ERC80VH, ERC100VH, ERC100VHS, ERC120VH (A938)

SERVICE MANUAL CONTENTS

PART YRM REV
SECTION NUMBER NUMBER DATE
FRAME............................................................................................................................ 524319489 0100 YRM 1342 09/14
AC MOTOR REPAIR...................................................................................................... 524327049 0620 YRM 1385 09/14
DRIVE AXLE/WET BRAKES.......................................................................................... 550053518 1300 YRM 1575 09/13
STEERING AXLE............................................................................................................ 524319491 1600 YRM 1360 09/14
STEERING SYSTEM...................................................................................................... 524319492 1600 YRM 1363 09/14
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
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 REPAIRS (S/N A551, A555, A559, A751, A752, B586, B587, B588, B590,
B591, B749, B750, B751, B752, AND B754)............................................................ 550053523 4000 YRM 1576 02/14
METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13
DIAGRAMS..................................................................................................................... 524332383 8000 YRM 1384 09/14
PERIODIC MAINTENANCE............................................................................................ 550053528 8000 YRM 1577 09/14
CAPACITIES AND SPECIFICATIONS........................................................................... 550053536 8000 YRM 1578 12/12
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. 550053510 (12/14)
0100 YRM 1342 General

General
DESCRIPTION FRAME
This section contains a description and service The frame is a single weldment with mounts for:
procedures for the parts of the frame. These parts • Counterweight
include the frame, counterweight assembly, overhead
guard, hood and seat assembly, access panels, and • Overhead guard
labels. • Tilt cylinders
• Drive axle, or if equipped, transaxle
Throughout this section, forward will refer to travel in
the direction of the forks and left and right will be • Floor plate and pedals
determined by an operator sitting in the seat facing • Side step and fender weldments
forward. See Figure 1. • 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
A. LEFT SIDE (ERP080-120VM, ERP100VML) (A985)
B. RIGHT SIDE
C. FORWARD TRAVEL See Figure 6 for lift truck models
Figure 1. Truck Orientation • ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938)
If a torque value is not specified, go to Metric and
Inch (SAE) Fasteners 8000YRM0231 for torque
values.

1
General 0100 YRM 1342

1. FRONT OVERHEAD GUARD MOUNTING 5. RIGHT FRAME CHANNEL

BRACKET 6. LEFT FRAME CHANNEL
2. REAR OVERHEAD GUARD MOUNTING 7. REAR BULKHEAD
BRACKET 8. TILT ANCHOR PLATE
3. COUNTERWEIGHT MOUNTING PLATE 9. SIDE STEP MOUNTING BRACKET
4. FRONT BULKHEAD

Figure 2. Frame Weldment for Lift Truck ERC22-35VG (ERC045-070VG) (A968)

2
0100 YRM 1342 General

1. FRONT OVERHEAD GUARD MOUNTING 5. RIGHT FRAME CHANNEL

BRACKET 6. LEFT FRAME CHANNEL
2. REAR OVERHEAD GUARD MOUNTING 7. REAR BULKHEAD
BRACKET 8. TILT ANCHOR PLATE
3. COUNTERWEIGHT MOUNTING PLATE 9. SIDE STEP MOUNTING BRACKET
4. FRONT BULKHEAD

Figure 3. Frame Weldment for Lift Truck ERC16-20VA (ERC030-040VA) (A969)

3
General 0100 YRM 1342

1. FRONT OVERHEAD GUARD MOUNTING 7. RIGHT FENDER

BRACKET 8. RIGHT FRAME CHANNEL
2. OPERATOR MODULE PLATE 9. LEFT FRAME CHANNEL
3. FRONT BULKHEAD 10. TILT ANCHOR PION
4. REAR BULKHEAD 11. DRIVE AXLE MOUNTS
5. COUNTERWEIGHT MOUNTING PLATE 12. SIDE STEP MOUNTING BRACKET
6. LEFT FENDER

Figure 4. Frame Weldment for Lift Truck ERP22-35VL (ERP045-070VL) (A976)

4
0100 YRM 1342 General

1. FRONT OVERHEAD GUARD MOUNTING 7. RIGHT FENDER

BRACKET 8. RIGHT FRAME CHANNEL
2. OPERATOR MODULE PLATE 9. LEFT FRAME CHANNEL
3. FRONT BULKHEAD 10. TILT ANCHOR PION
4. REAR BULKHEAD 11. DRIVE AXLE MOUNTS
5. COUNTERWEIGHT MOUNTING PLATE 12. SIDE STEP MOUNTING BRACKET
6. LEFT FENDER

Figure 5. Frame Weldment for Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML)
(A985)

5
General 0100 YRM 1342

1. FRONT OVERHEAD GUARD MOUNTING 5. RIGHT FRAME CHANNEL

BRACKET 6. LEFT FRAME CHANNEL
2. REAR OVERHEAD GUARD MOUNTING 7. REAR BULKHEAD
BRACKET 8. TILT ANCHOR PLATE
3. COUNTERWEIGHT MOUNTING PLATE 9. SIDE STEP MOUNTING BRACKET
4. FRONT BULKHEAD

Figure 6. Frame Weldment for Lift Trucks ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938)

The hydraulic and traction motor electronic controllers NOTE: Lift truck models ERC22-35VG
and contactors are located in the counterweight cavity (ERC045-070VG) (A968) manufactured after June,
for the following lift truck models 2012 are equipped with a removable floor plate that
• ERC22-35VG (ERC045-070VG) (A968) requires no tools to remove.

• ERC16-20VA (ERC030-040VA) (A969) For all lift truck models covered in this Service
• ERC40-55VH, ERC50VHS (ERC80-120VH, Manual, the Vehicle Systems Manager (VSM) is
ERC100VHS) (A938) either mounted on or near the front bulkhead
underneath the floor mat and floor plate.
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)

6
0100 YRM 1342 General

DISCHARGING THE CAPACITORS 3. Disconnect the battery by separating the

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

7
General 0100 YRM 1342

• 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

8
0100 YRM 1342 General

1. SIDE PANEL CUTOUT 4. INTERLOCK SWITCH

2. COVER 5. BATTERY CONNECTOR
3. BATTERY CABLES

Figure 8. Integrated (Quick Connect) Rapid Charge System, Lift Truck Models ERP22-35VL
(ERP045-070VL) (A976)

9
General 0100 YRM 1342

1. SIDE PANEL CUTOUT 4. INTERLOCK SWITCH

2. COVER 5. BATTERY CONNECTOR
3. BATTERY CABLES

Figure 9. Integrated (Quick Connect) Rapid Charge System, Lift Truck Models ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985)

GROUND TEST 1. Using an ohm meter, place a test lead at the

armrest mounting bolt and another at the truck
NOTE: If the static discharge ground connection is frame. The resistance needs to read 5 Ohms or
not secured properly, it could lead to the possible less. See Figure 10.
failure of the traction motor and/or pump motor
controller. 2. If resistance is greater than 5 Ohms, double
check installation of seat assembly, both ends of
To ensure proper installation of seat assembly and seat wiring harness, and wiring harness ground
associated bracketing, perform continuity test as strap.
described below:

10
0100 YRM 1342

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.

A. ARMREST FOR LIFT TRUCK MODELS WIDE TREAD MUD GUARD IS SIMILAR.
ERC045-070VG (A968), ERC030-040VA (A969),
ERP045-070VL (A976), ERP080-120VM (A985), 1. CAPSCREW
AND ERC80-120VH, ERC100VHS (A938) 2. NUT
B. ARMREST FOR LIFT TRUCK MODELS 3. MUD GUARD
ERC22-35VG (A968), ERC16-20VA (A969),
ERP22-35VL (A976), ERP40-50VM, Figure 11. Mud Guards
ERP50-55VM6 (A985), AND ERC40-55VH,
ERC50VHS (A938)
1. ARMREST BOLT
2. FRAME
Figure 10. Ground Test

11
Covers and Floor Plates 0100 YRM 1342

Covers and Floor Plates

FOR LIFT TRUCK MODELS ERC22-35VG to the frame with capscrews and washers. The
(ERC045-070VG) (A968) manual hydraulic floor plate and e-hydraulic floor
plate hook onto the floor plate. See Figure 12.
Various covers and floor plates provide access to
components during service and securely cover areas 2. Counterweight cover is attached to counterweight
during normal operations. by two capscrews and allows access to electrical
controllers. See Figure 12.
NOTE: Lift truck models ERC22-35VG
3. Manual hydraulic covers protect links during oper-
(ERC045-070VG) (A968) manufactured after June,
ation. For removal procedures for these covers
2012 are equipped with a removable floor plate that
see Main Control Valves 2000YRM1334. See
requires no tools to remove.
Figure 12.
1. Floor mat and floor plates in operator compart-
4. Hood latch cover is attached to bulkhead using
ment allow access to traction motor, hydraulic
two capscrews. See Figure 12.
pump and motor, service and parking brakes, and
hydraulic control valve. The floor plate is fastened

A. MANUAL HYDRAULIC CONTROL LEVERS B. E-HYDRAULIC CONTROL LEVERS

1. COUNTERWEIGHT COVER 8. COWL
2. CAPSCREW 9. E-HYDRAULIC FLOOR MAT
3. HOOD LATCH COVER* 10. E-HYDRAULIC FLOOR PLATE
4. MANUAL HYDRAULIC COVERS 11. COUNTERWEIGHT
5. MANUAL HYDRAULIC FLOOR MAT 12. FRAME
6. WASHER 13. FLOOR PLATE
7. MANUAL HYDRAULIC 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)

12
0100 YRM 1342 Covers and Floor Plates

FOR LIFT TRUCK MODELS ERC16-20VA 2. Counterweight cover is attached to counterweight

(ERC030-040VA) (A969) by two capscrews and allows access to electrical
controllers. See Figure 13.
Various covers and floor plates provide access to
components during service and securely cover areas 3. Manual hydraulic covers protect links during oper-
during normal operations. ation. For removal procedures for these covers
see Main Control Valves 2000YRM1334. See
1. Floor mat and floor plates in operator compart- Figure 13.
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.

A. E-HYDRAULIC CONTROL LEVERS B. MANUAL HYDRAULIC CONTROL LEVERS

1. COUNTERWEIGHT 7. E-HYDRAULIC FLOOR PLATE
2. COUNTERWEIGHT COVER 8. E-HYDRAULIC FLOOR MAT
3. CAPSCREW 9. MANUAL HYDRAULIC COVERS
4. FRAME 10. MANUAL HYDRAULIC FLOOR PLATE
5. COWL 11. MANUAL HYDRAULIC FLOOR PLATE
6. E-HYDRAULIC FLOOR PLATE 12. MANUAL HYDRAULIC FLOOR MAT

Figure 13. Covers and Floor Plates for Lift Truck Models ERC16-20VA (ERC030-040VA) (A969)

13
Covers and Floor Plates 0100 YRM 1342

FOR LIFT TRUCK MODELS ERP22-35VL 2. Counterweight cover is attached to counterweight

(ERP045-070VL) (A976) by a tow pin and two capscrews. This cover al-
lows access to electrical controllers, hydraulic
Various covers and floor plates provide access to pump and motor, and hydraulic tank. See Fig-
components during service and securely cover areas ure 14.
during normal operations.
3. Manual hydraulic covers protect links during oper-
1. Floor mat and floor plates in operator compart- ation. For removal procedures for these covers
ment allow access to service and parking brakes see Main Control Valves 2000YRM1334. See
and hydraulic control valve. The floor plate is fas- Figure 14.
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.

A. E-HYDRAULIC CONTROL LEVERS B. MANUAL HYDRAULIC CONTROL LEVERS

1. COUNTERWEIGHT 8. MANUAL HYDRAULIC FLOOR PLATE
2. FRAME 9. MANUAL HYDRAULIC FLOOR MAT
3. COWL 10. MANUAL HYDRAULIC COVERS
4. COUNTERWEIGHT COVER 11. E-HYDRAULIC FLOOR PLATE
5. TOW PIN 12. E-HYDRAULIC FLOOR PLATE
6. CAPSCREW 13. E-HYDRAULIC FLOOR MAT
7. MANUAL HYDRAULIC FLOOR PLATE

Figure 14. Covers and Floor Plates for Lift Truck Models ERP22-35VL (ERP045-070VL) (A976)

14
0100 YRM 1342 Covers and Floor Plates

FOR LIFT TRUCK MODELS ERP40-50VM, 2. Counterweight cover is attached to counterweight

ERP50-55VM6 (ERP080-120VM, by three captive capscrews. This cover allows ac-
ERP100VML) (A985) cess to hydraulic pump electrical controller, hy-
draulic pump and motor, and hydraulic tank. See
Various covers and floor plates provide access to Figure 15 or Figure 16.
components during service and securely cover areas
during normal operations. 3. Manual hydraulic covers protect links during oper-
ation. For removal procedures for these covers
1. Floor mat and floor plates in operator compart- see Main Control Valves 2000YRM1334. See
ment allow access to service brakes, hydraulic Figure 15 or Figure 16.
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.

A. MANUAL HYDRAULIC CONTROL LEVERS B. E-HYDRAULIC CONTROL LEVERS

1. CAPTIVE CAPSCREW 7. FRAME
2. COUNTERWEIGHT COVER 8. MANUAL HYDRAULIC COVERS
3. COUNTERWEIGHT 9. COWL
4. MANUAL HYDRAULIC FLOOR MAT 10. E-HYDRAULIC FLOOR MAT
5. MANUAL HYDRAULIC FLOOR PLATE 11. E-HYDRAULIC FLOOR PLATE
6. MANUAL 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

15
Covers and Floor Plates 0100 YRM 1342

A. MANUAL HYDRAULIC CONTROL LEVERS B. E-HYDRAULIC CONTROL LEVERS

1. CAPTIVE CAPSCREW 7. FRAME
2. COUNTERWEIGHT COVER 8. MANUAL HYDRAULIC COVERS
3. COUNTERWEIGHT 9. COWL
4. MANUAL HYDRAULIC FLOOR MAT 10. E-HYDRAULIC FLOOR MAT
5. MANUAL HYDRAULIC FLOOR PLATE 11. E-HYDRAULIC FLOOR PLATE
6. MANUAL HYDRAULIC FLOOR PLATE 12. E-HYDRAULIC FLOOR PLATE

Figure 16. Covers and Floor Plates for Lift Truck Models ERP40-55VM (ERP080-120VM ) (A985)
Manufactured After Nov, 2014

16
0100 YRM 1342 Overhead Guard Replacement

FOR LIFT TRUCK MODELS ERC40-55VH, 2. Counterweight cover is attached to counterweight

ERC50VHS (ERC80-120VH, ERC100VHS) by two capscrews and allow access to electrical
(A938) controllers. See Figure 17.

Various covers and floor plates provide access to 3. Manual hydraulic covers protect links during oper-
components during service and securely cover areas ation. For removal procedures for these covers
during normal operations. see Main Control Valves 2000YRM1334. See
Figure 17.
1. Floor mat and floor plates in operator compart-
ment allow access to traction motor, hydraulic
pump and motor, service brakes, and hydraulic
control valve. The manual hydraulic floor plate
and e-hydraulic floor plate hook onto floor plate.
See Figure 17.

A. MANUAL HYDRAULIC CONTROL LEVERS B. E-HYDRAULIC CONTROL LEVERS

1. CAPSCREW 7. MANUAL HYDRAULIC FLOOR PLATE
2. COUNTERWEIGHT COVER 8. MANUAL HYDRAULIC FLOOR MAT
3. COUNTERWEIGHT 9. COWL
4. FRAME 10. E-HYDRAULIC FLOOR PLATE
5. MANUAL HYDRAULIC COVERS 11. E-HYDRAULIC FLOOR PLATE
6. MANUAL HYDRAULIC FLOOR PLATE 12. E-HYDRAULIC FLOOR MAT

Figure 17. Covers and Floor Plates for Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938)

17
Overhead Guard Replacement 0100 YRM 1342

Overhead Guard Replacement

REMOVE See Periodic Maintenance 8000YRM1442 for lift
truck models
For Lift Trucks ERC22-35VG (ERC045-070VG) • ERC16-20VA (ERC030-040VA) (A969)
(A968), ERC16-20VA (ERC030-040VA) (A969),
and ERC40-55VH, ERC50VHS (ERC80-120VH, See Periodic Maintenance 8000YRM1577 for lift
ERC100VHS) (A938) truck models
• ERC40-55VH, ERC50VHS (ERC80-120VH,
WARNING ERC100VHS) (A938)
DO NOT operate lift truck without overhead guard 1. Remove battery from lift truck. See How to
correctly fastened to the lift truck frame. Change Battery in the Operating Manual or Pe-
riodic Maintenance manual above for proce-
WARNING dures.
DO NOT weld, drill, grind, or cut the overhead 2. Remove hood and seat assembly from lift truck.
guard for mounts of lights or accessories. The See section Hood and Seat Assembly Repair,
strength of the overhead guard can be reduced. Remove for procedures.

3. Access to rear capscrews is from the battery com-

WARNING
partment. Remove rear capscrews from rear over-
PUTTING THE LIFT TRUCK ON BLOCKS head guard legs and plates.
The lift truck must be put on blocks for some See Figure 18 for lift truck models
types of maintenance and repair. The removal of
the mast, drive axle, battery, or counterweight as- • ERC22-35VG (ERC045-070VG) (A968)
semblies will cause large changes in the center of • ERC16-20VA (ERC030-040VA) (A969)
gravity. When the lift truck is put on blocks, put
additional blocks in the following positions: See Figure 19 for lift truck models
If the mast and drive axle are removed, put • ERC40-55VH, ERC50VHS (ERC80-120VH,
blocks under the counterweight so the lift ERC100VHS) (A938)
truck cannot fall backward.
4. Remove front capscrews from front overhead
If the counterweight is removed, put blocks guard legs and from the right and left plates.
under the mast so that the lift truck cannot
fall forward. See Figure 18 for lift truck models
• ERC22-35VG (ERC045-070VG) (A968)
Put the lift truck on blocks on a solid, even, and
level surface. Verify the blocks or stands have • ERC16-20VA (ERC030-040VA) (A969)
enough capacity to hold the lift truck. Use addi-
tional blocks next to the tires as necessary to pre- See Figure 19 for lift truck models
vent movement of the lift truck. • ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938)
Verify the lifting devices used during repairs can
lift the weight of the parts and assemblies. NOTE: Note routing of electrical wires prior to discon-
necting.
See the Operating Manual or one of the following
service manuals for the procedure to put the lift NOTE: Tag electrical connectors during removal to
truck on blocks. aid in installation.

See Periodic Maintenance 8000YRM1364 for lift 5. Tag and disconnect electrical wires that go
truck models through the legs of overhead guard.
• ERC22-35VG (ERC045-070VG) (A968)

18
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