Maintenance
HYDRAULIC SYSTEM
ERC20-35VG (ERC045-070VG) [A968];
ERC16-20VA (ERC030-040VA) [A969];
ERP20-35VL (ERP045-070VL) [A976];
ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) [A985];
ERC40-55VH, ERC50VHS
(ERC80-120VH, ERC100VHS) [A938]
PART NO. 524319494 1900 YRM 1367
SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Yale
®
dealer.
Service Manuals provide general guidelines for maintenance and service and are intended for use by
trained and experienced technicians. Failure to properly maintain equipment or to follow instructions con-
tained in the Service Manual could result in damage to the products, personal injury, property damage or
death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the
load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the
weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK
ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the
specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to re-
move parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable.
Be sure to follow the necessary safety precautions when handling these fuels and when working on these
fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area.
Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this man-
ual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
©2014 Yale Materials Handling Corp.
TABLE OF CONTENTS
General ..................................................................................................................................................................... 1
Discharging the Capacitors .................................................................................................................................. 2
Hydraulic Pump and Motor ....................................................................................................................................... 2
Remove ................................................................................................................................................................ 2
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968)............................................................................... 3
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969)............................................................................... 6
Lift Truck Models ERP22-25VL (ERP045-070VL) (A976).................................................................................9
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)............................ 12
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938)..................................... 13
Disassemble ....................................................................................................................................................... 19
Lift Truck Models , ERC22-35VG (ERC045-070VG) (A968)........................................................................... 19
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976)...............................................................................21
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)............................ 23
Inspect ................................................................................................................................................................ 25
Clean .................................................................................................................................................................. 25
Assemble ............................................................................................................................................................ 25
Lift Truck Models , ERC22-35VG (ERC045-070VG) (A968)........................................................................... 25
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976)...............................................................................25
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)............................ 26
Install .................................................................................................................................................................. 26
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938)................................... 26
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968)............................................................................. 27
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969)............................................................................. 28
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976)...............................................................................29
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)............................ 29
Hydraulic Tank ........................................................................................................................................................ 30
Remove .............................................................................................................................................................. 30
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968)............................................................................. 31
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938)................................... 31
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969)............................................................................. 35
Lift Truck Models ERP22-25VL (ERP045-070VL) (A976)...............................................................................38
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)............................ 39
Disassemble ....................................................................................................................................................... 43
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968)............................................................................. 43
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938)................................... 43
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969)............................................................................. 44
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976)...............................................................................45
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)............................ 45
Clean .................................................................................................................................................................. 48
Steam Method ................................................................................................................................................ 48
Chemical Method ........................................................................................................................................... 49
Inspect ................................................................................................................................................................ 49
Small Leaks, Repair ....................................................................................................................................... 49
Large Leaks, Repair ....................................................................................................................................... 49
Additional Methods for Metal Tank Repair ..................................................................................................... 49
Assemble ............................................................................................................................................................ 50
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968)............................................................................. 50
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938)................................... 51
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969)............................................................................. 51
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976)...............................................................................51
Table of Contents
i
TABLE OF CONTENTS (Continued)
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)............................ 52
Install .................................................................................................................................................................. 52
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968).............................................................................52
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938)................................... 53
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969)............................................................................. 54
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976)...............................................................................54
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)............................ 55
Hydraulic Filter Replacement ............................................................................................................................. 55
Breather Clean and Inspect ................................................................................................................................ 56
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969)...... 56
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938)................................... 59
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976)...............................................................................59
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)............................ 59
Hydraulic Oil Cooler for Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM,
ERP100VML) (A985)........................................................................................................................................... 60
Add Hydraulic Oil ................................................................................................................................................ 60
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968)............................................................................. 60
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938)................................... 60
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969)............................................................................. 60
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976)...............................................................................62
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)............................ 63
Steer Accumulator Replacement ............................................................................................................................ 64
Remove .............................................................................................................................................................. 64
Install .................................................................................................................................................................. 70
Specifications for Lift Truck ERC22-35VG (ERC045-070VG) (A968)..................................................................... 71
Tank Capacity .....................................................................................................................................................71
Specifications for Lift Truck ERC16-20VA (ERC030-040VA) (A969)...................................................................... 71
Tank Capacity .....................................................................................................................................................71
Specifications for Lift Truck ERP22-25VL (ERP045-070VL) (A976)....................................................................... 72
Tank Capacity .....................................................................................................................................................72
Specifications for Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)..................... 72
Tank Capacity .....................................................................................................................................................72
Specifications for Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938)............................ 72
Tank Capacity .....................................................................................................................................................72
Torque Specifications for Lift Truck ERC22-35VG (ERC045-070VG) (A968)......................................................... 73
Hydraulic Pump and Motor ................................................................................................................................. 73
Hydraulic Tank ....................................................................................................................................................73
Torque Specifications for Lift Truck ERC16-20VA (ERC030-040VA) (A969).......................................................... 73
Hydraulic Pump and Motor ................................................................................................................................. 73
Hydraulic Tank ....................................................................................................................................................73
Torque Specifications for Lift Truck ERP22-35VL (ERP045-070VL) (A976)........................................................... 74
Hydraulic Pump and Motor ................................................................................................................................. 74
Hydraulic Tank ....................................................................................................................................................74
Torque Specifications for Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)........ 74
Hydraulic Pump and Motor ................................................................................................................................. 74
Hydraulic Tank ....................................................................................................................................................74
Torque Specifications for Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938)............... 75
Hydraulic Pump and Motor ................................................................................................................................. 75
Hydraulic Tank ....................................................................................................................................................75
Table of Contents
ii
This section is for the following models:
ERC20-35VG (ERC045-070VG) [A968];
ERC16-20VA (ERC030-040VA) [A969];
ERP20-35VL (ERP045-070VL) [A976];
ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) [A985];
ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) [A938]
Table of Contents
iii
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Description
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