Yale ERC 040 - 065 RF / ZF (E108) Lift Truck Parts Manual
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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.
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 ........................................................................................................................... 2-48
DASH .............................................................................................................................................................. 2-44
FRONT LIGHTS.............................................................................................................................................. 2-45
MAIN ............................................................................................................................................................... 2-46
REAR LIGHTS ................................................................................................................................................ 9-13
SWITCH.......................................................................................................................................................... 9-23
TRACTION CUT-OUT .................................................................................................................................... 9-24
vi
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This is the complete factory Parts manual for the Yale ERC 040 - 065 RF / ZF (E108) Lift Truck. This Manual has easy-to-read text sections with top quality diagrams and instructions. They are specifically written for the do-it-yourselfer as well as the experienced mechanic. With step by step instruction & highly detailed exploded pictures & diagrams to show you how to complete the required job correctly & efficiently. Yale ERC 040 - 065 RF / ZF (E108) Lift Truck Parts Manual covers every single detail on your machine, providing step-by-step instructions based on the complete disassembly of the machine. This repair manual is an inexpensive way to keep your vehicle working properly.
Models:
- Yale ERC 040 - 065 RF / ZF (E108) Lift Truck
Manual Covers:
- General Truck
- Electrical System
- Drive Unit Assembly
- Brake System
- Steering System
- Lifting Mechanism
- Hydraulic System
- Attachments And Hose Take-UPS
- Accessories
- Field Conversion Kits
- Numerical Index
- User Support Information
- And More......
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe Reader & Win
NO waiting, All pages are printable. Yale ERC 040 - 065 RF / ZF (E108) Lift Truck Parts Manual are saving you money on postage and packaging. It is great to have.
