Professional Documents
Culture Documents
ERC040-65GH
(A908)
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 for further information.
SECTIONS
1 GENERAL TRUCK
2 ELECTRICAL SYSTEM
3 DRIVE UNIT
4 STEERING SYSTEM
5 BRAKE SYSTEM
6 HYDRAULIC SYSTEM
12 OPTIONS
14 NUMERICAL INDEX
This Parts Manual is divided into 15 major sections which are listed above. Quick reference to these sections can
be made by placing the right thumb on the tab of the desired section, bending the book back and thumbing the pages
to the corresponding tab.
GENERAL INFORMATION
TABLE OF CONTENTS
DESCRIPTION PAGE
A
ACCELERATOR ASSEMBLY ......................................................................................................................... 1-60
AUXILIARY SECTION
HIGH FLOW - ELECTRONIC HYDRAULIC CONTROL VALVE (S/N A908N03342C →) ......................... 6-54
STANDARD FLOW - ELECTRONIC HYDRAULIC CONTROL VALVE (S/N A908N03342C →) .............. 6-52
B
BACK-UP ALARM ........................................................................................................................................... 12-12
BATTERY ROLLER TRAY, SLIDES, AND SPACERS ................................................................................... 12-14
BRAKE AND BACK-UP LIGHTS ..................................................................................................................... 12-2
BRAKE ASSEMBLY
→ S/N A908N04981D ................................................................................................................................ 5-6
S/N A908N04982D → ................................................................................................................................ 5-8
BRAKE PEDAL ................................................................................................................................................ 5-2
BRAKE SWITCH HARNESS ........................................................................................................................... 5-26
C
CARRIAGE
FOUR STAGE FULL FREE-LIFT ................................................................................................................ 10-22
SIX ROLLER - THREE STAGE FULL FREE-LIFT ...................................................................................... 8-30
SIX ROLLER - TWO STAGE FULL FREE-LIFT ......................................................................................... 9-18
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 7-13
CARRIAGE ASSEMBLY
HEAVY DUTY - THREE STAGE FULL FREE-LIFT .................................................................................... 8-32
HEAVY DUTY - TWO STAGE FULL FREE-LIFT ........................................................................................ 9-20
HEAVY DUTY - FOUR STAGE FULL FREE-LIFT ...................................................................................... 10-24
CONTACTOR
LINE ............................................................................................................................................................ 2-18
POWER STEERING ................................................................................................................................... 2-30
CONTACTOR PANEL
CONTACTOR (LINE AND POWER STEERING ......................................................................................... 2-16
CONTACTOR HYDRAULIC ........................................................................................................................ 2-32
CONTROL PANEL
CONTACTOR HYDRAULIC ........................................................................................................................ 2-12
TRACTION AND PUMP CONTROLLER .................................................................................................... 2-10
CONTROL VALVE .......................................................................................................................................... 13-2
CONTROL VALVE CONVERSION KITS ........................................................................................................ 13-12
COUNTERWEIGHT ........................................................................................................................................ 1-22
COVERS ......................................................................................................................................................... 1-6
COWL AND FLOOR PLATES ......................................................................................................................... 1-2
D
DASH DISPLAY .............................................................................................................................................. 2-8
DC TO DC CONVERTER
36/48 VOLT TO 12 VOLT ............................................................................................................................ 12-11
DIRECTIONAL CONTROL CONVERSION ..................................................................................................... 13-2
DRIVE AND REAR LIGHTS ............................................................................................................................ 12-6
DRIVE UNIT ASSEMBLY ................................................................................................................................ 3-2
DRIVE WHEEL AND TIRE .............................................................................................................................. 3-12
DESCRIPTION PAGE
E
ELECTRICAL CONVERSIONS ....................................................................................................................... 13-2
ELECTRICAL SYSTEM ................................................................................................................................... 2-2
ELECTRONIC HYDRAULICS (S/N A908N03342C →) ............................................................................. 2-6
ELECTRONIC CONTROL LEVERS
MINI-LEVER MODULE (FOUR FUNCTION) - DATE CODE 0744 ............................................................. 2-28
MINI-LEVER MODULES - DATE CODE 0724 ............................................................................................ 2-20
MINI-LEVER MODULES (FOUR FUNCTION) - DATE CODE 0725 THRU 0743 ....................................... 2-24
MINI-LEVER MODULES (THREE FUNCTION) - DATE CODE 0725 THRU 0743 ..................................... 2-22
MINI-LEVER MODULES (THREE FUNCTION) - DATE CODE 0744 ......................................................... 2-26
ELECTRONIC HYDRAULIC CONTROL VALVE ASSEMBLY
S/N A908N03342C → ................................................................................................................................ 6-48
ELECTRONIC HYDRAULIC CONTROL VALVE ATTACHING PARTS
S/N A908N03342C → ................................................................................................................................ 6-46
F
FENDER .......................................................................................................................................................... 13-4
FOOT DIRECTIONAL CONTROL PEDAL ...................................................................................................... 1-62
FORK
ERC 040-050 GH ........................................................................................................................................ 1-50
ERC 060-065 GH ........................................................................................................................................ 1-52
FREE-LIFT
FOUR STAGE FULL FREE-LIFT ................................................................................................................ 10-12
THREE STAGE FULL FREE-LIFT .............................................................................................................. 8-18
TWO STAGE FULL FREE-LIFT .................................................................................................................. 9-8
FREE-LIFT CYLINDER
FOUR STAGE FULL FREE-LIFT ................................................................................................................ 10-20
THREE STAGE FULL FREE-LIFT .............................................................................................................. 8-26
TWO STAGE FULL FREE-LIFT .................................................................................................................. 9-15
FULL SUSPENSION SEAT
ELECTRONIC HYDRAULICS (S/N A908N03342 ↔ 3/2006) .................................................................... 1-39
MANUAL HYDRAULICS (7/2005 ↔ 3/2006) ............................................................................................. 1-38
SHEET 1 OF 2 (→ 7/2005) ........................................................................................................................ 1-32
SHEET 2 OF 2 (→ 7/2005) ........................................................................................................................ 1-36
WITH AND WITHOUT ELECTRONIC CONTROLS (4/2006 →) ................................................................ 1-40
FULL SUSPENSION SWIVEL SEAT
ELECTRONIC HYDRAULICS (S/N A908N03342C →) ............................................................................. 1-46
G
GEAR PUMP ................................................................................................................................................... 4-12
H
HEADER HOSE
FOUR STAGE FULL FREE-LIFT - WITH WIRE TAKE-UP ......................................................................... 11-26
FOUR STAGE FULL FREE-LIFT - WITH HYDRAULIC TAKE-UP ............................................................. 11-30
THREE STAGE FULL FREE-LIFT .............................................................................................................. 11-22
TWO STAGE FULL FREE-LIFT .................................................................................................................. 11-18
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 11-14
DESCRIPTION PAGE
HOOD
ELECTRONIC HYDRAULICS (S/N A908N03342C →) ............................................................................. 1-16
MANUAL HYDRAULICS (→ S/N A908N03341C) ...................................................................................... 1-8
MANUAL HYDRAULICS (S/N A908N03342C →) ...................................................................................... 1-12
HOSE TAKE-UP
HYDRAULIC CONTROL VALVE
FOUR FUNCTION - MANUAL HYDRAULICS ............................................................................................ 6-42
THREE FUNCTION - MANUAL HYDRAULICS .......................................................................................... 6-38
HYDRAULIC CONTROL VALVE AND ATTACHING PARTS
MANUAL HYDRAULICS - SHEET 1 0F 2 ................................................................................................... 6-32
MANUAL HYDRAULICS - SHEET 2 0F 2 ................................................................................................... 6-36
HYDRAULIC FILTER
S/N A908N03342C → ................................................................................................................................ 6-60
HYDRAULIC GEAR PUMP
6/2005 → .................................................................................................................................................... 6-20
HYDRAULIC HAND LEVERS
MANUAL HYDRAULICS ............................................................................................................................. 6-28
HYDRAULIC PUMP
12 CC .......................................................................................................................................................... 6-13
19 CC (→ 7/2005) ...................................................................................................................................... 6-14
19 CC - LOW NOISE ................................................................................................................................... 6-16
HYDRAULIC PUMP MOTOR
AC ............................................................................................................................................................... 6-18
OPEN CONSTRUCTION - WITH BWI AND TEMPERATURE SENSOR ................................................... 6-22
OPEN CONSTRUCTION - WITH BWI AND TEMPERATURE SENSOR ................................................... 6-24
HYDRAULIC PUMP MOTOR MOUNT ............................................................................................................ 6-26
HYDRAULIC SUPPLY AND RETURN
ELECTRONIC HYDRAULICS (S/N A908N03342C →) ............................................................................. 6-10
MANUAL HYDRAULICS (→ 7/2005) ......................................................................................................... 6-2
MANUAL HYDRAULICS (7/2005 →) ......................................................................................................... 6-6
HYDRAULIC TANK AND ATTACHING PARTS
→ S/N A908N03341C ................................................................................................................................ 6-56
S/N A908N03342C → ................................................................................................................................ 6-58
I
INNER MAST
FOUR STAGE FULL FREE-LIFT ................................................................................................................ 10-8
THREE STAGE FULL FREE-LIFT .............................................................................................................. 8-10
TWO STAGE FULL FREE-LIFT .................................................................................................................. 9-4
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 7-4
INTEGRAL SIDE-SHIFT CARRIAGE
THREE STAGE FULL FREE-LIFT .............................................................................................................. 11-4
TWO AND FOUR STAGE FULL FREE-LIFT .............................................................................................. 11-6
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 11-2
INTEGRAL SIDE-SHIFT CYLINDER .............................................................................................................. 11-8
INTEGRAL SIDE-SHIFT HYDRAULIC HOSES
THREE STAGE FULL FREE-LIFT .............................................................................................................. 11-11
TWO AND FOUR STAGE FULL FREE-LIFT .............................................................................................. 11-12
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 11-10
DESCRIPTION PAGE
INTERMEDIATE 2 MAST
FOUR STAGE FULL FREE-LIFT ................................................................................................................ 10-4
INTERMEDIATE 3 MAST
FOUR STAGE FULL FREE-LIFT ................................................................................................................ 10-6
INTERMEDIATE MAST
THREE STAGE FULL FREE-LIFT .............................................................................................................. 8-6
J
JOYSTICK
S/N A908N03342C → ................................................................................................................................ 2-34
JOYSTICK LABELS
S/N A908N03342C → ................................................................................................................................ 1-56
L
LABELS ........................................................................................................................................................... 1-54
LIFT
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 7-6
LIFT CYLINDER
TWO STAGE LIMITED FREE-LIFT - ERC 040-050 GH ............................................................................. 7-9
TWO STAGE LIMITED FREE-LIFT - ERC 060-065 GH ............................................................................. 7-11
LIGHTS, LED BACK-UP AND BRAKE
4/2004 → .................................................................................................................................................... 12-4
LOAD BACKREST .......................................................................................................................................... 1-48
M
MAIN CYLINDER
LEFT HAND - TWO STAGE FULL FREE-LIFT ........................................................................................... 9-11
LEFT HAND - FOUR STAGE FULL FREE-LIFT ......................................................................................... 10-15
RIGHT HAND - TWO STAGE FULL FREE-LIFT ........................................................................................ 9-13
RIGHT HAND - FOUR STAGE FULL FREE-LIFT ...................................................................................... 10-18
THREE STAGE FULL FREE-LIFT .............................................................................................................. 8-22
MAIN LIFT
FOUR STAGE FULL FREE-LIFT ................................................................................................................ 10-10
THREE STAGE FULL FREE-LIFT .............................................................................................................. 8-14
TWO STAGE FULL FREE-LIFT .................................................................................................................. 9-6
MAIN SECTION
ELECTRONIC HYDRAULIC CONTROL VALVE (S/N A908N03342C →) ................................................. 6-50
MAST INSTALLATION .................................................................................................................................... 6-62
MAST TILT ...................................................................................................................................................... 13-2
MASTER CYLINDER ...................................................................................................................................... 5-4
MINI LEVER LABELS
S/N A908N03342C → ................................................................................................................................ 1-58
N
NON SUSPENSION SEAT
4/2006 → .................................................................................................................................................... 1-28
NON-SUSPENSION SEAT
→ 7/2005 .................................................................................................................................................... 1-24
MANUAL HYDRAULICS (7/2005 ↔ 3/2006) ............................................................................................. 1-26
DESCRIPTION PAGE
O
OUTER MAST
FOUR STAGE FULL FREE-LIFT ................................................................................................................ 10-2
THREE STAGE FULL FREE-LIFT .............................................................................................................. 8-2
TWO STAGE FULL FREE-LIFT .................................................................................................................. 9-2
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 7-2
OVERHEAD GUARD ...................................................................................................................................... 1-20
P
PARK BRAKE
SEAT ACTUATED ....................................................................................................................................... 5-10
PARK BRAKE LINKAGE
LEVER ACTUATED .................................................................................................................................... 5-12
SEAT ACTUATED (→ S/N A908V02782C) ............................................................................................... 5-16
SEAT ACTUATED (S/N A908V02783C ↔ S/N A908N06029E) ................................................................ 5-18
SEAT ACTUATED (S/N A908N06030E →) ............................................................................................... 5-22
S
SEAT BELT KITS ............................................................................................................................................ 13-13
SEMI-SUSPENSION SEAT
ELECTRONIC HYDRAULICS (S/N A908N03342C ↔ 4/2006) ................................................................. 1-43
MANUAL HYDRAULICS (7/2005 ↔ 3/2006) ............................................................................................. 1-42
WITH AND WITHOUT ELECTRONIC CONTROLS (4/2006 →) ................................................................ 1-44
SHIFT LEVER ................................................................................................................................................. 4-4
SPOT LIGHT ................................................................................................................................................... 12-10
STEER WHEEL AND TIRE ASSEMBLY ......................................................................................................... 4-20
STEERING AXLE ............................................................................................................................................ 4-16
OPTIONAL .................................................................................................................................................. 4-18
STEERING CONTROL UNIT .......................................................................................................................... 4-6
STEERING CYLINDER ................................................................................................................................... 4-10
STEERING HYDRAULICS .............................................................................................................................. 4-8
STEERING MOTOR ........................................................................................................................................ 4-14
STEERING POD ............................................................................................................................................. 4-2
STROBE LIGHT .............................................................................................................................................. 12-8
SUSPENSION SEAT
→ 7/2005 .................................................................................................................................................... 1-30
T
TILT CYLINDERS ............................................................................................................................................ 6-64
TRACTION MOTOR ........................................................................................................................................ 3-10
TRANSMISSION AND DIFFERENTIAL .......................................................................................................... 3-6
TUBE EXTENSION
W
WIDE TREAD KITS ......................................................................................................................................... 13-4
DESCRIPTION PAGE
WIRE HARNESS
ELECTRONIC HYDRAULIC CONTROL VALVES (S/N A908N03342C →) .............................................. 2-44
HOOD (S/N A908N03342C →) .................................................................................................................. 2-50
JOYSTICK (S/N A908N03342C →) ........................................................................................................... 2-51
LIGHT .......................................................................................................................................................... 2-46
MAIN (→ S/N A908V02782C) .................................................................................................................... 2-36
MAIN (S/N A908V02783C →) .................................................................................................................... 2-38
MAIN - WITH ELECTRONIC HYDRAULICS (S/N A908N03342C →) ....................................................... 2-40
OPERATOR PRESENCE - SHEET 1 OF 2 ................................................................................................ 2-52
OPERATOR PRESENCE - SHEET 2 OF 2 ................................................................................................ 2-56
PRESSURE SWITCH (4/2004 →) ............................................................................................................. 2-48
REAR LIGHTS (→ S/N A908N08692F) ..................................................................................................... 12-18
REAR LIGHTS (S/N A908N08693F →) ..................................................................................................... 12-20
SWITCH ...................................................................................................................................................... 12-17
TRACTION CUT-OUT (→ S/N A910N03903D) ......................................................................................... 12-22
TRACTION CUT-OUT (S/N A910N03904D →) ......................................................................................... 12-24
Listed below are abbreviations used in parts manuals to denote the following expressions:
spacer
TERM DEFINITION TERM DEFINITION
Amp Amperes FRE Freezer Environment
AR As Required in. inches
BDI Battery Discharge Indicators LPG Liquefied Petroleum Gas
BWI Brush Wear Indicator MAP Manifold Absolute Pressure
CE Communicator End mm millimeters
CRE Corrosive Environment MSTS Microprocessor Spark Timing System
D/B Date Break NPT National Pipe Threads
dbA Decibel "A" Scale O/S Oversize
DE Drive End PTO Power Take Off
ECH Empty Container Handler RPM Revolutions per Minute
ECH-3 Empty Container Handler - 3 High S/N Serial Number
Stacking TMM Truck Management Module
ECH-4 Empty Container Handler - 4 High UL Type D Diesel-Powered Safety Rating
Stacking
UL Type DS Diesel-Powered Safety Rating
ECH-5 Empty Container Handler - 5 High
Stacking UL Type E Battery-Powered Safety Rating
This parts manual describes and illustrates assemblies, The different constructions are indicated by keys and
subassemblies, and detail parts needed for service footnotes. The callouts correspond to descriptions
replacement. found on the next page.
1. Determine the function and application of the part 9. Quantities shown are for one assembly. The
required. Turn to the Sections Page. Choose the quantities of the subpart BEARING CAP are
general area of reference most likely to include the indicated as two and two. This means two per
part. CASE assembly.
2. Turn to the section you chose. Use the Section 10. Serial number breaks identify the most current
Table of Contents to determine the assembly parts information and are shown as follows:
which would normally contain the part required. → S/N A810N2639
Then locate the part on the assembly breakdown Indicates last serial number affected.
page. S/N A810N2640 →
Indicates the first serial number affected.
WHEN THE PART NUMBER IS NOT KNOWN S/N A810N1553 ↔ S/N A810N3291
AND THE NEXT HIGHER ASSEMBLY IS Indicates a range of serial numbers affected.
KNOWN:
ECN numbers for pending serial numbers are
3. Determine the assembly the required part is used shown to allow for the inclusion of the most current
on. Turn to the Table of Contents (Page i). parts information and are identified as follows:
→ S/N Pending Per ECN 63243
4. Locate the assembly the required part is used on
Indicates a pending serial number for last unit
and turn to the page indicated for that assembly.
affected.
Then locate the part on the assembly breakdown
S/N Pending Per ECN 63243 →
page.
Indicates a pending serial number for first unit
WHEN THE PART NUMBER IS KNOWN: affected.
5. Use the Numerical Index (Page 14-1) to find the Date breaks are used to indicate when a change
part number. Turn to the page listed and locate the occurred but a subsequent serial number break
part as indicated by the item number. was not recorded. This is an arbitrary date usually
based on the ECN release and are identified as
GENERAL: follows:
→ D/B 3/00
The assembly breakdowns include part numbers, Indicates that a change occurred sometime
descriptions, quantities required, keys and within that month for the item affected.
footnotes to help in selecting correct parts. D/B 3/00 →
Indicates that a change occurred sometime
6. Five periods in the PART NO. column (. . . . .)
within that month for the item affected.
indicate that the part is either Not Serviced
D/B 3/00 ↔ D/B 4/00
Separately or there is a reference to another figure.
Indicates a range of production dates of the item
A figure reference is denoted by a pointing hand
affected.
followed by a parts page number in the
DESCRIPTION column (F7A56) Contact your local dealer for Yale lift trucks for
serial number information for items with a ECN or
7. Keys are used to show two or more similar
a date break.
assemblies, RH and LH assembly parts, etc.
Select the appropriate key, "A", "B", "C", "D", or "E" ORDERING PARTS:
and the corresponding quantity column to find the
required parts. Two periods in the QTY column (..) When ordering replacement parts, give the unit serial
indicate that the part is not used for that assembly. number, part number, name of part and quantity
required.
8. Indented descriptions under the DESCRIPTION
column are used to indicate assemblies and For any further information on parts, service, or
subparts of assemblies. In the example on the ordering, consult your local dealer for Yale lift trucks.
NOTE: Serial Number breakdown is only for trucks built after 1994.
(1) and (2) The first letter and three numbers indicate the truck unit code.
(3) The second letter indicates the plant of manufacture.
(4) The four or five digit number indicates the production sequence number of the truck.
(5) The final letter indicates the year of manufacture starting with "A" in 1957, 1980, and 2003.
The letters "I", "O", and "Q" will not be used.
For pending serial numbers contact your local dealer for Yale lift trucks.
Parts referred to in this book as right or left hand parts are in accordance with the illustration above.
(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.
(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.
PUBLICATIONS
Every new lift truck is provided with an OPERATING MANUALS with complete replacement part
MANUAL. This manual has information that the identification, are available at a nominal fee from your
operator must know for inspection and operation of the Yale dealer to assist users in effectively maintaining
lift truck. Yale lift trucks in a safe, useful condition. See the list
below for information on ordering specific publications
SERVICE MAINTENANCE MANUALS, which provide for this model lift truck.
service and overhaul procedures, and PARTS
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:
Below is a numerical listing of Part Sheet Numbers found in this parts book and what page number they are on.
NOTES
1 GENERAL TRUCK
CONTENTS
SECTION 1
GENERAL TRUCK
DESCRIPTION PAGE
FOOTNOTES:
a 27.50 in. Battery Compartment d 36.73 in. Battery Compartment
b 30.94 in. Battery Compartment e → 7/2005
c 33.38 in. Battery Compartment f 7/2005 →
NOTES
COVERS
ITEM PART NO. DESCRIPTION QTY
1 505972586 Nut (Foldover) ..................................................................................................... 14
2 518791613 Capscrew ............................................................................................................ 3
2 449021003 Washer ............................................................................................................... 3
3 a 580014397 Plate (Manual Hydraulics With Low Hood) ......................................................... 1
3 a 580016056 Plate (Manual Hydraulics With High Hood) ........................................................ 1
4 c 580064531 Cover (Manual Hydraulics With Low Hood) ........................................................ 1
4 c 580064532 Cover (Manual Hydraulics With High Hood) ....................................................... 1
5 d 580064530 Cover (Electronic Hydraulics With Low Hood) .................................................... 1
5 d 580065082 Cover (Electronic Hydraulics With High Hood) ................................................... 1
6 520041817 Panel (End) (End) ............................................................................................... 2
6 520041892 Panel (Center) (Center) ...................................................................................... 1
7 520041863 Cover (With Lights) ............................................................................................. 2
7 520041863 Cover (Without Lights) ........................................................................................ 3
8 524139124 Dash Display ....................................................................................................... 1
9 505970553 Capscrew ............................................................................................................ 7
10 524137579 Liner .................................................................................................................... 1
11 580032373 Capscrew ............................................................................................................ 2
12 504226242 Washer ............................................................................................................... 2
13 449022016 Lockwasher ......................................................................................................... 2
14 449015014 Nut ...................................................................................................................... 2
15 520039887 Nut (Foldover) ..................................................................................................... 2
16 520039846 Screw .................................................................................................................. 2
17 b 504288726 Cover .................................................................................................................. 1
17 d 520049842 Cover .................................................................................................................. 1
18 504288725 Cover .................................................................................................................. 1
19 518803677 Nut ...................................................................................................................... 4
20 518803626 Cover .................................................................................................................. 1
21 518803696 Screw .................................................................................................................. 3
22 518803671 Trim ..................................................................................................................... 1
23 016103500 Washer ............................................................................................................... 3
24 580052727 Capscrew ............................................................................................................ 3
FOOTNOTES:
a → 7/2005 c 7/2005 →
b → S/N A908N03341C d S/N A908N03342C →
HOOD
MANUAL HYDRAULICS (→ S/N A908N03341C)
KEY:
A: 27.50 in. Battery Compartment
B: 30.94 in. Battery Compartment
C: 33.38 in. Battery Compartment
D: 36.73 in. Battery Compartment
QTY
ITEM PART NO. DESCRIPTION A B C D
1 c 524213286 Hood ......................................................................................... 1 .. .. ..
1 b 524213280 Hood ......................................................................................... 1 .. .. ..
1 c 524213287 Hood ......................................................................................... .. 1 .. ..
1 b 524213281 Hood ......................................................................................... .. 1 .. ..
1 c 524213288 Hood ......................................................................................... .. .. 1 ..
1 b 524213282 Hood ......................................................................................... .. .. 1 ..
1 c 524213289 Hood ......................................................................................... .. .. .. 1
1 b 524213283 Hood ......................................................................................... .. .. .. 1
2 504244784 Door .......................................................................................... 1 1 1 1
3 e 504236268 Screw ........................................................................................ 2 2 2 2
3 d 518790649 Screw ........................................................................................ 2 2 2 2
4 015026200 Lockwasher ............................................................................... 4 4 4 4
5 e 014936600 Nut ............................................................................................ 4 4 4 4
5 d 014936600 Nut ............................................................................................ 2 2 2 2
6 580043473 Hood Frame Wldmt ................................................................... 1 .. .. ..
6 580043474 Hood Frame Wldmt ................................................................... .. 1 .. ..
6 580043475 Hood Frame Wldmt ................................................................... .. .. 1 ..
6 580043476 Hood Frame Wldmt ................................................................... .. .. .. 1
7 518791665 Hinge (RH) ................................................................................ 1 1 1 1
8 518791603 Hinge (LH) ................................................................................ 1 1 1 1
9 518791655 Spring ....................................................................................... 2 2 2 2
10 518791613 Capscrew .................................................................................. 4 4 4 4
11 016103500 Washer ..................................................................................... 4 4 4 4
12 504231270 Nut ............................................................................................ 2 2 2 2
13 518791605 Pin ............................................................................................. 2 2 2 2
14 518791646 Capscrew .................................................................................. 2 2 2 2
15 501702904 Loctite ....................................................................................... AR AR AR AR
16 900014293 Capscrew .................................................................................. 4 4 4 4
17 909882404 Nut ............................................................................................ 4 4 4 4
18 449021006 Washer ..................................................................................... 3 3 3 3
19 016103700 Washer ..................................................................................... 6 6 6 6
20 449022013 Lockwasher ............................................................................... 4 4 4 4
21 580042617 Shaft ......................................................................................... 1 1 1 1
22 518808666 Spring ....................................................................................... 1 1 1 1
23 016110500 Washer ..................................................................................... 1 1 1 1
24 518797670 Spring ....................................................................................... 1 1 1 1
25 580042975 Handle ...................................................................................... 1 1 1 1
26 520045079 Pin ............................................................................................. 1 1 1 1
27 518797621 Plate .......................................................................................... 2 2 2 2
28 520045103 Gas Spring ................................................................................ 1 .. .. 1
28 520045102 Gas Spring ................................................................................ .. 1 1 ..
29 504223299 Clamp ....................................................................................... 1 1 1 1
30 580014197 Bar ............................................................................................ 1 1 1 1
HOOD
MANUAL HYDRAULICS (→ S/N A908N03341C)
KEY:
A: 27.50 in. Battery Compartment
B: 30.94 in. Battery Compartment
C: 33.38 in. Battery Compartment
D: 36.73 in. Battery Compartment
QTY
ITEM PART NO. DESCRIPTION A B C D
31 449001023 Capscrew .................................................................................. 2 2 2 2
31 449001302 Capscrew (Optional) ................................................................. 2 2 2 2
32 449015044 Nut ............................................................................................ 2 2 2 2
33 520045149 Rod ........................................................................................... 1 1 1 1
34 518790606 Spring ....................................................................................... 1 1 1 1
35 518790609 Spacer ...................................................................................... 1 1 1 1
36 518809668 Clevis ........................................................................................ 1 1 1 1
37 518790656 Knob ......................................................................................... 1 1 1 1
38 014972700 Nut ............................................................................................ 1 1 1 1
39 061277800 Washer ..................................................................................... 2 2 2 2
40 015416200 Cotter Pin .................................................................................. 2 2 2 2
41 504231270 Nut ............................................................................................ 1 1 1 1
42 932200909 Capscrew .................................................................................. 1 1 1 1
43 520044831 Spacer ...................................................................................... 4 4 1 4
44 504235245 Handle ...................................................................................... 1 1 1 1
45 449001121 Capscrew .................................................................................. 2 2 2 2
46 449015002 Nut ............................................................................................ 2 2 2 2
47 e 449022018 Washer ..................................................................................... 2 2 2 2
47 d 449022018 Washer ..................................................................................... 4 4 1 4
48 e 580047752 Latch ......................................................................................... 1 1 1 1
48 d 580047811 Latch ......................................................................................... 1 1 1 1
49 f 518790660 Wire Harness ............................................................................ 1 1 1 1
50 f 312850042 Strap Clamp .............................................................................. 5 5 5 5
51 f 518790699 Grommet ................................................................................... 1 1 1 1
52 021676700 E-Ring ....................................................................................... 1 1 1 1
53 504228276 Bushing ..................................................................................... 2 2 2 2
54 518808617 Link ........................................................................................... 1 1 1 1
55 518809671 Collar ........................................................................................ 1 1 1 1
56 504223295 Spacer ...................................................................................... AR AR AR AR
57 504071785 Washer ..................................................................................... 4 4 4 4
58 502398907 Washer ..................................................................................... 4 4 4 4
59 504239227 Pin ............................................................................................. 1 1 1 1
60 d 518791654 Bracket Wldmt .......................................................................... 1 1 1 1
61 d 519609816 Capscrew .................................................................................. 2 2 2 2
62 d 520037836 Bracket ...................................................................................... 1 1 1 1
63 d 931013904 Capscrew .................................................................................. 2 2 2 2
64 d 449022016 Lockwasher ............................................................................... 2 2 2 2
65 d 518797663 Spacer ...................................................................................... 2 2 2 2
66 d 059863600 Capscrew .................................................................................. 2 2 2 2
67 d 449001040 Capscrew .................................................................................. 2 2 2 2
68 580001698 Washer ..................................................................................... 2 2 2 2
69 016110000 Washer ..................................................................................... AR AR AR AR
70 910792100 Clip ............................................................................................ 1 1 1 1
HOOD
MANUAL HYDRAULICS (→ S/N A908N03341C)
KEY:
A: 27.50 in. Battery Compartment
B: 30.94 in. Battery Compartment
C: 33.38 in. Battery Compartment
D: 36.73 in. Battery Compartment
QTY
ITEM PART NO. DESCRIPTION A B C D
71 505977534 Rivet .......................................................................................... 2 2 2 2
72 016103200 Washer ..................................................................................... 2 2 2 2
73 580014829 Washer ..................................................................................... 2 2 2 2
74 520044831 Spacer ...................................................................................... 2 2 2 2
75 504229298 Nut ............................................................................................ 2 2 2 2
a 015040600 Lockwasher ............................................................................... 1 1 1 1
FOOTNOTES:
a Not Illustrated d With Raised Hood
b Optional, Without Doors e Without Raised Hood
c With Flip-up Doors f Without Seat Brake
HOOD
MANUAL HYDRAULICS (S/N A908N03342C →)
KEY:
A: 27.50 in. Battery Compartment
B: 30.94 in. Battery Compartment
C: 33.38 in. Battery Compartment
D: 36.73 in. Battery Compartment
QTY
ITEM PART NO. DESCRIPTION A B C D
1 580042975 Handle ...................................................................................... 1 1 1 1
2 580052727 Capscrew .................................................................................. 1 1 1 1
3 524240815 Hood ......................................................................................... 1 .. .. ..
3 524240816 Hood ......................................................................................... .. 1 .. ..
3 524240817 Hood ......................................................................................... .. .. 1 ..
3 524240818 Hood ......................................................................................... .. .. .. 1
4 580068361 Grommet ................................................................................... 1 1 1 1
5 900014293 Capscrew .................................................................................. 4 4 4 4
6 504071785 Washer ..................................................................................... 4 4 4 4
7 520044831 Spacer ...................................................................................... 4 4 4 4
8 580064737 Wire Harness (Hood) (FP14288 [Page 2-50])......................... 1 1 1 1
9 504228276 Bushing ..................................................................................... 2 2 2 2
10 016110500 Washer ..................................................................................... 2 2 2 2
11 021676700 E-Ring ....................................................................................... 3 3 3 3
12 518797670 Spring ....................................................................................... 1 1 1 1
13 580042617 Shaft ......................................................................................... 1 1 1 1
14 015914400 Snap Ring ................................................................................. 2 2 2 2
15 518808666 Spring ....................................................................................... 1 1 1 1
16 520045079 Pin ............................................................................................. 1 1 1 1
17 518808617 Link ........................................................................................... 1 1 1 1
18 518809671 Collar ........................................................................................ 1 1 1 1
19 b 059716300 Capscrew .................................................................................. 2 2 2 2
20 518797663 Spacer ...................................................................................... 1 1 1 1
21 016103700 Washer ..................................................................................... 6 6 6 6
22 015026200 Lockwasher ............................................................................... 4 4 4 4
23 014936600 Nut ............................................................................................ 4 4 4 4
24 c 504236268 Screw ........................................................................................ 2 2 2 2
24 b 518790649 Screw ........................................................................................ 2 2 2 2
25 518797621 Plate .......................................................................................... 2 2 2 2
26 c 580047752 Latch ......................................................................................... 1 1 1 1
26 b 580047811 Latch ......................................................................................... 1 1 1 1
27 449022013 Lockwasher ............................................................................... 4 4 4 4
28 449001040 Capscrew .................................................................................. 2 2 2 2
29 312850042 Strap Clamp .............................................................................. 5 5 5 5
30 449021003 Washer ..................................................................................... 1 1 1 1
31 504231270 Nut ............................................................................................ 2 2 2 2
32 580064386 Hood Frame Wldmt ................................................................... 1 .. .. ..
32 580064383 Hood Frame Wldmt ................................................................... .. 1 .. ..
32 580064387 Hood Frame Wldmt ................................................................... .. .. 1 ..
32 580064384 Hood Frame Wldmt ................................................................... .. .. .. 1
33 501729901 Capscrew .................................................................................. 2 2 2 2
34 524183344 Bracket ...................................................................................... 1 1 1 1
35 909882404 Nut ............................................................................................ 4 4 4 4
HOOD
MANUAL HYDRAULICS (S/N A908N03342C →)
KEY:
A: 27.50 in. Battery Compartment
B: 30.94 in. Battery Compartment
C: 33.38 in. Battery Compartment
D: 36.73 in. Battery Compartment
QTY
ITEM PART NO. DESCRIPTION A B C D
36 449015044 Nut ............................................................................................ 2 2 2 2
37 504223295 Spacer ...................................................................................... AR AR AR AR
38 016110000 Washer ..................................................................................... AR AR AR AR
39 504223299 Clamp ....................................................................................... 1 1 1 1
40 449021006 Washer ..................................................................................... 3 3 3 3
41 449001023 Capscrew .................................................................................. 2 2 2 2
42 580014197 Bar ............................................................................................ 1 1 1 1
43 502398907 Washer ..................................................................................... 4 4 4 4
44 c 580064651 Bracket Wldmt .......................................................................... 1 1 1 1
44 b 580064665 Bracket Wldmt .......................................................................... 1 1 1 1
45 015416200 Cotter Pin .................................................................................. 2 2 2 2
46 504239227 Pin ............................................................................................. 1 1 1 1
47 d 520045104 Gas Spring ................................................................................ 1 .. .. ..
47 e 580084179 Gas Spring (With Spacer) ......................................................... 1 .. .. ..
47 d 520045102 Gas Spring ................................................................................ .. 1 .. ..
47 e 580084180 Gas Spring (With Spacer) ......................................................... .. 1 .. ..
47 d 520045102 Gas Spring ................................................................................ .. .. 1 ..
47 e 580084180 Gas Spring (With Spacer) ......................................................... .. .. 1 ..
47 d 520045103 Gas Spring ................................................................................ .. .. .. 1
47 e 580084182 Gas Spring (With Spacer) ......................................................... .. .. .. 1
48 520045149 Rod ........................................................................................... 1 1 1 1
49 014972700 Nut ............................................................................................ 1 1 1 1
50 518809668 Clevis ........................................................................................ 1 1 1 1
51 932200909 Capscrew .................................................................................. 1 1 1 1
52 518790656 Knob ......................................................................................... 1 1 1 1
53 061277800 Washer ..................................................................................... 2 2 2 2
54 518790609 Spacer ...................................................................................... 1 1 1 1
55 518790606 Spring ....................................................................................... 1 1 1 1
a 910792100 Clip (Memo Clip) ....................................................................... 1 1 1 1
a 505977534 Rivet (Memo Clip) ..................................................................... 2 2 2 2
a 016103200 Washer (Memo Clip) ................................................................. 2 2 2 2
a 015040600 Lockwasher ............................................................................... 1 1 1 1
FOOTNOTES:
a Not Illustrated d → 8/2007
b With Raised Hood e PENDING PER ECN 103236 →
c Without Raised Hood
NOTES
HOOD
ELECTRONIC HYDRAULICS (S/N A908N03342C →)
KEY:
A: 27.50 in. Battery Compartment
B: 33.38 in. Battery Compartment
QTY
ITEM PART NO. DESCRIPTION A B
1 520045149 Rod ............................................................................................................. 1 1
2 580064737 Wire Harness (Hood) (FP14288 [Page 2-50])........................................... 1 1
3 b 520045104 Gas Spring ................................................................................................. 1 ..
3 c 580084179 Gas Spring (With Spacer) .......................................................................... 1 ..
3 b 520045102 Gas Spring ................................................................................................. .. 1
3 c 580084180 Gas Spring (With Spacer) .......................................................................... .. 1
4 501702904 Loctite ......................................................................................................... AR AR
5 014972700 Nut .............................................................................................................. 1 1
6 518809668 Clevis ......................................................................................................... 1 1
7 932200909 Capscrew ................................................................................................... 1 1
8 518790656 Knob ........................................................................................................... 1 1
9 518790609 Spacer ........................................................................................................ 1 1
10 518790606 Spring ......................................................................................................... 1 1
11 061277800 Washer ....................................................................................................... 2 2
12 504231270 Nut .............................................................................................................. 1 1
13 312850042 Strap Clamp ............................................................................................... 4 4
14 524242358 Hood ........................................................................................................... 1 ..
14 524242360 Hood ........................................................................................................... .. 1
15 580068361 Grommet .................................................................................................... 1 1
16 580063784 Hood Frame Wldmt .................................................................................... 1 ..
16 580063786 Hood Frame Wldmt .................................................................................... .. 1
17 900014293 Capscrew ................................................................................................... 4 4
18 504071785 Washer ....................................................................................................... 4 4
19 502398907 Washer ....................................................................................................... 4 4
20 909882404 Nut .............................................................................................................. 4 4
21 504228276 Bushing ...................................................................................................... 2 2
22 016110500 Washer ....................................................................................................... 2 2
23 021676700 E-Ring ........................................................................................................ 3 3
24 580042617 Shaft ........................................................................................................... 1 1
25 015914400 Snap Ring .................................................................................................. 2 2
26 580042975 Handle ........................................................................................................ 1 1
27 520045079 Pin .............................................................................................................. 1 1
28 518808617 Link ............................................................................................................. 1 1
29 518808666 Spring ......................................................................................................... 1 1
30 518809671 Collar .......................................................................................................... 1 1
31 518797670 Spring ......................................................................................................... 1 1
32 580047752 Latch (Without Battery Rollers Or Slide) .................................................... 1 1
32 580047811 Latch (With Battery Rollers Or Slide) ......................................................... 1 1
33 518797621 Plate ........................................................................................................... 2 2
34 059863600 Capscrew (With Battery Rollers Or Slide) .................................................. 2 2
35 015026200 Lockwasher ................................................................................................ 4 4
36 016103700 Washer ....................................................................................................... 6 6
37 518797663 Spacer (With Battery Rollers Or Slide) ....................................................... 2 2
38 014936600 Nut (Without Battery Rollers Or Slide) ....................................................... 2 2
39 504236268 Screw (Without Battery Rollers Or Slide) ................................................... 2 2
HOOD
ELECTRONIC HYDRAULICS (S/N A908N03342C →)
KEY:
A: 27.50 in. Battery Compartment
B: 33.38 in. Battery Compartment
QTY
ITEM PART NO. DESCRIPTION A B
39 518790649 Screw (With Battery Rollers Or Slide) ........................................................ 2 2
40 449022013 Lockwasher ................................................................................................ 4 4
41 449001040 Capscrew ................................................................................................... 2 2
42 520044831 Spacer ........................................................................................................ 4 4
43 449015044 Nut .............................................................................................................. 2 2
44 504223295 Spacer ........................................................................................................ AR AR
45 016110000 Washer ....................................................................................................... AR AR
46 504223299 Clamp ......................................................................................................... 1 1
47 449021006 Washer ....................................................................................................... 3 3
48 449001023 Capscrew ................................................................................................... 2 2
49 580014197 Bar .............................................................................................................. 1 1
50 580064666 Bracket Wldmt ............................................................................................ 1 1
51 580032373 Capscrew ................................................................................................... 3 3
52 449015014 Nut .............................................................................................................. 3 3
53 504226242 Washer ....................................................................................................... 3 3
54 504239227 Pin .............................................................................................................. 1 1
55 015416200 Cotter Pin ................................................................................................... 2 2
56 524183344 Bracket ....................................................................................................... 2 2
57 501729901 Capscrew ................................................................................................... 2 2
a 015040600 Lockwasher ................................................................................................ 1 1
FOOTNOTES:
a Not Illustrated c PENDING PER ECN 103236 →
b → 8/2007
NOTES
OVERHEAD GUARD
ITEM PART NO. DESCRIPTION QTY
1 af 504300751 Overhead Guard ................................................................................................. 1
1 bf 504300752 Overhead Guard ................................................................................................. 1
1 cf 504300753 Overhead Guard ................................................................................................. 1
1 df 504300754 Overhead Guard ................................................................................................. 1
1 ae 524144330 Overhead Guard ................................................................................................. 1
1 be 524144331 Overhead Guard ................................................................................................. 1
1 ce 524144332 Overhead Guard ................................................................................................. 1
1 de 524144333 Overhead Guard ................................................................................................. 1
2 504241783 Plug ..................................................................................................................... 4
3 504241782 Plug ..................................................................................................................... 16
4 504060774 Screw .................................................................................................................. 2
5 580056526 Handle (Grab) ..................................................................................................... 1
6 520053804 Nut ...................................................................................................................... 10
7 449021010 Washer ............................................................................................................... 10
8 311321035 Capscrew ............................................................................................................ 4
9 932731912 Capscrew ............................................................................................................ 6
10 520053810 Washer (Black) (Optional) .................................................................................. 6
FOOTNOTES:
a 27.50 in. Battery Compartment d 36.73 in. Battery Compartment
b 30.94 in. Battery Compartment e Raised Height
c 33.38 in. Battery Compartment f Standard Height
COUNTERWEIGHT
ITEM PART NO. DESCRIPTION QTY
1 a 524185784 Counterweight ..................................................................................................... 1
1 b 524185785 Counterweight ..................................................................................................... 1
1 c 524185786 Counterweight ..................................................................................................... 1
2 504241221 Cover .............................................................................................................. 1
3 504224291 Tow Pin .......................................................................................................... 1
4 449001351 Capscrew ....................................................................................................... 2
5 504233271 Washer ........................................................................................................... 4
6 061278400 Washer ........................................................................................................... 2
7 015027000 Lockwasher .................................................................................................... 2
8 014717600 Capscrew ....................................................................................................... 2
9 909882405 Nut .................................................................................................................. 2
10 504224270 Foam Tape ..................................................................................................... AR
10 580047833 Foam Tape ..................................................................................................... AR
11 016104000 Washer ........................................................................................................... 2
12 900005218 Capscrew ....................................................................................................... 2
13 015026400 Lockwasher .................................................................................................... 2
d 016100800 Shim ............................................................................................................... AR
FOOTNOTES:
a ERC 040 GH, ERC 050 GH (27.50, 30.94, 33.38, c ERC 050 GH, ERC 060 GH, ERC 065 GH (27.50,
and 39.97 in. Battery Compartment) 33.38, 36.73 in. Battery Compartment)
b ERC 050 GH (30.94 in. Battery Compartment) d Not Illustrated
NON-SUSPENSION SEAT
(→ 7/2005)
FOOTNOTES:
a Not Illustrated
NOTES
FOOTNOTES:
a Not Illustrated
SUSPENSION SEAT
(→ 7/2005)
FOOTNOTES:
a Fabric b Vinyl
FOOTNOTES:
a Not Illustrated
NOTES
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Not Illustrated
SEMI-SUSPENSION SEAT
WITH AND WITHOUT ELECTRONIC CONTROLS (4/2006 →)
KEY:
A: Cloth
B: Vinyl
QTY
ITEM PART NO. DESCRIPTION A B
1 580070837 Seat Assy (Vinyl) (With E-Hydraulic Arm) .................................................. .. 1
1 580070838 Seat Assy (Cloth) (With E-Hydraulic Arm) ................................................. 1 ..
1 580071143 Seat Assy (Vinyl) (With Left and Right Hip Restraints) .............................. .. 1
1 580071144 Seat Assy (Cloth) (With Left and Right Hip Restraints) .............................. 1 ..
1 520041836 Kit-Shock Absorber ................................................................................ 1 1
1 520041644 Kit-Spring ............................................................................................... 1 1
2 580057311 Seat Cushion (Back Cushion) (Cloth) .................................................... 1 ..
2 580057305 Seat Cushion (Back Cushion) (Vinyl) .................................................... .. 1
3 580049897 Hip Restraint (LH) .................................................................................. 1 1
4 580049898 Hip Restraint (RH) ................................................................................. 1 1
5 580062078 Kit-Seat Belt ........................................................................................... 1 1
6 580056919 Seat Cushion (Cloth) ............................................................................. 1 ..
6 580056942 Seat Cushion (Vinyl) .............................................................................. .. 1
7 580010704 Kit-Seat Rail ........................................................................................... 1 1
8 518793606 Switch .................................................................................................... 1 1
8 505968533 Connector .......................................................................................... 1 1
8 505968540 Connector (Secondary Lock) ............................................................. 1 1
8 505972554 Terminal ............................................................................................ 2 1
8 580022887 E-Ring ............................................................................................... 1 1
9 580080127 Wire Harness (With E-Hydraulic Arm) ................................................... 1 1
9 580059816 Wire Harness (With Left and Right Hip Restraints) ............................... 1 1
10 580049900 Knob ...................................................................................................... 1 1
11 520041822 Cover ..................................................................................................... 1 1
12 520041852 Information Case ................................................................................... 1 1
13 a 524302630 Operator Manual .................................................................................... 1 1
a 580078361 Foam ...................................................................................................... 1 1
15 a 900008245 Stud ....................................................................................................... 4 4
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Not Illustrated c 3/2006 →
b → 3/2006
LOAD BACKREST
KEY:
A: ERC40-50GH
B: ERC60-65GH
QTY
ITEM PART NO. DESCRIPTION A B
1 504242751 Load Backrest (38.5 in.) ............................................................................. 1 ..
1 a 504246704 Load Backrest (38 in.) ................................................................................ .. 1
2 505960578 Capscrew ................................................................................................... 4 4
3 061278200 Washer ....................................................................................................... 4 4
3 504233271 Washer (Optional) ...................................................................................... 4 4
4 909882405 Nut .............................................................................................................. 4 4
FOOTNOTES:
a For Polished Forks with Full Bottom Taper
FORK
ERC 040-050 GH
KEY:
A: ERC 040 GH (100 mm x 40 mm [4.00 in. x 1.50 in.])
B: ERC 050 GH (100 mm x 45 mm [4.00 in. x 1.75 in.])
C: ERC 050 GH (125 mm x 45 mm [5.00 in. x 1.75 in.])
QTY
ITEM PART NO. DESCRIPTION A B C
1 d 504111201 Fork (36 in.) ....................................................................................... 2 .. ..
1 d 504111202 Fork (42 in.) ....................................................................................... 2 .. ..
1 d 504111203 Fork (48 in.) ....................................................................................... 2 .. ..
1 d 504111204 Fork (54 in.) ....................................................................................... 2 .. ..
1 d 504110201 Fork (36 in.) ....................................................................................... .. 2 ..
1 d 504110203 Fork (48 in.) ....................................................................................... .. 2 ..
1 d 504110204 Fork (54 in.) ....................................................................................... .. 2 ..
1 b 518648602 Fork (42 in.) ....................................................................................... 2 .. ..
1 b 518648603 Fork (48 in.) ....................................................................................... 2 .. ..
1 b 518649602 Fork (42 in.) ....................................................................................... .. .. 2
1 b 518649603 Fork (48 in.) ....................................................................................... .. .. 2
1 a 505861502 Fork (42 in.) ....................................................................................... 2 .. ..
1 a 505861503 Fork (48 in.) ....................................................................................... 2 .. ..
1 a 518647602 Fork (42 in.) ....................................................................................... .. .. 2
1 a 518647603 Fork (48 in.) ....................................................................................... .. .. 2
2 505850500 Lever ............................................................................................. 1 1 1
3 505854501 Pin ................................................................................................. 1 1 1
4 505852500 Washer .......................................................................................... 1 1 1
5 505853500 Spring ............................................................................................ 1 1 1
6 505851500 Roll Pin .......................................................................................... 1 1 1
7 580034999 Knob .............................................................................................. 1 1 1
8 580035000 Pin ................................................................................................. 1 1 1
9 580026749 Spring ............................................................................................ 1 1 1
10 c 580016727 Washer .......................................................................................... 1 1 1
11 c 580016728 Wedge Band ................................................................................. 1 1 1
580035002 Kit-Latch ............................................................................................ 2 2 2
FOOTNOTES:
a Polished Fork with Full Bottom Taper c Refer to Latch Kit Installation Instruction
b Polished Fork with Full Top Taper d Standard Taper
FORK
ERC 060-065 GH
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.])
QTY
ITEM PART NO. DESCRIPTION A B C
1 503998701 Fork (36 in.) ....................................................................................... 2 .. ..
1 503998702 Fork (42 in.) ....................................................................................... 2 .. ..
1 503998703 Fork (48 in.) ....................................................................................... 2 .. ..
1 503998704 Fork (54 in.) ....................................................................................... 2 .. ..
1 505862501 Fork (36 in.) ....................................................................................... .. 2 ..
1 505862502 Fork (42 in.) ....................................................................................... .. 2 ..
1 505862503 Fork (48 in.) ....................................................................................... .. 2 ..
1 505862504 Fork (54 in.) ....................................................................................... .. 2 ..
1 518650601 Fork (36 in.) ....................................................................................... .. .. 2
1 518650602 Fork (42 in.) ....................................................................................... .. .. 2
1 518650603 Fork (48 in.) ....................................................................................... .. .. 2
1 518650604 Fork (54 in.) ....................................................................................... .. .. 2
2 505850500 Lever ............................................................................................. 1 1 1
3 504236227 Pin ................................................................................................. 1 1 1
4 505852500 Washer .......................................................................................... 1 1 1
5 505853500 Spring ............................................................................................ 1 1 1
6 505851500 Roll Pin .............................................................................................. 1 1 1
7 580034999 Knob .................................................................................................. 1 1 1
8 580035011 Pin ..................................................................................................... 1 1 1
9 580026751 Spring ................................................................................................ 1 1 1
10 a 580016727 Washer .............................................................................................. 1 1 1
11 a 580016736 Wedge Band ...................................................................................... 1 1 1
580035017 Kit-Latch ............................................................................................ 2 2 2
FOOTNOTES:
a Refer to Latch Kit Installation Instruction
LABELS
ITEM PART NO. DESCRIPTION QTY
1 580058821 Label (Mast Warning) ......................................................................................... 2
2 518807649 Label (Battery Disconnect) ................................................................................. 1
3 504231248 Label (No Riders) ................................................................................................ 2
4 519798601 Label (Hoist Handle) ........................................................................................... 1
5 524162256 Label (Patents and Trademarks) ........................................................................ 1
6 752953403 Label (Overhead Guard) ..................................................................................... 1
7 504231230 Label (Battery Spacer) ........................................................................................ 1
8 519798602 Label (Tilt Handle) .............................................................................................. 1
9 912331302 Label (Yale) ........................................................................................................ 2
9 258984900 Label (Yale) (Counterweight) .............................................................................. 1
10 504229273 Label (Operator Warning) ................................................................................... 1
11 504231265 Label (Nameplate Tag) ....................................................................................... 1
12 504231215 Label (Mast Warning) ......................................................................................... 1
13 504231296 Label (Operator Restraint) .................................................................................. 2
14 d 504229214 Label (Park Brake Warning) ............................................................................... 1
14 ae 504575274 Label (Park Brake) .............................................................................................. 1
14 ac 504574279 Label (Park Brake) .............................................................................................. 1
15 e 504231252 Label (Pinch Point) ............................................................................................. 3
15 b 504231252 Label (Pinch Point) ............................................................................................. 4
16 504575235 Label (UL Type EE) ............................................................................................ 2
16 751435300 Label (Type ES) .................................................................................................. 2
17 520041868 Label (Hood Latch) ............................................................................................. 1
18 504231234 Label (Freezer) ................................................................................................... 2
18 580013408 Label (Corrosion) ................................................................................................ 2
19 519798604 Label (Auxiliary Function - Side-Shift) ................................................................ 1
20 518808611 Label (Prop Rod) ................................................................................................ 1
21 504266703 Nameplate .......................................................................................................... 1
22 504266716 Cover .................................................................................................................. 1
23 520045143 Rivet .................................................................................................................... 4
24 518803661 Washer ............................................................................................................... 4
25 504955200 Label (Tilt Column) ............................................................................................. 1
26 524196756 Label (AC Power) ............................................................................................... 2
504300703 Kit-Label .............................................................................................................. 1
FOOTNOTES:
a With Park Brake Alarm d Without Park Brake Alarm
b With Seat Brake e Without Seat Brake Switch
c With Seat Brake Switch
JOYSTICK LABELS
(S/N A908N03342C →)
ACCELERATOR ASSEMBLY
ITEM PART NO. DESCRIPTION QTY
1 524137528 Foot Directional Control Pedal (FP14018 [Page 1-62])..................................... 1
1 a 505974543 Accelerator Pedal ............................................................................................... 1
2 a 505974506 Pedal .............................................................................................................. 1
3 a 504228276 Bushing .......................................................................................................... 2
4 a 505974595 Pin .................................................................................................................. 1
5 a 504228259 Rubber Pad .................................................................................................... 1
6 580060429 Bracket ................................................................................................................ 1
7 505977519 Tube Assy ........................................................................................................... 1
8 449001233 Capscrew ............................................................................................................ 1
9 449021006 Washer ............................................................................................................... 2
10 449022013 Lockwasher ......................................................................................................... 2
11 449015044 Nut ...................................................................................................................... 2
12 449001134 Capscrew ............................................................................................................ 2
13 580061110 Stop .................................................................................................................... 2
14 501702904 Loctite ................................................................................................................. AR
15 504228295 Switch ................................................................................................................. 1
15 580072128 Switch (Accelerator Control) (Alternate Part) ...................................................... 1
16 014862000 Screw .................................................................................................................. 2
17 014936000 Nut ...................................................................................................................... 2
18 502137903 Lockwasher ......................................................................................................... 2
19 016103200 Washer ............................................................................................................... 4
20 580010427 Insulator .............................................................................................................. 1
21 449007040 Screw .................................................................................................................. 2
22 449022016 Lockwasher ......................................................................................................... 3
23 449021001 Washer ............................................................................................................... 2
24 449015014 Nut ...................................................................................................................... 4
25 505974576 Spring ................................................................................................................. 1
26 505966574 Sensor ................................................................................................................ 1
27 449001052 Capscrew ............................................................................................................ 1
28 312850042 Strap Clamp ........................................................................................................ 1
29 504057758 Terminal .............................................................................................................. 1
b 940102903 Washer ............................................................................................................... 1
b 580003615 Nut ...................................................................................................................... 1
FOOTNOTES:
a Forward/Reverse b Not Illustrated
NOTES
2 ELECTRICAL SYSTEM
CONTENTS
SECTION 2
ELECTRICAL SYSTEM
DESCRIPTION PAGE
CONTACTOR
LINE ............................................................................................................................................................ 2-18
POWER STEERING ................................................................................................................................... 2-30
CONTACTOR PANEL
CONTACTOR (LINE AND POWER STEERING ......................................................................................... 2-16
CONTACTOR HYDRAULIC ........................................................................................................................ 2-32
CONTROL PANEL
CONTACTOR HYDRAULIC ........................................................................................................................ 2-12
TRACTION AND PUMP CONTROLLER .................................................................................................... 2-10
DASH DISPLAY .............................................................................................................................................. 2-8
ELECTRICAL SYSTEM ................................................................................................................................... 2-2
ELECTRONIC HYDRAULICS (S/N A908N03342C →) ............................................................................. 2-6
ELECTRONIC CONTROL LEVERS
MINI-LEVER MODULE (FOUR FUNCTION) - DATE CODE 0744 ............................................................. 2-28
MINI-LEVER MODULES - DATE CODE 0724 ............................................................................................ 2-20
MINI-LEVER MODULES (FOUR FUNCTION) - DATE CODE 0725 THRU 0743 ....................................... 2-24
MINI-LEVER MODULES (THREE FUNCTION) - DATE CODE 0725 THRU 0743 ..................................... 2-22
MINI-LEVER MODULES (THREE FUNCTION) - DATE CODE 0744 ......................................................... 2-26
JOYSTICK
S/N A908N03342C → ................................................................................................................................ 2-34
WIRE HARNESS
ELECTRONIC HYDRAULIC CONTROL VALVES (S/N A908N03342C →) .............................................. 2-44
HOOD (S/N A908N03342C →) .................................................................................................................. 2-50
JOYSTICK (S/N A908N03342C →) ........................................................................................................... 2-51
LIGHT .......................................................................................................................................................... 2-46
MAIN (→ S/N A908V02782C) .................................................................................................................... 2-36
MAIN (S/N A908V02783C →) .................................................................................................................... 2-38
MAIN - WITH ELECTRONIC HYDRAULICS (S/N A908N03342C →) ....................................................... 2-40
OPERATOR PRESENCE - SHEET 1 OF 2 ................................................................................................ 2-52
OPERATOR PRESENCE - SHEET 2 OF 2 ................................................................................................ 2-56
PRESSURE SWITCH (4/2004 →) ............................................................................................................. 2-48
ELECTRICAL SYSTEM
ITEM PART NO. DESCRIPTION QTY
1 d 580040447 Wire Harness (Main) (Main) (FP13994 [Page 2-36])......................................... 1
1 e 580056317 Wire Harness (Main) (FP15269 [Page 2-38]).................................................... 1
2 518793603 Strap ................................................................................................................... 1
3 518793632 Clamp ................................................................................................................. 1
4 449001013 Capscrew (Not Illustrated) .................................................................................. 5
5 449001014 Screw .................................................................................................................. 2
6 449021001 Washer ............................................................................................................... 3
7 518798685 Wire Harness (Dash) .......................................................................................... 1
8 518798642 Terminal Block .................................................................................................... 2
9 449022016 Lockwasher ......................................................................................................... 6
10 504070790 Strap Clamp ........................................................................................................ AR
11 518803628 Capscrew ............................................................................................................ 2
12 518807623 Washer ............................................................................................................... 2
13 449022022 Lockwasher ......................................................................................................... 2
14 937100902 Nut ...................................................................................................................... 2
15 580026968 Wire Harness (Control Valve Switch) (Hydraulic Levers) ................................... 1
16 580010571 Connector (End Cap) .......................................................................................... 1
17 449015014 Nut ...................................................................................................................... 1
18 520044880 Clamp ................................................................................................................. 2
19 580044884 Resistor ............................................................................................................... 2
20 a 580044746 Power Cable (UT) (A/C or D/C) .......................................................................... 2
20 c 580044754 Power Cable (UT) (A/C or D/C) .......................................................................... 2
20 b 580044762 Power Cable (UT) (A/C or D/C) .......................................................................... 2
21 a 580044747 Power Cable (VT) (A/C or D/C) .......................................................................... 2
21 c 580044755 Power Cable (VT) (A/C or D/C) .......................................................................... 2
21 b 580044763 Power Cable (VT) (A/C or D/C) .......................................................................... 2
22 a 580044748 Power Cable (WT) (A/C or D/C) ......................................................................... 2
22 c 580044756 Power Cable (WT) (A/C or D/C) ......................................................................... 2
22 b 580044764 Power Cable (WT) (A/C or D/C) ......................................................................... 2
23 a 580044749 Power Cable (UP) (A/C or D/C) .......................................................................... 1
23 c 580044757 Power Cable (UP) (A/C) ..................................................................................... 1
23 b 580044766 Power Cable (UP) (A/C) ..................................................................................... 1
24 a 580044750 Power Cable (VP) (A/C) ...................................................................................... 1
24 a 580044752 Power Cable (PM2) (D/C) ................................................................................... 1
24 c 580044758 Power Cable (PM2) (A/C) ................................................................................... 1
24 b 580044767 Power Cable (PM2) (A/C) ................................................................................... 1
24 c 580044760 Power Cable (PM2) (D/C) ................................................................................... 1
25 a 580044751 Power Cable (WP) (A/C) ..................................................................................... 1
25 c 580044759 Power Cable (PM1) (A/C) ................................................................................... 1
25 b 580044769 Power Cable (PM2) (D/C) ................................................................................... 1
25 b 580044768 Power Cable (PM1) (A/C) ................................................................................... 1
25 a 580044753 Power Cable (PM1) (D/C) ................................................................................... 1
25 c 580044761 Power Cable (PM1) (D/C) ................................................................................... 1
25 b 580044770 Power Cable (PM1) (D/C) ................................................................................... 1
26 580044572 Battery Connector and Cable (48 Volt) ............................................................... 1
26 514268309 Battery Connector .......................................................................................... 1
26 504236237 Cable .............................................................................................................. AR
26 520045094 Cable .............................................................................................................. AR
26 0620533AM E-Ring ............................................................................................................ 1
26 580044571 E-Ring ............................................................................................................ 1
26 580044573 Battery Connector and Cable (36 Volt) ............................................................... 1
ELECTRICAL SYSTEM
ITEM PART NO. DESCRIPTION QTY
26 514268301 Battery Connector (Gray) ............................................................................... 1
26 504236237 Cable .............................................................................................................. AR
26 520045094 Cable .............................................................................................................. AR
26 0620533AM E-Ring ............................................................................................................ 1
26 580044571 E-Ring ............................................................................................................ 1
27 d 580018832 Horn (36/48 Volt) ................................................................................................ 1
27 e 580039661 Horn .................................................................................................................... 1
28 449001386 Capscrew ............................................................................................................ 2
29 449001202 Capscrew ............................................................................................................ 2
30 449022018 Washer ............................................................................................................... 2
31 449021003 Washer ............................................................................................................... 6
32 449015002 Nut ...................................................................................................................... 2
33 580021375 Ignition Switch ..................................................................................................... 1
34 580008325 Key ................................................................................................................. 1
35 449001134 Capscrew ............................................................................................................ 1
36 504230271 Nut ...................................................................................................................... 1
37 504226242 Washer ............................................................................................................... 1
38 580041029 Wire Harness (Light) (FP13995 [Page 2-46]).................................................... 1
FOOTNOTES:
a 1015/933 Wheel Base d → S/N A908V02782C
b 700 Wheel Base e S/N A908V02783C →
c 847/786 Wheel Base
NOTES
ELECTRICAL SYSTEM
ELECTRONIC HYDRAULICS (S/N A908N03342C →)
FOOTNOTES:
a → S/N A908NO05707D b S/N A908NO05708D →
FOOTNOTES:
a With E-Hydraulic Software c S/N A908N05444D →
b → S/N A908N05443D
NOTES
CONTROL PANEL
TRACTION AND PUMP CONTROLLER
KEY:
A: Traction Controller
B: Pump Controller
QTY
ITEM PART NO. DESCRIPTION A B
1 580046724 Heatsink ..................................................................................................... 1 1
2 449021001 Washer ....................................................................................................... 16 14
3 449022016 Lockwasher ................................................................................................ 16 14
4 932201905 Capscrew ................................................................................................... 8 8
5 580046725 Control Panel ............................................................................................. 1 1
6 580011651 Washer (Copper) ........................................................................................ 2 2
7 518796606 Fuse (40 Amp) ........................................................................................... 1 1
8 518796653 Label (Fuse, 40 Amp) ................................................................................. 1 1
9 580034404 Module ....................................................................................................... 1 1
10 312850042 Strap Clamp ............................................................................................... 1 1
11 449022016 Lockwasher ................................................................................................ 2 2
12 449001013 Capscrew ................................................................................................... 2 2
13 580046726 Spacer ........................................................................................................ 2 2
14 580047743 Fan ............................................................................................................. 2 2
15 580046727 Screw ......................................................................................................... 8 8
16 580051609 Guard ......................................................................................................... 2 2
17 580032413 Power Cable ............................................................................................... .. 1
18 580047581 Power Cable ............................................................................................... .. 1
19 580051869 Power Cable ............................................................................................... 1 ..
20 580047580 Controller (Pump) ....................................................................................... .. 1
21 580058322 Controller .................................................................................................... 1 ..
22 580081662 Bracket ....................................................................................................... 1 1
23 a 580034980 Controller (Master) ..................................................................................... 1 ..
23 f 580044985 Controller (Master) ..................................................................................... 1 ..
23 b 580054360 Controller (Master) ..................................................................................... 1 1
23 c 580072504 Controller (Master) ..................................................................................... 1 1
23 d 580079567 Controller (Master) ..................................................................................... 1 1
23 e 580085262 Controller (Master) ..................................................................................... 1 1
23 g 580094434 Controller (Master) ..................................................................................... 1 1
24 504226242 Washer ....................................................................................................... 2 2
25 449022016 Lockwasher ................................................................................................ 2 2
26 449001134 Capscrew ................................................................................................... 2 2
27 449022018 Washer ....................................................................................................... 3 3
28 449001170 Capscrew ................................................................................................... 3 3
29 449021003 Washer ....................................................................................................... 3 3
30 932201908 Capscrew ................................................................................................... 6 4
504223239 Silicone Grease .......................................................................................... AR AR
FOOTNOTES:
a → S/N A908V02154B e S/N A908N08358F ↔ S/N A908N09485F
b S/N A908N02171C ↔ S/N A908N05186D f S/N A908V02155B ↔ S/N A908N02171C
c S/N A908N05187D ↔ S/N A908N05597D g S/N A908N09486F →
d S/N A908N05598D ↔ S/N A908N08357F
CONTROL PANEL
CONTACTOR HYDRAULIC
FOOTNOTES:
a → 11/2003 e S/N A908N05187D ↔ S/N A908N05597D
b → S/N A908N08357F f S/N A908V02155B ↔ S/N A908N05186D
c → S/N A908V02154B g S/N A908V02230B →
d → S/N A908V02229B h S/N A908N05598D →
NOTES
CONTACTOR PANEL
CONTACTOR (LINE AND POWER STEERING
CONTACTOR
LINE
NOTES
FOOTNOTES:
a Kit Includes: 1 Interlock Rocker (must be used in c Kit Includes: 1 Momentary Interlock Switch Plug, 1
combination with a Momentary Interlock Switch), 1 Gasket (parts are NSS)
Gasket, 4 Screws (parts are NSS) d Kit Includes: 1 Momentary Switch, 1 Lockwasher,
b Kit Includes: 1 Mini-Lever Plug, 1 Gasket (parts are 1 Gasket, 1 Nut (parts are NSS)
NSS)
FOOTNOTES:
a Kit Includes: 1 Interlock Mini-Lever (must be used c Kit Includes: 1 Momentary Switch, 1 Lockwasher,
in combination with a Momentary Interlock Switch), 1 Gasket, 1 Nut (parts are NSS)
1 Gasket, 4 Screws (parts are NSS) d Kit Includes: 1 Plain Mini-Lever, 1 Gasket, 4
b Kit Includes: 1 Momentary Switch Hole Plug, 1 Screws (parts are NSS)
Gasket (parts are NSS)
FOOTNOTES:
a Kit Includes: 1 Interlock Rocker (must be used in c Kit Includes: 1 Momentary Interlock Switch Plug, 1
combination with a Momentary Interlock Switch), 1 Gasket (parts are NSS)
Gasket, 4 Screws (parts are NSS) d Kit Includes: 1 Momentary Switch, 1 Lockwasher,
b Kit Includes: 1 Mini-Lever Plug, 1 Gasket (parts are 1 Gasket, 1 Nut (parts are NSS)
NSS)
FOOTNOTES:
a Kit Includes: 1 Momentary Switch Hole Plug, 1 b Kit Includes: 1 Plain Mini-Lever, 1 Gasket, 4
Gasket (parts are NSS) Screws (parts are NSS)
NOTES
CONTACTOR PANEL
CONTACTOR HYDRAULIC
JOYSTICK
(S/N A908N03342C →)
WIRE HARNESS
MAIN (→ S/N A908V02782C)
WIRE HARNESS
MAIN (S/N A908V02783C →)
WIRE HARNESS
MAIN – WITH ELECTRONIC HYDRAULICS (S/N A908N03342C →)
WIRE HARNESS
MAIN – WITH ELECTRONIC HYDRAULICS (S/N A908N03342C →)
WIRE HARNESS
MAIN – WITH ELECTRONIC HYDRAULICS (S/N A908N03342C →)
WIRE HARNESS
ELECTRONIC HYDRAULIC CONTROL VALVES (S/N A908N03342C →)
NOTES
WIRE HARNESS
PRESSURE SWITCH (4/2004 →)
WIRE HARNESS
OPERATOR PRESENCE – SHEET 1 OF 2
WIRE HARNESS
OPERATOR PRESENCE – SHEET 1 OF 2
NOTES
WIRE HARNESS
OPERATOR PRESENCE – SHEET 2 OF 2
WIRE HARNESS
OPERATOR PRESENCE – SHEET 2 OF 2
3 DRIVE UNIT
CONTENTS
SECTION 3
DRIVE UNIT
DESCRIPTION PAGE
FOOTNOTES:
a Use Adhesive 520042831 As Required b Use Lubricant 504226218 As Required
NOTES
FOOTNOTES:
a → 3/2006 b 3/2006 →
NOTES
TRACTION MOTOR
ITEM PART NO. DESCRIPTION QTY
580043343 Traction Motor (36/48 Volt) ................................................................................. 1
1 580047487 Retaining Ring ................................................................................................ 1
2 580047489 Spring ............................................................................................................. 1
3 580047490 Seal ................................................................................................................ 1
4 580047491 Pin .................................................................................................................. 2
5 580047492 Seal ................................................................................................................ 2
6 580047493 O-Ring ............................................................................................................ 1
7 580047494 Ball Bearing .................................................................................................... 1
8 580047495 Connector ....................................................................................................... 1
9 580047496 Nut .................................................................................................................. 12
10 580047497 Housing .......................................................................................................... 1
11 580047535 Washer ........................................................................................................... 3
12 ..... Nameplate ...................................................................................................... 1
13 931013904 Capscrew ....................................................................................................... 3
14 580074668 End Bell, DE ................................................................................................... 1
15 580063683 End Bell, NDE ................................................................................................ 1
16 580047500 O-Ring ............................................................................................................ 1
17 449022019 Lockwasher .................................................................................................... 5
18 449022016 Lockwasher .................................................................................................... 12
19 580035673 Capscrew ....................................................................................................... 3
20 580032670 Capscrew ....................................................................................................... 2
21 932201908 Capscrew ....................................................................................................... 12
22 ..... Terminal Block ................................................................................................ 3
23 ..... Cover .............................................................................................................. 3
24 580047506 Nut .................................................................................................................. 3
25 ..... Terminal Flag ................................................................................................. 3
26 580047507 Rubber Mount ................................................................................................. 1
27 580047508 Bracket ........................................................................................................... 1
28 580047509 Bracket ........................................................................................................... 1
29 580047510 Air Guide ........................................................................................................ 1
30 a 580047511 Ball Bearing .................................................................................................... 1
31 580047512 Rotor ............................................................................................................... 1
32 580047503 Tube ............................................................................................................... AR
33 580047501 Strap Clamp ................................................................................................... AR
34 580085283 Cap (Grease) .................................................................................................. 1
35 580047502 Sleeve (Not Illustrated) ................................................................................... AR
580051039 Kit-Motor Band .................................................................................................... 1
580077888 Kit-Terminal ........................................................................................................ 1
FOOTNOTES:
a Includes Sensor
KEY:
A: ERC40-50GH (21 x 7 x 15)
B: ERC60-65GH (21 x 8 x 15)
C: ERC40-50GH (21 x 7 x 15 Wide)
D: ERC60-65GH (21 x 8 x 15 Wide)
E: ERC40-65GH
QTY
ITEM PART NO. DESCRIPTION A B C D E
1 b 520038891 Wheel and Tire ................................................................. 2 .. .. .. ..
1 b 520038832 Wheel and Tire ................................................................. .. 2 .. .. ..
1 b 520038862 Wheel and Tire ................................................................. .. .. 2 .. ..
1 b 520038822 Wheel and Tire ................................................................. .. .. .. 2 ..
1 c 518803683 Wheel and Tire ................................................................. 2 .. .. .. ..
1 c 518803603 Wheel and Tire ................................................................. .. 2 .. .. ..
1 c 518803654 Wheel and Tire ................................................................. .. .. 2 .. ..
1 c 518803667 Wheel and Tire ................................................................. .. .. .. 2 ..
1 d 520038890 Wheel and Tire (21 x 7 x 15) ............................................ .. .. .. .. 2
1 d 520038829 Wheel and Tire (21 x 7 x 15 Wide) ................................... .. .. .. .. 2
1 a 520038892 Wheel and Tire ................................................................. 2 .. .. .. ..
1 a 520038823 Wheel and Tire ................................................................. .. 2 .. .. ..
1 a 520038881 Wheel and Tire ................................................................. .. .. 2 .. ..
1 a 520038874 Wheel and Tire ................................................................. .. .. .. 2 ..
2 518803694 Wheel ............................................................................... 2 .. .. .. 2
2 518803689 Wheel ............................................................................... .. 2 .. .. ..
2 518803627 Wheel ............................................................................... .. .. 2 2 2
3 b 505965590 Cushion Tire ..................................................................... 2 .. 2 .. ..
3 b 505965537 Cushion Tire ..................................................................... .. 2 .. 2 ..
3 c 505965541 Cushion Tire ..................................................................... 2 .. 2 .. ..
3 c 505965553 Cushion Tire ..................................................................... .. 2 .. 2 ..
3 d 505965532 Cushion Tire (21 x 7 x 15 Standard and Wide) ................ .. .. .. .. 2
KEY:
A: ERC40-50GH (21 x 7 x 15)
B: ERC60-65GH (21 x 8 x 15)
C: ERC40-50GH (21 x 7 x 15 Wide)
D: ERC60-65GH (21 x 8 x 15 Wide)
E: ERC40-65GH
QTY
ITEM PART NO. DESCRIPTION A B C D E
3 a 505965501 Cushion Tire ..................................................................... 2 .. 2 .. ..
3 a 505965516 Cushion Tire ..................................................................... .. 2 .. 2 ..
FOOTNOTES:
a Electric Compound, Lugged Tread c Non-Marking Compound, Smooth Tread
b Electric Compound, Smooth Tread d Polyurethane Compound, Smooth Tread
NOTES
4 STEERING SYSTEM
CONTENTS
SECTION 4
STEERING SYSTEM
DESCRIPTION PAGE
STEERING POD
ITEM PART NO. DESCRIPTION QTY
1 505977597 Bracket ........................................................................................................... 1
2 518796642 Latch ............................................................................................................... 1
3 505977589 Pin .................................................................................................................. 1
4 015416200 Cotter Pin ....................................................................................................... 1
5 580045338 Steering Wheel (With Spinner Knob) ............................................................. 1
5 580046399 Steering Wheel (Without Spinner Knob) ........................................................ 1
5 580058078 Knob ........................................................................................................... 1
6 a 580065002 Horn Button .................................................................................................... 1
7 580001077 Steering Pump (FP14003 [Page 4-6])........................................................... 1
8 059719100 Capscrew ....................................................................................................... 4
9 016104000 Washer ........................................................................................................... 4
10 015026400 Lockwasher .................................................................................................... 4
11 580023576 Steering Column ............................................................................................. 1
12 518794682 Nut .............................................................................................................. 1
13 580000284 Kit-Horn ...................................................................................................... 1
13 580041282 Rivet ....................................................................................................... 2
14 580028072 Sensor ........................................................................................................ 1
15 518807647 Lockwasher .................................................................................................... 4
16 504574275 Lever (Dual) (Forward/Reverse) (FP14002 [Page 4-4])................................ 1
17 505977550 Plate (Forward/Reverse) ................................................................................ 1
18 580025784 Switch (Forward/Reverse) .............................................................................. 2
19 932200902 Capscrew ....................................................................................................... 4
20 504225202 Screw (Forward/Reverse) .............................................................................. 4
21 500552902 Lockwasher (Forward/Reverse) ..................................................................... 8
22 032643500 Nut (Forward/Reverse) ................................................................................... 4
23 449001170 Capscrew (Forward/Reverse) ........................................................................ 4
24 449022018 Washer (Forward/Reverse) ............................................................................ 4
25 449021003 Washer (Forward/Reverse) ............................................................................ 4
26 580027136 Wire Harness (Shift Lever) (Forward/Reverse) .............................................. 1
27 520037801 Spring ............................................................................................................. 1
28 505977562 Shaft ............................................................................................................... 1
29 505977538 Plate ............................................................................................................... 2
30 449001014 Screw ............................................................................................................. 4
31 449022016 Lockwasher .................................................................................................... 4
32 580022964 Capscrew ....................................................................................................... 1
33 449015098 Nut .................................................................................................................. 1
34 505977566 Handle Grip (Latch) ........................................................................................ 1
35 504235265 Capscrew ....................................................................................................... 2
36 505977509 Rod ................................................................................................................. 1
37 504574273 Spring ............................................................................................................. 1
38 449021002 Washer ........................................................................................................... 1
39 504574274 Screw ............................................................................................................. 6
40 504503703 Cover .............................................................................................................. 1
41 504504703 Cover .............................................................................................................. 1
42 520045057 Plug ................................................................................................................ 1
43 580034132 Static Strap ..................................................................................................... 1
FOOTNOTES:
a Service with Horn Replacement Kit 524276062
SHIFT LEVER
ITEM PART NO. DESCRIPTION QTY
504574275 Lever ................................................................................................................... 1
1 504574276 Base ............................................................................................................... 1
2 504574277 Link ................................................................................................................. 1
3 505977569 Crank .............................................................................................................. 1
4 505977542 Crank .............................................................................................................. 1
5 505977598 Lever .............................................................................................................. 2
6 505977590 Screw ............................................................................................................. 4
7 449015112 Locknut ........................................................................................................... 4
8 580022130 Spring ............................................................................................................. 2
9 505977516 Bolt ................................................................................................................. 2
10 449015002 Nut .................................................................................................................. 2
11 505977500 Spring Washer ................................................................................................ 4
12 580054547 Bracket ................................................................................................................ 1
13 015026400 Lockwasher ......................................................................................................... 1
14 014970900 Nut ...................................................................................................................... 1
STEERING HYDRAULICS
ITEM PART NO. DESCRIPTION QTY
1 518793656 Hose Assy ........................................................................................................... 1
2 502056906 Clamp ................................................................................................................. 1
3 518807656 Hose Assy ........................................................................................................... 1
4 013405200 Fitting .................................................................................................................. 1
5 520043880 Hose Assy ........................................................................................................... 2
6 502625905 Hose Assy ........................................................................................................... 1
7 019905000 Nut ...................................................................................................................... 1
8 055485700 Fitting .................................................................................................................. 2
8 052645200 O-Ring ............................................................................................................ 1
9 504228214 Hose ................................................................................................................... 1
10 062159500 Clamp ................................................................................................................. 2
11 723689100 Fitting .................................................................................................................. 1
11 052645400 O-Ring ............................................................................................................ 1
12 312850032 Strap Clamp ........................................................................................................ 2
13 518796622 Bracket ................................................................................................................ 1
14 ..... Steering Cylinder (FP14005 [Page 4-10])......................................................... 1
15 520045096 Hose Assy (27.55 in., 30.94 in., 33.38 in. Battery Compartment) ....................... 2
15 518793665 Hose Assy (39.36 in. Battery Compartment) ...................................................... 2
16 580043481 Steering Motor (36/48V) (FP14008 [Page 4-14])............................................... 1
17 580000127 Gear Pump (FP14006 [Page 4-12])................................................................... 1
18 580043502 Bracket Wldmt .................................................................................................... 1
19 080143400 Motor Mount ........................................................................................................ 1
20 449001050 Capscrew ............................................................................................................ 1
21 518796686 Washer ............................................................................................................... 2
22 504226242 Washer ............................................................................................................... 2
23 449022016 Lockwasher ......................................................................................................... 2
24 057780800 Fitting .................................................................................................................. 1
24 052645300 O-Ring ............................................................................................................ 1
25 449015014 Nut ...................................................................................................................... 1
26 449001013 Capscrew ............................................................................................................ 2
27 504223274 O-Ring ................................................................................................................ 1
28 055486700 Capscrew ............................................................................................................ 2
29 015026400 Lockwasher ......................................................................................................... 2
30 501729901 Capscrew ............................................................................................................ 2
31 449022013 Lockwasher ......................................................................................................... 2
32 449015044 Nut ...................................................................................................................... 2
33 504228208 Bracket ................................................................................................................ 2
34 502056907 Clamp ................................................................................................................. 1
35 504228261 Strip Seal (Rubber) ............................................................................................. 2
FOOTNOTES:
a → S/N A908N03647D b S/N A908N03648D →
NOTES
GEAR PUMP
ITEM PART NO. DESCRIPTION QTY
580000127 Gear Pump ......................................................................................................... 1
1 580000821 Screw ............................................................................................................. 8
2 519249804 Kit-Gasket ....................................................................................................... 1
3 131635419 Needle Bearing ............................................................................................... 4
4 503144800 Snap Ring ....................................................................................................... 2
5 515685804 Gear ............................................................................................................... 3
6 504226234 Drive Shaft ...................................................................................................... 1
7 515686846 Drive Shaft ...................................................................................................... 1
8 515689803 Pin .................................................................................................................. 2
9 519729801 Plug ................................................................................................................ 1
10 506395589 Key ................................................................................................................. 2
STEERING MOTOR
ITEM PART NO. DESCRIPTION QTY
1 580043481 Steering Motor .................................................................................................... 1
STEERING AXLE
ITEM PART NO. DESCRIPTION QTY
1 504227280 Steering Axle (Frame) ......................................................................................... 1
2 065267300 Nut ...................................................................................................................... 2
3 580011755 Spindle (RH) ....................................................................................................... 1
3 580011756 Spindle (LH) ........................................................................................................ 1
4 ..... Steering Cylinder (FP14005 [Page 4-10])......................................................... 1
5 311323023 Capscrew ............................................................................................................ 4
6 015918200 Snap Ring ........................................................................................................... 4
7 580052360 Pin ....................................................................................................................... 2
8 504224271 Boot .................................................................................................................... 2
9 062159700 Clamp ................................................................................................................. 2
10 502056904 Clamp (Hose) ...................................................................................................... 2
11 504224219 Tie Rod ............................................................................................................... 2
11 504224264 Bushing .......................................................................................................... 1
12 015418400 Cotter Pin ............................................................................................................ 2
13 022784400 Grease Fitting ..................................................................................................... 2
14 931014904 Capscrew ............................................................................................................ 6
15 504224285 Bearing Cap ........................................................................................................ 2
16 504224222 Shim (0.005 in.) .................................................................................................. AR
16 504224232 Shim (0.007 in.) .................................................................................................. AR
16 504224292 Shim (0.020 in.) .................................................................................................. AR
17 504225236 O-Ring ................................................................................................................ 2
18 065001000 Bearing Cone ...................................................................................................... 2
18 065000900 Bearing Cup ........................................................................................................ 2
19 504224242 Seal ..................................................................................................................... 2
20 502029903 Bearing Cup ........................................................................................................ 4
20 502029902 Bearing Cone ...................................................................................................... 2
21 015418600 Cotter Pin ............................................................................................................ 2
22 504227283 Cap ..................................................................................................................... 2
23 580010477 Nut ...................................................................................................................... 2
24 580010476 Washer ............................................................................................................... 2
25 ..... Tire Assembly (FP14011 [Page 4-20]).............................................................. 2
26 504224217 Wear Sleeve ....................................................................................................... 2
27 504224218 Seal ..................................................................................................................... 2
28 909882405 Nut ...................................................................................................................... 4
29 449021010 Washer ............................................................................................................... 8
30 504224298 Seal ..................................................................................................................... 2
31 504224231 Wear Sleeve ....................................................................................................... 2
32 059695500 Bearing Cup ........................................................................................................ 2
32 059695600 Bearing Cone ...................................................................................................... 2
33 504224266 Plug ..................................................................................................................... 2
34 504224214 Plate .................................................................................................................... 2
35 502565903 Capscrew ............................................................................................................ 4
36 504224240 Rubber Mount ..................................................................................................... 2
STEERING AXLE
OPTIONAL
KEY:
A: ERC40-50GH (16 x 5 x 10.5)
B: ERC40-65GH (16 x 6 x 10.5)
QTY
ITEM PART NO. DESCRIPTION A B
1 b 580010817 Wheel and Tire ........................................................................................... 2 ..
1 b 580010818 Wheel and Tire ........................................................................................... .. 2
1 c 580010816 Wheel and Tire ........................................................................................... .. 2
1 c 580081160 Wheel and Tire ........................................................................................... 2 ..
1 d 580010821 Wheel and Tire ........................................................................................... .. 2
1 a 580010819 Wheel and Tire ........................................................................................... 2 ..
1 a 580010820 Wheel and Tire ........................................................................................... .. 2
2 580010474 Wheel ......................................................................................................... 2 2
3 b 504227292 Cushion Tire ............................................................................................... 2 ..
3 b 504227279 Cushion Tire ............................................................................................... .. 2
3 c 504227259 Cushion Tire ............................................................................................... .. 2
3 c 580080843 Cushion Tire ............................................................................................... 2 ..
3 d 504227206 Cushion Tire ............................................................................................... .. 2
3 a 504227238 Cushion Tire ............................................................................................... 2 ..
3 a 504227223 Cushion Tire ............................................................................................... .. 2
FOOTNOTES:
a Electric Compound, Lugged Tread c Non-Marking Compound, Smooth Tread
b Electric Compound, Smooth Tread d Polyurethane Compound, Smooth Tread
5 BRAKE SYSTEM
CONTENTS
SECTION 5
BRAKE SYSTEM
DESCRIPTION PAGE
BRAKE ASSEMBLY
→ S/N A908N04981D ................................................................................................................................ 5-6
S/N A908N04982D → ................................................................................................................................ 5-8
BRAKE PEDAL ................................................................................................................................................ 5-2
BRAKE SWITCH HARNESS ........................................................................................................................... 5-26
MASTER CYLINDER ...................................................................................................................................... 5-4
PARK BRAKE
SEAT ACTUATED ....................................................................................................................................... 5-10
PARK BRAKE LINKAGE
LEVER ACTUATED .................................................................................................................................... 5-12
SEAT ACTUATED (→ S/N A908V02782C) ............................................................................................... 5-16
SEAT ACTUATED (S/N A908V02783C ↔ S/N A908N06029E) ................................................................ 5-18
SEAT ACTUATED (S/N A908N06030E →) ............................................................................................... 5-22
BRAKE PEDAL
ITEM PART NO. DESCRIPTION QTY
1 520046880 Brake Pedal ........................................................................................................ 1
2 504224226 Bushing .......................................................................................................... 2
3 449022013 Lockwasher ......................................................................................................... 2
4 518795619 Tube Assy ........................................................................................................... 1
5 502398908 Washer ............................................................................................................... 1
6 449001310 Capscrew ............................................................................................................ 1
7 504225240 Nut ...................................................................................................................... 1
8 449001302 Capscrew ............................................................................................................ 1
9 449015044 Nut ...................................................................................................................... 3
10 505963537 Master Cylinder (FP14013 [Page 5-4]).............................................................. 1
11 449001302 Capscrew ............................................................................................................ 2
12 505966598 Spring ................................................................................................................. 1
13 580008780 Bolt ...................................................................................................................... 1
14 449021006 Washer ............................................................................................................... 2
15 449015098 Nut ...................................................................................................................... 1
16 505972532 Pressure Switch .................................................................................................. 1
17 505966570 Tube Assy ........................................................................................................... 1
18 a 580001623 Tube Assy ........................................................................................................... 1
18 b 580082352 Tube Assy ........................................................................................................... 2
19 900001201 Pad ..................................................................................................................... 1
20 502079902 Fitting .................................................................................................................. 1
21 013376100 Fitting .................................................................................................................. 1
22 a 580001624 Tube Assy ........................................................................................................... 1
22 b 580070486 Tube Assy ........................................................................................................... 1
23 580033689 Bracket (Relay) ................................................................................................... 1
24 449001121 Capscrew ............................................................................................................ 1
25 580017101 Washer ............................................................................................................... 2
26 449022018 Washer ............................................................................................................... 1
27 449015002 Nut ...................................................................................................................... 1
28 580008812 Relay (12 Volt) .................................................................................................... 1
29 502632907 Screw .................................................................................................................. 2
30 016103100 Washer ............................................................................................................... 2
31 015027700 Lockwasher ......................................................................................................... 2
32 021197300 Nut ...................................................................................................................... 2
33 504070790 Strap Clamp ........................................................................................................ 4
34 580007783 Splice .................................................................................................................. 1
35 505968565 Heat Shrink ......................................................................................................... 1
36 580049058 Wire Harness (FP14753 [Page 5-26])............................................................... 1
FOOTNOTES:
a → 7/2005 b 7/2005 →
MASTER CYLINDER
ITEM PART NO. DESCRIPTION QTY
505963537 Master Cylinder ................................................................................................... 1
1 505963544 Piston ............................................................................................................. 1
2 505963540 Pin .................................................................................................................. 1
3 505963519 Reservoir ........................................................................................................ 1
4 505963583 Cap ............................................................................................................. 1
5 505964540 Push Rod ........................................................................................................ 1
6 505964578 Dust Cover ..................................................................................................... 1
7 505964586 Lockwasher .................................................................................................... 1
8 505964597 Snap Ring ....................................................................................................... 1
9 505964577 Clevis .............................................................................................................. 1
10 505963565 Piston ............................................................................................................. 1
11 ..... Seal ................................................................................................................ 2
12 ..... Seal ................................................................................................................ 2
505963564 Kit-Seal ............................................................................................................... 1
BRAKE ASSEMBLY
(→ S/N A908N04981D)
KEY:
A: Right Hand
B: Left Hand
QTY
ITEM PART NO. DESCRIPTION A B
580021710 Brake Assembly ......................................................................................... 1 ..
580021716 Brake Assembly ......................................................................................... .. 1
1 505963500 Wheel Cylinder ...................................................................................... 1 1
2 505963578 Kit-Repair Wheel Cylinder ................................................................. 1 1
2 936302302 Kit-Repair Wheel Cylinder ............................................................. 1 1
3 900488834 Bleeder Screw ................................................................................... 1 1
4 900488835 Cap .................................................................................................... 1 1
5 ..... Plug ................................................................................................... 1 1
6 900488827 Cover ..................................................................................................... 1 1
7 580059825 Kit-Brake Shoe (RH) .............................................................................. 1 ..
7 580059824 Kit-Brake Shoe (LH) ............................................................................... .. 1
8 904258300 Kit-Hold Down ........................................................................................ 1 1
9 913589300 Kit-Spring ............................................................................................... 2 2
10 518798674 Parking Brake Cable .............................................................................. .. 1
10 518798647 Parking Brake Cable .............................................................................. 1 ..
11 580030135 Backplate ............................................................................................... 1 ..
11 580030134 Backplate ............................................................................................... .. 1
12 903198401 Parking Brake ........................................................................................ .. 1
12 903198402 Kit-Park Brake ........................................................................................ 1 ..
12 900488822 Bracket .............................................................................................. 1 ..
12 900488821 Strut ................................................................................................... .. 1
13 900488812 Lever ...................................................................................................... 1 ..
13 900488811 Lever ...................................................................................................... .. 1
14 900488816 Spring .................................................................................................... 1 1
15 900488838 Cable Assy ............................................................................................. 1 1
16 900488825 Bolt ......................................................................................................... 2 2
17 ..... Nut ......................................................................................................... 1 1
18 ..... Washer .................................................................................................. 1 1
19 900488817 Wear Plate ............................................................................................. 1 1
20 900488826 Snap Ring .............................................................................................. 1 1
21 900488810 Adjuster .................................................................................................. 1 ..
21 900488809 Adjuster .................................................................................................. .. 1
22 ..... Sheave ................................................................................................... 1 1
23 ..... Pin .......................................................................................................... 1 1
919139450 Kit-Sheave .................................................................................................. 1 1
BRAKE ASSEMBLY
(S/N A908N04982D →)
KEY:
A: Right Hand
B: Left Hand
QTY
ITEM PART NO. DESCRIPTION A B
580073948 Brake Assembly (RH) ................................................................................. 1 ..
580073947 Brake Assembly (LH) ................................................................................. .. 1
1 900488803 Wheel Cylinder ...................................................................................... 1 1
2 580073946 Body .................................................................................................. 1 1
3 ..... Piston ................................................................................................ 2 2
4 ..... Cup .................................................................................................... 2 2
5 ..... Spring ................................................................................................ 1 1
6 ..... Boot ................................................................................................... 2 2
7 900488834 Bleeder Screw ................................................................................... 1 1
8 900488835 Cap .................................................................................................... 1 1
9 900488827 Cover ..................................................................................................... 1 1
10 518798674 Parking Brake Cable (LH) ...................................................................... .. 1
10 518798647 Parking Brake Cable (RH) ..................................................................... 1 ..
11 580030135 Backplate (RH) ...................................................................................... 1 ..
11 580030134 Backplate (LH) ....................................................................................... .. 1
12 900488808 Parking Brake Lever (RH) ...................................................................... 1 ..
12 900488807 Parking Brake Lever (LH) ...................................................................... .. 1
13 900488804 Spring .................................................................................................... 1 1
14 900488822 Bracket (RH) .......................................................................................... 1 ..
14 900488821 Strut (LH) ............................................................................................... .. 1
15 900488823 Washer .................................................................................................. 1 1
16 900488824 Retainer ................................................................................................. 1 1
17 ..... Nut ......................................................................................................... 1 1
18 580059825 Kit-Brake Shoe (RH) .............................................................................. 1 ..
18 580059824 Kit-Brake Shoe (LH) ............................................................................... .. 1
19 904258300 Kit-Hold Down ........................................................................................ 1 1
20 900488826 Snap Ring .............................................................................................. 1 1
21 900488810 Adjuster (RH) ......................................................................................... 1 ..
21 900488809 Adjuster (LH) .......................................................................................... .. 1
22 900488838 Cable Assy ............................................................................................. 1 1
23 919139450 Kit-Sheave ............................................................................................. 1 1
23 901202806 Sheave .............................................................................................. 1 1
23 901202808 Washer .............................................................................................. 1 1
24 ..... Pin .......................................................................................................... 1 1
25 900488817 Wear Plate ............................................................................................. 1 1
26 913589300 Kit-Spring ............................................................................................... 2 2
27 900488812 Lever (RH) ............................................................................................. 1 ..
27 900488811 Lever (LH) .............................................................................................. .. 1
28 900488816 Spring .................................................................................................... 1 1
29 900488825 Bolt ......................................................................................................... 2 2
903198401 Parking Brake (LH) ..................................................................................... .. 1
903198402 Kit-Park Brake (RH) ................................................................................... 1 ..
912761401 Kit-Adjuster (LH) ......................................................................................... .. 1
912761402 Kit-Self Adjusting (RH) ............................................................................... 1 ..
PARK BRAKE
SEAT ACTUATED
FOOTNOTES:
a → S/N A908N04576D b S/N A908N04577D →
NOTES
FOOTNOTES:
a Not Illustrated
NOTES
FOOTNOTES:
a Not Illustrated
NOTES
NOTES
6 HYDRAULIC SYSTEM
CONTENTS
SECTION 6
HYDRAULIC SYSTEM
DESCRIPTION PAGE
AUXILIARY SECTION
HIGH FLOW - ELECTRONIC HYDRAULIC CONTROL VALVE (S/N A908N03342C →) ......................... 6-54
STANDARD FLOW - ELECTRONIC HYDRAULIC CONTROL VALVE (S/N A908N03342C →) .............. 6-52
ELECTRONIC HYDRAULIC CONTROL VALVE ASSEMBLY
S/N A908N03342C → ................................................................................................................................ 6-48
ELECTRONIC HYDRAULIC CONTROL VALVE ATTACHING PARTS
S/N A908N03342C → ................................................................................................................................ 6-46
HYDRAULIC CONTROL VALVE
FOUR FUNCTION - MANUAL HYDRAULICS ............................................................................................ 6-42
THREE FUNCTION - MANUAL HYDRAULICS .......................................................................................... 6-38
HYDRAULIC CONTROL VALVE AND ATTACHING PARTS
MANUAL HYDRAULICS - SHEET 1 0F 2 ................................................................................................... 6-32
MANUAL HYDRAULICS - SHEET 2 0F 2 ................................................................................................... 6-36
HYDRAULIC FILTER
S/N A908N03342C → ................................................................................................................................ 6-60
HYDRAULIC GEAR PUMP
6/2005 → .................................................................................................................................................... 6-20
HYDRAULIC HAND LEVERS
MANUAL HYDRAULICS ............................................................................................................................. 6-28
HYDRAULIC PUMP
12 CC .......................................................................................................................................................... 6-13
19 CC (→ 7/2005) ...................................................................................................................................... 6-14
19 CC - LOW NOISE ................................................................................................................................... 6-16
HYDRAULIC PUMP MOTOR
AC ............................................................................................................................................................... 6-18
OPEN CONSTRUCTION - WITH BWI AND TEMPERATURE SENSOR ................................................... 6-22
OPEN CONSTRUCTION - WITH BWI AND TEMPERATURE SENSOR ................................................... 6-24
HYDRAULIC PUMP MOTOR MOUNT ............................................................................................................ 6-26
HYDRAULIC SUPPLY AND RETURN
ELECTRONIC HYDRAULICS (S/N A908N03342C →) ............................................................................. 6-10
MANUAL HYDRAULICS (→ 7/2005) ......................................................................................................... 6-2
MANUAL HYDRAULICS (7/2005 →) ......................................................................................................... 6-6
HYDRAULIC TANK AND ATTACHING PARTS
→ S/N A908N03341C ................................................................................................................................ 6-56
S/N A908N03342C → ................................................................................................................................ 6-58
MAIN SECTION
ELECTRONIC HYDRAULIC CONTROL VALVE (S/N A908N03342C →) ................................................. 6-50
MAST INSTALLATION .................................................................................................................................... 6-62
TILT CYLINDERS ............................................................................................................................................ 6-64
FOOTNOTES:
a 12 cc d Not Illustrated
b 19 cc and Low Noise e Three Function
c Four Function
NOTES
NOTES
HYDRAULIC PUMP
19 CC (→ 7/2005)
FOOTNOTES:
a Not Illustrated
NOTES
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Not Illustrated b Optional
FOOTNOTES:
a Not Illustrated b Optional
FOOTNOTES:
a Closed with BWI and Temperature Sensor d → 7/2005
b Not Illustrated e 7/2005 →
c Open with BWI and Temperature Sensor
FOOTNOTES:
a → S/N A908N04379D b S/N A908N04380D →
NOTES
NOTES
FOOTNOTES:
a Illustrated c Operator Presence System
b Not Illustrated
NOTES
NOTES
NOTES
MAIN SECTION
ELECTRONIC HYDRAULIC CONTROL VALVE (S/N A908N03342C →)
AUXILIARY SECTION
STANDARD FLOW – ELECTRONIC HYDRAULIC CONTROL VALVE (S/N A908N03342C →)
KEY:
A: Three Function
B: Four Function
QTY
ITEM PART NO. DESCRIPTION A B
1 580063648 Flow Valve (Three Function, Standard Flow) ............................................. 1 ..
2 580063646 Flow Valve (Four Function, Standard Flow) ............................................... .. 1
3 580066421 Coil ......................................................................................................... 2 2
4 580066418 Nut ......................................................................................................... 1 2
5 580066419 Spacer ................................................................................................... 1 2
6 580067260 Solenoid Valve ....................................................................................... 1 2
6 580066420 Kit-Seal .............................................................................................. 1 2
AUXILIARY SECTION
HIGH FLOW – ELECTRONIC HYDRAULIC CONTROL VALVE (S/N A908N03342C →)
HYDRAULIC FILTER
(S/N A908N03342C →)
MAST INSTALLATION
ITEM PART NO. DESCRIPTION QTY
1 bc 505965521 Tilt Cylinder (FP14029 [Page 6-64]).................................................................. 2
1 a 505965550 Tilt Cylinder (FP14029 [Page 6-64]).................................................................. 2
2 504229210 Pin ....................................................................................................................... 2
3 015420300 Cotter Pin ............................................................................................................ 4
4 504229225 Bushing ............................................................................................................... 4
5 518790673 Rod End .............................................................................................................. 2
6 311321033 Capscrew ............................................................................................................ 2
7 449022017 Lockwasher ......................................................................................................... 2
8 580033885 Nut ...................................................................................................................... 2
9 518809677 Pin ....................................................................................................................... 2
10 518809641 Capscrew ............................................................................................................ 4
10 580019847 Capscrew (12 Point Head) (Optional) ................................................................. 4
11 505974573 Pin ....................................................................................................................... 2
12 b 518803695 Spacer ................................................................................................................ 2
13 b 012828000 O-Ring ................................................................................................................ 2
14 b 505974501 Shim .................................................................................................................... AR
14 b 505970567 Shim .................................................................................................................... AR
15 580024553 Washer ............................................................................................................... 4
FOOTNOTES:
a 10° Forward/5° Back c 5° Forward/8° Back
b 5° Forward/5° Back
TILT CYLINDERS
KEY:
A: 5° Forward
B: 10° Forward
QTY
ITEM PART NO. DESCRIPTION A B
505965521 Tilt Cylinder ................................................................................................ 2 ..
505965550 Tilt Cylinder ................................................................................................ .. 2
1 580022514 Rod Wiper .............................................................................................. 1 1
2 518852600 Gland ..................................................................................................... 1 1
3 580022505 Rod Seal ................................................................................................ 1 1
4 502011914 Back-Up Ring ......................................................................................... 1 1
5 015493400 O-Ring ................................................................................................... 1 1
6 501802906 O-Ring ................................................................................................... 1 1
7 504305701 Piston Seal ............................................................................................. 1 1
8 506002500 Piston ..................................................................................................... 1 1
9 502637902 Locknut .................................................................................................. 1 1
10 506001502 Cylinder Rod .......................................................................................... 1 ..
10 506001501 Cylinder Rod .......................................................................................... .. 1
11 518842602 Tube Wldmt-Cylinder ............................................................................. 1 ..
11 518842603 Tube Wldmt-Cylinder ............................................................................. .. 1
580022411 Kit-Seal ....................................................................................................... 1 1
NOTES
SECTION 7
MAST-TWO STAGE LIMITED FREE-LIFT
DESCRIPTION PAGE
CARRIAGE
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 7-13
INNER MAST
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 7-4
LIFT
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 7-6
LIFT CYLINDER
TWO STAGE LIMITED FREE-LIFT - ERC 040-050 GH ............................................................................. 7-9
TWO STAGE LIMITED FREE-LIFT - ERC 060-065 GH ............................................................................. 7-11
OUTER MAST
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 7-2
OUTER MAST
TWO STAGE LIMITED FREE-LIFT
ERC 040-050 GH
ERC 060-065 GH
FOOTNOTES:
a Refer to Table
INNER MAST
TWO STAGE LIMITED FREE-LIFT
ERC 040-050 GH
ERC 060-065 GH
KEY:
A: ERC 040-050 GH
B: ERC 060-065 GH
QTY
ITEM PART NO. DESCRIPTION A B
a. . . . . Mast Assy ................................................................................................... 1 1
1 a. . . . . Inner Mast .................................................................................................. 1 1
2 504066700 Stubshaft ................................................................................................ 2 2
3 015916300 Snap Ring .................................................................................................. 2 2
4 504233232 Shim (0.020 in.) .......................................................................................... AR AR
5 520036837 Load Roller ................................................................................................. 2 2
6 518801662 Pin .............................................................................................................. 2 2
7 504281792 Spacer ........................................................................................................ 4 4
8 504281794 Chain Sheave ............................................................................................. 2 ..
8 504282703 Chain Sheave ........................................................................................ 1 ..
8 504281793 Chain Sheave ............................................................................................. .. 2
8 504282702 Chain Sheave ........................................................................................ .. 1
9 449034021 Roll Pin ....................................................................................................... 2 2
FOOTNOTES:
a Refer to Table
LIFT
TWO STAGE LIMITED FREE-LIFT
ERC 040-050 GH
ERC 060-065 GH
KEY:
A: ERC 040-050 GH
B: ERC 060-065 GH
QTY
ITEM PART NO. DESCRIPTION A B
1 a. . . . . Chain .......................................................................................................... 2 2
2 ..... Cylinder ...................................................................................................... 1 ..
2 ..... Cylinder ...................................................................................................... .. 1
3 504575298 Lowering Control Valve .............................................................................. 1 ..
3 504064721 Lowering Control Valve .............................................................................. .. 1
3 052645600 O-Ring ................................................................................................... 1 1
4 015415900 Cotter Pin ................................................................................................... 2 2
5 580033718 Pin .............................................................................................................. 2 2
6 518801644 Chain Anchor ............................................................................................. 2 ..
6 518801615 Chain Anchor ............................................................................................. .. 2
7 500227907 Snap Ring .................................................................................................. 2 2
8 504064767 Washer (0.060 in.) ...................................................................................... AR AR
8 504064769 Washer (0.010 in.) ...................................................................................... AR AR
8 504069791 Washer (0.030 in.) ...................................................................................... AR AR
8 504069702 Washer (0.060 in.) ...................................................................................... AR AR
9 449001068 Capscrew ................................................................................................... 2 2
10 502566902 Washer ....................................................................................................... 4 4
11 504064739 Spacer ........................................................................................................ 2 2
12 909882405 Nut .............................................................................................................. 2 2
13 449001172 Capscrew ................................................................................................... 2 2
14 449021001 Washer ....................................................................................................... 2 2
15 080437000 Plug ............................................................................................................ 1 1
15 052645500 O-Ring ................................................................................................... 1 1
16 520044803 Housing (Lowering Control) ....................................................................... 1 1
16 504064742 Housing (Optional) ..................................................................................... 1 1
18 504240229 Spring ......................................................................................................... 2 2
LIFT
TWO STAGE LIMITED FREE-LIFT
KEY:
A: ERC 040-050 GH
B: ERC 060-065 GH
QTY
ITEM PART NO. DESCRIPTION A B
19 504064761 Washer ....................................................................................................... 2 2
20 504064729 Fitting ......................................................................................................... 2 2
20 052645400 O-Ring ................................................................................................... 1 1
21 504064740 Hose Assy .................................................................................................. 1 1
22 052641400 Fitting ......................................................................................................... 1 1
22 052645400 O-Ring ................................................................................................... 1 1
23 502566903 Washer ....................................................................................................... 2 2
24 580010912 Hose Assy .................................................................................................. 1 1
25 504234266 Nut .............................................................................................................. 2 2
26 504230271 Nut .............................................................................................................. 2 2
27 053349600 Fitting ......................................................................................................... 1 1
28 504069765 Side Plate ................................................................................................... 1 1
FOOTNOTES:
a Refer to Table
LIFT CYLINDER
TWO STAGE LIMITED FREE-LIFT – ERC 040-050 GH
LEFT HAND
RIGHT HAND
LIFT CYLINDER
TWO STAGE LIMITED FREE-LIFT – ERC 040-050 GH
FOOTNOTES:
a Refer to Table
LIFT CYLINDER
TWO STAGE LIMITED FREE-LIFT – ERC 060-065 GH
LEFT HAND
LIFT CYLINDER
TWO STAGE LIMITED FREE-LIFT – ERC 060-065 GH
RIGHT HAND
FOOTNOTES:
a Refer to Table
KEY:
A: ERC 040-050 GH
B: ERC 060-065 GH
QTY
ITEM PART NO. DESCRIPTION A B
518795638 Carriage (38.5 in.) (38.5 in.) ....................................................................... 1 ..
518795617 Carriage (38.5 in.) (38.5 in.) ....................................................................... .. 1
1 518795608 Carriage Wldmt (38.5 in.) (38.5 in.) ....................................................... 1 ..
1 518795611 Carriage Wldmt (38.5 in.) (38.5 in.) ....................................................... .. 1
2 520036816 Load Roller (4.36/4.35 in.) (4.36/4.35 in.) .............................................. 6 6
2 520052899 Load Roller (Optional) ............................................................................ 6 6
2 580001436 Load Roller (Optional) ............................................................................ 6 6
3 015916500 Snap Ring .............................................................................................. 6 6
4 504071779 Shim (0.020 in.) ..................................................................................... AR AR
5 504072717 Spacer ................................................................................................... 2 2
6 505978527 Chain Anchor (Dual Hole) ...................................................................... 2 ..
6 505978544 Chain Anchor (Dual Hole) ...................................................................... .. 2
6 580027878 Chain Anchor (Single Hole) ................................................................... 2 ..
6 580027879 Chain Anchor (Single Hole) ................................................................... .. 2
7 504075781 Pin .......................................................................................................... 2 2
KEY:
A: ERC 040-050 GH
B: ERC 060-065 GH
QTY
ITEM PART NO. DESCRIPTION A B
8 500227907 Snap Ring .............................................................................................. 4 4
9 580033718 Pin .......................................................................................................... 2 2
10 015415900 Cotter Pin ............................................................................................... 2 2
SECTION 8
MAST-THREE STAGE FULL FREE-LIFT
DESCRIPTION PAGE
CARRIAGE
SIX ROLLER - THREE STAGE FULL FREE-LIFT ...................................................................................... 8-30
CARRIAGE ASSEMBLY
HEAVY DUTY - THREE STAGE FULL FREE-LIFT .................................................................................... 8-32
FREE-LIFT
THREE STAGE FULL FREE-LIFT .............................................................................................................. 8-18
FREE-LIFT CYLINDER
THREE STAGE FULL FREE-LIFT .............................................................................................................. 8-26
INNER MAST
THREE STAGE FULL FREE-LIFT .............................................................................................................. 8-10
INTERMEDIATE MAST
THREE STAGE FULL FREE-LIFT .............................................................................................................. 8-6
MAIN CYLINDER
THREE STAGE FULL FREE-LIFT .............................................................................................................. 8-22
MAIN LIFT
THREE STAGE FULL FREE-LIFT .............................................................................................................. 8-14
OUTER MAST
THREE STAGE FULL FREE-LIFT .............................................................................................................. 8-2
OUTER MAST
THREE STAGE FULL FREE-LIFT
ERC 040-050 GH
ERC 040-050 GH
ERC 060-065 GH
ERC 060-065 GH
OUTER MAST
THREE STAGE FULL FREE-LIFT
FOOTNOTES:
a Refer to Table
NOTES
INTERMEDIATE MAST
THREE STAGE FULL FREE-LIFT
ERC 040-050 GH
ERC 040-050 GH
ERC 060-065 GH
ERC 060-065 GH
INTERMEDIATE MAST
THREE STAGE FULL FREE-LIFT
FOOTNOTES:
a Refer to Table
NOTES
INNER MAST
THREE STAGE FULL FREE-LIFT
ERC 040-050 GH
ERC 040-050 GH
ERC 060-065 GH
ERC 060-065 GH
INNER MAST
THREE STAGE FULL FREE-LIFT
FOOTNOTES:
a Refer to Table
NOTES
MAIN LIFT
THREE STAGE FULL FREE-LIFT
ERC 040-050 GH
ERC 040-050 GH
ERC 060-065 GH
ERC 060-065 GH
KEY:
A: ERC 040-050 GH
B: ERC 060-065 GH
QTY
ITEM PART NO. DESCRIPTION A B
1 a. . . . . Chain .......................................................................................................... 2 2
2 ..... Cylinder (RH) ............................................................................................. 1 1
3 ..... Cylinder (LH) .............................................................................................. 1 1
4 502566903 Washer ....................................................................................................... 4 4
5 504234266 Nut .............................................................................................................. 4 4
6 518801644 Chain Anchor ............................................................................................. 2 ..
6 518801615 Chain Anchor ............................................................................................. .. 2
MAIN LIFT
THREE STAGE FULL FREE-LIFT
KEY:
A: ERC 040-050 GH
B: ERC 060-065 GH
QTY
ITEM PART NO. DESCRIPTION A B
7 580033718 Pin .............................................................................................................. 4 4
8 015415900 Cotter Pin ................................................................................................... 4 4
9 015418200 Cotter Pin ................................................................................................... 2 2
10 504075767 Chain Anchor ............................................................................................. 2 ..
10 504064751 Chain Anchor ............................................................................................. .. 2
11 500227907 Snap Ring .................................................................................................. 2 2
12 504064767 Washer (0.060 in.) ...................................................................................... 2 2
13 504064769 Washer (0.010 in.) ...................................................................................... AR AR
13 504069791 Washer (0.030 in.) ...................................................................................... AR AR
13 504069702 Washer (0.060 in.) ...................................................................................... AR AR
14 449001068 Capscrew ................................................................................................... 2 2
15 502566902 Washer ....................................................................................................... 4 4
16 504064739 Spacer ........................................................................................................ 2 2
17 909882405 Nut .............................................................................................................. 2 2
18 449021001 Washer ....................................................................................................... 2 2
19 449001052 Capscrew ................................................................................................... 2 2
20 500111905 Fitting ......................................................................................................... 1 1
20 052645500 O-Ring ................................................................................................... 1 1
21 504064742 Housing ...................................................................................................... 1 1
22 504575298 Lowering Control Valve .............................................................................. 1 ..
22 504064721 Lowering Control Valve .............................................................................. .. 1
22 052645600 O-Ring ................................................................................................... 1 1
23 504064740 Hose Assy .................................................................................................. 2 2
24 504230271 Nut .............................................................................................................. 2 2
25 052641400 Fitting ......................................................................................................... 1 1
25 052645400 O-Ring ................................................................................................... 1 1
26 504064729 Fitting ......................................................................................................... 2 2
26 052645400 O-Ring ................................................................................................... 1 1
27 504240229 Spring ......................................................................................................... 2 2
28 504064761 Washer ....................................................................................................... 2 2
29 053349600 Fitting ......................................................................................................... 1 1
30 580010912 Hose Assy .................................................................................................. 1 1
FOOTNOTES:
a Refer to Table
NOTES
FREE-LIFT
THREE STAGE FULL FREE-LIFT
ERC 040-050 GH
ERC 040-050 GH
ERC 060-065 GH
ERC 060-065 GH
FREE-LIFT
THREE STAGE FULL FREE-LIFT
KEY:
A: ERC 040-050 GH
B: ERC 060-065 GH
QTY
ITEM PART NO. DESCRIPTION A B
1 a. . . . . Chain .......................................................................................................... 2 2
2 a. . . . . Hose Assy .................................................................................................. 1 1
3 a. . . . . Tube Assy .................................................................................................. 1 1
4 ..... Lift Cylinder ................................................................................................ 1 1
5 504064702 Fitting ......................................................................................................... 1 1
5 052645400 O-Ring ................................................................................................... 1 1
6 504064795 Spring ......................................................................................................... 1 1
7 504064734 Washer ....................................................................................................... 1 1
8 449001072 Capscrew ................................................................................................... 2 2
9 504230271 Nut .............................................................................................................. 3 3
10 449001389 Capscrew ................................................................................................... 1 1
11 505966572 Bracket ....................................................................................................... 1 1
12 505966510 Clamp ......................................................................................................... 1 1
13 449001004 Capscrew ................................................................................................... 4 4
14 449001013 Capscrew ................................................................................................... 1 1
15 449001049 Capscrew ................................................................................................... 2 ..
15 449001018 Capscrew ................................................................................................... .. 2
16 909882405 Nut .............................................................................................................. 6 6
17 500227907 Snap Ring .................................................................................................. 1 1
18 518801644 Chain Anchor ............................................................................................. 2 ..
18 518801615 Chain Anchor ............................................................................................. .. 2
19 502566903 Washer ....................................................................................................... 2 2
20 504234266 Nut .............................................................................................................. 2 2
21 504064782 Hose Sheave .............................................................................................. 1 1
22 504064778 Spacer ........................................................................................................ 2 2
23 015415900 Cotter Pin ................................................................................................... 2 2
24 449021010 Washer ....................................................................................................... 8 8
25 449022017 Lockwasher ................................................................................................ 3 3
26 580033718 Pin .............................................................................................................. 2 2
27 900002259 Stubshaft .................................................................................................... 1 1
28 501877901 Fitting ......................................................................................................... 1 1
29 504301785 Chain Guard ............................................................................................... 2 2
30 504281796 Chain Sheave Assembly ............................................................................ 2 ..
30 504281799 Chain Sheave ........................................................................................ 1 ..
30 500343914 Snap Ring .............................................................................................. 1 ..
30 520040899 Ball Bearing ........................................................................................... 1 ..
30 504281797 Chain Sheave Assembly ............................................................................ .. 2
30 504282701 Chain Sheave ........................................................................................ .. 1
30 500343914 Snap Ring .............................................................................................. .. 1
30 520040899 Ball Bearing ........................................................................................... .. 1
31 504281795 Crosshead .................................................................................................. 1 1
32 449034054 Roll Pin ....................................................................................................... 2 2
33 449001007 Capscrew ................................................................................................... 2 2
34 500227910 Snap Ring .................................................................................................. 2 2
35 580012382 Tie Down .................................................................................................... 1 1
FREE-LIFT
THREE STAGE FULL FREE-LIFT
KEY:
A: ERC 040-050 GH
B: ERC 060-065 GH
QTY
ITEM PART NO. DESCRIPTION A B
36 504064718 Spacer ........................................................................................................ .. 2
37 b 505973584 Bracket Wldmt ............................................................................................ 1 1
37 c 580095068 Bracket ....................................................................................................... 1 1
38 504223295 Spacer ........................................................................................................ AR AR
39 449021001 Washer ....................................................................................................... 2 ..
FOOTNOTES:
a Refer to Table c 10/2008 →
b → 10/2008
MAIN CYLINDER
THREE STAGE FULL FREE-LIFT
ERC 040-050 GH (LEFT HAND)
MAIN CYLINDER
THREE STAGE FULL FREE-LIFT
ERC 040-050 GH (RIGHT HAND)
MAIN CYLINDER
THREE STAGE FULL FREE-LIFT
ERC 060-065 GH (LEFT HAND)
MAIN CYLINDER
THREE STAGE FULL FREE-LIFT
KEY:
A: ERC 040-050 GH
B: ERC 060-065 GH
QTY
ITEM PART NO. DESCRIPTION A B
a. . . . . Cylinder Assy ............................................................................................. 1 1
1 a. . . . . Tube Wldmt-Cylinder ............................................................................. 1 1
2 a. . . . . Cylinder Rod .......................................................................................... 1 1
3 506410501 Gland ..................................................................................................... 1 ..
3 505587501 Gland ..................................................................................................... .. 1
4 505657522 Spacer (88 in. to 94 in. OALH) ............................................................... 1 ..
4 505657523 Spacer (102 in. and Above OALH) ........................................................ 1 ..
4 505657512 Spacer (76 in., 82 in., and 84 in. OALH) ................................................ .. 1
4 505657517 Spacer (88 in. to 94 in. OALH) ............................................................... .. 1
4 505657518 Spacer (102 in. and Above OALH) ........................................................ .. 1
5 504235239 Check Valve ........................................................................................... 1 1
6 504148200 Washer .................................................................................................. 1 1
7 501850904 Snap Ring .............................................................................................. 1 1
8 504163200 Rod Wiper .............................................................................................. 1 1
9 504450755 Rod Seal ................................................................................................ 1 ..
9 504160200 Rod Seal ................................................................................................ .. 1
10 015492900 O-Ring ................................................................................................... .. 1
10 012827100 O-Ring ................................................................................................... 1 ..
11 504154200 Back-Up Ring ......................................................................................... 1 ..
11 504161200 Back-Up Ring ......................................................................................... .. 1
12 518794659 Wear Ring .............................................................................................. 1 ..
12 504024202 Wear Ring .............................................................................................. .. 1
13 580011167 O-Ring ................................................................................................... 1 1
14 502787901 Rod Seal ................................................................................................ 1 1
15 502895203 Piston Ring ............................................................................................ 1 ..
15 502895201 Piston Ring ............................................................................................ .. 1
504154200 Back-Up Ring ......................................................................................... 1 1
518794659 Wear Ring .............................................................................................. 1 1
505136041 Kit-Seal ....................................................................................................... 1 ..
505136037 Kit-Seal ....................................................................................................... .. 1
FOOTNOTES:
a Refer to Table
FREE-LIFT CYLINDER
THREE STAGE FULL FREE-LIFT
ERC 040-050 GH
ERC 040-050 GH
ERC 060-065 GH
FREE-LIFT CYLINDER
THREE STAGE FULL FREE-LIFT
ERC 060-065 GH
KEY:
A: ERC 040-050 GH
B: ERC 060-065 GH
QTY
ITEM PART NO. DESCRIPTION A B
a. . . . . Cylinder Assy ............................................................................................. 1 1
1 a. . . . . Tube Wldmt-Cylinder ............................................................................. 1 1
2 a. . . . . Cylinder Rod .......................................................................................... 1 1
3 519493600 Gland ..................................................................................................... 1 ..
3 518938600 Gland ..................................................................................................... .. 1
4 501753904 Screw ..................................................................................................... 1 1
5 504235239 Check Valve ........................................................................................... 1 1
6 504148200 Washer .................................................................................................. 1 1
7 501850904 Snap Ring .............................................................................................. 1 1
8 504450758 Rod Wiper .............................................................................................. 1 1
9 502787903 Rod Seal ................................................................................................ 1 1
10 502011903 Back-Up Ring ......................................................................................... 1 ..
10 502011929 Back-Up Ring ......................................................................................... .. 1
11 500348901 O-Ring ................................................................................................... 1 ..
11 015493500 O-Ring ................................................................................................... .. 1
12 502687901 Sealing Ring .......................................................................................... 1 1
13 504232230 O-Ring ................................................................................................... 1 1
14 504024210 Wear Ring .............................................................................................. 1 ..
14 504450757 Wear Ring .............................................................................................. .. 1
15 504450734 Rod Seal ................................................................................................ 1 ..
15 504450754 Rod Seal ................................................................................................ .. 1
16 504450732 Back-Up Ring ......................................................................................... 1 ..
16 504450756 Back-Up Ring ......................................................................................... .. 1
505136046 Kit-Seal ....................................................................................................... 1 ..
505136047 Kit-Seal ....................................................................................................... .. 1
FOOTNOTES:
a Refer to Table
NOTES
CARRIAGE
SIX ROLLER – THREE STAGE FULL FREE-LIFT
KEY:
A: ERC 040-050 GH
B: ERC 060-065 GH
QTY
ITEM PART NO. DESCRIPTION A B
520040873 Carriage (38.5 in.) ...................................................................................... 1 ..
520040892 Carriage (38.5 in.) ...................................................................................... .. 1
1 520041853 Carriage Wldmt (38.5 in.) ....................................................................... 1 ..
1 520041865 Carriage Wldmt (38.5 in.) ....................................................................... .. 1
2 520036852 Load Roller (3.61 in./3.60 in.) ................................................................ 6 6
2 520053821 Load Roller (Optional) ............................................................................ 6 6
2 580001435 Load Roller (Optional) ............................................................................ 6 6
2 580001437 Load Roller (Optional) ............................................................................ 6 6
3 015916300 Snap Ring .............................................................................................. 6 6
4 504233232 Shim (0.020 in.) ..................................................................................... AR AR
5 504235278 Spacer ................................................................................................... 2 2
6 505978527 Chain Anchor (Dual Hole) ...................................................................... 2 2
6 580027878 Chain Anchor (Single Hole) (Optional) .................................................. 2 ..
6 580027880 Chain Anchor (Single Hole) (Optional) .................................................. .. 2
7 504071702 Pin .......................................................................................................... 2 2
8 500227907 Snap Ring .............................................................................................. 4 4
9 580033718 Pin .......................................................................................................... 2 2
10 015415900 Cotter Pin ............................................................................................... 2 2
CARRIAGE ASSEMBLY
HEAVY DUTY – THREE STAGE FULL FREE-LIFT
KEY:
A: ERC40-50GH
B: ERC60-65GH
QTY
ITEM PART NO. DESCRIPTION A B
580052391 Carriage (Group No. 8526354) .................................................................. 1 ..
580052392 Carriage (Group No. 8526355) .................................................................. .. 1
1 580051924 Carriage Wldmt ...................................................................................... 1 ..
1 504066700 Stubshaft ........................................................................................... 6 ..
1 580051908 Carriage Wldmt ...................................................................................... .. 1
1 504066700 Stubshaft ........................................................................................... 6 6
2 520036852 Load Roller ............................................................................................ 6 6
2 520053821 Load Roller (Optional) ............................................................................ 6 6
2 580001437 Load Roller (Optional) ............................................................................ 6 6
2 580001435 Load Roller (Optional) ............................................................................ 6 6
3 015916300 Snap Ring .............................................................................................. 6 6
4 504233232 Shim (0.020 in.) ..................................................................................... AR AR
5 504235278 Spacer ................................................................................................... 2 2
6 505978544 Chain Anchor (Dual Hole) ...................................................................... 2 ..
6 580027878 Chain Anchor (Single Hole) (Optional) .................................................. 2 ..
6 505978527 Chain Anchor (Dual Hole) ...................................................................... .. 2
6 580027880 Chain Anchor (Single Hole) (Optional) .................................................. .. 2
7 504071702 Pin .......................................................................................................... 2 2
8 500227907 Snap Ring .............................................................................................. 4 4
9 580033718 Pin (Chain Anchor) ................................................................................ 2 2
10 015415900 Cotter Pin ............................................................................................... 2 2
NOTES
SECTION 9
MAST-TWO STAGE FULL FREE-LIFT
DESCRIPTION PAGE
CARRIAGE
SIX ROLLER - TWO STAGE FULL FREE-LIFT ......................................................................................... 9-18
CARRIAGE ASSEMBLY
HEAVY DUTY - TWO STAGE FULL FREE-LIFT ........................................................................................ 9-20
FREE-LIFT
TWO STAGE FULL FREE-LIFT .................................................................................................................. 9-8
FREE-LIFT CYLINDER
TWO STAGE FULL FREE-LIFT .................................................................................................................. 9-15
INNER MAST
TWO STAGE FULL FREE-LIFT .................................................................................................................. 9-4
MAIN CYLINDER
LEFT HAND - TWO STAGE FULL FREE-LIFT ........................................................................................... 9-11
RIGHT HAND - TWO STAGE FULL FREE-LIFT ........................................................................................ 9-13
MAIN LIFT
TWO STAGE FULL FREE-LIFT .................................................................................................................. 9-6
OUTER MAST
TWO STAGE FULL FREE-LIFT .................................................................................................................. 9-2
OUTER MAST
TWO STAGE FULL FREE-LIFT
ERC 040-050 GH
ERC 060-065 GH
FOOTNOTES:
a Refer to Table
INNER MAST
TWO STAGE FULL FREE-LIFT
ERC 040-050 GH
ERC 060-065 GH
FOOTNOTES:
a Refer to Table
MAIN LIFT
TWO STAGE FULL FREE-LIFT
FREE-LIFT
TWO STAGE FULL FREE-LIFT
ERC 040-050 GH
ERC 060-065 GH
KEY:
A: ERC 040-050 GH
B: ERC 060-065 GH
QTY
ITEM PART NO. DESCRIPTION A B
1 a. . . . . Tube Wldmt-Cylinder ................................................................................. 1 1
2 a. . . . . Chain .......................................................................................................... 1 1
3 520044802 Fitting ......................................................................................................... 1 1
3 052645400 O-Ring ................................................................................................... 1 1
4 449001004 Capscrew ................................................................................................... 2 2
5 909882404 Nut .............................................................................................................. 2 2
6 504069724 Clamp ......................................................................................................... 2 2
7 932202907 Capscrew ................................................................................................... 1 1
8 449021006 Washer ....................................................................................................... 3 3
9 449001302 Capscrew ................................................................................................... 1 1
10 505973536 Fitting ......................................................................................................... 1 1
10 052645400 O-Ring ................................................................................................... 1 1
11 504064795 Spring ......................................................................................................... 1 1
12 504064734 Washer ....................................................................................................... 1 1
13 580012382 Tie Down .................................................................................................... 1 1
14 505973527 Bracket Wldmt ............................................................................................ 1 1
15 504064718 Spacer ........................................................................................................ .. 4
16 449001049 Capscrew ................................................................................................... 2 ..
16 449001018 Capscrew ................................................................................................... .. 2
17 449021010 Washer ....................................................................................................... 6 6
18 909882405 Nut .............................................................................................................. 4 4
19 502566903 Washer ....................................................................................................... 2 2
20 504234266 Nut .............................................................................................................. 2 2
FREE-LIFT
TWO STAGE FULL FREE-LIFT
KEY:
A: ERC 040-050 GH
B: ERC 060-065 GH
QTY
ITEM PART NO. DESCRIPTION A B
21 518801644 Chain Anchor ............................................................................................. 2 ..
21 518801615 Chain Anchor ............................................................................................. .. 2
22 580033718 Pin .............................................................................................................. 2 2
23 015415900 Cotter Pin ................................................................................................... 2 2
24 504281795 Crosshead .................................................................................................. 1 1
25 504281796 Chain Sheave Assembly ............................................................................ 2 ..
25 504281799 Chain Sheave ........................................................................................ 1 1
25 500343914 Snap Ring .............................................................................................. 1 1
25 520040899 Ball Bearing ........................................................................................... 1 1
25 504281797 Chain Sheave Assembly ............................................................................ .. 2
25 504282701 Chain Sheave ........................................................................................ 1 1
25 500343914 Snap Ring .............................................................................................. 1 1
25 520040899 Ball Bearing ........................................................................................... 1 1
26 504301785 Chain Guard ............................................................................................... 2 2
27 449034054 Roll Pin ....................................................................................................... 2 2
28 449001003 Capscrew ................................................................................................... 2 2
29 449022017 Lockwasher ................................................................................................ 2 2
30 500227910 Snap Ring .................................................................................................. 3 3
31 ..... Lift Cylinder ................................................................................................ 1 1
32 500227907 Snap Ring .................................................................................................. 1 1
FOOTNOTES:
a Refer to Table
MAIN CYLINDER
LEFT HAND – TWO STAGE FULL FREE-LIFT
ERC 040-050 GH
ERC 060-065 GH
MAIN CYLINDER
LEFT HAND – TWO STAGE FULL FREE-LIFT
KEY:
A: ERC 040-050 GH
B: ERC 060-065 GH
QTY
ITEM PART NO. DESCRIPTION A B
a. . . . . Cylinder Assy ............................................................................................. 1 1
1 a. . . . . Tube Wldmt-Cylinder ............................................................................. 1 1
2 a. . . . . Cylinder Rod .......................................................................................... 1 1
3 502687901 Sealing Ring .......................................................................................... 1 1
4 501753914 Screw ..................................................................................................... 1 1
5 504163200 Rod Wiper .............................................................................................. 1 1
6 b 580006341 Gland ..................................................................................................... 1 1
6 c 580049889 Gland ..................................................................................................... 1 1
7 500167920 Back-Up Ring ......................................................................................... 1 1
8 015492900 O-Ring ................................................................................................... 1 1
9 b 504154200 Back-Up Ring ......................................................................................... 1 1
10 502787901 Rod Seal ................................................................................................ 1 1
11 b 518794659 Wear Ring .............................................................................................. 1 1
12 505657539 Spacer ................................................................................................... .. 1
13 504017203 Wear Ring .............................................................................................. 1 1
505136048 Kit-Seal ....................................................................................................... 1 1
FOOTNOTES:
a Refer to Table c 2/2004 →
b → 2/2004
MAIN CYLINDER
RIGHT HAND – TWO STAGE FULL FREE-LIFT
ERC 040-050 GH
ERC 060-065 GH
MAIN CYLINDER
RIGHT HAND – TWO STAGE FULL FREE-LIFT
KEY:
A: ERC 040-050 GH
B: ERC 060-065 GH
QTY
ITEM PART NO. DESCRIPTION A B
a. . . . . Cylinder Assy ............................................................................................. 1 1
1 a. . . . . Tube Wldmt-Cylinder ............................................................................. 1 1
2 a. . . . . Cylinder Rod .......................................................................................... 1 1
3 502687901 Sealing Ring .......................................................................................... 1 1
4 501753914 Screw ..................................................................................................... 1 1
5 504163200 Rod Wiper .............................................................................................. 1 1
6 b 580006341 Gland ..................................................................................................... 1 1
6 c 580049889 Gland ..................................................................................................... 1 1
7 500167920 Back-Up Ring ......................................................................................... 1 1
8 015492900 O-Ring ................................................................................................... 1 1
9 b 504154200 Back-Up Ring ......................................................................................... 1 1
10 502787901 Rod Seal ................................................................................................ 1 1
11 b 518794659 Wear Ring .............................................................................................. 1 1
12 505657539 Spacer ................................................................................................... .. 1
13 504017203 Wear Ring .............................................................................................. 1 1
14 502895201 Piston Ring ............................................................................................ 1 1
580025048 Kit-Seal ....................................................................................................... 1 1
FOOTNOTES:
a Refer to Table c 2/2004 →
b → 2/2004
FREE-LIFT CYLINDER
TWO STAGE FULL FREE-LIFT
ERC 040-050 GH
FREE-LIFT CYLINDER
TWO STAGE FULL FREE-LIFT
ERC 060-065 GH
KEY:
A: ERC 040-050 GH
B: ERC 060-065 GH
QTY
ITEM PART NO. DESCRIPTION A B
a. . . . . Cylinder Assy ............................................................................................. 1 1
1 a. . . . . Tube Wldmt-Cylinder ............................................................................. 1 1
2 a. . . . . Cylinder Rod .......................................................................................... 1 1
3 519493600 Gland ..................................................................................................... 1 ..
3 518938600 Gland ..................................................................................................... .. 1
4 501753904 Screw ..................................................................................................... 1 1
5 504235239 Check Valve ........................................................................................... 1 1
6 504148200 Washer .................................................................................................. 1 1
7 501850904 Snap Ring .............................................................................................. 1 1
8 504450758 Rod Wiper .............................................................................................. 1 1
9 502787903 Rod Seal ................................................................................................ 1 1
10 502011903 Back-Up Ring ......................................................................................... 1 ..
10 502011929 Back-Up Ring ......................................................................................... .. 1
11 500348901 O-Ring ................................................................................................... 1 ..
11 015493500 O-Ring ................................................................................................... .. 1
12 502687901 Sealing Ring .......................................................................................... 1 1
13 504232230 O-Ring ................................................................................................... 1 1
14 504024210 Wear Ring .............................................................................................. 1 ..
14 504450757 Wear Ring .............................................................................................. .. 1
15 504450734 Rod Seal ................................................................................................ 1 ..
15 504450754 Rod Seal ................................................................................................ .. 1
16 504450732 Back-Up Ring ......................................................................................... 1 ..
16 504450756 Back-Up Ring ......................................................................................... .. 1
505136046 Kit-Seal ....................................................................................................... 1 ..
505136047 Kit-Seal ....................................................................................................... .. 1
FOOTNOTES:
a Refer to Table
NOTES
CARRIAGE
SIX ROLLER – TWO STAGE FULL FREE-LIFT
KEY:
A: ERC 040-050 GH
B: ERC 060-065 GH
QTY
ITEM PART NO. DESCRIPTION A B
518795649 Carriage (38.5 in.) ...................................................................................... 1 ..
518795664 Carriage (38.5 in.) ...................................................................................... .. 1
1 518795613 Carriage Wldmt (38.5 in.) ....................................................................... 1 ..
1 518795654 Carriage Wldmt (38.5 in.) ....................................................................... .. 1
2 520036816 Load Roller (4.36/4.35 in.) ..................................................................... 6 6
2 520052899 Load Roller (Optional) ............................................................................ 6 6
2 580001436 Load Roller (Optional) ............................................................................ 6 6
3 015916500 Snap Ring .............................................................................................. 6 6
4 504071779 Shim (0.020 in.) ..................................................................................... AR AR
5 504072717 Spacer ................................................................................................... 2 2
6 505978544 Chain Anchor (Dual Hole) ...................................................................... 2 ..
6 505978527 Chain Anchor (Dual Hole) ...................................................................... .. 2
7 504071702 Pin .......................................................................................................... 2 2
7 580027878 Chain Anchor (Single Hole) ................................................................... 2 ..
7 580027880 Chain Anchor (Single Hole) ................................................................... .. 2
8 500227907 Snap Ring .............................................................................................. 4 4
9 580033718 Pin .......................................................................................................... 2 2
10 015415900 Cotter Pin ............................................................................................... 2 2
CARRIAGE ASSEMBLY
HEAVY DUTY – TWO STAGE FULL FREE-LIFT
KEY:
A: ERC40-50GH
B: ERC60-65GH
QTY
ITEM PART NO. DESCRIPTION A B
580052394 Carriage ..................................................................................................... 1 ..
580052395 Carriage ..................................................................................................... .. 1
1 580051923 Carriage Wldmt ...................................................................................... 1 ..
1 504071721 Stubshaft ........................................................................................... 6 ..
1 580051918 Carriage Wldmt ...................................................................................... .. 1
1 504071721 Stubshaft ........................................................................................... .. 6
2 520036816 Load Roller (4.36/4.35 in.) ..................................................................... 6 6
2 520052899 Load Roller (Optional) ............................................................................ 6 6
2 580001436 Load Roller (Optional) ............................................................................ 6 6
3 015916500 Snap Ring .............................................................................................. 6 6
4 504071779 Shim (0.020 in.) ..................................................................................... AR AR
5 504072717 Spacer ................................................................................................... 2 2
6 505978544 Chain Anchor (Dual Hole) ...................................................................... 2 ..
6 580027878 Chain Anchor (Single Hole) (Optional) .................................................. 2 ..
6 505978527 Chain Anchor (Dual Hole) ...................................................................... .. 2
6 580027880 Chain Anchor (Single Hole) (Optional) .................................................. .. 2
7 504071702 Pin .......................................................................................................... 2 2
8 500227907 Snap Ring .............................................................................................. 4 4
9 580033718 Pin .......................................................................................................... 2 2
10 015415900 Cotter Pin ............................................................................................... 2 2
NOTES
SECTION 10
MAST-FOUR STAGE FULL FREE-LIFT
DESCRIPTION PAGE
CARRIAGE
FOUR STAGE FULL FREE-LIFT ................................................................................................................ 10-22
CARRIAGE ASSEMBLY
HEAVY DUTY - FOUR STAGE FULL FREE-LIFT ...................................................................................... 10-24
FREE-LIFT
FOUR STAGE FULL FREE-LIFT ................................................................................................................ 10-12
FREE-LIFT CYLINDER
FOUR STAGE FULL FREE-LIFT ................................................................................................................ 10-20
INNER MAST
FOUR STAGE FULL FREE-LIFT ................................................................................................................ 10-8
INTERMEDIATE 2 MAST
FOUR STAGE FULL FREE-LIFT ................................................................................................................ 10-4
INTERMEDIATE 3 MAST
FOUR STAGE FULL FREE-LIFT ................................................................................................................ 10-6
MAIN CYLINDER
LEFT HAND - FOUR STAGE FULL FREE-LIFT ......................................................................................... 10-15
RIGHT HAND - FOUR STAGE FULL FREE-LIFT ...................................................................................... 10-18
MAIN LIFT
FOUR STAGE FULL FREE-LIFT ................................................................................................................ 10-10
OUTER MAST
FOUR STAGE FULL FREE-LIFT ................................................................................................................ 10-2
OUTER MAST
FOUR STAGE FULL FREE-LIFT
ERC 040-065 GH
FOOTNOTES:
a Refer to Table
INTERMEDIATE 2 MAST
FOUR STAGE FULL FREE-LIFT
ERC 040-065 GH
FOOTNOTES:
a Alternate Part b Refer to Table
INTERMEDIATE 3 MAST
FOUR STAGE FULL FREE-LIFT
ERC 040-065 GH
FOOTNOTES:
a Refer to Table
INNER MAST
FOUR STAGE FULL FREE-LIFT
ERC 040-065 GH
FOOTNOTES:
a Refer to Table
MAIN LIFT
FOUR STAGE FULL FREE-LIFT
FREE-LIFT
FOUR STAGE FULL FREE-LIFT
ERC 040-065 GH
FOOTNOTES:
a Refer to Table
MAIN CYLINDER
LEFT HAND – FOUR STAGE FULL FREE-LIFT
ERC 040-065 GH
MAIN CYLINDER
LEFT HAND – FOUR STAGE FULL FREE-LIFT
FOOTNOTES:
a Refer to Table
NOTES
MAIN CYLINDER
RIGHT HAND – FOUR STAGE FULL FREE-LIFT
ERC 040-065 GH
FOOTNOTES:
a Refer to Table
FREE-LIFT CYLINDER
FOUR STAGE FULL FREE-LIFT
C515
FREE-LIFT CYLINDER
FOUR STAGE FULL FREE-LIFT
FOOTNOTES:
a Refer to Table
CARRIAGE
FOUR STAGE FULL FREE-LIFT
CARRIAGE ASSEMBLY
HEAVY DUTY – FOUR STAGE FULL FREE-LIFT
NOTES
SECTION 11
ATTACHMENTS AND HEADER HOSE GROUP
DESCRIPTION PAGE
HEADER HOSE
FOUR STAGE FULL FREE-LIFT - WITH WIRE TAKE-UP ......................................................................... 11-26
FOUR STAGE FULL FREE-LIFT - WITH HYDRAULIC TAKE-UP ............................................................. 11-30
THREE STAGE FULL FREE-LIFT .............................................................................................................. 11-22
TWO STAGE FULL FREE-LIFT .................................................................................................................. 11-18
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 11-14
INTEGRAL SIDE-SHIFT CARRIAGE
THREE STAGE FULL FREE-LIFT .............................................................................................................. 11-4
TWO AND FOUR STAGE FULL FREE-LIFT .............................................................................................. 11-6
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 11-2
INTEGRAL SIDE-SHIFT CYLINDER .............................................................................................................. 11-8
INTEGRAL SIDE-SHIFT HYDRAULIC HOSES
THREE STAGE FULL FREE-LIFT .............................................................................................................. 11-11
TWO AND FOUR STAGE FULL FREE-LIFT .............................................................................................. 11-12
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 11-10
KEY:
A: ERC40-50GH (B507)
B: ERC60-65GH (B562)
QTY
ITEM PART NO. DESCRIPTION A B
1 580027669 Hose Assy .................................................................................................. 1 ..
1 580027670 Hose Assy .................................................................................................. .. 1
2 580027667 Hose Assy .................................................................................................. 1 ..
2 580020742 Hose Assy .................................................................................................. .. 1
3 312850042 Strap Clamp ............................................................................................... 1 1
4 052642200 Fitting ......................................................................................................... 2 2
4 052645200 O-Ring ................................................................................................... 1 1
KEY:
A: ERC45-50GH (B508)
B: ERC60-65GH (B563)
QTY
ITEM PART NO. DESCRIPTION A B
1 580027672 Hose Assy .................................................................................................. 1 ..
1 580027673 Hose Assy .................................................................................................. .. 1
2 580020736 Hose Assy .................................................................................................. 1 ..
2 580027667 Hose Assy .................................................................................................. .. 1
3 312850042 Strap Clamp ............................................................................................... 1 1
4 052642200 Fitting ......................................................................................................... 2 2
4 052645200 O-Ring ................................................................................................... 1 1
KEY:
A: ERC40-50GH (B509)
B: ERC60-65GH (B564)
C: ERC40-55GH (C515)
QTY
ITEM PART NO. DESCRIPTION A B C
1 580027672 Hose Assy ......................................................................................... 1 .. ..
1 580027673 Hose Assy ......................................................................................... .. 1 ..
1 580027674 Hose Assy (Four Stage Full Free-Lift) ............................................... .. .. 1
2 580020736 Hose Assy ......................................................................................... 1 .. ..
2 580027667 Hose Assy ......................................................................................... .. 1 ..
2 580027666 Hose Assy (Four Stage Full Free-Lift) ............................................... .. .. 1
3 312850042 Strap Clamp ...................................................................................... 1 1 1
4 052642200 Fitting ................................................................................................. 2 2 2
4 052645200 O-Ring ........................................................................................... 1 1 1
NOTES
HEADER HOSE
TWO STAGE LIMITED FREE-LIFT
ERC 040-050 GH
ERC 060-065 GH
KEY:
A: Three Function
B: Four Function
QTY
ITEM PART NO. DESCRIPTION A B
1 d. . . . . Hose Assy .................................................................................................. 2 4
2 449001072 Capscrew ................................................................................................... 2 4
3 449001028 Capscrew ................................................................................................... 4 8
4 504069707 Bracket (RH) .............................................................................................. 1 1
4 504069711 Bracket (LH) ............................................................................................... .. 1
5 504230271 Nut .............................................................................................................. 6 12
6 505962533 Spacer ........................................................................................................ 1 2
7 505961568 Stubshaft .................................................................................................... 1 2
8 580023124 Hose Sheave .............................................................................................. 1 2
9 504070716 Washer ....................................................................................................... 1 2
10 449022017 Lockwasher ................................................................................................ 1 2
11 449001389 Capscrew ................................................................................................... 1 2
12 504068794 Clamp ......................................................................................................... 1 2
13 504068772 Bracket (RH) .............................................................................................. 1 1
13 504068705 Bracket (LH) ............................................................................................... .. 1
14 449001272 Capscrew ................................................................................................... 2 4
15 504231270 Nut .............................................................................................................. 2 4
16 505962578 Clamp ......................................................................................................... 2 4
17 504068704 Hose Clamp ............................................................................................... 4 8
18 505965586 Clamp ......................................................................................................... 2 4
19 a 504068704 Hose Clamp ............................................................................................... 1 2
19 c 504068704 Hose Clamp ............................................................................................... 1 2
20 ab 505965586 Clamp ......................................................................................................... 1 2
20 c 505965586 Clamp ......................................................................................................... 1 2
FOOTNOTES:
a ERC 040-050 GH B507-3792 c ERC 060-065 GH B562-3659
b ERC 060-065 GH B507-3792 d Refer to Table
NOTES
HEADER HOSE
TWO STAGE FULL FREE-LIFT
ERC 040-050 GH
ERC 060-065 GH
KEY:
A: Three Function
B: Four Function
QTY
ITEM PART NO. DESCRIPTION A B
1 a. . . . . Hose Guard ................................................................................................ 1 1
2 a. . . . . Hose Guard ................................................................................................ 1 1
3 a. . . . . Hose Assy .................................................................................................. 2 2
4 a. . . . . Hose Assy .................................................................................................. .. 2
5 932200905 Capscrew ................................................................................................... 4 ..
5 932200910 Capscrew ................................................................................................... .. 4
6 504068703 Hose Assy .................................................................................................. .. 2
7 505965586 Clamp ......................................................................................................... 3 6
8 449001014 Screw ......................................................................................................... 2 4
9 504230271 Nut .............................................................................................................. 2 4
10 504070756 Hose Guide ................................................................................................ 2 4
11 504070721 Snap Ring .................................................................................................. 2 4
HEADER HOSE
TWO STAGE FULL FREE-LIFT
KEY:
A: Three Function
B: Four Function
QTY
ITEM PART NO. DESCRIPTION A B
12 580024707 Capscrew ................................................................................................... 2 4
13 312850034 Strap Clamp ............................................................................................... 1 1
14 504068794 Clamp ......................................................................................................... 3 6
15 505959500 Clamp ......................................................................................................... 2 2
16 504068704 Hose Clamp ............................................................................................... 5 10
17 580075519 Hose Clamp ............................................................................................... 1 2
18 505961505 Bracket ....................................................................................................... 1 1
19 505965586 Clamp ......................................................................................................... 6 6
20 013397900 Fitting ......................................................................................................... 2 2
21 a. . . . . Tube Assy .................................................................................................. 1 1
22 a. . . . . Tube Assy .................................................................................................. 1 1
23 449034054 Roll Pin ....................................................................................................... 2 2
24 580009288 Bracket (RH) .............................................................................................. 1 1
25 580009289 Bracket (LH) ............................................................................................... .. 1
26 580009290 Stubshaft .................................................................................................... 1 2
27 449001389 Capscrew ................................................................................................... 1 2
28 580023124 Hose Sheave .............................................................................................. 1 2
29 504070716 Washer ....................................................................................................... 1 2
30 520045181 Washer ....................................................................................................... 1 2
31 909882405 Nut .............................................................................................................. 1 2
FOOTNOTES:
a Refer to Table
NOTES
HEADER HOSE
THREE STAGE FULL FREE-LIFT
ERC 040-050 GH
ERC 040-050 GH
ERC 060-065 GH
ERC 060-065 GH
KEY:
A: Three Function
B: Four Function
QTY
ITEM PART NO. DESCRIPTION A B
1 a. . . . . Hose Assy .................................................................................................. 2 4
2 580023124 Hose Sheave .............................................................................................. 1 2
3 909882404 Nut .............................................................................................................. 1 2
4 504068704 Hose Clamp ............................................................................................... 4 8
5 505965586 Clamp ......................................................................................................... 2 4
6 449001014 Screw ......................................................................................................... 8 10
7 504230271 Nut .............................................................................................................. 9 12
HEADER HOSE
THREE STAGE FULL FREE-LIFT
KEY:
A: Three Function
B: Four Function
QTY
ITEM PART NO. DESCRIPTION A B
8 504070756 Hose Guide ................................................................................................ 2 4
9 504070721 Snap Ring .................................................................................................. 2 4
10 505962533 Spacer ........................................................................................................ 1 2
11 518797639 Stubshaft .................................................................................................... 1 2
12 504070716 Washer ....................................................................................................... 1 2
13 520053804 Nut .............................................................................................................. 1 2
14 449001389 Capscrew ................................................................................................... 1 2
15 504068794 Clamp ......................................................................................................... 2 2
16 504070735 Bracket (RH) .............................................................................................. 1 1
16 504069792 Bracket (LH) ............................................................................................... 1 1
17 449001117 Capscrew ................................................................................................... 1 2
18 932200905 Capscrew ................................................................................................... 4 8
19 504071785 Washer ....................................................................................................... 1 2
20 580075519 Hose Clamp ............................................................................................... 1 2
21 504069761 Tube Assy .................................................................................................. 1 2
22 520039810 Hose Guide (RH) ........................................................................................ 1 1
22 520039872 Hose Guide (LH) ........................................................................................ .. 1
23 504069740 Plate ........................................................................................................... 1 1
24 504071766 Spacer ........................................................................................................ 1 2
25 449001052 Capscrew ................................................................................................... 1 2
26 504226242 Washer ....................................................................................................... 1 2
27 449001302 Capscrew ................................................................................................... 1 2
28 580009290 Stubshaft .................................................................................................... 1 2
29 580009288 Bracket (RH) .............................................................................................. 1 1
30 580009289 Bracket (LH) ............................................................................................... .. 1
31 520045181 Washer ....................................................................................................... 1 2
32 580023124 Hose Sheave .............................................................................................. 2 2
33 449034054 Roll Pin ....................................................................................................... 2 2
34 580051876 Cap (Not Illustrated) ................................................................................... 1 1
FOOTNOTES:
a Refer to Table
NOTES
HEADER HOSE
FOUR STAGE FULL FREE-LIFT – WITH WIRE TAKE-UP
ERC 040-065 GH
KEY:
A: Three Function
B: Four Function
QTY
ITEM PART NO. DESCRIPTION A B
1 b. . . . . Hose Assy .................................................................................................. 1 2
2 504068704 Hose Clamp ............................................................................................... 2 4
3 505965586 Clamp ......................................................................................................... 2 4
4 449001272 Capscrew ................................................................................................... 2 4
5 504068794 Clamp ......................................................................................................... 2 4
6 504231270 Nut .............................................................................................................. 6 12
7 909882405 Nut .............................................................................................................. 3 6
8 505962533 Spacer ........................................................................................................ 2 4
9 580023124 Hose Sheave .............................................................................................. 4 8
10 518807652 Stubshaft .................................................................................................... 1 2
11 504070716 Washer ....................................................................................................... 2 4
12 449001059 Capscrew ................................................................................................... 1 2
13 505961568 Stubshaft .................................................................................................... 1 2
14 505960578 Capscrew ................................................................................................... 1 2
15 520038830 Hose Guard (LH) (Outer) ........................................................................... 1 2
16 520038821 Hose Guard (LH) (Inner) ............................................................................ 1 2
17 520038863 Stubshaft .................................................................................................... 2 4
18 520038896 Roller .......................................................................................................... 4 8
19 520038841 Spacer ........................................................................................................ 4 8
20 518807678 Idler Pulley ................................................................................................. 2 4
21 b 520042815 Cable Assy ................................................................................................. 2 4
21 b 520042816 Cable Assy ................................................................................................. 2 4
21 b 520042817 Cable Assy ................................................................................................. 2 4
22 016103500 Washer ....................................................................................................... 6 12
23 520038805 Spring ......................................................................................................... 2 4
24 502097901 Locknut ....................................................................................................... 2 4
25 015414700 Cotter Pin ................................................................................................... 2 4
26 518807634 Pin .............................................................................................................. 1 2
27 518807684 Block .......................................................................................................... 1 2
28 449001013 Capscrew ................................................................................................... 9 15
29 449022016 Lockwasher ................................................................................................ 2 4
30 449001202 Capscrew ................................................................................................... 4 8
31 504071785 Washer ....................................................................................................... 2 4
32 520038870 Hose Guard (RH Inner) .............................................................................. 1 2
HEADER HOSE
FOUR STAGE FULL FREE-LIFT – WITH WIRE TAKE-UP
KEY:
A: Three Function
B: Four Function
QTY
ITEM PART NO. DESCRIPTION A B
33 520038859 Hose Guard (RH Outer) ............................................................................. 1 2
34 449001351 Capscrew ................................................................................................... 1 2
35 449021001 Washer ....................................................................................................... 2 4
36 504230271 Nut .............................................................................................................. 7 11
37 500412904 Clamp ......................................................................................................... 2 4
38 312850046 Strap Clamp (Strap) ................................................................................... 2 4
39 518807639 Bracket Wldmt ............................................................................................ 1 2
40 932200905 Capscrew ................................................................................................... 2 4
41 518809665 Plate ........................................................................................................... 1 1
42 015915200 Snap Ring .................................................................................................. 1 2
43 520045181 Washer ....................................................................................................... 1 2
44 580017088 Stubshaft .................................................................................................... 1 2
45 580018276 Guard (RH) ................................................................................................. 1 ..
45 580018279 Guard (LH) ................................................................................................. .. 1
46 449022034 Lockwasher ................................................................................................ 1 2
47 449001296 Capscrew ................................................................................................... 1 2
48 518790623 Capscrew ................................................................................................... 2 4
49 580075519 Hose Clamp ............................................................................................... 3 ..
49 518808669 Hose Clamp ............................................................................................... .. 1
FOOTNOTES:
a Alternate Part b Refer to Table
NOTES
HEADER HOSE
FOUR STAGE FULL FREE-LIFT – WITH HYDRAULIC TAKE-UP
C515
KEY:
A: Three Function
B: Four Function
QTY
ITEM PART NO. DESCRIPTION A B
1 580055744 Capscrew ................................................................................................... 1 2
2 580061564 Metric Washer ............................................................................................ 1 2
3 580018276 Guard (RH) ................................................................................................. 1 1
4 580017088 Stubshaft .................................................................................................... 1 2
5 504070711 Bushing ...................................................................................................... 1 2
6 580023124 Hose Sheave .............................................................................................. 2 4
7 580055636 Washer ....................................................................................................... 1 2
8 015915200 Snap Ring .................................................................................................. 1 2
9 580052881 Clamp ......................................................................................................... 2 3
10 524141696 Hose Clamp ............................................................................................... 2 3
11 580055650 Nut .............................................................................................................. 18 36
12 580086384 Washer ....................................................................................................... 11 22
13 ..... Bracket ....................................................................................................... 1 ..
13 580080835 Bracket ....................................................................................................... .. 1
14 580056001 Nut .............................................................................................................. 2 4
15 504070716 Washer ....................................................................................................... 1 2
16 504068794 Clamp ......................................................................................................... 4 8
17 580093044 Capscrew ................................................................................................... 8 16
18 504068786 Bar .............................................................................................................. 4 4
19 504070732 Stubshaft .................................................................................................... 1 2
20 580055731 Capscrew ................................................................................................... 1 2
21 580055731 Capscrew ................................................................................................... 2 4
22 580061562 Capscrew ................................................................................................... 1 2
23 580055634 Washer ....................................................................................................... 1 2
24 580056001 Nut .............................................................................................................. 2 4
25 505962533 Spacer ........................................................................................................ 1 2
26 580018279 Guard (LH) ................................................................................................. .. 1
27 580055651 Nut .............................................................................................................. 8 14
28 500412904 Clamp ......................................................................................................... 2 4
29 ..... Formed Plate .............................................................................................. 1 2
30 ..... Plate ........................................................................................................... 1 2
31 580055733 Capscrew ................................................................................................... 8 14
32 580055631 Washer ....................................................................................................... 2 4
33 518808669 Hose Clamp ............................................................................................... .. 1
HEADER HOSE
FOUR STAGE FULL FREE-LIFT – WITH HYDRAULIC TAKE-UP
KEY:
A: Three Function
B: Four Function
QTY
ITEM PART NO. DESCRIPTION A B
34 312850046 Strap Clamp (Strap) ................................................................................... 2 4
35 580075519 Hose Clamp ............................................................................................... 1 1
36 580039424 Fitting ......................................................................................................... 2 4
37 a. . . . . Hose Assy .................................................................................................. 1 1
38 a. . . . . Hose Assy .................................................................................................. .. 1
39 518809665 Plate ........................................................................................................... 1 1
FOOTNOTES:
a Refer to Table
12 OPTIONS
CONTENTS
SECTION 12
OPTIONS
DESCRIPTION PAGE
STROBE LIGHT
KEY:
A: Rear Mount
B: Top Mount
QTY
ITEM PART NO. DESCRIPTION A B
1 a 580000037 Strobe Light ................................................................................................ 1 1
1 a 580035844 Lens (Amber) ......................................................................................... 1 1
1 a 504232212 Strobe Light ........................................................................................... 1 1
1 b 580078920 Strobe Light (LED) ..................................................................................... 1 1
4 580040898 Plate ........................................................................................................... 1 ..
5 580055135 Wire Harness ............................................................................................. 1 1
6 449001014 Screw ......................................................................................................... 2 ..
7 449015014 Nut .............................................................................................................. 2 ..
8 449022016 Lockwasher ................................................................................................ 2 ..
9 449001072 Capscrew ................................................................................................... .. 4
10 504230271 Nut .............................................................................................................. .. 4
11 449021001 Washer ....................................................................................................... .. 1
12 900003231 Clamp ......................................................................................................... .. 1
13 504232297 Guard ......................................................................................................... 1 1
14 504236207 Screw ......................................................................................................... 2 2
15 016103300 Washer ....................................................................................................... 4 4
16 015025600 Lockwasher ................................................................................................ 2 2
17 014936200 Nut .............................................................................................................. 2 2
18 518796690 Bracket ....................................................................................................... .. 2
19 900003245 Grommet .................................................................................................... 1 1
20 900013286 Grommet (Plate Type Overhead Guard) .................................................... .. 1
21 504059726 Terminal ..................................................................................................... 2 2
FOOTNOTES:
a → S/N A908N06887E b PENDING PER ECN 10298203 →
FOOTNOTES:
a → 4/2006 b 4/2006 →
NOTES
FOOTNOTES:
a → 2/2007 d 2/2007 →
b → S/N A908N03903D e S/N A908N03904D →
c → S/N A908N04798D f S/N A908N04799D →
NOTES
WIRE HARNESS
REAR LIGHTS (S/N A908N08693F →)
WIRE HARNESS
TRACTION CUT-OUT (→ S/N A910N03903D)
WIRE HARNESS
TRACTION CUT-OUT (S/N A910N03904D →)
NOTES
SECTION 13
FIELD CONVERSION KITS
DESCRIPTION PAGE
ELECTRICAL CONVERSIONS
FOOTNOTES:
a 36/48V to 12V
b 72/80V to 12V
c Unless truck is already equiped with a 12V DC-DC Converter then the the following part must be
ordered--520086612
d → S/N A908N06028E
e S/N A908N06029E →
CONTROL VALVE
MAST TILT
TUBE EXTENSION
TWO STAGE LIMITED FREE-LIFT
FOOTNOTES:
a ERC040-050GH
b ERC060-065GH
TUBE EXTENSION
TWO AND THREE STAGE FULL FREE-LIFT
FOOTNOTES:
a ERC040-050GH
b ERC060-065GH
TUBE EXTENSION
FOUR STAGE FULL FREE-LIFT
TUBE EXTENSION
FOUR STAGE FULL FREE-LIFT
(CONTINUED)
FENDER
HOSE TAKE-UP
TWO STAGE LIMITED FREE-LIFT
HOSE TAKE-UP
TWO STAGE FULL FREE-LIFT
HOSE TAKE-UP
THREE STAGE FULL FREE-LIFT — ERC040-050GH
HOSE TAKE-UP
THREE STAGE FULL FREE-LIFT — ERC060-065GH
HOSE TAKE-UP
FOUR STAGE FULL FREE-LIFT
FOOTNOTES:
a High Flow
b Standard Flow
FOOTNOTES:
a Full Suspension Seat
NOTES
14 NUMERICAL INDEX
NUMERICAL INDEX
SECTION 14
NUMERICAL INDEX
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM
SECTION 15
USER SUPPORT INFORMATION
DESCRIPTION PAGE
Your investment in a Yale Industrial Truck is important to you and to your Yale Dealer. You measure the return on
that investment through the performance of these trucks and the drivers who operate and the mechanics who service
them safely and efficiency. The following information is intended to help you to achieve your investments objectives:
SERVICE PARTS ORDERING INSTRUCTIONS operators manual is missing from any Yale Industrial
Truck, it should be replaced. Replacement copies are
HOW TO ORDER SERVICE PARTS available for a nominal fee from your Yale Dealer.
In order to prevent delay, too much communication and OPERATOR TRAINING
to have your orders filled correctly, quickly, and at the
least possible cost, the following is the correct procedure The Yale "Basic Operator Training" program helps
to use to order replacement parts. industrial truck users increase their materials handling
production and safety through correct lift truck operation,
WHEN ORDERING PARTS training, and motivation. The Yale program is based
upon real life experience – not theoretical concepts. We
Contact your authorized Yale Industrial Truck Dealer
developed a "complete" program that is totally self-
giving them the following information:
contained – incorporating the most modern instructional
1. Your Purchase order number. techniques including elements of self-study, audio-visual
support (both video and slides), and classroom study.
2. Complete addresses for sending the invoice and
parts. SERVICE TRAINING COURSE
3. Tell us how you want your parts sent. If we do not Operators and Yale dealer service technicians can
get this information, we will send the parts using the improve their technical ability for maintaining and
lowest priced method. repairing Yale Industrial Trucks, which decreases repair
time and cost, by taking Yale Service Training courses.
4. Correct part number(s) and description(s). Use your Different types of mechanical, electric, and electronic
parts manual as a reference. subjects are available. Courses can be held at customer
or Dealer locations in addition to regularly scheduled
5. Model and serial number of the truck. courses which are held at Yale Corporate Headquarters
in Greenville, NC.
TECHNICAL SERVICE PUBLICATIONS
SERVICE TRAINING MATERIALS
Technical literature, with detailed information, is
available at a nominal fee to assist users to effectively Your own service training can be supported through a
maintain Yale Industrial Trucks in a safe, useful complete line of Yale Service Training materials. An
condition. Part Manuals with complete replacement parts Index is available from your Yale Dealer which lists
identification, Service Maintenance Manuals which textbooks, audio-visual programs and films. These
provide service and overhaul procedures and additional materials will provide your training staff with everything
copies of the Operating Manual can be obtained from necessary for training your group.
your Yale Industrial Truck Dealer.
For additional information or assistance in obtaining
To provide instructions for safely operating and servicing these user support publications and programs, contact:
Yale Industrial Trucks, each truck is equipped with an
operators manual. It describes various operating Yale Materials Handling Corporation
techniques and safety warnings to the operator. It 1400 Sullivan Drive
contains a guide to safe maintenance practices and Caller No. 12011
recommended schedules for maintenance. if the Greenville, NC 27834-2011