Yale (a955) erp20 vf europe forklift service repair manual

1600 YRM 1360 General
General
This section has the description and repair procedures
for the steering axle.
The steering axle assembly includes an axle frame,
steering cylinder, two spindle assemblies, and two hub
assemblies. The steering axle is articulated and is
connected to the frame by center pivot mounts. The
center pivot mounts permit the steering axle to move in
the frame mount when the lift truck travels over rough
surfaces. See Figure 1.
The end caps of the steering cylinder also serve as the
axle mounts for the cylinder. The piston rod extends
from both ends of the cylinder and is connected to the
tie rods which are connected to the spindle assemblies.
1

General 1600 YRM 1360
NOTE: MOUNTS AND TIRES MAY BE DIFFERENT BETWEEN TRUCK MODELS.
A. CUSHION TRUCKS ONLY B. PNEUMATIC TRUCKS ONLY
1. AXLE FRAME
2. STEERING DIRECTION SENSOR CABLE
BRACKET
3. STEERING DIRECTION SENSOR
4. MOUNT
5. MOUNT BRACKET
6. STEERING CYLINDER
7. TIE ROD
8. SPINDLE ASSEMBLY
9. MOUNT
10. CUSHION TIRE WHEEL ASSEMBLY
11. PNEUMATIC HUB ASSEMBLY
Figure 1. Steering Axle
2

1600 YRM 1360 Steering Axle Assembly Repair
Steering Axle Assembly Repair
REMOVE ERC22-35VG (ERC045-070VG)
(A968), ERC16-20VA (ERC030-040VA)
(A969) AND ERC40-55VH, ERC50VHS
(ERC80-120VH, ERC100VHS) (A938)
WARNING
PUTTING THE LIFT TRUCK ON BLOCKS
The lift truck must be put on blocks for some
types of maintenance and repair. The removal
of the mast, drive axle, battery, or counterweight
assemblies will cause large changes in the center
of gravity. When the lift truck is put on blocks, put
additional blocks in the following positions:
• If the mast and drive axle are removed, put blocks
under the counterweight so the lift truck cannot
fall backward.
• If the counterweight is removed, put blocks under
the mast so that the lift truck cannot fall forward.
Put the lift truck on blocks on a solid, even, and
level surface. Verify the blocks or stands have
enough capacity to hold the lift truck. Use ad-
ditional blocks next to the tires as necessary to
prevent movement of the lift truck. Verify the lifting
devices used during repairs can lift the weight of
the parts and assemblies.
See the Operating Manual or Periodic Maintenance
section for your lift truck model, for the procedures
to put the lift truck on blocks.
The steering axle can be removed without removing the
counterweight.
1. Place the lift trucks on blocks. The procedure for
placing the lift truck on blocks may be found in the
Operating Manual or in one of the following service
manuals:
Periodic Maintenance 8000 YRM 1364 for lift truck
models
• ERC22-35VG (ERC045-070VG) (A968)
models
• ERC16-20VA (ERC030-040VA) (A969)
models
• ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938)
2. Slide floor jack under steering axle. Raise floor jack
until it holds the weight of the axle assembly.
NOTE: Tag hydraulic lines prior to disconnecting from
steering cylinder to aid in the correct connection of hy-
draulic lines during installation.
3. Disconnect hydraulic hoses at steering cylinder. In-
stall plug fittings in cylinder and put caps on hy-
draulic hoses. Plug fittings will prevent spindles
from turning as axle is removed from under the lift
truck.
4. Remove four capscrews that fasten the mount
brackets under the rubber mounts.
See Figure 2 for lift truck models
• ERC22-35VG (ERC045-070VG) (A968)
• ERC16-20VA (ERC030-040VA) (A969)
ERC100VHS) (A938)
1. CAPSCREW
2. WASHER
3. NUT
4. REAR MOUNT BRACKET
5. STEER AXLE
6. FRONT MOUNT BRACKET
Figure 2. Steer Axle Removal ERC22-35VG
(ERC045-070VG) (A968)
3

Steering Axle Assembly Repair 1600 YRM 1360
1. CAPSCREW
2. WASHER
3. NUT
5. STEER AXLE
Figure 3. Steer Axle Removal ERC16-20VA
(ERC030-040VA) (A969)
1. CAPSCREW
2. WASHER
3. NUT
5. STEER AXLE
Figure 4. Steer Axle Removal ERC40-55VH,
ERC50VHS (ERC80-120VH, ERC100VHS) (A938)
NOTE: The steering direction sensor is an op-
tional feature on ERC22-35VG (ERC045-070VG)
(A968), ERC16-20VA (ERC030-040VA) (A969)
and ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938) lift trucks.
5. Carefully lower the floor jack enough to disconnect,
if installed, steering direction sensor cable from the
main wiring harness.
• ERC22-35VG (ERC045-070VG) (A968)
• ERC16-20VA (ERC030-040VA) (A969)
ERC100VHS) (A938)
6. Remove the steer axle from the under the lift truck.
DISASSEMBLE ERC22-35VG
(ERC045-070VG) (A968), ERC16-20VA
(ERC030-040VA) (A969) AND ERC40-55VH,
ERC50VHS (ERC80-120VH, ERC100VHS)
(A938)
1. Place steering axle on blocks so the wheels just
touch the floor.
2. Remove hub cap, cotter pin, castle nut, and washer.
Discard cotter pin.
• ERC22-35VG (ERC045-070VG) (A968)
• ERC16-20VA (ERC030-040VA) (A969)
ERC100VHS) (A938)
4

1. HUB CAP
2. CASTLE NUT
3. COTTER PIN
4. WASHER
5. OUTER BEARING CONE
6. OUTER BEARING CUP
7. SOLID TIRE WHEEL
8. INNER BEARING CUP
9. INNER BEARING CONE
10. WEAR RING
11. OIL SEAL
12. AXLE ASSEMBLY
13. MOUNT
14. CAPSCREW
15. BRACKET
16. WASHER
17. LOCKNUT
BRACKET
Figure 5. Steering Axle Assembly for ERC22-35VG (ERC045-070VG) (A968)
5

1. HUB CAP
2. CASTLE NUT
3. COTTER PIN
4. WASHER
7. SOLID TIRE WHEEL
10. OIL SEAL
11. AXLE ASSEMBLY
12. MOUNT
13. CAPSCREW
14. BRACKET
15. WASHER
16. LOCKNUT
Figure 6. Steering Axle Assembly for ERC16-20VA (ERC030-040VA) (A969)
6

1. HUB CAP
2. CASTLE NUT
3. COTTER PIN
4. WASHER
7. SOLID TIRE WHEEL
10. WEAR RING
11. OIL SEAL
12. AXLE ASSEMBLY
13. MOUNT
14. CAPSCREW
15. BRACKET
16. WASHER
17. LOCKNUT
BRACKET
Figure 7. Steering Axle Assembly for Lift Trucks ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS)
(A938)
7

NOTE: Identify and tag the outer and inner bearing
cones so they can be reassembled in their original
locations.
3. Remove outer bearing cone from the wheel.
4. Remove wheel from spindle.
NOTE: For correct orientation during installation, note
the position of the oil seal during removal.
NOTE: The wear ring may not be present on all steering
axles.
5. Remove inner bearing cone, wear ring (if present)
and oil seal from spindle.
• ERC22-35VG (ERC045-070VG) (A968)
• ERC16-20VA (ERC030-040VA) (A969)
ERC100VHS) (A938)
6. Remove the mounts from the axle assembly.
NOTE: Bearing cones are to be replaced as sets. If one
bearing cone has been determined to be unserviceable,
then both must be replaced.
7. If the bearing cones are to be replaced, remove the
inner and outer bearing cups from the wheel using
a brass drift pin.
8. Repeat Step 1 through Step 7 for the other wheel.
CLEAN
WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufacturer’s
recommended safety procedures.
WARNING
Compressed air is used for cleaning or drying pur-
poses, or for clearing restrictions. Wear protective
clothing (goggles/shield, gloves, etc.) to avoid in-
jury to personnel.
1. Clean bearing cones by placing them in a wire bas-
ket and immersing in a container of fresh solvent.
Agitate the bearing cones in the solvent to remove
all traces of old lubricant.
2. Clean all remaining components, except the oil
seals and mounts, with solvent.
3. Clean the oil seals and rubber mounts in warm
soapy water. Rinse with clean warm water and al-
low to air dry.
4. After cleaning, dry bearing cones with compressed
air. Take care to prevent spinning the bearing cones
when using a compressed air jet.
5. Immediately wrap bearing cones in a lint-free cloth
to protect them from dust and other foreign matter.
INSPECT
1. Inspect bearing cones for burned or damaged
rollers. If either condition exists, replace both sets
of bearing cones and bearing cups.
2. Inspect bearing cups for signs of overheating or
scoring. If either condition exists, replace both sets
of bearing cones and bearing cups.
3. Inspect the rubber mounts for signs of damage or
cracking. Replace, if necessary.
4. Inspect the oils seals and wear rings for any dam-
age. Replace, if damaged.
5. Inspect spindle assemblies and tie rods for signs of
damage. Replace, if necessary, in accordance with
Spindles, Bearings and Tie Rods Repair.
6. Inspect the remainder of the axle assembly for dam-
age, and repair or replace as necessary.
8

ASSEMBLE ERC22-35VG (ERC045-070VG)
(A968), ERC16-20VA (ERC030-040VA)
(A969) AND ERC40-55VH, ERC50VHS
(ERC80-120VH, ERC100VHS) (A938)
1. If bearing cups have been removed, use a press to
install new bearing cups in wheel. See Figure 8.
2. For specified lubricant see
model
• ERC22-35VG (ERC045-070VG) (A968)
model
• ERC16-20VA (ERC030-040VA) (A969)
models
ERC100VHS) (A938)
Verify bearings are filled with grease.
3. Install oil seal, as noted during removal, wear ring
(if removed), and inner bearing cone on spindle.
CAUTION
DO NOT damage the seals during installation.
4. Carefully slide wheel onto spindle. Install outer
bearing cone and install washer.
NOTE: Ensure that the washer is seated properly
against the bearing cone and not against the shaft
shoulder before tightening the castle nut.
NOTE: Perform Step 5 through Step 8 for lift truck mod-
els ERC22-35VG (ERC045-070VG) (A968).
5. Install the castle nut as follows:
a. Install and tighten the castle nut to seat the
bearing, and back off completely.
b. Tighten castle nut to 68 N•m (50 lbf ft) while
rotating the wheel in both directions to properly
seat the bearings.
c. Loosen the castle nut 1/4 turn.
d. Tighten nut to 3 N•m (27 lbf in).
e. Pull on the wheel assembly to ensure that there
is no end play. If there is excessive end play,
reassemble washer and repeat Step a through
Step c.
6. Install new cotter pin in castle nut. If cotter pin can-
not be installed, tighten castle nut to the first align-
ment position where the cotter pin can be installed.
7. Install hub cap.
8. Repeat Step 1 through Step 7 for other wheel.
NOTE: Ensure that the washer is seated properly
against the bearing cone and not against the shaft
shoulder before tightening the castle nut.
NOTE: Perform Step 9 through Step 12 for lift truck
models ERC16-20VA (ERC030-040VA) (A969).
a. Install and tighten the castle nut to seat the
bearing, and back off completely.
b. Tighten castle nut to 200 N•m (148 lbf ft) while
rotating the wheel in both directions to properly
seat the bearings.
c. Loosen the castle nut 1/4 turn.
d. Tighten nut to 12 N•m (106 lbf in).
e. Pull on the wheel assembly to ensure that there
is no end play. If there is excessive end play,
reassemble washer and repeat Step a through
Step c.
9

10. Install new cotter pin in castle nut. If cotter pin can-
not be installed, tighten castle nut to the first align-
ment position where the cotter pin can be installed.
11. Install hub cap.
12. Repeat Step 1 through Step 4 and Step 9 through
Step 11 for other wheel.
NOTE: Perform Step 13 through Step 15 for lift truck
models
ERC100VHS) (A938)
a. Install castle nut and tighten to 203 N•m
(150 lbf ft) while rotating the wheel in both
directions to properly seat the bearings.
b. Back off castle nut until wheel turns freely with
no end play. Torque should be less than 27 N•m
(238 lbf in).
c. If there is excessive end play, reassemble
washer and repeat Step a and Step b.
d. Re-torque castle nut to 34 N•m (25 lbf ft) and
lock in place at first alignment position which
occurs at or above 34 N•m (25 lbf ft).
e. Install new cotter pin and bend one prong over
castle nut. Bend other prong over spindle and
cut flush with end of spindle.
14. Install hub cap.
15. Perform Step 1 through Step 4 and Step 13 and
Step 14 for other wheel.
INSTALL ERC22-35VG (ERC045-070VG)
(A968)
1. Install rubber mounts and top mount(s) on axle.
Verify that the face of rubber mount with the word
"TOP" and the arrow (pointing up) is facing away
from the steer axle. See Figure 9.
2. Apply lubricant (that is approved for use with rub-
ber) to rubber mount. The lubricant is used to ease
assembly of the rubber mounts into lift truck frame
and mount brackets.
3. Using a floor jack, position the steering axle under
the frame.
4. If the lift truck is equipped with the steering direc-
tion sensor option, connect steering direction sen-
sor cable to the main wiring harness. See Figure 5.
5. Lift the steer axle into position on the lift truck frame,
and install the rear and front mount brackets, four
washers, four capscrews, and four nuts. Tighten
capscrews to 90 N•m (66 lbf ft). See Figure 10.
6. Remove plugs and caps and connect hydraulic
lines to steering cylinder as noted during removal.
7. Remove the floor jack from under the lift truck, and
remove the lift truck from the blocks.
8. Operate steering system to remove air from sys-
tem. Turn steering wheel several times from one
stop to the other. Check for hydraulic leaks.
10

1. WASHER
2. HUB CAP
3. COTTER PIN
4. CASTLE NUT
5. BEARING CONE
6. BEARING CUP
7. SPINDLE
8. WEAR RING
9. OIL SEAL
Figure 8. Bearing Arrangement for Lift Truck
Models ERC22-35VG (ERC045-070VG) (A968),
ERC16-20VA (ERC030-040VA) (A969) and
ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938)
1. RUBBER MOUNT
2. TOP MOUNT
3. STEER AXLE
Figure 9. Mount Installation for Lift truck Model
ERC22-35VG (ERC045-070VG) (A968)
1. CAPSCREW
2. WASHER
3. NUT
5. STEER AXLE
Figure 10. Steer Axle Installation for Lift Truck
Model ERC22-35VG (ERC045-070VG) (A968)
11

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INSTALL ERC16-20VA (ERC030-040VA)
(A969)
ber), to rubber mount. The lubricant is used to ease
and mount brackets.
the frame.
and install the rear and front mount brackets, four
capscrews to 41 to 49 N•m (30.2 to 36.1 lbf ft). See
Figure 12.
1. RUBBER MOUNT
2. TOP MOUNT
3. STEER AXLE
Figure 11. Mount Installation for Lift Truck Model
ERC16-20VA (ERC030-040VA) (A969)
1. CAPSCREW
2. WASHER
3. NUT
5. STEER AXLE
Figure 12. Steer Axle Installation for Lift Truck
Model ERC16-20VA (ERC030-040VA) (A969)
12

INSTALL ERC40-55VH, ERC50VHS
(ERC80-120VH, ERC100VHS) (A938)
ber) to rubber mount. The lubricant is used to ease
and mount brackets.
the frame.
and install the rear and front mount brackets, eight
capscrews to 225 to 280 N•m (166 to 207 lbf ft).
See Figure 14.
1. RUBBER MOUNT
2. TOP MOUNTS
4. STEER AXLE
5. WASHER
6. NUT
8. CAPSCREW
Figure 13. Mount Installation, Lift Trucks
ERC100VHS) (A938)
1. CAPSCREW
2. WASHER
3. NUT
5. STEER AXLE
Figure 14. Steer Axle Installation, Lift Trucks
ERC100VHS) (A938)
13

REMOVE ERP22-35VL (ERP045-070VL)
(A976) AND ERP40-50VM (ERP080-100VM)
(A985)
WARNING
PUTTING THE LIFT TRUCK ON BLOCKS
The lift truck must be put on blocks for some
types of maintenance and repair. The removal
of the mast, drive axle, battery, or counterweight
assemblies will cause large changes in the center
of gravity. When the lift truck is put on blocks, put
additional blocks in the following positions:
• If the mast and drive axle are removed, put blocks
under the counterweight so the lift truck cannot
fall backward.
• If the counterweight is removed, put blocks under
the mast so that the lift truck cannot fall forward.
Put the lift truck on blocks on a solid, even, and
level surface. Verify the blocks or stands have
enough capacity to hold the lift truck. Use ad-
ditional blocks next to the tires as necessary to
prevent movement of the lift truck. Verify the lifting
devices used during repairs can lift the weight of
the parts and assemblies.
See the Operating Manual or Periodic Maintenance
section for your lift truck model, for the procedures
to put the lift truck on blocks.
The steering axle can be removed without removing the
counterweight.
1. Remove the battery from the lift truck. The proce-
dure for removing the battery may be found in the
Operating Manual or in one of the following ser-
vice manuals:
models
• ERP22-35VL (ERP045-070VL) (A976)
models
• ERP40-50VM (ERP080-100VM) (A985)
2. Place the lift trucks on blocks. The procedure for
placing the lift truck on blocks may be found in the
Operating Manual or in one of the following service
manuals:
models
• ERP22-35VL (ERP045-070VL) (A976)
models
• ERP40-50VM (ERP080-100VM) (A985)
3. Slide floor jack under steering axle. Raise lifting
device until it holds the weight of the axle assembly.
NOTE: Tag hydraulic lines prior to disconnecting from
steering cylinder to aid in the correct connection of the
hydraulic lines during installation.
4. Disconnect hydraulic lines at steering cylinder. In-
stall plug fittings in cylinder and put caps on hy-
draulic lines. Plug fittings will prevent spindles from
turning as axle is removed from under the lift truck.
NOTE: Perform Step 5 and Step 6 for lift truck model
ERP22-35VL (ERP045-070VL) (A976) only.
5. Remove two lower nuts, capscrews, and washers
from the battery box and front mount bracket. See
Figure 15.
1. CAPSCREW
2. WASHER
3. BATTERY COMPARTMENT
5. NUT
Figure 15. Steer Axle Replacement ERP22-35VL
(ERP045-070VL) (A976)
14

6. Remove the top capscrew and washer from the bat-
tery box and front mount bracket. See Figure 15.
7. Remove two capscrews, washers, and rear mount
bracket.
See Figure 16 for lift truck model
• ERP22-35VL (ERP045-070VL) (A976)
See Figure 17 for lift truck model
• ERP40-50VM (ERP080-100VM) (A985)
NOTE: The front mount bracket may not be able to be
removed until the steering axle is lowered during Step 9.
8. Remove two capscrews, washers, hydraulic hose
mounting brackets, and front mount bracket from
the counterweight.
• ERP22-35VL (ERP045-070VL) (A976)
• ERP40-50VM (ERP080-100VM) (A985)
NOTE: The steering direction sensor is standard
on ERP22-35VL (ERP045-070VL) (A976) and
ERP40-50VM (ERP080-100VM) (A985) lift trucks.
9. Carefully lower the floor jack enough to remove cap-
screw and cover to disconnect steering direction
sensor cable from the main wiring harness, and re-
move the main wiring harness from the conduit clip
located on the steering axle. See Figure 18. Install
cover and capscrew. Move the steer axle clear of
the lift truck.
1. WASHER
2. CAPSCREW
5. STEER AXLE
6. PNEUMATIC HUB
7. RUBBER MOUNTS
Figure 16. Steer Axle Removal ERP22-35VL (ERP045-070VL) (A976)
15

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Yale (a955) erp20 vf europe forklift service repair manual