service repair manual

1. ERC20VG-ERC35VG (A968)
SERVICE MANUAL CONTENTS
SECTION
PART
NUMBER
YRM
NUMBER
REV
DATE
FRAME............................................................................................................................ 524319489 0100 YRM 1342 09/14
OPERATOR'S CAB........................................................................................................ 550025937 0100 YRM 1446 09/14
AC MOTOR REPAIR...................................................................................................... 524327049 0620 YRM 1385 09/14
DRIVE AXLE/SPEED REDUCER/DIFFERENTIAL........................................................ 524319490 1300 YRM 1366 09/13
STEERING AXLE............................................................................................................ 524319491 1600 YRM 1360 09/14
STEERING SYSTEM...................................................................................................... 524319492 1600 YRM 1363 09/14
BRAKE SYSTEM............................................................................................................ 524319493 1800 YRM 1359 03/12
HYDRAULIC SYSTEM.................................................................................................... 524319494 1900 YRM 1367 09/14
HYDRAULIC CLEANLINESS PROCEDURES............................................................... 550073240 1900 YRM 1620 12/14
MAIN CONTROL VALVES............................................................................................. 524319495 2000 YRM 1334 09/14
CYLINDER REPAIR (MAST S/N A270-72, A551, A555, A559, A626, A627, A751-52,
B551, B555, B586-91, B749-54, C661-63, C665, D507-09, D515, D562-64, E509,
E564).......................................................................................................................... 524319496 2100 YRM 1382 03/14
CYLINDER REPAIR (MAST S/N F507, F508, F562, F563)........................................... 550093750 2100 YRM 1668 12/14
WIRE HARNESS REPAIR.............................................................................................. 524223769 2200 YRM 1128 12/14
USER INTERFACE SUPERVISOR................................................................................. 524319497 2200 YRM 1335 09/14
USER INTERFACE SERVICE TECHNICIAN................................................................. 524319498 2200 YRM 1336 09/14
ELECTRICAL SYSTEM.................................................................................................. 524319499 2200 YRM 1369 09/14
INDUSTRIAL BATTERY................................................................................................. 524158040 2240 YRM 0001 09/14
MAST REPAIR (S/N A551, A555, A559, B551, B555, D507, D562, D508, D563,
D509, D564, D515, E509, E564................................................................................. 524319500 4000 YRM 1338 01/14
MAST REPAIR (S/N F507, F508, F562, F563)............................................................... 550093755 4000 YRM 1669 12/14
METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13
PERIODIC MAINTENANCE............................................................................................ 524319560 8000 YRM 1364 09/14
CAPACITIES AND SPECIFICATIONS........................................................................... 524319502 8000 YRM 1374 09/13
DIAGRAMS..................................................................................................................... 524332383 8000 YRM 1384 09/14
DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................ 524319504 9000 YRM 1377 10/14
Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center.
PART NO. 524319598 (12/14)

2. General
DESCRIPTION
This section contains a description and service
procedures for the parts of the frame. These parts
include the frame, counterweight assembly, overhead
guard, hood and seat assembly, access panels, and
labels.
Throughout this section, forward will refer to travel in
the direction of the forks and left and right will be
determined by an operator sitting in the seat facing
forward. See Figure 1.
A. LEFT SIDE
B. RIGHT SIDE
C. FORWARD TRAVEL
Figure 1. Truck Orientation
If a torque value is not specified, go to Metric and
Inch (SAE) Fasteners 8000YRM0231 for torque
values.
FRAME
The frame is a single weldment with mounts for:
• Counterweight
• Overhead guard
• Tilt cylinders
• Drive axle, or if equipped, transaxle
• Floor plate and pedals
• Side step and fender weldments
• Hood and seat assembly
• Front drop-in bulkhead for lift truck models
ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938)
See Figure 2 for lift truck models
• ERC22-35VG (ERC045-070VG) (A968)
See Figure 3 for lift truck models
• ERC16-20VA (ERC030-040VA) (A969)
See Figure 4 for lift truck models
• ERP22-35VL (ERP045-070VL) (A976)
See Figure 5 for lift truck models
• ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985)
See Figure 6 for lift truck models
• ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938)
0100 YRM 1342 General
1

3. 1. FRONT OVERHEAD GUARD MOUNTING
BRACKET
2. REAR OVERHEAD GUARD MOUNTING
BRACKET
3. COUNTERWEIGHT MOUNTING PLATE
4. FRONT BULKHEAD
5. RIGHT FRAME CHANNEL
6. LEFT FRAME CHANNEL
7. REAR BULKHEAD
8. TILT ANCHOR PLATE
9. SIDE STEP MOUNTING BRACKET
Figure 2. Frame Weldment for Lift Truck ERC22-35VG (ERC045-070VG) (A968)
General 0100 YRM 1342
2

4. 1. FRONT OVERHEAD GUARD MOUNTING
BRACKET
2. REAR OVERHEAD GUARD MOUNTING
BRACKET
3. COUNTERWEIGHT MOUNTING PLATE
4. FRONT BULKHEAD
5. RIGHT FRAME CHANNEL
6. LEFT FRAME CHANNEL
7. REAR BULKHEAD
8. TILT ANCHOR PLATE
9. SIDE STEP MOUNTING BRACKET
Figure 3. Frame Weldment for Lift Truck ERC16-20VA (ERC030-040VA) (A969)
0100 YRM 1342 General
3

5. 1. FRONT OVERHEAD GUARD MOUNTING
BRACKET
2. OPERATOR MODULE PLATE
3. FRONT BULKHEAD
4. REAR BULKHEAD
5. COUNTERWEIGHT MOUNTING PLATE
6. LEFT FENDER
7. RIGHT FENDER
8. RIGHT FRAME CHANNEL
9. LEFT FRAME CHANNEL
10. TILT ANCHOR PION
11. DRIVE AXLE MOUNTS
12. SIDE STEP MOUNTING BRACKET
Figure 4. Frame Weldment for Lift Truck ERP22-35VL (ERP045-070VL) (A976)
General 0100 YRM 1342
4

6. 1. FRONT OVERHEAD GUARD MOUNTING
BRACKET
2. OPERATOR MODULE PLATE
3. FRONT BULKHEAD
4. REAR BULKHEAD
5. COUNTERWEIGHT MOUNTING PLATE
6. LEFT FENDER
7. RIGHT FENDER
8. RIGHT FRAME CHANNEL
9. LEFT FRAME CHANNEL
10. TILT ANCHOR PION
11. DRIVE AXLE MOUNTS
12. SIDE STEP MOUNTING BRACKET
Figure 5. Frame Weldment for Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML)
(A985)
0100 YRM 1342 General
5

7. 1. FRONT OVERHEAD GUARD MOUNTING
BRACKET
2. REAR OVERHEAD GUARD MOUNTING
BRACKET
3. COUNTERWEIGHT MOUNTING PLATE
4. FRONT BULKHEAD
5. RIGHT FRAME CHANNEL
6. LEFT FRAME CHANNEL
7. REAR BULKHEAD
8. TILT ANCHOR PLATE
9. SIDE STEP MOUNTING BRACKET
Figure 6. Frame Weldment for Lift Trucks ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938)
The hydraulic and traction motor electronic controllers
and contactors are located in the counterweight cavity
for the following lift truck models
• ERC22-35VG (ERC045-070VG) (A968)
• ERC16-20VA (ERC030-040VA) (A969)
• ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938)
The hydraulic motor electronic controller and
contactor are located in the counterweight cavity and
the traction motor controller is attached to the front
bulkhead for the following lift truck models
• ERP22-35VL (ERP045-070VL) (A976)
• ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985)
NOTE: Lift truck models ERC22-35VG
(ERC045-070VG) (A968) manufactured after June,
2012 are equipped with a removable floor plate that
requires no tools to remove.
For all lift truck models covered in this Service
Manual, the Vehicle Systems Manager (VSM) is
either mounted on or near the front bulkhead
underneath the floor mat and floor plate.
General 0100 YRM 1342
6

8. DISCHARGING THE CAPACITORS
WARNING
DO NOT make repairs or adjustments unless you
have been properly trained and authorized to do
so. Improper repairs and adjustments can create
dangerous operating conditions. DO NOT operate
a lift truck that needs repairs. Report the need for
repairs to your supervisor immediately. If repair is
necessary, attach a DO NOT OPERATE tag on the
steering wheel and disconnect the battery.
Disconnect the battery and allow the capacitors to
discharge before opening any compartment
covers or inspecting or repairing the electrical
system. DO NOT place tools on top of the battery.
If a tool causes a short circuit, the high current
flow from the battery can cause personal injury or
property damage.
Some checks and adjustments are performed with
the battery connected. DO NOT connect the
battery until the procedure instructs you to do so.
Never wear any metallic items on your fingers,
arms, or neck. Metal items can accidentally make
an electrical connection and cause injury.
Before performing any tests or adjustments, block
the lift truck to prevent unexpected movement.
The capacitor in the transistor controller(s) can
hold an electrical charge for about 10 seconds
after the battery is disconnected. To prevent an
electrical shock and personal injury, discharge
the capacitor(s) before inspecting or repairing any
component in the drive unit compartment. Make
certain that the battery has been disconnected.
DO NOT short across the motor controller
terminals with a screwdriver or jumper wire.
Make certain the Emergency-Disconnect switch
has not been activated. This will isolate the
controller and prevent the capacitors from
discharging properly. The proper way to
disconnect the battery is by separating the battery
connectors.
1. Ensure the capacitors are discharged by
performing Step 2 through Step 6 below.
2. Turn the key or keyless switch to the OFF
position.
3. Disconnect the battery by separating the
connectors.
4. Block the drive wheels to prevent the lift truck
from moving.
5. Make sure the Emergency-Disconnect switch
HAS NOT been activated. If the Emergency-
Disconnect switch is activated, rotate the switch
to the right until it pops up.
6. Press horn button. Wait 30 seconds to be sure
capacitors are fully discharged.
RAPID CHARGE
All the lift trucks covered in this Service Manual may
be equipped with an optional Basic Rapid Charge
System. See Figure 7. Lift truck models ERP22-35VL
(ERP045-070VL) (A976) and ERP40-50VM,
ERP50-55VM6 (ERP080-120VM, ERP100VML)
(A985) may also be equipped with an optional
Integrated (Quick Disconnect) Rapid Charge System.
See Figure 8 or Figure 9.
On lift trucks equipped with either Rapid Charge
System, the battery is charged during operator breaks
or when the lift truck is not being used. Both systems
provide extended operation with a single battery.
Connect or disconnect battery from the Rapid Charge
System using the battery connectors.
Some of the features of the Basic Rapid Charge
System include (see Figure 7):
• Battery connector externally mounted for easy
access.
• Vented side covers for improved battery
cooling.
• Requires rapid charge vented battery and
sealed battery fan box with thermostat.
Some of the features of the Integrated (Quick
Disconnect) Rapid Charge System include (see
Figure 8 or Figure 9):
• Power cables from hood mounted connector
are wired to the existing truck battery
connections, eliminating the need to run cables
from the battery to the top side of hood.
• The Integrated Rapid Charge System easily
supports rapid, fast, and convenient charging.
0100 YRM 1342 General
7

9. • Cutouts in the battery compartment side panel
are standard with the Integrated Rapid Charge
System and help support vented tray batteries
and batteries with side-mounted cooling fans.
• An interlock switch on the hood mounted
connector housing door prevents truck from
being operated during charging.
NOTE: LIFT TRUCK MODELS ERP22-35VL
(ERP045-070VL) (A976) SHOWN.
1. RAPID CHARGE CONNECTOR
2. VENTED SIDE COVER
Figure 7. Basic Rapid Charge System
General 0100 YRM 1342
8

10. 1. SIDE PANEL CUTOUT
2. COVER
3. BATTERY CABLES
4. INTERLOCK SWITCH
5. BATTERY CONNECTOR
Figure 8. Integrated (Quick Connect) Rapid Charge System, Lift Truck Models ERP22-35VL
(ERP045-070VL) (A976)
0100 YRM 1342 General
9

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12. 1. SIDE PANEL CUTOUT
2. COVER
3. BATTERY CABLES
4. INTERLOCK SWITCH
5. BATTERY CONNECTOR
Figure 9. Integrated (Quick Connect) Rapid Charge System, Lift Truck Models ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985)
GROUND TEST
NOTE: If the static discharge ground connection is
not secured properly, it could lead to the possible
failure of the traction motor and/or pump motor
controller.
To ensure proper installation of seat assembly and
associated bracketing, perform continuity test as
described below:
1. Using an ohm meter, place a test lead at the
armrest mounting bolt and another at the truck
frame. The resistance needs to read 5 Ohms or
less. See Figure 10.
2. If resistance is greater than 5 Ohms, double
check installation of seat assembly, both ends of
seat wiring harness, and wiring harness ground
strap.
General 0100 YRM 1342
10

13. A. ARMREST FOR LIFT TRUCK MODELS
ERC045-070VG (A968), ERC030-040VA (A969),
ERP045-070VL (A976), ERP080-120VM (A985),
AND ERC80-120VH, ERC100VHS (A938)
B. ARMREST FOR LIFT TRUCK MODELS
ERC22-35VG (A968), ERC16-20VA (A969),
ERP22-35VL (A976), ERP40-50VM,
ERP50-55VM6 (A985), AND ERC40-55VH,
ERC50VHS (A938)
1. ARMREST BOLT
2. FRAME
Figure 10. Ground Test
MUD GUARDS
Lift truck models equipped with mud guards will have
mud guards attached to front fender extensions and
suspended between drive wheels and carriage. The
mud guards are not serviceable and should be re-
placed if damaged or no longer providing shielding
from debris.
1. Set parking brake and turn key or keyless switch
to OFF position.
2. Remove capscrew and nut from lift truck frame
and fender extension. Discard mud guard. See
Figure 11.
3. Install new mud guard, capscrew, and nut into
fender extension and frame. Tighten capscrew to
66 N•m (49 lbf ft).
NOTE: STANDARD TREAD MUD GUARD SHOWN.
WIDE TREAD MUD GUARD IS SIMILAR.
1. CAPSCREW
2. NUT
3. MUD GUARD
Figure 11. Mud Guards
0100 YRM 1342
11

14. Covers and Floor Plates
FOR LIFT TRUCK MODELS ERC22-35VG
(ERC045-070VG) (A968)
Various covers and floor plates provide access to
components during service and securely cover areas
during normal operations.
NOTE: Lift truck models ERC22-35VG
(ERC045-070VG) (A968) manufactured after June,
2012 are equipped with a removable floor plate that
requires no tools to remove.
1. Floor mat and floor plates in operator compart-
ment allow access to traction motor, hydraulic
pump and motor, service and parking brakes, and
hydraulic control valve. The floor plate is fastened
to the frame with capscrews and washers. The
manual hydraulic floor plate and e-hydraulic floor
plate hook onto the floor plate. See Figure 12.
2. Counterweight cover is attached to counterweight
by two capscrews and allows access to electrical
controllers. See Figure 12.
3. Manual hydraulic covers protect links during oper-
ation. For removal procedures for these covers
see Main Control Valves 2000YRM1334. See
Figure 12.
4. Hood latch cover is attached to bulkhead using
two capscrews. See Figure 12.
A. MANUAL HYDRAULIC CONTROL LEVERS B. E-HYDRAULIC CONTROL LEVERS
1. COUNTERWEIGHT COVER
2. CAPSCREW
3. HOOD LATCH COVER*
4. MANUAL HYDRAULIC COVERS
5. MANUAL HYDRAULIC FLOOR MAT
6. WASHER
7. MANUAL HYDRAULIC FLOOR PLATE
8. COWL
9. E-HYDRAULIC FLOOR MAT
10. E-HYDRAULIC FLOOR PLATE
11. COUNTERWEIGHT
12. FRAME
13. FLOOR PLATE
*HOOD LATCH COVER USED ON LIFT TRUCKS EQUIPPED WITH EITHER MANUAL OR E-HYDRAULIC
CONTROL LEVERS.
Figure 12. Covers and Floor Plates for Lift Truck Models ERC22-35VG (ERC045-070VG) (A968)
Covers and Floor Plates 0100 YRM 1342
12

15. FOR LIFT TRUCK MODELS ERC16-20VA
(ERC030-040VA) (A969)
Various covers and floor plates provide access to
components during service and securely cover areas
during normal operations.
1. Floor mat and floor plates in operator compart-
ment allow access to traction motor, hydraulic
pump and motor, service and parking brakes, and
hydraulic control valve. The floor plate is fastened
to the frame with capscrews and washers. The
manual hydraulic floor plate and e-hydraulic floor
plate hook onto the floor plate. See Figure 13.
2. Counterweight cover is attached to counterweight
by two capscrews and allows access to electrical
controllers. See Figure 13.
3. Manual hydraulic covers protect links during oper-
ation. For removal procedures for these covers
see Main Control Valves 2000YRM1334. See
Figure 13.
A. E-HYDRAULIC CONTROL LEVERS B. MANUAL HYDRAULIC CONTROL LEVERS
1. COUNTERWEIGHT
2. COUNTERWEIGHT COVER
3. CAPSCREW
4. FRAME
5. COWL
6. E-HYDRAULIC FLOOR PLATE
7. E-HYDRAULIC FLOOR PLATE
8. E-HYDRAULIC FLOOR MAT
9. MANUAL HYDRAULIC COVERS
10. MANUAL HYDRAULIC FLOOR PLATE
11. MANUAL HYDRAULIC FLOOR PLATE
12. MANUAL HYDRAULIC FLOOR MAT
Figure 13. Covers and Floor Plates for Lift Truck Models ERC16-20VA (ERC030-040VA) (A969)
0100 YRM 1342 Covers and Floor Plates
13

16. FOR LIFT TRUCK MODELS ERP22-35VL
(ERP045-070VL) (A976)
Various covers and floor plates provide access to
components during service and securely cover areas
during normal operations.
1. Floor mat and floor plates in operator compart-
ment allow access to service and parking brakes
and hydraulic control valve. The floor plate is fas-
tened to the frame with capscrews and washers.
The manual hydraulic floor plate and e-hydraulic
floor plate hook onto the floor plate. See Fig-
ure 14.
2. Counterweight cover is attached to counterweight
by a tow pin and two capscrews. This cover al-
lows access to electrical controllers, hydraulic
pump and motor, and hydraulic tank. See Fig-
ure 14.
3. Manual hydraulic covers protect links during oper-
ation. For removal procedures for these covers
see Main Control Valves 2000YRM1334. See
Figure 14.
A. E-HYDRAULIC CONTROL LEVERS B. MANUAL HYDRAULIC CONTROL LEVERS
1. COUNTERWEIGHT
2. FRAME
3. COWL
4. COUNTERWEIGHT COVER
5. TOW PIN
6. CAPSCREW
7. MANUAL HYDRAULIC FLOOR PLATE
8. MANUAL HYDRAULIC FLOOR PLATE
9. MANUAL HYDRAULIC FLOOR MAT
10. MANUAL HYDRAULIC COVERS
11. E-HYDRAULIC FLOOR PLATE
12. E-HYDRAULIC FLOOR PLATE
13. E-HYDRAULIC FLOOR MAT
Figure 14. Covers and Floor Plates for Lift Truck Models ERP22-35VL (ERP045-070VL) (A976)
Covers and Floor Plates 0100 YRM 1342
14

17. FOR LIFT TRUCK MODELS ERP40-50VM,
ERP50-55VM6 (ERP080-120VM,
ERP100VML) (A985)
Various covers and floor plates provide access to
components during service and securely cover areas
during normal operations.
1. Floor mat and floor plates in operator compart-
ment allow access to service brakes, hydraulic
control valve, and traction motor electrical control-
ler. The manual hydraulic floor plate and e-hy-
draulic floor plate hook onto the floor plate. See
Figure 15 or Figure 16.
2. Counterweight cover is attached to counterweight
by three captive capscrews. This cover allows ac-
cess to hydraulic pump electrical controller, hy-
draulic pump and motor, and hydraulic tank. See
Figure 15 or Figure 16.
3. Manual hydraulic covers protect links during oper-
ation. For removal procedures for these covers
see Main Control Valves 2000YRM1334. See
Figure 15 or Figure 16.
A. MANUAL HYDRAULIC CONTROL LEVERS B. E-HYDRAULIC CONTROL LEVERS
1. CAPTIVE CAPSCREW
2. COUNTERWEIGHT COVER
3. COUNTERWEIGHT
4. MANUAL HYDRAULIC FLOOR MAT
5. MANUAL HYDRAULIC FLOOR PLATE
6. MANUAL HYDRAULIC FLOOR PLATE
7. FRAME
8. MANUAL HYDRAULIC COVERS
9. COWL
10. E-HYDRAULIC FLOOR MAT
11. E-HYDRAULIC FLOOR PLATE
12. E-HYDRAULIC FLOOR PLATE
Figure 15. Covers and Floor Plates for Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM,
ERP100VML) (A985) Manufactured Before Nov, 2014
0100 YRM 1342 Covers and Floor Plates
15