Yale ERC 030 AG, ERC 030 BG, ERC 040 AG, ERC 040 BG (A814) Lift Truck Parts Manual
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PARTS MANUAL
ERC 030 AG, ERC 030 BG, ERC 040 AG,
ERC 040 BG
(A814)
S/N A814V-4056 INC. 3749,
4021, 4022, 4027
Yale Materials Corp.
1400 Sullivan Drive
Caller No. 12011
Greenville, NC 27834-2011
P/N 524140147
© Yale Corp.
01/2002
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 ix 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 ................................................................................................. vi
ACCELERATOR CONTROL PEDAL LINKAGE................................................................................................ 1-12
ALPHABETICAL INDEX......................................................................................................................................... i
B
BACKUP ALARM ............................................................................................................................................... 9-9
BATTERY CONNECTOR ................................................................................................................................. 2-34
BATTERY SLIDE AND ROLLER TRAY ............................................................................................................ 9-12
BRAKE ASSEMBLY ........................................................................................................................................... 5-2
BRAKE PEDAL ASSEMBLY ............................................................................................................................... 5-4
BRAKE/BACKUP LIGHT .................................................................................................................................... 9-2
C
CARRIAGE
SIX ROLLER
THREE STAGE FULL FREE-LIFT ............................................................................................................ 7-32
TWO STAGE FULL FREE-LIFT ................................................................................................................ 7-54
TWO STAGE LIMITED FREE-LIFT ........................................................................................................... 7-12
CONTACTOR ................................................................................................................................................... 2-22
1A AND RB ................................................................................................................................................... 2-18
CONTROL CONTACTOR PANEL..................................................................................................................... 2-14
CONTROL PANEL
CONTACTOR HYDRAULICS
TYPE 1 ...................................................................................................................................................... 2-10
TYPE 2 ...................................................................................................................................................... 2-16
TRANSISTOR HYDRAULIC ......................................................................................................................... 2-12
CONTROL VALVE ............................................................................................................................................ 10-2
FOUR FUNCTION ........................................................................................................................................ 6-28
THREE FUNCTION ...................................................................................................................................... 6-24
CONTROL VALVE ATTACHING PARTS
FOUR FUNCTION ........................................................................................................................................ 6-20
THREE FUNCTION ...................................................................................................................................... 6-16
TWO FUNCTION .......................................................................................................................................... 6-12
COUNTERWEIGHT ......................................................................................................................................... 1-19
COVERS .......................................................................................................................................................... 1-28
D
DIFFERENTIAL .................................................................................................................................................. 3-6
DOME LIGHT ..................................................................................................................................................... 9-8
DRIVE AND REAR LIGHTS ............................................................................................................................... 9-4
DRIVE AXLE ...................................................................................................................................................... 3-2
DRIVE WHEEL AND TIRE
CUSHION ....................................................................................................................................................... 3-8
PNEUMATIC ................................................................................................................................................. 3-10
i
GENERAL INFORMATION
DESCRIPTION PAGE NO.
E
ELECTRICAL
CONTACTOR HYDRAULICS .......................................................................................................................... 2-2
TRANSISTOR HYDRAULICS ......................................................................................................................... 2-6
F
FENDER........................................................................................................................................................... 10-2
FLOOR PLATES ............................................................................................................................................... 1-30
FOOT DIRECTIONAL CONTROL PEDAL ....................................................................................................... 1-14
FORK................................................................................................................................................................ 1-22
FREE-LIFT
THREE STAGE FULL FREE-LIFT ................................................................................................................ 7-24
TWO STAGE FULL FREE-LIFT .................................................................................................................... 7-40
FREE-LIFT CYLINDER
THREE STAGE FULL FREE-LIFT ................................................................................................................ 7-30
TWO STAGE FULL FREE-LIFT .................................................................................................................... 7-52
FULL SUSPENSION SEAT
SHEET 1 OF 2 ................................................................................................................................................ 1-8
SHEET 2 OF 2 .............................................................................................................................................. 1-10
G
GEAR PUMP .................................................................................................................................................... 4-10
OPTIONAL .................................................................................................................................................... 4-11
GENERAL TRUCK ............................................................................................................................................. 1-2
H
HAND LEVER
FOUR FUNCTION WITH DETENT LEVERS ................................................................................................. 6-8
THREE FUNCTION WITH DETENT LEVERS ............................................................................................... 6-6
THREE FUNCTION WITHOUT DETENT LEVERS ........................................................................................ 6-4
TWO FUNCTION ............................................................................................................................................ 6-2
HOIST HYDRAULIC PUMP
LOW NOISE.................................................................................................................................................. 6-42
HOIST PUMP AND MOTOR MOUNT .............................................................................................................. 6-36
HOOD............................................................................................................................................................... 1-24
HOSE TAKE-UP
FOUR FUNCTION
THREE STAGE FULL FREE-LIFT ............................................................................................................ 8-20
TWO STAGE FULL FREE-LIFT ................................................................................................................ 8-26
TWO STAGE LIMITED FREE-LIFT ........................................................................................................... 8-16
THREE FUNCTION
THREE STAGE FULL FREE-LIFT ............................................................................................................ 8-18
TWO STAGE FULL FREE-LIFT ................................................................................................................ 8-24
TWO STAGE LIMITED FREE-LIFT ........................................................................................................... 8-14
HOSE TAKE-UP THREE STAGE FULL FREE-LIFT ........................................................................................ 10-7
HOSE TAKE-UP TWO STAGE FULL FREE-LIFT ............................................................................................ 10-6
HOSE TAKE-UP TWO STAGE LIMITED FREE-LIFT ....................................................................................... 10-4
HOW TO FIND THE DESIRED PART NUMBER................................................................................................. viii
HOW TO USE THE ILLUSTRATED PARTS MANUAL ........................................................................................ viii
HYDRAULIC GROUP ....................................................................................................................................... 6-56
ii
GENERAL INFORMATION
DESCRIPTION PAGE NO.
H (continued)
HYDRAULIC MOTOR
CLOSED CONSTRUCTION WITH BWI
S/N PENDING PER ECN 73755 ........................................................................................................... 6-54
PREMIUM PERFORMANCE WITH BWI ...................................................................................................... 6-52
STANDARD PERFORMANCE WITH BWI
D/B 01/2000 .......................................................................................................................................... 6-48
D/B 01/2000 .......................................................................................................................................... 6-50
STANDARD PERFORMANCE WITHOUT BWI
D/B 01/2000 .......................................................................................................................................... 6-44
D/B 01/2000 .......................................................................................................................................... 6-46
HYDRAULIC PUMP
12 CC............................................................................................................................................................ 6-38
19 CC............................................................................................................................................................ 6-41
OPTIONAL .................................................................................................................................................... 6-40
HYDRAULIC STEERING SYSTEM.................................................................................................................. 4-14
HYDRAULIC TANK ........................................................................................................................................... 6-59
I
IDENTIFICATION OF TRUCK SERIAL NUMBER ................................................................................................. ix
INNER MAST
THREE STAGE FULL FREE-LIFT ..................................................................................................... 7-16 , 7-18
TWO STAGE FULL FREE-LIFT .................................................................................................................... 7-36
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 7-4
INSTRUMENT PANEL ...................................................................................................................................... 2-24
INTEGRAL SIDE-SHIFT CARRIAGE
TWO AND THREE STAGE FULL FREE-LIFT ................................................................................................ 8-8
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 8-6
INTEGRAL SIDE-SHIFT CYLINDER ............................................................................................................... 8-10
INTEGRAL SIDE-SHIFT HYDRAULIC HOSES
TWO AND THREE STAGE FULL FREE-LIFT .............................................................................................. 8-13
TWO STAGE LIMITED FREE-LIFT............................................................................................................... 8-12
L
LABEL AND PLATE LOCATION ....................................................................................................................... 1-17
LIFT
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 7-6
LIFT CYLINDER
LEFT HAND
TWO STAGE LIMITED FREE-LIFT ............................................................................................................. 7-8
RIGHT HAND
TWO STAGE LIMITED FREE-LIFT ........................................................................................................... 7-10
LIGHTS 12 VOLT.............................................................................................................................................. 10-2
LIGHTS 36/48 VOLT......................................................................................................................................... 10-3
LOAD BACKREST ........................................................................................................................................... 1-20
iii
GENERAL INFORMATION
DESCRIPTION PAGE NO.
M
MAIN CYLINDER
LEFT HAND
THREE STAGE FULL FREE-LIFT ............................................................................................................ 7-26
TWO STAGE FULL FREE-LIFT
S/N PENDING PER ECN 73680 ....................................................................................................... 7-44
S/N PENDING PER ECN 73680 ........................................................................................................ 7-46
RIGHT HAND
THREE STAGE FULL FREE-LIFT ............................................................................................................ 7-28
TWO STAGE FULL FREE-LIFT
S/N PENDING PER ECN 73680 ....................................................................................................... 7-48
S/N PENDING PER ECN 73680 ........................................................................................................ 7-50
MAIN LIFT
THREE STAGE FULL FREE-LIFT ................................................................................................................ 7-20
TWO STAGE FULL FREE-LIFT .................................................................................................................... 7-38
MAST INSTALLATION ...................................................................................................................................... 6-32
MAST TILT........................................................................................................................................................ 10-2
MASTER CYLINDER ....................................................................................................................................... 5-14
MASTER PART SHEET CROSS-REFERENCE ................................................................................................... xi
N
NON-SUSPENSION SEAT ................................................................................................................................. 1-4
O
OUTER MAST
THREE STAGE FULL FREE-LIFT ................................................................................................................ 7-14
TWO STAGE FULL FREE-LIFT .................................................................................................................... 7-34
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 7-2
OVERHEAD GUARD........................................................................................................................................ 1-21
P
PARK BRAKE ................................................................................................................................................... 5-13
PARK BRAKE LINKAGE
LEVER ACTUATED ...................................................................................................................................... 5-10
SEAT ACTUATED ........................................................................................................................................... 5-6
S
SHIFT LEVER .................................................................................................................................................. 2-26
SIDE-SHIFT...................................................................................................................................................... 10-2
SIDE-SHIFT CARRIAGE .................................................................................................................................... 8-2
SIDE-SHIFT CYLINDER .................................................................................................................................... 8-4
STEER WHEEL AND TIRE ASSEMBLY
CUSHION ..................................................................................................................................................... 4-21
PNEUMATIC ................................................................................................................................................. 4-20
STEERING AXLE ............................................................................................................................................... 4-2
STEERING CONTACTOR ................................................................................................................................ 2-20
STEERING CONTROL UNIT ............................................................................................................................. 4-8
STEERING CYLINDER .................................................................................................................................... 4-12
STEERING MOTOR
WITH BWI ..................................................................................................................................................... 4-16
iv
GENERAL INFORMATION
DESCRIPTION PAGE NO.
S (continued)
WITHOUT BWI ............................................................................................................................................. 4-18
STEERING POD ................................................................................................................................................ 4-4
STROBE LIGHT ................................................................................................................................................. 9-6
SUSPENSION SEAT .......................................................................................................................................... 1-6
T
TILT CYLINDER ............................................................................................................................................... 6-34
TRACTION MOTOR
HIGH SPEED WITH BWI .............................................................................................................................. 2-28
HIGH SPEED WITHOUT BWI ...................................................................................................................... 2-30
LOW SPEED WITH BWI ............................................................................................................................... 2-32
TRANSMISSION ................................................................................................................................................ 3-4
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 ......................................................................................................................... 2-40
IGNITION SWITCH ....................................................................................................................................... 2-35
LIGHT ................................................................................................................................................ 2-36 , 9-10
MAIN ............................................................................................................................................................. 2-38
WIRE HARNESS AND DC-DC CONVERTOR ................................................................................................. 10-3
v
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
AR As Required
BDI Battery Discharge Indicators
BWI Brush Wear Indicator
CE Communicator End
CRE Corrosive Environment
D/B Date Break
dbA Decibel "A" Scale
DE Drive End
ECM Electronic Control Module
ECN Engineering Change Notice
EEPROM Electrically Erasable Programmable
Read Only Memory
EPROM Electrically Programmable Read Only
Memory
FRE Freezer Environment
in. inches
LPG Liquefied Petroleum Gas
MAP Manifold Absolute Pressure
mm
millimeters
MSTS Microprocessor Spark Timing System
NPT National Pipe Threads
O/S Oversize
PTO Power Take Off
RPM Revolutions per Minute
S/N Serial Number
TMM Truck Management Module
UL Type D Diesel-Powered Safety Rating
UL Type DS Diesel-Powered Safety Rating
UL Type E Battery-Powered Safety Rating
UL Type EE Battery-Powered Safety Rating
UL Type ES Battery-Powered Safety Rating
UL Type G Gasoline-Powered Safety Rating
UL Type GS Gasoline-Powered Safety Rating
UL Type LP Gas-Powered Safety Rating
UL Type LPS LP Gas-Powered Safety Rating
U/S Undersize
UL Underwriters Laboratory
V Volts
vi
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This is the complete factory Parts manual for the Yale ERC 030 AG, ERC 030 BG, ERC 040 AG, ERC 040 BG (A814) 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 030 AG, ERC 030 BG, ERC 040 AG, ERC 040 BG (A814) 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 :
- ERC 030 AG
- ERC 030 BG
- ERC 040 AG
- ERC 040 BG
- (A814)
S/N:
- A814V-4056 INC. 3749
- 4021
- 4022
- 4027
Manual Covers:
- General Truck
- Electrical System
- Drive Unit
- Brake System
- Steering System
- Lifting Mechanism
- Hydraulic System
- Attachments And Header Hose Group
- Options
- Field Conversion Kits
- Numerical Index
- User Support Information
- And More......
File Format:
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe Reader & Win
NO waiting, All pages are printable. Yale ERC 030 AG, ERC 030 BG, ERC 040 AG, ERC 040 BG (A814) Lift Truck Parts Manual are saving you money on postage and packaging. It is great to have.
