Fork (36 in.) ............................................................................................

Fork (42 in.) ............................................................................................

Fork (48 in.) ............................................................................................

Fork (54 in.) ............................................................................................

Fork (36 in.) ............................................................................................

Fork (42 in.) ............................................................................................

Fork (48 in.) ............................................................................................

Fork (54 in.) ............................................................................................

Lever ..................................................................................................

Pin ......................................................................................................

Washer ...............................................................................................

Spring.................................................................................................

Pin ..........................................................................................................

Knob .......................................................................................................

Pin ..........................................................................................................

Spring .....................................................................................................

Washer ...................................................................................................

Wedge ....................................................................................................

2 2 2 .. .. .. .. .. .. .. ..

1 1 1 1 1 1 1 1 1 1

.. .. ..

2 2 2 2 .. .. .. ..

1 1 1 1 1 1 1 1 1 1

.. .. .. .. .. .. ..

2 2 2 2 1 1 1 1 1 1 1 1 1 1

580035017 Latch Kit (Class III) (Includes Items 7-11) ..............................................

2

2

2

FOOTNOTES: a Refer to Latch Kit Installation Instruction.

1-7

P11193

09-99

LOAD BACKREST

LOAD BACKREST

1-8

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