YALE (A968) ERC065VG FORKLIFT Service Repair Manual

Service Repair ERC22-35VG (ERC045-070VG) [A968]

PART NO. 524319502

8000 YRM 1374

8000 YRM 1374

Hydraulic System

Counterweights Model

* mm (* in.)

Weight

*Approximate battery compartment lengths (identifies frame size).

ERC22VG (ERC045VG)

786 mm (31 in.)

ERC22VG (ERC045VG) and ERC25VG (ERC050VG)

847 mm (33 in.)

ERC22VG (ERC045VG)

700 mm (28 in.)

ERC25VG (ERC050VG)

786 mm (31 in.)

ERC055VG

847 mm (33 in.)

ERC32VG (ERC065VG)

1015 mm (40 in.)

ERC25VG (ERC050VG)

700 mm (28 in.)

ERC30VG (ERC060VG)

847 mm (33 in.)

ERC32VG (ERC065VG)

933 mm (37 in.)

ERC35VG (ERC070VG)

1015 mm (40 in.)

571 kg (1259 lb)

764 kg (1684 lb)

948 kg (2090 lb)

Hydraulic System Table 1. Manual Hydraulic Control Valve Item Relief Valve Pressure Oil Temperature

Specification 50 to 65°C (122 to 149°F)

Relief Valve Pressure ERC22-25VG (ERC045-055VG) Primary at Pump Pressure Gauge Port

21.9 ±0.48 MPa (3177.3 ±69.6 psi)

Relief Valve Pressure ERC30-35VG (ERC060-070VG) Primary at Pump Pressure Gauge Port

23.9 ±0.48 MPa (3466.4 ±69.6 psi)

Relief Valve Pressure ERC22-35VG (ERC045-070VG) Secondary at tilt or auxiliary port Secondary at Pump Pressure Gauge Port

15.5 ±0.48 MPa (2248.1 ±69.6 psi) 16.5 ±0.48 MPa (2398 ±69.6 psi)

1

Steering System

8000 YRM 1374

Table 2. E-Hydraulic Control Valve Item

Specification

Relief Valve Pressure Oil Temperature

50 to 65°C (122 to 149°F)

Relief Valve Pressure ERC22-25VG (ERC045-055VG) Primary at Pump Pressure Gauge Port

21.9 ±0.48 MPa (3177.3 ±69.6 psi)

Relief Valve Pressure ERC30-35VG (ERC060-070VG) Primary at Pump Pressure Gauge Port

23.9 ±0.48 MPa (3466.4 ±69.6 psi)

Relief Valve Pressure ERC22-35VG (ERC045-070VG) Secondary at tilt or auxiliary port

15.5 ±0.48 MPa (2248.1 ±69.6 psi)

Secondary at Pump Pressure Gauge Port

16.5 ±0.48 MPa (2398 ±69.6 psi)

Steering System SPECIFICATIONS Item

Specification

Steering Oil Temperature

50 to 65°C (122 to 149°F)

Inside Tire angle

82°

Number of Turns on Steer Wheel

4.2

Steer Relief Pressure at Pressure Line of SCU

11.0 ±0.3 MPa (1595.4 ±43.5 psi)

Steering Cylinder Stroke

169.2 mm (6.6 in.)

3.0 sec

Steering Time at Idle

TURNING RADIUS Model

Turning Radius 700 mm (28 in.) Battery Compartment

ERC22VG (ERC045VG)

1735 mm (68 in.)

ERC25VG (ERC050VG)

1757 mm (69 in.)

786 mm (31 in.) Battery Compartment ERC22VG (ERC045VG)

1825 mm (72 in.)

ERC25VG (ERC050VG)

1825 mm (72 in.)

847 mm (33 in.) Battery Compartment ERC22VG (ERC045VG)

1884 mm (74 in.)

ERC25VG (ERC050VG)

1884 mm (74 in.)

ERC055VG

1893 mm (75 in.)

ERC30VG (ERC060VG)

1915 mm (75 in.)

933 mm (37 in.) Battery Compartment

2

8000 YRM 1374

Wheels and Tires Model

Turning Radius

ERC32VG (ERC065VG)

2008 mm (79 in.)

1015 mm (40 in.) Battery Compartment ERC32VG (ERC065VG)

2074 mm (82 in.)

ERC35VG (ERC070VG)

2094 mm (82 in.)

Wheels and Tires Item Torque - Wheel Nuts, Drive Tires

Specification 340 to 380 N•m (251 to 280 lbf ft)

Torque - Steering Wheel Bearing Nut** Initial Torque

68 N•m (50 lbf ft)

Final Torque

3 N•m (27 lbf in)

Drive Tires* ERC22-25VG (ERC045-050VG)

21 × 7 × 15

ERC30-32VG (ERC055-060VG)

21 × 8 × 15

ERC35VG (ERC070VG)

21 × 9 × 15

Steer Tires* ERC22-25VG (ERC045-055VG)

16 × 5 × 10.5

ERC30-32VG (ERC060-065VG)

16 × 6 × 10.5

ERC35VG (ERC070VG)

16 × 7 × 10.5

*Smooth, lug tread; standard, and non-marking, compound **See Steering Axle 1600 YRM 1360 for correct procedure.

3

Battery Specifications

8000 YRM 1374

Battery Specifications Table 3. ERC20-35VG (ERC045-070VG) (A968) Model Trucks

Model

ERC22VGERC25VG (ERC045VGERC050VG) ERC045VGERC050VG ERC22VGERC30VG (ERC045VGERC060VG) ERC065VG

ERC32-35VG (ERC070VG)

Minimum Compartment Size Length Ă— Width

Battery Size Min/Max Length

Weight

Width

Minimum

Maximum

978 to 983 mm (38.5 to 38.7 in.)

1050 kg (2314 lb)

1500 kg (3307 lb)

781 x 987 mm 978/983 mm 739/777 mm (30.7 x (38.5/ (29.1/30.6 in.)

38.9 in.)

38.7 in.)

1150 kg (2535 lb)

1600 kg (3527 lb)

842 x 987 mm 978/983 mm 800/838 mm (33.1 x (38.5/ (31.5/32.9 in.)

38.9 in.)

38.7 in.)

1317 kg (2903 lb)

1771 kg (3904 lb)

928 x 987 mm 978/983 mm 900/924 mm (36.5 x (38.5/ (35.4/36.4 in.)

38.9 in.)

38.7 in.)

1410 kg (3108 lb)

1860 kg (4100 lb)

1010 x 1001/ 978/983 mm 987 mm (39.8 1006 mm (38.5/ x 38.9 in.) (39.4/39.6 in.) 38.7 in.)

1550 kg (3417 lb)

2000 kg (4409 lb)

695 x 987 mm 681 to (27.4 x 691 mm (26.8 38.9 in.) to 27.2 in.)

Maximum Battery Height

585 mm (23.0 in.)

585 mm (23.0 in.)

585 mm (23.0 in.)

585 mm (23.0 in.)

585 mm (23.0 in.)

NOTE: Tolerances of the battery compartment are +3 and 0 mm (+0.12 and 0 in.). The battery size column shows the size range that will permit the battery to still fit into a battery compartment.

NOTE: Battery compartment length is front to back. Width is side to side. The "length" dimension of the battery must fit within the battery compartment front-to-back dimension with a clearance of 0 to 13 mm (0 to 0.5 in.) maximum.

Battery width must fit within the battery compartment side-to-side dimension.

WARNING

The battery must fit the battery compartment so that the battery restraint system will operate correctly. Use only batteries with the correct length shown in this table. Adjust the spacer plate to prevent the battery from moving more than 13 mm (0.5 in.) forward or backward.

4

8000 YRM 1374

Tilt Angles

Capacities Item

Specification

Hydraulic System (Full Mark on Dipstick)* Drain and Refill

29.7 liter (31.4 qt)

Usable Oil

20.8 liter (22.0 qt)

Differential/Speed Reducer ERC22-35VG (ERC045-070VG)

4.8 liter (5.1 qt)

Brake Fluid ERC22-35VG (ERC045-070VG)

0.18 liter (0.4 pt)

Hydraulic Pump** 22.0 cm 3 /rev (1.34 in. 3 /rev)

Displacement System Relief Pressure

20.6 MPa (2987.8 psi)

Max Peak Pressure

24.5 MPa (3553.4 psi)

Speed

300 to 3000 RPM

Inlet Pressure

20 to +49 kPa ( 3 to +7 psi)

*Check after all air is removed from the system and with the mast fully lowered. **Oil temperature at 80 to 100°C (176 to 212°F)

Tilt Angles Tilt Angles: Measure with lift truck on level ground and in unloaded condition.

Forward

Tolerance (Ref)

Back

Tolerance

10°

+1°,

0.5°

5°

+0°,

0.5°

5°

+1°,

0.5°

5°

+0°,

0.5°

5°

+1°,

0.5°

4°

+0°,

0.5°

NOTE: With reference to mast mounting assembly drawings, section B-B dimension "X" must not exceed 20 mm (0.8 in.) in all rod end configurations.

Back tilt tolerance must be obtained for all rod end configurations.

In some truck/tire configurations, some rod end configurations may not achieve the "ref only" forward tilt tolerance.

But forward tilt is still satisfactory.

5

Mast Speeds

8000 YRM 1374

Maximum Carriage and Tilt Creep Rates Hydraulic Oil Temperature/Mast Tilt Rate Lift Truck Model

All Models

Hydraulic Oil Temperature

Maximum Vertical Creep at Carriage

Maximum Tilt Creep Mast Angle

Cylinder Stroke

°C

°F

mm/min

in./min

Deg/Min

mm/min

in./min

20

68

2.2

0.086

0.10

0.88

0.035

30

86

3.3

0.130

0.15

1.32

0.05

40

104

6.3

0.247

0.29

2.56

0.10

50

122

10.0

0.394

0.47

4.14

0.16

60

140

14.6

0.575

0.68

5.99

0.24

Mast Speeds Table 4. Lift/Lower Speed, Standard Performance, 36 Volts Model

ERC22VG (ERC045VG)

ERC25VG (ERC050VG)

ERC055VG

6

Mast

Lowering Speed m/sec (ft/sec)

Lifting Speed m/sec (ft/sec)

No Load

Rated Load

No Load

Rated Load

Two-Stage LFL

0.51 m (1.67 ft)

0.57 m (1.87 ft)

0.51 m (1.67 ft)

0.30 m (0.98 ft)

Two-Stage FFL

0.46 m (1.51 ft)

0.52 m (1.70 ft)

0.47 m (1.54 ft)

0.30 m (0.98 ft)

Three-Stage FFL

0.47 m (1.54 ft)

0.54 m (1.77 ft)

0.48 m (1.57 ft)

0.30 m (0.98 ft)

Four-Stage FFL

0.39 m (1.28 ft)

0.45 m (1.48 ft)

0.49 m (1.61 ft)

0.30 m (0.98 ft)

Two-Stage LFL

0.51 m (1.67 ft)

0.57 m (1.87 ft)

0.51 m (1.67 ft)

0.28 m (0.92 ft)

Two-Stage FFL

0.46 m (1.51 ft)

0.54 m (1.77 ft)

0.47 m (1.54 ft)

0.29 m (0.95 ft)

Three-Stage FFL

0.47 m (1.54 ft)

0.55 m (1.55 ft)

0.48 m (1.57 ft)

0.29 m (0.95 ft)

Four-Stage FFL

0.39 m (1.28 ft)

0.46 m (1.51 ft)

0.49 m (1.61 ft)

0.29 m (0.95 ft)

Two-Stage LFL

0.51 m (1.67 ft)

0.58 m (1.90 ft)

0.51 m (1.67 ft)

0.27 m (0.89 ft)

Two-Stage FFL

0.46 m (1.51 ft)

0.55 m (1.55 ft)

0.47 m (1.54 ft)

0.29 m (0.95 ft)

Three-Stage FFL

0.47 m (1.54 ft)

0.56 m (1.84 ft)

0.48 m (1.57 ft)

0.28 m (0.92 ft)

Four-Stage FFL

0.39 m (1.28 ft)

0.46 m (1.51 ft)

0.49 m (1.61 ft)

0.29 m (0.95 ft)

8000 YRM 1374

Mast Speeds

Table 4. Lift/Lower Speed, Standard Performance, 36 Volts (Continued) Model

ERC30VG (ERC060VG)

ERC32VG (ERC065VG)

ERC35VG (ERC070VG)

Mast

Lowering Speed m/sec (ft/sec)

Lifting Speed m/sec (ft/sec)

No Load

Rated Load

No Load

Rated Load

Two-Stage LFL

0.46 m (1.51 ft)

0.56 m (1.84 ft)

0.47 m (1.54 ft)

0.25 m (0.82 ft)

Two-Stage FFL

0.37 m (1.21 ft)

0.52 m (1.70 ft)

0.42 m (1.38 ft)

0.25 m (0.82 ft)

Three-Stage FFL

0.40 m (1.31 ft)

0.53 m (1.74 ft)

0.43 m (1.41 ft)

0.25 m (0.82 ft)

Four-Stage FFL

0.39 m (1.28 ft)

0.46 m (1.51 ft)

0.49 m (1.61 ft)

0.29 m (0.95 ft)

Two-Stage LFL

0.46 m (1.51 ft)

0.56 m (1.84 ft)

0.47 m (1.54 ft)

0.24 m (0.79 ft)

Two-Stage FFL

0.37 m (1.21 ft)

0.53 m (1.74 ft)

0.42 m (1.38 ft)

0.24 m (0.79 ft)

Three-Stage FFL

0.40 m (1.31 ft)

0.54 m (1.77 ft)

0.43 m (1.41 ft)

0.24 m (0.79 ft)

Four-Stage FFL

0.39 m (1.28 ft)

0.46 m (1.51 ft)

0.49 m (1.61 ft)

0.29 m (0.95 ft)

Two-Stage LFL

0.46 m (1.51 ft)

0.58 m (1.90 ft)

0.47 m (1.54 ft)

0.23 m (0.75 ft)

Two-Stage FFL

0.37 m (1.21 ft)

0.54 m (1.77 ft)

0.42 m (1.38 ft)

0.23 m (0.75 ft)

Three-Stage FFL

0.40 m (1.31 ft)

0.56 m (1.84 ft)

0.43 m (1.41 ft)

0.23 m (0.75 ft)

Four-Stage FFL

0.39 m (1.28 ft)

0.46 m (1.51 ft)

0.49 m (1.61 ft)

0.29 m (0.95 ft)

Table 5. Lift/Lower Speed, Standard Performance, 48 Volts Model

ERC22VG (ERC045VG)

Mast

Lowering Speed m/sec (ft/sec)

Lifting Speed m/sec (ft/sec)

No Load

Rated Load

No Load

Rated Load

Two-Stage LFL

0.51 m (1.67 ft)

0.57 m (1.87 ft)

0.53 m (1.74 ft)

0.40 m (1.31 ft)

Two-Stage FFL

0.46 m (1.51 ft)

0.52 m (1.70 ft)

0.63 m (2.10 ft)

0.41 m (1.35 ft)

Three-Stage FFL

0.47 m (1.54 ft)

0.54 m (1.77 ft)

0.63 m (2.10 ft)

0.40 m (1.35 ft)

Four-Stage FFL

0.39 m (1.28 ft)

0.45 m (1.48 ft)

0.63 m (2.10 ft)

0.40 m (1.35 ft)

7

Mast Speeds

8000 YRM 1374

Table 5. Lift/Lower Speed, Standard Performance, 48 Volts (Continued) Model

ERC25VG (ERC050VG)

ERC055VG

ERC30VG (ERC060VG)

ERC32VG (ERC065VG)

8

Mast

Lowering Speed m/sec (ft/sec)

Lifting Speed m/sec (ft/sec)

No Load

Rated Load

No Load

Rated Load

Two-Stage LFL

0.51 m (1.67 ft)

0.57 m (1.87 ft)

0.63 m (2.10 ft)

0.38 m (1.25 ft)

Two-Stage FFL

0.46 m (1.51 ft)

0.54 m (1.77 ft)

0.63 m (2.10 ft)

0.39 m (1.28 ft)

Three-Stage FFL

0.47 m (1.54 ft)

0.55 m (1.55 ft)

0.63 m (2.10 ft)

0.39 m (1.28 ft)

Four-Stage FFL

0.39 m (1.28 ft)

0.46 m (1.51 ft)

0.63 m (2.10 ft)

0.38 m (1.25 ft)

Two-Stage LFL

0.51 m (1.67 ft)

0.58 m (1.90 ft)

0.63 m (2.10 ft)

0.36 m (1.18 ft)

Two-Stage FFL

0.46 m (1.51 ft)

0.55 m (1.55 ft)

0.63 m (2.10 ft)

0.38 m (1.25 ft)

Three-Stage FFL

0.47 m (1.54 ft)

0.56 m (1.84 ft)

0.63 m (2.10 ft)

0.37 m (1.21 ft)

Four-Stage FFL

0.39 m (1.28 ft)

0.46 m (1.51 ft)

0.63 m (2.10 ft)

0.38 m (1.25 ft)

Two-Stage LFL

0.46 m (1.51 ft)

0.56 m (1.84 ft)

0.59 m (1.94 ft)

0.33 m (1.10 ft)

Two-Stage FFL

0.37 m (1.21 ft)

0.52 m (1.70 ft)

0.55 m (1.80 ft)

0.33 m (1.10 ft)

Three-Stage FFL

0.40 m (1.31 ft)

0.53 m (1.74 ft)

0.57 m (1.87 ft)

0.33 m (1.10 ft)

Four-Stage FFL

0.39 m (1.28 ft)

0.46 m (1.51 ft)

0.63 m (2.10 ft)

0.38 m (1.25 ft)

Two-Stage LFL

0.46 m (1.51 ft)

0.57 m (1.87 ft)

0.59 m (1.94 ft)

0.32 m (1.05 ft)

Two-Stage FFL

0.37 m (1.21 ft)

0.53 m (1.74 ft)

0.55 m (1.80 ft)

0.32 m (1.05 ft)

Three-Stage FFL

0.40 m (1.31 ft)

0.54 m (1.77 ft)

0.57 m (1.87 ft)

0.32 m (1.05 ft)

Four-Stage FFL

0.39 m (1.28 ft)

0.46 m (1.51 ft)

0.63 m (2.10 ft)

0.38 m (1.25 ft)

8000 YRM 1374

Mast Speeds

Table 5. Lift/Lower Speed, Standard Performance, 48 Volts (Continued) Model

ERC35VG (ERC070VG)

Mast

Lowering Speed m/sec (ft/sec)

Lifting Speed m/sec (ft/sec)

No Load

Rated Load

No Load

Rated Load

Two-Stage LFL

0.46 m (1.51 ft)

0.58 m (1.90 ft)

0.59 m (1.94 ft)

0.31 m (1.02 ft)

Two-Stage FFL

0.37 m (1.21 ft)

0.54 m (1.77 ft)

0.55 m (1.80 ft)

0.31 m (1.02 ft)

Three-Stage FFL

0.40 m (1.31 ft)

0.56 m (1.84 ft)

0.57 m (1.87 ft)

0.31 m (1.02 ft)

Four-Stage FFL

0.39 m (1.28 ft)

0.46 m (1.51 ft)

0.63 m (2.10 ft)

0.38 m (1.25 ft)

Table 6. Lift/Lower Speed Enhanced Performance, 48 Volts Model

ERC22VG (ERC045VG)

ERC25VG (ERC050VG)

ERC055VG

Mast

Lowering Speed m/sec (ft/sec)

Lifting Speed m/sec (ft/sec)

No Load

Rated Load

No Load

Rated Load

Two-Stage LFL

0.51 m (1.67 ft)

0.57 m (1.87 ft)

0.72 m (2.36 ft)

0.52 m (1.70 ft)

Two-Stage FFL

0.46 m (1.51 ft)

0.52 m (1.70 ft)

0.66 m (2.17 ft)

0.50 m (1.64 ft)

Three-Stage FFL

0.47 m (1.54 ft)

0.54 m (1.77 ft)

0.68 m (2.23 ft)

0.51 m (1.67 ft)

Four-Stage FFL

0.39 m (1.28 ft)

0.45 m (1.48 ft)

0.69 m (2.26 ft)

0.51 m (1.67 ft)

Two-Stage LFL

0.51 m (1.67 ft)

0.57 m (1.87 ft)

0.72 m (2.36 ft)

0.49 m (1.61 ft)

Two-Stage FFL

0.46 m (1.51 ft)

0.54 m (1.77 ft)

0.66 m (2.17 ft)

0.47 m (1.54 ft)

Three-Stage FFL

0.47 m (1.54 ft)

0.55 m (1.80 ft)

0.68 m (2.23 ft)

0.48 m (1.57 ft)

Four-Stage FFL

0.39 m (1.28 ft)

0.46 m (1.51 ft)

0.69 m (2.26 ft)

0.48 m (1.57 ft)

Two-Stage LFL

0.51 m (1.67 ft)

0.58 m (1.90 ft)

0.72 m (2.36 ft)

0.47 m (1.54 ft)

Two-Stage FFL

0.46 m (1.51 ft)

0.55 m (1.80 ft)

0.66 m (2.17 ft)

0.45 m (1.48 ft)

Three-Stage FFL

0.47 m (1.54 ft)

0.56 m (1.84 ft)

0.68 m (2.23 ft)

0.46 m (1.51 ft)

Four-Stage FFL

0.39 m (1.28 ft)

0.46 m (1.51 ft)

0.69 m (2.26 ft)

0.48 m (1.57 ft)

9

Mast Speeds

8000 YRM 1374

Table 6. Lift/Lower Speed Enhanced Performance, 48 Volts (Continued) Model

ERC30VG (ERC060VG)

ERC32VG (ERC065VG)

ERC35VG (ERC070VG)

Mast

Lowering Speed m/sec (ft/sec)

Lifting Speed m/sec (ft/sec)

No Load

Rated Load

No Load

Rated Load

Two-Stage LFL

0.46 m (1.51 ft)

0.56 m (1.84 ft)

0.63 m (2.10 ft)

0.42 m (1.38 ft)

Two-Stage FFL

0.37 m (1.21 ft)

0.52 m (1.70 ft)

0.59 m (1.94 ft)

0.41 m (1.35 ft)

Three-Stage FFL

0.40 m (1.31 ft)

0.53 m (1.74 ft)

0.60 m (1.97 ft)

0.41 m (1.35 ft)

Four-Stage FFL

0.39 m (1.28 ft)

0.46 m (1.51 ft)

0.69 m (2.26 ft)

0.48 m (1.57 ft)

Two-Stage LFL

0.46 m (1.51 ft)

0.57 m (1.87 ft)

0.63 m (2.10 ft)

0.40 m (1.31 ft)

Two-Stage FFL

0.37 m (1.21 ft)

0.53 m (1.74 ft)

0.59 m (1.94 ft)

0.39 m (1.28 ft)

Three-Stage FFL

0.40 m (1.31 ft)

0.54 m (1.77 ft)

0.60 m (1.97 ft)

0.39 m (1.28 ft)

Four-Stage FFL

0.39 m (1.28 ft)

0.46 m (1.51 ft)

0.69 m (2.26 ft)

0.48 m (1.57 ft)

Two-Stage LFL

0.46 m (1.51 ft)

0.58 m (1.90 ft)

0.63 m (2.10 ft)

0.37 m (1.21 ft)

Two-Stage FFL

0.37 m (1.21 ft)

0.54 m (1.77 ft)

0.59 m (1.94 ft)

0.37 m (1.21 ft)

Three-Stage FFL

0.40 m (1.31 ft)

0.56 m (1.84 ft)

0.60 m (1.97 ft)

0.37 m (1.21 ft)

Four-Stage FFL

0.39 m (1.28 ft)

0.46 m (1.51 ft)

0.69 m (2.26 ft)

0.48 m (1.57 ft)

Table 7. Lift/Lower Speed, Enhanced Performance, 80 Volts Model

ERC22VG (ERC045VG)

10

Mast

Lowering Speed m/sec (ft/sec)

Lifting Speed m/sec (ft/sec)

No Load

Rated Load

No Load

Rated Load

Two-Stage LFL

0.51 m (1.67 ft)

0.57 m (1.87 ft)

0.72 m (2.36 ft)

0.52 m (1.70 ft)

Two-Stage FFL

0.46 m (1.51 ft)

0.52 m (1.70 ft)

0.66 m (2.17 ft)

0.50 m (1.64 ft)

Three-Stage FFL

0.47 m (1.54 ft)

0.54 m (1.77 ft)

0.68 m (2.23 ft)

0.51 m (1.67 ft)

Four-Stage FFL

0.39 m (1.28 ft)

0.45 m (1.48 ft)

0.69 m (2.26 ft)

0.51 m (1.67 ft)

8000 YRM 1374

Mast Speeds

Table 7. Lift/Lower Speed, Enhanced Performance, 80 Volts (Continued) Model

ERC25VG (ERC050VG)

ERC055VG

ERC30VG (ERC060VG)

ERC32VG (ERC065VG)

Mast

Lowering Speed m/sec (ft/sec)

Lifting Speed m/sec (ft/sec)

No Load

Rated Load

No Load

Rated Load

Two-Stage LFL

0.51 m (1.67 ft)

0.57 m (1.87 ft)

0.72 m (2.36 ft)

0.49 m (1.61 ft)

Two-Stage FFL

0.46 m (1.51 ft)

0.54 m (1.77 ft)

0.66 m (2.17 ft)

0.47 m (1.54 ft)

Three-Stage FFL

0.47 m (1.54 ft)

0.55 m (1.55 ft)

0.68 m (2.23 ft)

0.48 m (1.57 ft)

Four-Stage FFL

0.39 m (1.28 ft)

0.46 m (1.51 ft)

0.69 m (2.26 ft)

0.48 m (1.57 ft)

Two-Stage LFL

0.51 m (1.67 ft)

0.58 m (1.90 ft)

0.72 m (2.36 ft)

0.47 m (1.54 ft)

Two-Stage FFL

0.46 m (1.51 ft)

0.55 m (1.55 ft)

0.66 m (2.17 ft)

0.45 m (1.48 ft)

Three-Stage FFL

0.47 m (1.54 ft)

0.56 m (1.84 ft)

0.68 m (1.57 ft)

0.46 m (0.92 ft)

Four-Stage FFL

0.39 m (1.28 ft)

0.46 m (1.51 ft)

0.69 m (2.26 ft)

0.48 m (1.57 ft)

Two-Stage LFL

0.46 m (1.51 ft)

0.56 m (1.84 ft)

0.63 m (2.10 ft)

0.42 m (1.38 ft)

Two-Stage FFL

0.37 m (1.21 ft)

0.52 m (1.70 ft)

0.59 m (1.94 ft)

0.41 m (1.35 ft)

Three-Stage FFL

0.40 m (1.31 ft)

0.53 m (1.74 ft)

0.60 m (1.97 ft)

0.41 m (1.35 ft)

Four-Stage FFL

0.39 m (1.28 ft)

0.46 m (1.51 ft)

0.69 m (2.26 ft)

0.48 m (1.57 ft)

Two-Stage LFL

0.46 m (1.51 ft)

0.57 m (1.87 ft)

0.63 m (2.10 ft)

0.40 m (1.31 ft)

Two-Stage FFL

0.37 m (1.21 ft)

0.53 m (1.74 ft)

0.59 m (1.94 ft)

0.39 m (1.28 ft)

Three-Stage FFL

0.40 m (1.31 ft)

0.53 m (1.74 ft)

0.60 m (1.97 ft)

0.39 m (1.28 ft)

Four-Stage FFL

0.39 m (1.28 ft)

0.46 m (1.51 ft)

0.69 m (2.26 ft)

0.48 m (1.57 ft)

11

Torque Specifications

8000 YRM 1374

Table 7. Lift/Lower Speed, Enhanced Performance, 80 Volts (Continued) Model

ERC35VG (ERC070VG)

Lowering Speed m/sec (ft/sec)

Mast

Lifting Speed m/sec (ft/sec)

No Load

Rated Load

No Load

Rated Load

Two-Stage LFL

0.46 m (1.51 ft)

0.58 m (1.90 ft)

0.63 m (2.10 ft)

0.37 m (1.21 ft)

Two-Stage FFL

0.37 m (1.21 ft)

0.54 m (1.77 ft)

0.59 m (1.94 ft)

0.37 m (1.21 ft)

Three-Stage FFL

0.40 m (1.31 ft)

0.56 m (1.84 ft)

0.60 m (1.97 ft)

0.37 m (1.21 ft)

Four-Stage FFL

0.39 m (1.28 ft)

0.46 m (1.51 ft)

0.69 m (2.26 ft)

0.48 m (1.57 ft)

Torque Specifications FRAME

DIFFERENTIAL AND SPEED REDUCER

Overhead Guard Front Leg Capscrew 66 N•m (49 lbf ft) Rear Leg Capscrew 270 N•m (199 lbf ft)

Bearing Cap Capscrews for Differential Bearings (4) 225 to 270 N•m (166 to 199 lbf ft)

Counterweight Upper Capscrew 755 N•m (557 lbf ft) Lower Capscrew 90 N•m (67 lbf ft)

Center Section Cover Capscrews 19 to 23 N•m (168 to 204 lbf in)

Traction Motor to Mounting Flange 38 to 48 N•m (28 to 35 lbf ft)

DRIVE AXLE Wheel Nuts 340 to 380 N•m (251 to 280 lbf ft) Axle Shaft to Drive Hub Capscrews M12 × 1.75 × 35 (16 each side) 90 to 99 N•m (66 to 73 lbf ft) Drive Axle Mounting Bolts 755 to 830 N•m (557 to 612 lbf ft) Axle Hangers to Drive Axle Housing Capscrews 90 to 99 N•m (66 to 73 lbf ft) Brake Assembly to Axle Mount Capscrews 255 to 306 N•m ( lbf ft)

12

Figure 1. Tightening Sequence - Hub Capscrews

8000 YRM 1374

Torque Specifications

Differential Case Half Capscrews (Speed Reducer) 125 to 145 N•m (92 to 107 lbf ft)

Brake Pedal Lock Nut 15 to 17 N•m (133 to 150 lbf in)

Differential Assembly Capscrews (Speed Reducer) 152 to 167 N•m (112 to 123 lbf ft)

Brake Pedal Assembly to Bracket Capscrew 165 N•m (122 lbf ft)

Bearing Retainer Capscrews (Speed Reducer) 19 to 23 N•m (168 to 204 lbf in)

STEERING AXLE

Pinion Nut (Speed Reducer) Initial Torque 530 to 645 N•m (391 to 476 lbf ft) Final Torque 370 to 410 N•m (273 to 302 lbf ft) Pinion Shaft Rotating Torque (Speed Reducer) 4 to 6 N•m (35 to 53 lbf in)

BRAKE SYSTEM Back Plate Lock Bolts 255 to 306 N•m (188 to 226 lbf ft)

Axle to Mount Brackets Capscrews 90 N•m (66 lbf ft) Steering Cylinder to Axle Capscrews 225 to 280 N•m (166 to 206 lbf ft) Bearing Cap Capscrews 44 N•m (32 lbf ft) Castle Nut, Wheel Nut (2) Initial 68 N•m (50 lbf ft) while rotating wheel. Loosen, then 3 N•m (25 lbf in) Castle Nut to Tie Rod Assembly 163 N•m (120 lbf ft)

MASTS Sideshift Carriage Cylinder Retainer Screws 325 ±30 N•m (240 ±25 lbf ft) Lower Mounting Hook Capscrews 165 ±15 N•m (120 ±12 lbf ft) Backrest to Carriage Capscrews 195 N•m (144 lbf ft) Capscrews, Hanger Caps Mast to Mount Pivot Pins 270 N•m (199 lbf ft)

Figure 2. Tightening Sequence - Lock Bolts Wheel Bearing Lock Nut Alignment 14 to 18 N•m (124 to 159 lbf in) Bearing Seat 175 to 215 N•m (129 to 159 lbf ft) Bearing Preload and Final 14 to 18 N•m (124 to 159 lbf in) Wheel Cylinder to Back Plate Capscrew 18 to 27 N•m (159 to 239 lbf in) Master Cylinder Push Rod Lock Nut 15 to 17 N•m (133 to 150 lbf in) Master Cylinder to Mounting Plate Nuts 19 N•m (168 lbf in) Brake Sensor 23 to 28 N•m (203 to 247 lbf in)

Main Lift Cylinder Mount Capscrews 40 N•m (30 lbf ft) Lowering Control Valve Housing to Mast Capscrews 18 N•m (159 lbf in) Sheave Assembly Capscrews (13) 66 N•m (49 lbf ft) Header Hose Clamp Hardware (12) 8 N•m (71 lbf in) Free Lift Cylinder Bracket Capscrews 53 N•m (39 lbf ft) Header Hose Strap Clamp Capscrews 4-Stage Full Free-Lift 18 N•m (13 lbf ft)

13

Torque Specifications Hose Sheave Axle Capscrews and Sheave Nuts 4-Stage Full Free-Lift 57 N•m (39 lbf ft) Roller Guide Capscrews and Nuts 4-Stage Full Free-Lift 8 N•m (71 lbf in) Intermediate Channel Block Capscrews 4-Stage Full Free-Lift 18 N•m (13 lbf ft)

8000 YRM 1374 Suction Strainer 135 N•m (100 lbf ft) Filter Housing Capscrews 10 N•m (86 lbf in) Fitting 45 N•m (33 lbf ft) Tank Level Sensor 45 N•m (33 lbf ft)

Tilt Rod End Capscrews (2) 38 N•m (28 lbf ft)

Pressure Switch to Filter Housing 25 N•m (221 lbf in)

Tilt Cylinder Mount to Outer Mast Capscrew 90 N•m (66 lbf ft)

Breather Adapter Mounting Capscrews 25 N•m (221 lbf in)

TILT CYLINDERS

HYDRAULIC CONTROL VALVES

Tilt Rod End Capscrews (2) 38 N•m (28 lbf ft)

Manual Valve

Tilt Cylinder Mount to Outer Mast Capscrew 90 N•m (66 lbf ft)

HYDRAULIC PUMP AND MOTOR

Tie Rod Nuts 18 to 20 N•m (156 to 180 lbf in) Position Sensor Connector Nut 18 to 20 N•m (156 to 180 lbf in)

Motor Mount Capscrews 12 N•m (106 lbf in)

Steer Load Sense Fitting 16 N•m (142 lbf in)

Pump to Motor Capscrews 25 N•m (221 lbf in)

Diagnostic Fitting 16 N•m (142 lbf in)

Pump Flange Head Screws 88 to 98 N•m (65 to 72 lbf ft)

Main Relief Valve 27 N•m (20 lbf ft)

Coupling Setscrews 11 to 13 N•m (97 to 115 lbf in)

Compensator Plug 47 N•m (35 lbf ft)

Pressure Line Fitting to Hydraulic Pump 49 to 59 N•m (36 to 44 lbf ft)

Small Port Plugs 13.5 N•m (119 lbf in)

Suction Hose Adapter to Hydraulic Pump 91 to 100 N•m (67 to 74 lbf ft)

Medium Port Plugs 65 N•m (48 lbf ft)

Motor Power Cable Nuts 24 N•m (212 lbf in)

Large Port Plugs 60 to 72 N•m (44 to 53 lbf ft)

HYDRAULIC TANK

Manual Lowering Valve 54 N•m (40 lbf ft)

Drain Plug 40 N•m (30 lbf ft) Temperature Sensor 19 to 21 N•m (168 to 186 lbf in)

14

Lift Port Plug - Long 27 N•m (20 lbf ft) Lift Port Plug - Short 54 N•m (40 lbf ft)

8000 YRM 1374

Adhesives and Sealants

Tilt Relief Cartridge 27 N•m (20 lbf ft)

Manual Lowering Valve 54 N•m (40 lbf ft)

End Auxiliary Port Plugs 14 N•m (124 lbf in)

Tilt Relief Valve 27 N•m (20 lbf ft)

Position Sensor Capscrews 4.7 N•m (42 lbf in)

Tilt Section Plug 27 N•m (20 lbf ft)

Spool Lock Solenoid 7.5 N•m (66 lbf in)

Lift Section Plug 27 N•m (20 lbf ft)

Manual Handles and Levers

Pilot Cartridge 65 N•m (45 lbf ft)

Outer Capscrews 1.36 to 1.65 N•m (11.9 to 14.6 lbf in)

Connector Jam Nuts 7 to 11 N•m (62 to 97 lbf in)

Manual Valve Covers

Solenoids 5 N•m (48 lbf in)

Lower Cover Capscrews 2.82 to 3.16 N•m (24.95 to 27.97 lbf in)

ELECTRICAL SYSTEM

Front Cover Capscrews 2.82 to 3.16 N•m (24.95 to 27.97 lbf in)

Controller Power Cable Capscrews M8 x 1.25 (10) 18 to 21 N•m (159 to 186 lbf in)

E-Hydraulic Valve

Traction Motor Power Cable Capscrews (3) 10 N•m (89 lbf in)

Tie Rod Nuts 19 to 22 N•m (168 to 195 lbf in)

Hydraulic Pump Motor Capscrews (3) 16 N•m (142 lbf in)

Elbow Fitting 16 N•m (142 lbf in)

Static Strap Capscrew (1) 15 to 17 N•m (133 to 150 lbf in)

Main Relief Valve 27 N•m (20 lbf ft)

Battery Connector to Line Contactor Nut (1) 14 to 15 N•m (124 to 133 lbf in)

Port Option Plug 54 N•m (40 lbf ft)

Adhesives and Sealants Yale Part No.

Loctite® Part No.

Description

520042831

515

HCE-98 Adhesive

504232260

24231

Removable Threadlock (Blue)

Size 50 ml (1.7 oz)

15

1300 YRM 1366

Drive Axle Repair

General This section has the repair procedures for the drive axle/speed reducer/differential.

Drive Axle Repair REMOVE 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 additional 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.

Periodic Maintenance 8000 YRM 1442 for lift truck models • ERC16-20VA (ERC030-040VA) (A969) 3. Remove the covers or plates and rollers from bottom of battery compartment. See Frame 100 YRM 1342 for procedures.

4. Remove the mast assembly. See one of the following service manuals for procedures.

Mast Repair, 2-, 3-, and 4-Stage Masts 4000 YRM 1338 for lift truck models • ERC22-35VG (ERC045-070VG) (A968) Mast Repair, 2- and 3-Stage Masts 4000 YRM 1441 for lift truck models • ERC16-20VA (ERC030-040VA) (A969) 5. Disconnect the brake line connecting the master cylinder to the manifold located on top of the drive axle assembly. See Figure 1.

See the Operating Manual or Periodic Maintenance section for your lift truck model, for the procedures to put the lift truck on blocks.

1. Place the lift truck on blocks. The procedure for placing the lift truck on blocks may be found in the Operating Manual or one of the following service manuals Periodic Maintenance 8000 YRM 1364 for lift truck models • ERC22-35VG (ERC045-070VG) (A968) Periodic Maintenance 8000 YRM 1442 for lift truck models • ERC16-20VA (ERC030-040VA) (A969) 2. Remove the battery from the lift truck. See How to Change Battery in the Operating Manual or Periodic Maintenance 8000 YRM 1364 for lift truck models • ERC22-35VG (ERC045-070VG) (A968)

NOTE: LIFT TRUCK MODELS ERC22-35VG (ERC045-070VG) (A968) SHOWN. LIFT TRUCK MODELS ERC16-20VA (ERC030-040VA) (A969) ARE SIMILAR. 1. JAM NUT 2. PARKING BRAKE CABLE 3. BRAKE LINE

Figure 1. Brake Line Removal

1

Drive Axle Repair 6. Loosen the jam nuts and remove the parking brake cables from the brackets. See Figure 1.

7. Remove the drain plug and drain the oil from the drive axle. See Figure 2.

1300 YRM 1366 See Brake System 1800 YRM 1359 for lift truck models • ERC22-35VG (ERC045-070VG) (A968) See Brake System 1800 YRM 1438 for lift truck models • ERC16-20VA (ERC030-040VA) (A969) NOTE: In Step 11 and Step 12 make sure NOT to lift the tires off the surface.

NOTE: Use a lift truck to support drive axle and traction motor as a unit or use a transmission jack under the traction motor and a floor jack under the drive axle during removal.

NOTE: DRIVE AXLE FOR LIFT TRUCK MODELS ERC22-35VG (ERC045-070VG) (A968) SHOWN. DRIVE AXLE FOR LIFT TRUCK MODELS ERC1620VA (ERC030-040VA) (A969) IS SIMILAR. 1.

2.

3.

4.

5.

DRAIN PLUG AXLE MOUNTING BOLT WASHER NUT DRIVE AXLE ASSEMBLY

Figure 2. Drive Axle NOTE: Tag electrical connectors during removal to aid in installation.

8. Tag and disconnect power cable from traction motor.

NOTE: Perform Step 9 only if lift truck is equipped with optional drip shield.

9. Remove capscrews, nuts, and drip shield from frame, allowing access to traction motor.

NOTE: Perform Step 10 if lift truck is equipped with an automatic park brake.

10. Disconnect automatic park brake from traction motor. See Figure 3.

2

11. Slide floor jack under the drive axle assembly differential. Raise floor jack until it supports the weight of the drive axle assembly.

NOTE: The traction motors are in different configurations for different applications of the lift trucks. Traction motors weigh approximately 90 to 140 kg (200 to 310 lb). Make sure transmission jack has capacity to hold traction motor.

12. Slide transmission jack under traction motor. Raise transmission jack until it supports the weight of the traction motor.

13. Remove the four axle mounting bolts, washers and nuts from the drive axle assembly. See Figure 2.

NOTE: Remove drive axle and traction motor as a single unit.

14. Roll the floor jack and transmission jack with drive axle and traction motor from underneath the lift truck.

NOTE: Forklift trucks with 4-Stage Quad Mast will have an optional spacer between the drive axle mount and the frame’s mounting bracket.

15. If lift truck is equipped with a 4-Stage Quad Mast, remove the spacer from the drive axle mount. Repeat for other side. See Figure 4.

1300 YRM 1366

Drive Axle Repair

NOTE: TRACTION MOTOR ARRANGEMENT FOR LIFT TRUCK MODELS ERC22-35VG (ERC045-070VG) (A968) SHOWN. TRACTION MOTOR ARRANGEMENT FOR LIFT TRUCK MODELS ERC16-20VA (ERC030-040VA) (A969) IS SIMILAR. A. TRACTION MOTOR

B. TRACTION MOTOR WITH OPTIONAL AUTOMATIC PARK BRAKE

1. TRACTION MOTOR 2. AUTOMATIC PARK BRAKE

3. DRIVE AXLE

Figure 3. Traction Motor

3

Drive Axle Repair

1300 YRM 1366 20. Place blocks under the center section assembly, and remove the lifting device.

21. Remove the wheels.

DISASSEMBLE 1. Remove capscrews, axle shaft, bearing locknut, bearing lock washer, wheel bearing washer, and hub assembly from the hanger assembly. Discard the bearing lock washer. See Figure 6.

2. Remove outer bearing cone from the hub. See Figure 6.

3. Remove the inner seal, inner bearing cone, and outer seal from the hub. Discard the inner and outer seals. See Figure 6.

NOTE: Locking feature of lock bolts is a ONE TIME ONLY. Be sure to discard lock bolts after removal.

1. DRIVE AXLE MOUNT 2. SPACER 3. FRAME MOUNTING BRACKET

Figure 4. Optional Spacer for 4-Stage Quad Mast 16. Remove capscrews from mounting flange and traction motor. See Figure 5.

17. Use pry bar, as necessary, to separate mounting flange and traction motor. See Figure 5.

18. Remove and discard O-ring from traction motor.

See Figure 5. Set traction motor aside.

19. Use a lifting device to raise the drive axle enough to lift the wheels off the floor. Remove the floor jack from under the drive axle.

4

4. Remove eight lock bolts and brake assembly from the hanger assembly. See Figure 6. Discard the lock bolts.

NOTE: Perform Step 5 for lift truck models ERC2235VG (ERC045-070VG) (A968).

5. Remove seven capscrews, seven washers, and the hanger assembly from the center section assembly.

See Figure 6.

NOTE: Perform Step 6 for lift truck models ERC1620VA (ERC030-040VA) (A969).

6. Remove six capscrews, six washers, and the hanger assembly from the center section assembly. See Figure 6.

1300 YRM 1366

Drive Axle Repair

NOTE: DRIVE AXLE AND TRACTION MOTOR ARRANGEMENT FOR LIFT TRUCK MODELS ERC22-35VG (ERC045-070VG) (A968) SHOWN. DRIVE AXLE AND TRACTION MOTOR ARRANGEMENT FOR LIFT TRUCK MODELS ERC16-20VA (ERC030-040VA) (A969) IS SIMILAR. 1. TRACTION MOTOR 2. MOUNTING FLANGE 3. CAPSCREW

4. O-RING 5. PRY POINT

Figure 5. Drive Axle and Traction Motor

5

Drive Axle Repair

1300 YRM 1366

NOTE: DRIVE AXLE ARRANGEMENT FOR LIFT TRUCK MODELS ERC22-35VG (ERC045-070VG) (A968) SHOWN. DRIVE AXLE ARRANGEMENT FOR LIFT TRUCK MODELS ERC16-20VA (ERC030-040VA) (A969) IS SIMILAR. 1.

2.

3.

4.

5.

6.

7.

8.

9.

CAPSCREW AXLE SHAFT BEARING LOCKNUT BEARING LOCK WASHER WHEEL BEARING WASHER OUTER BEARING CONE OUTER BEARING CUP HUB OUTER SEAL

10.

11.

12.

13.

14.

15.

16.

17.

INNER BEARING CUP INNER BEARING CONE INNER SEAL LOCK BOLT BRAKE ASSEMBLY WASHER L.H. HANGER CENTER SECTION ASSEMBLY

Figure 6. Drive Axle

6

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