Maintenance

STEERING AXLE
ERC22-35VG (ERC045-070VG) [A968];
ERC16-20VA (ERC030-040VA) [A969];
ERP22-35VL (ERP045-070VL) [A976];
ERP16-20VF (ERP30-40VF) [A955];
ERP40-50VM, ERP50-55VM6 (ERP080-120VM,
ERP100VML) [A985];
ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) [A938]

PART NO. 524319491 1600 YRM 1360

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• 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 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
remove 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.
 Table of Contents

TABLE OF CONTENTS
General ..................................................................................................................................................................... 1
Steering Axle Assembly Repair ................................................................................................................................ 2
Remove ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969) and
ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) ..................................................................... 3
Disassemble ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969)
and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) .............................................................. 4
Clean .....................................................................................................................................................................8
Inspect .................................................................................................................................................................. 8
Assemble ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969) and
ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) ..................................................................... 8
Install ERC22-35VG (ERC045-070VG) (A968) .................................................................................................. 10
Install ERC16-20VA (ERC030-040VA) (A969) .................................................................................................... 11
Install ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) .........................................................12
Remove ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985) ............................................................................................................. 14
Disassemble ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985) ............................................................................................................. 18
Clean ...................................................................................................................................................................20
Inspect ................................................................................................................................................................ 20
Assemble ERP40-50VM, ERP50-55MV6 (ERP080-120VM, ERP100VML) (A985) ........................................... 20
Assemble ERP22-35VL (ERP045-070VL) (A976) .............................................................................................. 21
Wheel Bearing Adjustment ERP22-35VL (ERP045-070VL) (A976) ............................................................... 22
Install ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) .........................................................................................................................23
Remove ERP16-20VF (ERP30-40VF) (A955) .................................................................................................... 29
Disassemble ERP16-20VF (ERP30-40VF) (A955) .............................................................................................29
Clean ...................................................................................................................................................................31
Inspect ................................................................................................................................................................ 31
Assemble ERP16-20VF (ERP30-40VF) (A955) ..................................................................................................31
Install ERP16-20VF (ERP30-40VF) (A955) ........................................................................................................ 32
Tie Rod Replacement ............................................................................................................................................. 32
Remove ERC20-35VG (ERC045-070VG) (A968) and ERC40-55VH, ERC50VHS
(ERC80-120VH, ERC100VHS) (A938) ............................................................................................................... 33
Clean ...................................................................................................................................................................34
Inspect ................................................................................................................................................................ 34
Install ERC20-35VG (ERC045-070VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938) .......................................................................................................................................... 34
Remove ERC16-20VA (ERC030-040VA) (A969) ................................................................................................34
Clean ...................................................................................................................................................................35
Inspect ................................................................................................................................................................ 35
Install ERC16-20VA (ERC030-040VA) (A969) ....................................................................................................35
Remove ERP20-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985) ............................................................................................................. 36
Clean ...................................................................................................................................................................36
Inspect ................................................................................................................................................................ 37
Install ERP20-35VL (ERP045-070VL) (A976) andERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985) ............................................................................................................. 37
Remove ERP16-20VF (ERP30-40VF) (A955) .................................................................................................... 37
Clean ...................................................................................................................................................................38
Inspect ................................................................................................................................................................ 38
Install ERP16-20VF (ERP30-40VF) (A955) ........................................................................................................ 38
Spindle Repair ........................................................................................................................................................ 38

©2018 Yale Materials Handling Corp. i

Table of Contents

TABLE OF CONTENTS (Continued)

Remove ERC22-35VG (ERC45-70VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938) .......................................................................................................................................... 38
Disassemble ERC22-35VG (ERC45-70VG) (A968) and ERC40-55VH, ERC50VHS
(ERC80-120VH, ERC100VHS) (A938) ............................................................................................................... 40
Clean ...................................................................................................................................................................40
Inspect ................................................................................................................................................................ 40
Assemble ERC22-35VG (ERC45-70VG) (A968) and ERC40-55VH, ERC50VHS
(ERC80-120VH, ERC100VHS) (A938) ............................................................................................................... 41
Install ERC22-35VG (ERC45-70VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938) .......................................................................................................................................... 41
Remove ERC16-20VA (ERC030-040VA) (A969) ................................................................................................42
Disassemble ERC16-20VA (ERC030-040VA) (A969) .........................................................................................42
Clean ...................................................................................................................................................................43
Inspect ................................................................................................................................................................ 43
Assemble ERC16-20VA (ERC030-040VA) (A969) ............................................................................................. 43
Install ERC16-20VA (ERC030-040VA) (A969) ....................................................................................................44
Remove ERP22-35VL (ERP45-70VL) (A976) and ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985) ............................................................................................................. 44
Disassemble ERP22-35VL (ERP45-70VL) (A976) and ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985) ............................................................................................................. 46
Clean ...................................................................................................................................................................46
Inspect ................................................................................................................................................................ 46
Assemble ERP22-35VL (ERP45-70VL) (A976) .................................................................................................. 47
Install ERP22-35VL (ERP45-70VL) (A976) ........................................................................................................ 47
Assemble ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) ........................................... 47
Install ERP22-35VL (ERP45-70VL) (A976) and ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985) ............................................................................................................. 47
Remove ERP16-20VF (ERP30-40VF) (A955) .................................................................................................... 48
Disassemble ERP16-20VF (ERP30-40VF) (A955) .............................................................................................49
Clean ...................................................................................................................................................................50
Inspect ................................................................................................................................................................ 50
Assemble ERP16-20VF (ERP30-40VF) (A955) ..................................................................................................50
Install ERP16-20VF (ERP30-40VF) (A955) ........................................................................................................ 50
Steering Cylinder Repair .........................................................................................................................................51
Remove ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) ......................... 51
Disassemble ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) .................. 54
Clean ...................................................................................................................................................................55
Inspect ................................................................................................................................................................ 55
Assemble ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) .......................55
Install ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) ............................. 55
Remove ERC16-20VA (ERC030-040VA) (A969) ................................................................................................56
Disassemble ERC16-20VA (ERC030-040VA) (A969) .........................................................................................57
Clean ...................................................................................................................................................................58
Inspect ................................................................................................................................................................ 59
Assemble ERC16-20VA (ERC030-040VA) (A969) ............................................................................................. 59
Install ERC16-20VA (ERC030-040VA) (A969) ....................................................................................................59
Remove ERP16-20VF (ERP30-40VF) (A955) .................................................................................................... 59
Disassemble ERP16-20VF (ERP30-40VF) (A955) .............................................................................................60
Clean ...................................................................................................................................................................61
Inspect ................................................................................................................................................................ 61
Assemble ERP16-20VF (ERP30-40VF) (A955) ..................................................................................................61
Install ERP16-20VF (ERP30-40VF) (A955) ........................................................................................................ 62

ii
 Table of Contents

TABLE OF CONTENTS (Continued)

Remove ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) ..............................................62
Disassemble ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) ...................................... 63
Clean ...................................................................................................................................................................64
Inspect ................................................................................................................................................................ 64
Assemble ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) ........................................... 65
Install ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) ..................................................65
Remove ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) .....................................................65
Disassemble ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) ..............................................67
Clean ...................................................................................................................................................................68
Inspect ................................................................................................................................................................ 68
Assemble ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) .................................................. 68
Install ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) .........................................................68

This section is for the following models:

ERC22-35VG (ERC045-070VG) [A968];

ERC16-20VA (ERC030-040VA) [A969];
ERP22-35VL (ERP045-070VL) [A976];
ERP16-20VF (ERP30-40VF) [A955];
ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) [A985];
ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) [A938]

iii
1600 YRM 1360 General

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

1
General 1600 YRM 1360

NOTE: MOUNTS AND TIRES MAY BE DIFFERENT BETWEEN TRUCK MODELS.

A. CUSHION TRUCKS ONLY B. PNEUMATIC TRUCKS ONLY

1. AXLE FRAME 7. TIE ROD

2. STEERING DIRECTION SENSOR CABLE 8. SPINDLE ASSEMBLY
BRACKET 9. MOUNT
3. STEERING DIRECTION SENSOR 10. CUSHION TIRE WHEEL ASSEMBLY
4. MOUNT 11. PNEUMATIC HUB ASSEMBLY
5. MOUNT BRACKET
6. STEERING CYLINDER

Figure 1. Steering Axle

2
1600 YRM 1360 Steering Axle Assembly Repair

Steering Axle Assembly Repair

REMOVE ERC22-35VG (ERC045-070VG) • ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938)
(A968), ERC16-20VA (ERC030-040VA)
(A969) AND ERC40-55VH, ERC50VHS 2. Slide floor jack under steering axle. Raise floor
(ERC80-120VH, ERC100VHS) (A938) jack until it holds the weight of the axle assembly.

NOTE: Tag hydraulic lines prior to disconnecting from

WARNING steering cylinder to aid in the correct connection of
PUTTING THE LIFT TRUCK ON BLOCKS hydraulic lines during installation.
The lift truck must be put on blocks for some types 3. Disconnect hydraulic hoses at steering cylinder.
of maintenance and repair. The removal of the Install plug fittings in cylinder and put caps on
mast, drive axle, battery, or counterweight hydraulic hoses. Plug fittings will prevent spindles
assemblies will cause large changes in the center from turning as axle is removed from under the lift
of gravity. When the lift truck is put on blocks, put truck.
additional blocks in the following positions:
4. Remove four capscrews that fasten the mount
• If the mast and drive axle are removed, put brackets under the rubber mounts.
blocks under the counterweight so the lift
truck cannot fall backward. See Figure 2 for lift truck models
• If the counterweight is removed, put blocks • ERC22-35VG (ERC045-070VG) (A968)
under the mast so that the lift truck cannot
fall forward. See Figure 3 for lift truck models
Put the lift truck on blocks on a solid, even, and • ERC16-20VA (ERC030-040VA) (A969)
level surface. Verify the blocks or stands have See Figure 4 for lift truck models
enough capacity to hold the lift truck. Use
additional blocks next to the tires as necessary to • ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938)
prevent movement of the lift truck. Verify the lifting
devices used during repairs can lift the weight of
the parts and assemblies.
See the Operating Manual or Periodic Maintenance
section for your lift truck model, for the
procedures to put the lift truck on blocks.

The steering axle can be removed without removing

the counterweight.

1. Place the lift trucks on blocks. The procedure for

placing the lift truck on blocks may be found in the
Operating Manual or in one of the following
service manuals:
Periodic Maintenance 8000YRM1364 for lift
truck models
• ERC22-35VG (ERC045-070VG) (A968)
1. CAPSCREW
Periodic Maintenance 8000YRM1442 for lift 2. WASHER
truck models 3. NUT
4. REAR MOUNT BRACKET
• ERC16-20VA (ERC030-040VA) (A969) 5. STEER AXLE
6. FRONT MOUNT BRACKET
Periodic Maintenance 8000YRM1577 for lift
truck models Figure 2. Steer Axle Removal ERC22-35VG
(ERC045-070VG) (A968)

3
Steering Axle Assembly Repair 1600 YRM 1360

NOTE: The steering direction sensor is an optional

feature on ERC22-35VG (ERC045-070VG) (A968),
ERC16-20VA (ERC030-040VA) (A969) and
ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938) lift trucks.
5. Carefully lower the floor jack enough to
disconnect, if installed, steering direction sensor
cable from the main wiring harness.
See Figure 5 for lift truck models
• ERC22-35VG (ERC045-070VG) (A968)
See Figure 6 for lift truck models
• ERC16-20VA (ERC030-040VA) (A969)
See Figure 7 for lift truck models
• ERC40-55VH, ERC50VHS (ERC80-120VH,
1. CAPSCREW ERC100VHS) (A938)
2. WASHER
3. NUT 6. Remove the steer axle from the under the lift
4. REAR MOUNT BRACKET truck.
5. STEER AXLE
6. FRONT MOUNT BRACKET
DISASSEMBLE ERC22-35VG
Figure 3. Steer Axle Removal ERC16-20VA (ERC045-070VG) (A968), ERC16-20VA
(ERC030-040VA) (A969) (ERC030-040VA) (A969) AND
ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938)
1. Place steering axle on blocks so the wheels just
touch the floor.

2. Remove hub cap, cotter pin, castle nut, and

washer. Discard cotter pin.
See Figure 5 for lift truck models
• ERC22-35VG (ERC045-070VG) (A968)
See Figure 6 for lift truck models
• ERC16-20VA (ERC030-040VA) (A969)
See Figure 7 for lift truck models
1. CAPSCREW
2. WASHER • ERC40-55VH, ERC50VHS (ERC80-120VH,
3. NUT ERC100VHS) (A938)
4. REAR MOUNT BRACKET
5. STEER AXLE
6. FRONT MOUNT BRACKET

Figure 4. Steer Axle Removal ERC40-55VH,

ERC50VHS (ERC80-120VH, ERC100VHS) (A938)

4
1600 YRM 1360 Steering Axle Assembly Repair

1. HUB CAP 11. OIL SEAL

2. CASTLE NUT 12. AXLE ASSEMBLY
3. COTTER PIN 13. MOUNT
4. WASHER 14. CAPSCREW
5. OUTER BEARING CONE 15. BRACKET
6. OUTER BEARING CUP 16. WASHER
7. SOLID TIRE WHEEL 17. LOCKNUT
8. INNER BEARING CUP 18. STEERING DIRECTION SENSOR
9. INNER BEARING CONE 19. STEERING DIRECTION SENSOR CABLE
10. WEAR RING BRACKET

Figure 5. Steering Axle Assembly for ERC22-35VG (ERC045-070VG) (A968)

5
Steering Axle Assembly Repair 1600 YRM 1360

1. HUB CAP 9. INNER BEARING CONE

2. CASTLE NUT 10. OIL SEAL
3. COTTER PIN 11. AXLE ASSEMBLY
4. WASHER 12. MOUNT
5. OUTER BEARING CONE 13. CAPSCREW
6. OUTER BEARING CUP 14. BRACKET
7. SOLID TIRE WHEEL 15. WASHER
8. INNER BEARING CUP 16. LOCKNUT

Figure 6. Steering Axle Assembly for ERC16-20VA (ERC030-040VA) (A969)

6
1600 YRM 1360 Steering Axle Assembly Repair

1. HUB CAP 11. OIL SEAL

2. CASTLE NUT 12. AXLE ASSEMBLY
3. COTTER PIN 13. MOUNT
4. WASHER 14. CAPSCREW
5. OUTER BEARING CONE 15. BRACKET
6. OUTER BEARING CUP 16. WASHER
7. SOLID TIRE WHEEL 17. LOCKNUT
8. INNER BEARING CUP 18. STEERING DIRECTION SENSOR
9. INNER BEARING CONE 19. STEERING DIRECTION SENSOR CABLE
10. WEAR RING BRACKET

Figure 7. Steering Axle Assembly for Lift Trucks ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS)
(A938)

NOTE: Identify and tag the outer and inner bearing 5. Remove inner bearing cone, wear ring (if present)
cones so they can be reassembled in their original and oil seal from spindle.
locations.
See Figure 5 for lift truck models
3. Remove outer bearing cone from the wheel. ERC22-35VG (ERC045-070VG) (A968)
•
4. Remove wheel from spindle. See Figure 6 for lift truck models
• ERC16-20VA (ERC030-040VA) (A969)
NOTE: For correct orientation during installation, note
the position of the oil seal during removal. See Figure 7 for lift truck models
NOTE: The wear ring may not be present on all • ERC40-55VH, ERC50VHS (ERC80-120VH,
steering axles. ERC100VHS) (A938)

6. Remove the mounts from the axle assembly.

7
Steering Axle Assembly Repair 1600 YRM 1360

NOTE: Bearing cones are to be replaced as sets. If 3. Inspect the rubber mounts for signs of damage or
one bearing cone has been determined to be cracking. Replace, if necessary.
unserviceable, then both must be replaced.
4. Inspect the oils seals and wear rings for any
7. If the bearing cones are to be replaced, remove
damage. Replace, if damaged.
the inner and outer bearing cups from the wheel
using a brass drift pin. 5. Inspect spindle assemblies and tie rods for signs
of damage. Replace, if necessary, in accordance
8. Repeat Step 1 through Step 7 for the other wheel.
with Spindle Repair and Tie Rod Replacement.
CLEAN 6. Inspect the remainder of the axle assembly for
damage, and repair or replace as necessary.
WARNING
Cleaning solvents can be flammable and toxic and ASSEMBLE ERC22-35VG (ERC045-070VG)
can cause skin irritation. When using cleaning (A968), ERC16-20VA (ERC030-040VA)
solvents, always follow the solvent manufacturer’s (A969) AND ERC40-55VH, ERC50VHS
recommended safety procedures. (ERC80-120VH, ERC100VHS) (A938)
1. If bearing cups have been removed, use a press
to install new bearing cups in wheel. See
WARNING Figure 8.
Compressed air is used for cleaning or drying
purposes, or for clearing restrictions. Wear
protective clothing (goggles/shield, gloves, etc.) to
avoid injury to personnel.

1. Clean bearing cones by placing them in a wire

basket and immersing in a container of fresh
solvent. Agitate the bearing cones in the solvent
to remove all traces of old lubricant.

2. Clean all remaining components, except the oil

seals and mounts, with solvent.

3. Clean the oil seals and rubber mounts in warm

soapy water. Rinse with clean warm water and
allow to air dry.

4. After cleaning, dry bearing cones with

compressed air. Take care to prevent spinning the
bearing cones when using a compressed air jet.

5. Immediately wrap bearing cones in a lint-free

cloth to protect them from dust and other foreign
matter.

INSPECT
1. Inspect bearing cones for burned or damaged
rollers. If either condition exists, replace both sets
of bearing cones and bearing cups.

2. Inspect bearing cups for signs of overheating or

scoring. If either condition exists, replace both
sets of bearing cones and bearing cups.

8
1600 YRM 1360 Steering Axle Assembly Repair

Legend for Figure 8.

1. WASHER
2. HUB CAP
3. COTTER PIN
4. CASTLE NUT
5. BEARING CONE
6. BEARING CUP
7. SPINDLE
8. WEAR RING
9. OIL SEAL

2. For specified lubricant see

Periodic Maintenance 8000YRM1364 for lift
truck model
• ERC22-35VG (ERC045-070VG) (A968)
Periodic Maintenance 8000YRM1442 for lift
truck model
• ERC16-20VA (ERC030-040VA) (A969)
Periodic Maintenance 8000YRM1577 for lift
truck models
• ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938)
Verify bearings are filled with grease.

3. Install oil seal, as noted during removal, wear ring

Figure 8. Bearing Arrangement for Lift Truck
(if removed), and inner bearing cone on spindle.
Models ERC22-35VG (ERC045-070VG) (A968),
ERC16-20VA (ERC030-040VA) (A969) and
ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938)
CAUTION
DO NOT damage the seals during installation.

4. Carefully slide wheel onto spindle. Install outer

bearing cone and install washer.

9
Steering Axle Assembly Repair 1600 YRM 1360

NOTE: Ensure that the washer is seated properly e. Pull on the wheel assembly to ensure that
against the bearing cone and not against the shaft there is no end play. If there is excessive end
shoulder before tightening the castle nut. play, reassemble washer and repeat Step a
through Step c.
NOTE: Perform Step 5 through Step 8 for lift truck
models ERC22-35VG (ERC045-070VG) (A968) .
10. Install new cotter pin in castle nut. If cotter pin
5. Install the castle nut as follows: cannot be installed, tighten castle nut to the first
alignment position where the cotter pin can be
a. Install and tighten the castle nut to seat the installed.
bearing, and back off completely.
11. Install hub cap.
b. Tighten castle nut to 68 N•m (50 lbf ft) while
rotating the wheel in both directions to properly 12. Repeat Step 1 through Step 4 and Step 9 through
seat the bearings. Step 11 for other wheel.

c. Loosen the castle nut 1/4 turn. NOTE: Perform Step 13 through Step 15 for lift truck
models ERC40-55VH, ERC50VHS (ERC80-120VH,
d. Tighten nut to 3 N•m (27 lbf in). ERC100VHS) (A938) .

e. Pull on the wheel assembly to ensure that 13. Install the castle nut as follows:
there is no end play. If there is excessive end
a. Install castle nut and tighten to
play, reassemble washer and repeat Step a
203 N•m (150 lbf ft) while rotating the wheel in
through Step c.
both directions to properly seat the bearings.
6. Install new cotter pin in castle nut. If cotter pin
b. Back off castle nut until wheel turns freely with
cannot be installed, tighten castle nut to the first
no end play. Torque should be less than
alignment position where the cotter pin can be
27 N•m (238 lbf in).
installed.
c. If there is excessive end play, reassemble
7. Install hub cap.
washer and repeat Step a and Step b.
8. Repeat Step 1 through Step 7 for other wheel.
d. Re-torque castle nut to 34 N•m (25 lbf ft) and
NOTE: Ensure that the washer is seated properly lock in place at first alignment position which
against the bearing cone and not against the shaft occurs at or above 34 N•m (25 lbf ft).
shoulder before tightening the castle nut.
e. Install new cotter pin and bend one prong over
NOTE: Perform Step 9 through Step 12 for lift truck castle nut. Bend other prong over spindle and
models ERC16-20VA (ERC030-040VA) (A969) . cut flush with end of spindle.
9. Install the castle nut as follows:
14. Install hub cap.
a. Install and tighten the castle nut to seat the
bearing, and back off completely. 15. Repeat Step 1 through Step 4 and Step 13 and
Step 14 for other wheel.
b. Tighten castle nut to 200 N•m (148 lbf ft) while
rotating the wheel in both directions to properly INSTALL ERC22-35VG (ERC045-070VG)
seat the bearings. (A968)
1. Install rubber mounts and top mount(s) on axle.
c. Loosen the castle nut 1/4 turn.
Verify that the face of rubber mount with the word
d. Tighten nut to 12 N•m (106 lbf in). "TOP" and the arrow (pointing up) is facing away
from the steer axle. See Figure 9.

10
1600 YRM 1360 Steering Axle Assembly Repair

1. CAPSCREW
2. WASHER
3. NUT
4. REAR MOUNT BRACKET
1. RUBBER MOUNT 5. STEER AXLE
2. TOP MOUNT 6. FRONT MOUNT BRACKET
3. STEER AXLE
Figure 10. Steer Axle Installation for Lift Truck
Figure 9. Mount Installation for Lift truck Model Model ERC22-35VG (ERC045-070VG) (A968)
ERC22-35VG (ERC045-070VG) (A968)
6. Remove plugs and caps and connect hydraulic
2. Apply lubricant (that is approved for use with lines to steering cylinder as noted during removal.
rubber) to rubber mount. The lubricant is used to
ease assembly of the rubber mounts into lift truck 7. Remove the floor jack from under the lift truck,
frame and mount brackets. and remove the lift truck from the blocks.
3. Using a floor jack, position the steering axle under 8. Operate steering system to remove air from
the frame. system. Turn steering wheel several times from
one stop to the other. Check for hydraulic leaks.
4. If the lift truck is equipped with the steering
direction sensor option, connect steering direction INSTALL ERC16-20VA (ERC030-040VA)
sensor cable to the main wiring harness. See
Figure 5. (A969)
1. Install rubber mounts and top mount(s) on axle.
5. Lift the steer axle into position on the lift truck Verify that the face of rubber mount with the word
frame, and install the rear and front mount "TOP" and the arrow (pointing up) is facing away
brackets, four washers, four capscrews, and four from the steer axle. See Figure 11.
nuts. Tighten capscrews to 90 N•m (66 lbf ft). See
Figure 10.

11
Steering Axle Assembly Repair 1600 YRM 1360

1. RUBBER MOUNT
2. TOP MOUNT 1. CAPSCREW
3. STEER AXLE 2. WASHER
3. NUT
Figure 11. Mount Installation for Lift Truck Model 4. REAR MOUNT BRACKET
5. STEER AXLE
ERC16-20VA (ERC030-040VA) (A969) 6. FRONT MOUNT BRACKET
2. Apply lubricant (that is approved for use with Figure 12. Steer Axle Installation for Lift Truck
rubber), to rubber mount. The lubricant is used to Model ERC16-20VA (ERC030-040VA) (A969)
ease assembly of the rubber mounts into lift truck
frame and mount brackets. 6. Remove plugs and caps and connect hydraulic
lines to steering cylinder as noted during removal.
3. Using a floor jack, position the steering axle under
the frame. 7. Remove the floor jack from under the lift truck,
and remove the lift truck from the blocks.
4. If the lift truck is equipped with the steering
direction sensor option, connect steering direction 8. Operate steering system to remove air from
sensor cable to the main wiring harness. See system. Turn steering wheel several times from
Figure 6. one stop to the other. Check for hydraulic leaks.

5. Lift the steer axle into position on the lift truck INSTALL ERC40-55VH, ERC50VHS
frame, and install the rear and front mount
(ERC80-120VH, ERC100VHS) (A938)
brackets, four washers, four capscrews, and four
nuts. Tighten capscrews to 1. Install rubber mounts and top mount(s) on axle.
41 to 49 N•m (30.2 to 36.1 lbf ft). See Figure 12. Verify that the face of rubber mount with the word
"TOP" and the arrow (pointing up) is facing away
from the steer axle. See Figure 13.

2. Apply lubricant (that is approved for use with

rubber) to rubber mount. The lubricant is used to
ease assembly of the rubber mounts into lift truck
frame and mount brackets.

3. Using a floor jack, position the steering axle under

the frame.

12
1600 YRM 1360 Steering Axle Assembly Repair

4. If the lift truck is equipped with the steering

direction sensor option, connect steering direction
sensor cable to the main wiring harness. See
Figure 7.

1. CAPSCREW
2. WASHER
3. NUT
4. REAR MOUNT BRACKET
5. STEER AXLE
6. FRONT MOUNT BRACKET

Figure 14. Steer Axle Installation, Lift Trucks

ERC40-55VH, ERC50VHS (ERC80-120VH,
1. RUBBER MOUNT ERC100VHS) (A938)
2. TOP MOUNTS
3. REAR MOUNT BRACKET
4. STEER AXLE
5. WASHER
6. NUT
7. FRONT MOUNT BRACKET
8. CAPSCREW

Figure 13. Mount Installation, Lift Trucks

ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938)

5. Lift the steer axle into position on the lift truck

frame, and install the rear and front mount
brackets, eight washers, four capscrews, and four
nuts. Tighten capscrews to
225 to 280 N•m (166 to 207 lbf ft). See Figure 14.

6. Remove plugs and caps and connect hydraulic

lines to steering cylinder as noted during removal.

7. Remove the floor jack from under the lift truck,

and remove the lift truck from the blocks.

8. Operate steering system to remove air from

system. Turn steering wheel several times from
one stop to the other. Check for hydraulic leaks.

13
Steering Axle Assembly Repair 1600 YRM 1360

REMOVE ERP22-35VL (ERP045-070VL) Periodic Maintenance 8000YRM1372 for lift

(A976) AND ERP40-50VM, ERP50-55VM6 truck models
(ERP080-120VM, ERP100VML) (A985) • ERP22-35VL (ERP045-070VL) (A976)
Periodic Maintenance 8000YRM1541 for lift
truck models
WARNING
PUTTING THE LIFT TRUCK ON BLOCKS • ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985)
The lift truck must be put on blocks for some types
of maintenance and repair. The removal of the 3. Slide floor jack under steering axle. Raise lifting
mast, drive axle, battery, or counterweight device until it holds the weight of the axle
assemblies will cause large changes in the center assembly.
of gravity. When the lift truck is put on blocks, put
additional blocks in the following positions: NOTE: Tag hydraulic lines prior to disconnecting from
steering cylinder to aid in the correct connection of the
• If the mast and drive axle are removed, put
blocks under the counterweight so the lift hydraulic lines during installation.
truck cannot fall backward. 4. Disconnect hydraulic lines at steering cylinder.
• If the counterweight is removed, put blocks Install plug fittings in cylinder and put caps on
under the mast so that the lift truck cannot hydraulic lines. Plug fittings will prevent spindles
fall forward. from turning as axle is removed from under the lift
Put the lift truck on blocks on a solid, even, and truck.
level surface. Verify the blocks or stands have
enough capacity to hold the lift truck. Use NOTE: Perform Step 5 and Step 6 for lift truck model
additional blocks next to the tires as necessary to ERP22-35VL (ERP045-070VL) (A976) only.
prevent movement of the lift truck. Verify the lifting 5. Remove two lower nuts, capscrews, and washers
devices used during repairs can lift the weight of from the battery box and front mount bracket. See
the parts and assemblies. Figure 15.
See the Operating Manual or Periodic Maintenance
section for your lift truck model, for the
procedures to put the lift truck on blocks.

The steering axle can be removed without removing

the counterweight.

1. Remove the battery from the lift truck. The

procedure for removing the battery may be found
in the Operating Manual or in one of the
following service manuals:
Periodic Maintenance 8000YRM1372 for lift
truck models
• ERP22-35VL (ERP045-070VL) (A976)
1. CAPSCREW
Periodic Maintenance 8000YRM1541 for lift 2. WASHER
truck models 3. BATTERY COMPARTMENT
4. FRONT MOUNT BRACKET
• ERP40-50VM, ERP50-55VM6 5. NUT
(ERP080-120VM, ERP100VML) (A985)
Figure 15. Steer Axle Replacement ERP22-35VL
2. Place the lift trucks on blocks. The procedure for (ERP045-070VL) (A976)
placing the lift truck on blocks may be found in the
Operating Manual or in one of the following 6. Remove the top capscrew and washer from the
service manuals: battery box and front mount bracket. See
Figure 15.

14
1600 YRM 1360 Steering Axle Assembly Repair

7. Remove two capscrews, washers, and rear See Figure 18 for lift truck model
mount bracket. ERP40-50VM, ERP50-55VM6
•
See Figure 16 or Figure 17 for lift truck model (ERP080-120VM, ERP100VML) (A985)
• ERP22-35VL (ERP045-070VL) (A976)

1. WASHER 5. STEER AXLE

2. CAPSCREW 6. PNEUMATIC HUB
3. REAR MOUNT BRACKET 7. RUBBER MOUNTS
4. FRONT MOUNT BRACKET

Figure 16. Steer Axle Removal for Lift Trucks Manufactured Prior to November, 2015ERP22-35VL
(ERP045-070VL) (A976)

15
Steering Axle Assembly Repair 1600 YRM 1360

1. STEER AXLE 5. REAR MOUNT BRACKET

2. PNEUMATIC HUB 6. WASHER
3. RUBBER MOUNTS 7. CAPSCREW
4. FRONT MOUNT BRACKET

Figure 17. Steer Axle Removal for Lift Trucks Manufactured After November, 2015ERP22-35VL
(ERP045-070VL) (A976)

16
1600 YRM 1360 Steering Axle Assembly Repair

Figure 18. Steer Axle Removal ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)

17
Steering Axle Assembly Repair 1600 YRM 1360

Legend for Figure 18.

1. WASHER 5. STEER AXLE

2. CAPSCREW 6. PNEUMATIC HUB
3. REAR MOUNT BRACKET 7. RUBBER MOUNTS
4. FRONT MOUNT BRACKET

NOTE: The front mount bracket may not be able to be

removed until the steering axle is lowered during
Step 9.
8. Remove two capscrews, washers, hydraulic hose
mounting brackets, and front mount bracket from
the counterweight.
See Figure 16 or Figure 17 for lift truck models
• ERP22-35VL (ERP045-070VL) (A976)
See Figure 18 for lift truck models
• ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985)

NOTE: The steering direction sensor is standard on

ERP22-35VL (ERP045-070VL) (A976) and
ERP40-50VM, ERP50-55MV6 (ERP080-120VM,
ERP100VML) (A985) lift trucks.
9. Carefully lower the floor jack enough to remove
capscrew and cover to disconnect steering NOTE: MAJOR COMPONENTS NOT SHOWN FOR
direction sensor cable from the main wiring CLARITY. STEERING DIRECTION SENSOR FOR
harness, and remove the main wiring harness LIFT TRUCK MODELS ERP22-35VL (ERP045-070VL)
from the conduit clip located on the steering axle. (A976) SHOWN. STEERING DIRECTION SENSOR
See Figure 19. Install cover and capscrew. Move FOR LIFT TRUCK MODELS ERP40-50VM,
the steer axle clear of the lift truck. ERP50-55VM6 (ERP080-120VM, ERP100VML)
(A985) IS SIMILAR.

1. CAPSCREW
2. COVER
3. MAIN WIRING HARNESS
4. STEERING DIRECTION SENSOR
5. CONDUIT CLIP
6. STEERING AXLE

Figure 19. Main Wiring Harness Disconnect

DISASSEMBLE ERP22-35VL
(ERP045-070VL) (A976) AND ERP40-50VM,
ERP50-55VM6 (ERP080-120VM,
ERP100VML) (A985)
1. Place steering axle on blocks so the wheels just
touch the floor.

2. Remove six lug nuts and wheel from the

pneumatic hub. See Figure 20.

18
1600 YRM 1360 Steering Axle Assembly Repair

NOTE: STEERING AXLE FOR LIFT TRUCK MODELS ERP22-35VL (ERP045-070VL) (A976) SHOWN.
STEERING AXLE FOR LIFT TRUCK MODELS ERP40-50VM, ERP50-55MV6 (ERP080-120VM, ERP100VML)
(A985) IS SIMILAR.

1. HUB CAP 11. MOUNT

2. CASTLE NUT 12. CAPSCREW
3. COTTER PIN 13. BRACKET
4. OUTER BEARING CONE 14. WASHER
5. OUTER BEARING CUP 15. PNEUMATIC HUB
6. INNER BEARING CUP 16. PNEUMATIC TIRE WHEEL
7. INNER BEARING CONE 17. LUG NUTS
8. WEAR RING 18. STEERING DIRECTION SENSOR
9. OIL SEAL 19. STEERING DIRECTION SENSOR CABLE
10. AXLE ASSEMBLY BRACKET

Figure 20. Steering Axle Assemblies for ERP22-35VL (ERP045-070VL) (A976)

3. Remove hub cap, cotter pin, castle nut, and NOTE: Note the position of the oil seal during removal
pneumatic hub from the spindle. Discard cotter to ensure correct orientation during installation.
pin.
5. Remove the inner bearing cone and oil seal from
the spindle assembly.
NOTE: Identify and tag the outer and inner bearing
cones so they can be reassembled in their original
6. Remove the mounts from the axle assembly.
locations.
4. Remove the outer bearing cone from the
pneumatic hub.

19
Steering Axle Assembly Repair 1600 YRM 1360

NOTE: Bearing cones are to be replaced as sets. If INSPECT

one bearing cone has been determined to be
unserviceable, then both must be replaced. 1. Inspect bearing cones for burned or damaged
rollers. If either condition exists, replace both sets
7. If the bearing cones are to be replaced, remove of bearing cones and bearing cups.
the inner and outer bearing cups from the
pneumatic hub using a brass drift pin. 2. Inspect bearing cups for signs of overheating or
scoring. If either condition exists, replace both
8. Repeat Step 1 through Step 7 for the other wheel. sets of bearing cones and bearing cups.

CLEAN 3. Inspect the rubber mounts for signs of damage or

cracking. Replace, if necessary.
WARNING 4. Inspect the oils seals and wear rings for any
Cleaning solvents can be flammable and toxic and damage. Replace, if damaged.
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufacturer’s 5. Inspect spindle assemblies and tie rods for signs
recommended safety procedures. of damage. Replace, if necessary, in accordance
with Spindle Repair and Tie Rod Replacement.

WARNING 6. Inspect the remainder of the axle assembly for

Compressed air is used for cleaning or drying damage, and repair or replace as necessary.
purposes, or for clearing restrictions. Wear
7. For lift truck models ERP22-35VL
protective clothing (goggles/shield, gloves, etc.) to
(ERP045-070VL) (A976) see Frame
avoid injury to personnel.
0100YRM1342 for procedures to inspect parts of
1. Clean bearing cones by placing them in a wire the counterweight and bracket mounts before
basket and immersing in a container of fresh installing the steering axle.
solvent. Agitate the bearing cones in the solvent
to remove all traces of old lubricant. ASSEMBLE ERP40-50VM, ERP50-55MV6
(ERP080-120VM, ERP100VML) (A985)
2. Clean all remaining components, except the oil
1. If bearing cups have been removed, use a press
seals and mounts, with solvent.
to install new bearing cups in hub. See Figure 21.
3. Clean the oil seals and rubber mounts in warm
2.
soapy water. Rinse with clean warm water and
allow to air dry. Lubricate bearing cones with multipurpose
grease. See Periodic Maintenance
4. After cleaning, dry bearing cones with 8000YRM1541.
compressed air. Take care to prevent spinning the
Verify bearings are filled with grease.
bearing cones when using a compressed air jet.
3. Install oil seal, as noted during removal, and inner
5. Immediately wrap bearing cones in a lint-free
bearing cone on spindle.
cloth to protect them from dust and other foreign
matter.

6. For lift truck models ERP22-35VL

(ERP045-070VL) (A976) see Frame
0100YRM1342 for procedures to clean parts of
the counterweight and bracket mounts before
installing the steering axle.

20
1600 YRM 1360 Steering Axle Assembly Repair

e. Install cotter pin in castle nut.

6. Install hub cap.

7. Install wheel using six lug nuts.Tighten lug nuts to

610 to 680 N•m (450 to 502 lbf ft).

8. Repeat Step 1 through Step 7 for other wheel.

ASSEMBLE ERP22-35VL (ERP045-070VL)

(A976)
NOTE: Ensure to pack wheel, spindle bearing,
bearing cone roller and bearing cup with multipurpose
grease.

1. If bearing cups have been removed, use a press

to install new bearing cups in hub and lower
1. SPINDLE
2. HUB bearing cap. See Figure 22 .
3. HUB CAP
4. COTTER PIN 2. Lubricate bearing cones with multipurpose grease
5. CASTLE NUT through fittings. See Figure 22, Figure 23, and
6. BEARING CONE Periodic Maintenance 8000YRM1372 .
7. BEARING CUP
8. OIL SEAL Verify bearings are filled with grease.

Figure 21. Bearing Arrangement for Lift Truck

Models ERP40-50VM, ERP50-55VM6 CAUTION
(ERP080-120VM, ERP100VML) (A985) DO NOT damage the seals during installation.

3. Install bearing cap into axle without shims.

CAUTION
DO NOT damage the seals during installation.

4. Carefully slide hub onto spindle. Install outer

bearing cone and install washer.

NOTE: Ensure that the washer is seated properly

against the bearing cone and not against the shaft
shoulder before tightening the castle nut.
5. Tighten the castle nut as follows:

a. Install the castle nut and tighten to

200 N•m (147.5 lbf ft) while rotating the wheel
in both directions to properly seat the bearings.

b. Back off the castle nut until wheel turns freely

with no end play. Nut torque should be less
than 15 N•m (133 lbf in).

c. Retorque castle nut

to40 to 60 N•m (30 to 44 lbf ft).

d. Lock castle nut in place at first alignment

position when new cotter pin can be installed.

21
Steering Axle Assembly Repair 1600 YRM 1360

11. Ensure turning force of spindle is

48-101 N•m (35-74 lbf ft).

Wheel Bearing Adjustment ERP22-35VL

(ERP045-070VL) (A976)
Follow steps below for bearing adjustments:
1. Torque spindle nuts in proper sequence to
200 N•m (147 lbf ft).
2. Loosen spindle nuts until wheel hub turns freely
with no end play. At this point, wheel torque
should be less than 15 N•m (11 lbf ft).
3. Re-torque spindle nuts in proper sequence to
15 N•m (11 lbf ft) and lock in place at nearest
alignment position.
NOTE: Before installing the hub cap, apply lubricant
to both mounting surfaces.
Hub cap must be aligned with machining of
steer axle. Ensure hub cap is in contact with
steering axle. See Figure 23
1. SPINDLE
2. BEARING CUP
3. BEARING CONE
4. GREASE FITTING
5. BEARING CAP
6. CAPSCREW
7. SHIM (3)
8. SPINDLE NUT
9. HUB CAP
10. HUB ASSEMBLY

Figure 22. Bearing Arrangement for Lift Truck

Models ERP22-35VL (ERP045-070VL) (A976)

4. Apply Loctite® to capscrews and tighten to

5-8 N•m (4-6 lbf ft).

5. Tap bearing cap lightly with a rubber mallet to

ensure bearing races are seated. Re-torque the
capscrews to 5-8 N•m (4-6 lbf ft).

6. Measure gap between housing and bearing cap

at three locations around bearing cap. Place
shims to match lowest of three measured gaps 1. HUB CAP
(±0.7mm). 2. GREASE FITTING

7. Loosen capscrews completely and install shims. Figure 23. Hub Cap Alignment
See Figure 22

8. Re-tighten capscrews to 44-55 N•m (32-40 lbf ft).

9. Ensure gap has closed to 0mm.

10. Ensure bearings are filled with grease. Add more

grease if needed. See Figure 22 and Figure 23.

22
1600 YRM 1360 Steering Axle Assembly Repair

INSTALL ERP22-35VL (ERP045-070VL)

(A976) AND ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML)
1. Install rubber mounts and top mount(s) on axle.
Verify that the face of rubber mount with the word
"TOP" and the arrow (pointing up) is facing away
from the steer axle.
See Figure 24 for lift truck models
• ERP22-35VL (ERP045-070VL) (A976)
See Figure 25 for lift truck models
• ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985)

1. RUBBER MOUNT
2. TOP MOUNT
3. STEER AXLE

Figure 25. Mount Installation for Lift Truck Model

ERP40-50VM, ERP50-55VM6 (ERP080-120VM,
ERP100VML) (A985)

2. Apply lubricant, that is approved for use with

rubber, to rubber mount. The lubricant is used to
ease assembly of the rubber mounts into lift truck
frame and mount brackets.

3. Using a floor jack, position the steering axle under

the counterweight.

4. Raise the steering axle enough to connect

steering direction sensor cable to the main wiring
1. RUBBER MOUNT harness.
2. TOP MOUNT
3. STEER AXLE
5. Install the steering direction sensor cable cover
Figure 24. Mount Installation for Lift Truck Model on the axle, and the main wiring harness into the
ERP22-35VL (ERP045-070VL) (A976) conduit clips on the top of the axle. See
Figure 20.

6. Lift the steer axle into position on the lift truck

frame, and install the rear mount bracket, two
washers, and two capscrews. Tighten capscrews
to 225 to 280 N•m (166 to 207 lbf ft).
See Figure 26 or Figure 27 for lift truck models
• ERP22-35VL (ERP045-070VL) (A976)
See Figure 28 for lift truck models
• ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985)

23
Steering Axle Assembly Repair 1600 YRM 1360

1. WASHER 5. STEER AXLE

2. CAPSCREW 6. PNEUMATIC HUB
3. REAR MOUNT BRACKET 7. RUBBER MOUNTS
4. FRONT MOUNT BRACKET

Figure 26. Steer Axle Installation for Lift Truck Model ERP22-35VL (ERP045-070VL) (A976)

24
1600 YRM 1360 Steering Axle Assembly Repair

1. STEER AXLE 5. REAR MOUNT BRACKET

2. PNEUMATIC HUB 6. WASHER
3. RUBBER MOUNTS 7. CAPSCREW
4. FRONT MOUNT BRACKET

Figure 27. Steer Axle Installation for Lift Trucks Manufactured After November, 2015ERP22-35VL
(ERP045-070VL) (A976)

25
Steering Axle Assembly Repair 1600 YRM 1360

Figure 28. Steer Axle Installation ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)

26
1600 YRM 1360 Steering Axle Assembly Repair

Legend for Figure 28.

1. WASHER 5. STEER AXLE

2. CAPSCREW 6. PNEUMATIC HUB
3. REAR MOUNT BRACKET 7. RUBBER MOUNTS
4. FRONT MOUNT BRACKET

NOTE: Perform Step 7 through Step 10 for lift truck 9. After the front and rear mount brackets have been
models ERP22-35VL (ERP045-070VL) (A976) . installed, check to be sure there are no gaps
between the front and rear mount brackets and
7. Using a jack, install the front mount bracket
the counterweight hexagon surfaces. See
between the battery box and the front mount.
Figure 30.
Install steering hose brackets, two washers, and
capscrews. Tighten capscrews
225 to 280 N•m (166 to 207 lbf ft). See Figure 26.

8. From inside the battery box install the top

capscrew and washer. Tighten to
755 N•m (557 lbf ft). See Figure 29.

1. CAPSCREW
2. WASHER
3. BATTERY COMPARTMENT
4. FRONT MOUNT BRACKET
5. NUT

Figure 29. Steer Axle Replacement for Lift Truck

Model ERP22-35VL (ERP045-070VL) (A976)

27
Steering Axle Assembly Repair 1600 YRM 1360

NOTE: LIFT TRUCKS MANUFACTURED PRIOR TO NOVEMBER 2015 SHOWN, LIFT TRUCKS MANUFAC-
TURED AFTER NOVEMBER 2015 SIMILAR.

1. CAPSCREW 5. STEERING AXLE

2. WASHER 6. COUNTERWEIGHT
3. HEXAGON SURFACE 7. FRONT MOUNT BRACKET
4. REAR BULKHEAD 8. REAR MOUNT BRACKET

Figure 30. Clearance Between Mounting Brackets

NOTE: Perform Step 10 for lift trucks manufactured 14. Operate steering system to remove air from
prior to November, 2015. system. Turn steering wheel several times from
one stop to the other. Check for hydraulic leaks.
10. From inside the battery box install the two lower
capscrews, washers and nuts. Tighten nuts to
755 N•m (557 lbf ft). See Figure 29.

NOTE: Perform Step 11 for lift truck models

ERP40-50VM, ERP50-55VM6 (ERP080-120VM,
ERP100VML) (A985) .
11. Using a jack, install two capscrews, washers,
hydraulic hose mounting brackets, and front
mount bracket to the counterweight. Tighten
capscrews 225 to 280 N•m (166 to 207 lbf ft). See
Figure 28.

12. Remove plugs and caps and connect hydraulic

lines to steering cylinder as noted during removal.

13. Remove the floor jack from under the lift truck and
remove the lift truck from the blocks.

28
1600 YRM 1360 Steering Axle Assembly Repair

REMOVE ERP16-20VF (ERP30-40VF) 4. Remove four capscrews that fasten the mount
(A955) brackets under the rubber mounts. See Figure 31.

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 1. FLANGE HEAD CAPSCREW
enough capacity to hold the lift truck. Use 2. HYDRAULIC HOSES
additional blocks next to the tires as necessary to 3. REAR MOUNT BRACKET
prevent movement of the lift truck. Verify the lifting 4. STEER AXLE
5. FRONT MOUNT BRACKET
devices used during repairs can lift the weight of
the parts and assemblies. Figure 31. Steer Axle Removal ERP16-20VF
See the Operating Manual or Periodic Maintenance (ERP30-40VF) (A955)
section for your lift truck model, for the
procedures to put the lift truck on blocks. 5. Carefully lower the floor jack enough to
disconnect the steering direction sensor cable
The steering axle can be removed without removing from the wiring harness. Remove the steer axle
the counterweight. from the under the lift truck.

1. Place the lift trucks on blocks. The procedure for DISASSEMBLE ERP16-20VF (ERP30-40VF)
placing the lift truck on blocks may be found in the (A955)
Operating Manual or Periodic Maintenance
8000YRM1373. 1. Place steering axle on blocks so the wheels just
touch the floor.
2. Slide floor jack under steering axle. Raise floor
jack until it holds the weight of the axle assembly. 2. Remove five lug nuts and wheel from the hub.
See Figure 32.
3. Disconnect hydraulic hoses at steering cylinder.
Install plug fittings in cylinder and put caps on
hydraulic hoses. Plug fittings will prevent spindles
from turning as axle is removed from under the lift
truck.

29
Steering Axle Assembly Repair 1600 YRM 1360

1. LUG NUTS 10. INNER BEARING CUP

2. WHEEL 11. INNER BEARING CONE
3. HUB CAP 12. OIL SEAL
4. CASTLE NUT 13. STEERING DIRECTION SENSOR
5. COTTER PIN 14. AXLE ASSEMBLY
6. WASHER 15. MOUNT
7. OUTER BEARING CONE 16. BRACKET
8. OUTER BEARING CUP 17. FLANGE HEAD CAPSCREW
9. HUB

Figure 32. Steering Axle Assemblies for ERP16-20VF (ERP30-40VF) (A955) Lift Trucks

3. Remove hub cap, cotter pin, castle nut, washer, 6. Remove the mounts from the axle assembly.
and hub from the spindle. Discard cotter pin.
NOTE: Bearing cones are to be replaced as sets. If
NOTE: Identify and tag the outer and inner bearing one bearing cone has been determined to be
cones so they can be reassembled in their original unserviceable, then both must be replaced.
locations.
7. If the bearing cones are to be replaced, remove
4. Remove the outer bearing cone from the hub. the inner and outer bearing cups from the hub
using a brass drift pin.
NOTE: Note the position of the oil seal during removal
to ensure correct orientation during installation. 8. Repeat Step 1 through Step 7 for the other wheel.
5. Remove the inner bearing cone and oil seal from
the spindle assembly.

30
1600 YRM 1360 Steering Axle Assembly Repair

CLEAN 6. Inspect the remainder of the axle assembly for

damage, and repair or replace as necessary.

WARNING ASSEMBLE ERP16-20VF (ERP30-40VF)

Cleaning solvents can be flammable and toxic and (A955)
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufacturer’s 1. If bearing cups have been removed, use a press
recommended safety procedures. to install new bearing cups in hub. See Figure 33.

2. Lubricate bearing cones with multipurpose

grease. See Periodic Maintenance
WARNING 8000YRM1373 for specified lubricant. Verify
Compressed air is used for cleaning or drying bearings are filled with grease.
purposes, or for clearing restrictions. Wear
protective clothing (goggles/shield, gloves, etc.) to 3. Install oil seal, as noted during removal, and inner
avoid injury to personnel. bearing cone on spindle.
1. Clean bearing cones by placing them in a wire
basket and immersing in a container of fresh
solvent. Agitate the bearing cones in the solvent
to remove all traces of old lubricant.

2. Clean all remaining components, except the oil

seals and mounts, with solvent.

3. Clean the oil seals and rubber mounts in warm

soapy water. Rinse with clean warm water and
allow to air dry.

4. After cleaning, dry bearing cones with

compressed air. Take care to prevent spinning the
bearing cones when using a compressed air jet.

5. Immediately wrap bearing cones in a lint-free

cloth to protect them from dust and other foreign 1. HUB CAP
matter. 2. COTTER PIN
3. CASTLE NUT
4. WASHER
INSPECT 5. BEARING
6. HUB
1. Inspect bearing cones for burned or damaged 7. OIL SEAL
rollers. If either condition exists, replace both sets 8. SPINDLE
of bearing cones and bearing cups.
Figure 33. Bearing Arrangement for Lift Truck
2. Inspect bearing cups for signs of overheating or Models ERP16-20VF (ERP30-40VF) (A955)
scoring. If either condition exists, replace both
sets of bearing cones and bearing cups.
CAUTION
3. Inspect the rubber mounts for signs of damage or DO NOT damage the seals during installation.
cracking. Replace, if necessary.
4. Carefully slide hub onto spindle. Install outer
4. Inspect the oils seals and wear rings for any bearing cone and install washer.
damage. Replace, if damaged.

5. Inspect spindle assemblies and tie rods for signs

of damage. Replace, if necessary, in accordance
with Spindle Repair and Tie Rod Replacement.

31
Steering Axle Assembly Repair 1600 YRM 1360

NOTE: Ensure that the washer is seated properly 3. Using a floor jack, position the steering axle under
against the bearing cone. the frame.
5. Install the castle nut and tighten to
4. Raise the axle enough to connect steering
60 N•m (44 lbf ft) while rotating the wheel three
direction sensor cable to the wiring harness.
times in both directions to properly seat the
bearings. Loosen the castle nut and tighten nut to 5. Lift the steer axle into position on the lift truck
20 N•m (177 lbf in). frame. Install the rear and front mount brackets,
and four flange head capscrews. Tighten
6. Install new cotter pin in castle nut. If cotter pin
capscrews to 90 N•m (66 lbf ft). See Figure 35.
cannot be installed, tighten castle nut to the first
alignment position where the cotter pin can be
installed.

7. Install hub cap.

8. Repeat Step 1 through Step 7 for other wheel.

INSTALL ERP16-20VF (ERP30-40VF)

(A955)
1. Install rubber mounts and top mount(s) on axle.
Verify that the face of rubber mount with the word
"TOP" and the arrow (pointing up) is facing away
from the steer axle. See Figure 34.

1. FLANGE HEAD CAPSCREW

2. HYDRAULIC HOSES
3. REAR MOUNT BRACKET
4. STEER AXLE
5. FRONT MOUNT BRACKET

Figure 35. Steer Axle Installation ERP16-20VF

(ERP30-40VF) (A955)

6. Remove plugs and caps and connect hydraulic

lines to steering cylinder as noted during removal.

7. Remove the floor jack from under the lift truck,

and remove the lift truck from the blocks.
1. RUBBER MOUNT
2. TOP MOUNT
3. STEER AXLE 8. Operate steering system to remove air from
system. Turn steering wheel several times from
Figure 34. Mount Installation for Lift Truck Model one stop to the other. Check for hydraulic leaks.
ERP16-20VF (ERP30-40VF) (A955)

2. Apply lubricant (that is approved for use with

rubber) to rubber mount. The lubricant is used to
ease assembly of the rubber mounts into lift truck
frame and mount brackets.

32
1600 YRM 1360 Tie Rod Replacement

Tie Rod Replacement

REMOVE ERC20-35VG (ERC045-070VG)
(A968) AND ERC40-55VH, ERC50VHS
(ERC80-120VH, ERC100VHS) (A938)

WARNING
PUTTING THE LIFT TRUCK ON BLOCKS
The lift truck must be put on blocks for some types
of maintenance and repair. The removal of the
mast, drive axle, battery, or counterweight
assemblies will cause large changes in the center
of gravity. When the lift truck is put on blocks, put
additional blocks in the following positions:
• If the mast and drive axle are removed, put
blocks under the counterweight so the lift
truck cannot fall backward. 1. SPINDLE ASSEMBLY
• If the counterweight is removed, put blocks 2. COTTER PIN
under the mast so that the lift truck cannot 3. CASTLE NUT
fall forward. 4. TIE ROD
5. CLAMP
Put the lift truck on blocks on a solid, even, and 6. BOOT
level surface. Verify the blocks or stands have 7. SNAP RING
enough capacity to hold the lift truck. Use 8. STEERING CYLINDER ROD
9. PIN
additional blocks next to the tires as necessary to
prevent movement of the lift truck. Verify the lifting Figure 36. Tie Rod Removal for Lift Truck Model
devices used during repairs can lift the weight of ERC20-35VG (ERC045-070VG) (A968) and
the parts and assemblies. ERC40-55VH, ERC50VHS (ERC80-120VH,
See the Operating Manual or Periodic Maintenance ERC100VHS) (A938)
section for your lift truck model, for the
procedures to put the lift truck on blocks. NOTE: It may be necessary to use a brass drift pin to
remove the pin connecting the tie rod end to the
1. Place the lift trucks on blocks. The procedure for steering cylinder rod.
placing the lift truck on blocks may be found in the
4. Remove snap ring and pin connecting the tie rod
Operating Manual or Periodic Maintenance for
end to the steering cylinder rod.
your lift truck.
5. Remove cotter pin and castle nut from the tie rod.
2. Remove the wheel and bearings. See Steering
Discard the cotter pin.
Axle Assembly Repair.

3. Loosen two clamps and slide boot from the

steering cylinder rod onto the tie rod end. See CAUTION
Figure 36. DO NOT hit the threads of the tie rod.

6. Using a puller, remove the tie rod from the spindle

assembly.

7. If necessary to replace both tie rods, perform

Step 1 through Step 6 for the other side of the
steering axle.

33
Tie Rod Replacement 1600 YRM 1360

CLEAN 7. Install the pin that connects the tie rod end to the
steering cylinder rod, and install the snap ring on
the pin.
CAUTION
DO NOT use cleaning solvent to clean the tie rod 8. Slide the boot over the tie rod end and steering
assembly as it will destroy any rubber components cylinder rod. Tighten the clamps on both ends of
of the assembly. the boot.

Clean the tie rod assembly with warm soapy water. 9. Install the bearings and wheel. See Steering Axle
Rinse with clear warm water, and air dry completely. Assembly Repair.

INSPECT 10. If the tie rod was removed from the other side,
repeat Step 1 through Step 9.
Inspect the tie rod assembly for damage (i.e. damaged
threads, bent rod etc.). If found to be damaged, 11. Remove the lift truck from blocks.
replace the tie rod assembly.
REMOVE ERC16-20VA (ERC030-040VA)
INSTALL ERC20-35VG (ERC045-070VG) (A969)
(A968) AND ERC40-55VH, ERC50VHS
(ERC80-120VH, ERC100VHS) (A938)
WARNING
1. Install the tie rod assembly into the spindle PUTTING THE LIFT TRUCK ON BLOCKS
assembly. See Figure 36.
The lift truck must be put on blocks for some types
NOTE: Perform Step 2 and Step 3 for lift trucks of maintenance and repair. The removal of the
ERC20-35VG (ERC045-070VG) (A968) . mast, drive axle, battery, or counterweight
assemblies will cause large changes in the center
2. Install the castle nut onto the tie rod assembly. of gravity. When the lift truck is put on blocks, put
Tighten to 163 N•m (120 lbf ft). See Figure 36. additional blocks in the following positions:
3. Install new cotter pin in the castle nut. If the cotter • If the mast and drive axle are removed, put
pin cannot be installed, tighten the castle nut to blocks under the counterweight so the lift
the next position that will allow the cotter pin to be truck cannot fall backward.
installed. Bend one end of the cotter pin around • If the counterweight is removed, put blocks
the castle nut to the left and the other to the right. under the mast so that the lift truck cannot
See Figure 36. fall forward.
Put the lift truck on blocks on a solid, even, and
NOTE: Perform Step 4 and Step 5 for lift trucks level surface. Verify the blocks or stands have
ERC40-55VH, ERC50VHS (ERC80-120VH, enough capacity to hold the lift truck. Use
ERC100VHS) (A938) . additional blocks next to the tires as necessary to
4. Install the castle nut onto the tie rod assembly. prevent movement of the lift truck. Verify the lifting
Tighten castle nut to devices used during repairs can lift the weight of
163 to 200 N•m (120 to 148 lbf ft) and advance the parts and assemblies.
the castle nut to the next slot in the nut to install See the Operating Manual or Periodic Maintenance
cotter pin. section for your lift truck model, for the
procedures to put the lift truck on blocks.
5. Install new cotter pin in castle nut. Bend one end
of the cotter pin around castle nut to the left and 1. Place the lift trucks on blocks. The procedure for
the other to the right. placing the lift truck on blocks may be found in the
Operating Manual or Periodic Maintenance
6. Place the tie rod end into the steering cylinder rod Manual for your lift truck.
end.
2. Remove the wheel and bearings. See Steering
Axle Assembly Repair

34
1600 YRM 1360 Tie Rod Replacement

NOTE: It may be necessary to use a brass drift pin to Clean the tie rod assembly with warm soapy water.
remove the pin connecting the tie rod end to the Rinse with clear warm water, and air dry completely.
steering cylinder rod.
3. Remove two snap rings and pin connecting tie INSPECT
rod end to steering cylinder rod. See Figure 37. Inspect the tie rod assembly for damage (i.e. damaged
threads, bent rod etc.). If found to be damaged,
replace the tie rod assembly.

INSTALL ERC16-20VA (ERC030-040VA)

(A969)
1. Install four belleville washers and tie rod on
spindle assembly and steering cylinder rod.
Figure 37.

2. Install pin and two snap rings connecting tie rod

to spindle assembly. See Figure 37.

3. Install pin and two snap rings connecting tie rod

to steering cylinder rod. See Figure 37.

4. Install bearings and wheel. See Steering Axle

Assembly Repair.
1. SPINDLE ASSEMBLY
2. SNAP RING
3. PIN 5. If the tie rod was removed from the other side,
4. STEERING CYLINDER ROD repeat Step 1 through Step 4.
5. TIE ROD
6. BELLEVILLE WASHER 6. Remove the lift truck from blocks.
Figure 37. Tie Rod Removal for Lift Truck Model
ERC16-20VA (ERC030-040VA) (A969)

NOTE: It may be necessary to use a brass drift pin to

remove the pin connecting tie rod end to spindle
assembly.
4. Remove two snap rings and pin connecting tie
rod end to spindle assembly. See Figure 37.

5. Remove tie rod and four belleville washers from

spindle and steering cylinder rod. See Figure 37.

6. If necessary to replace both tie rods, perform

Step 1 through Step 5 for the other side of the
steering axle.

CLEAN

CAUTION
DO NOT use cleaning solvent to clean the tie rod
assembly as it will destroy any rubber components
of the assembly.

35
Tie Rod Replacement 1600 YRM 1360

REMOVE ERP20-35VL (ERP045-070VL)

(A976) AND ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985)

WARNING
PUTTING THE LIFT TRUCK ON BLOCKS
The lift truck must be put on blocks for some types
of maintenance and repair. The removal of the
mast, drive axle, battery, or counterweight
assemblies will cause large changes in the center
of gravity. When the lift truck is put on blocks, put
additional blocks in the following positions:
• If the mast and drive axle are removed, put
blocks under the counterweight so the lift
truck cannot fall backward.
• If the counterweight is removed, put blocks NOTE: TIE ROD ASSEMBLY FOR LIFT TRUCK
under the mast so that the lift truck cannot
MODELS ERP22-35VL (ERP045-070VL) (A976)
fall forward.
SHOWN. TIE ROD ASSEMBLY FOR LIFT TRUCK
Put the lift truck on blocks on a solid, even, and MODELS ERP40-50VM, ERP50-55MV6
level surface. Verify the blocks or stands have (ERP080-120VM, ERP100VML) (A985) IS SIMILAR.
enough capacity to hold the lift truck. Use
additional blocks next to the tires as necessary to 1. SPINDLE ASSEMBLY
prevent movement of the lift truck. Verify the lifting 2. SNAP RING
devices used during repairs can lift the weight of 3. BELLEVILLE WASHER
the parts and assemblies. 4. STEERING CYLINDER ROD
5. PIN
See the Operating Manual or Periodic Maintenance
section for your lift truck model, for the Figure 38. Tie Rod Removal for Lift Truck Models
procedures to put the lift truck on blocks. ERP22-35VL (ERP045-070VL) (A976) and
ERP40-50VM, ERP50-55VM6 (ERP080-120VM,
1. Place the lift trucks on blocks. The procedure for ERP100VML) (A985)
placing the lift truck on blocks may be found in the
Operating Manual or Periodic Maintenance 4. Remove the snap ring and pin connecting the tie
Manual for your lift truck. rod to the spindle assembly. See Figure 38.

2. Remove the wheel and bearings. See Steering 5. Remove the tie rod and belleville washers from
Axle Assembly Repair. the spindle and the steering cylinder rod.

NOTE: It may be necessary to use a brass drift pin to 6. Repeat Step 1 through Step 5 for the other side.
remove the pin connecting the tie rod end to the
steering cylinder rod and the pin connecting the tie rod CLEAN
end to the spindle.
3. Remove the snap ring and pin connecting the tie CAUTION
rod to the steering cylinder rod. See Figure 38.
DO NOT use cleaning solvent to clean the tie rod
assembly as it will destroy any rubber components
of the assembly.

Clean the tie rod assembly with warm soapy water.

Rinse with clear warm water, and air dry completely.

36
1600 YRM 1360 Tie Rod Replacement

INSPECT See the Operating Manual or Periodic Maintenance

section for your lift truck model, for the
Inspect the tie rod assembly for damage (i.e. bent rod procedures to put the lift truck on blocks.
etc.). If found to be damaged, replace the tie rod
assembly. 1. Place the lift trucks on blocks. The procedure for
placing the lift truck on blocks may be found in the
INSTALL ERP20-35VL (ERP045-070VL) Operating Manual or Periodic Maintenance
(A976) ANDERP40-50VM, ERP50-55VM6 Manual for your lift truck.
(ERP080-120VM, ERP100VML) (A985)
2. Remove the wheel and bearings. See Steering
1. Install the tie rod and belleville washers in the Axle Assembly Repair.
spindle and the steering cylinder rod. See
Figure 38. NOTE: It may be necessary to use a brass drift pin to
remove the pin connecting the tie rod end to the
2. Install the pin and snap ring connecting the tie rod steering cylinder rod and the pin connecting the tie rod
to the spindle assembly. See Figure 38. end to the spindle.

3. Install the pin and snap ring connecting the tie rod 3. Remove the snap ring and pin connecting the tie
to the steering cylinder rod. See Figure 38. rod to the steering cylinder rod. See Figure 39.

4. Install the wheel and bearings. See Steering Axle

Assembly Repair.

5. Repeat Step 1 through Step 4 for the other side.

6. Remove the lift truck from blocks.

REMOVE ERP16-20VF (ERP30-40VF)

(A955)

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 1. LUBRICATION FITTING
additional blocks in the following positions: 2. SNAP RING SPINDLE ASSEMBLY
3. STEERING CYLINDER ROD
• If the mast and drive axle are removed, put 4. BELLEVILLE WASHER
blocks under the counterweight so the lift 5. TIE ROD
truck cannot fall backward. 6. PIN
If the counterweight is removed, put blocks 7. SPINDLE
•
under the mast so that the lift truck cannot
fall forward. Figure 39. Tie Rod Removal for Lift Truck Model
ERP16-20VF (ERP30-40VF) (A955)
Put the lift truck on blocks on a solid, even, and
level surface. Verify the blocks or stands have 4. Remove the snap ring and pin connecting the tie
enough capacity to hold the lift truck. Use rod to the spindle assembly. See Figure 39.
additional blocks next to the tires as necessary to
prevent movement of the lift truck. Verify the lifting 5. Remove the tie rod and belleville washers from
devices used during repairs can lift the weight of the spindle and the steering cylinder rod.
the parts and assemblies.
6. Repeat Step 1 through Step 5 for the other side.

37
Spindle Repair 1600 YRM 1360

CLEAN 2. Install the pin and snap ring connecting the tie rod
to the spindle assembly. See Figure 39.

CAUTION 3. Install the pin and snap ring connecting the tie rod
DO NOT use cleaning solvent to clean the tie rod to the steering cylinder rod. See Figure 39.
assembly as it will destroy any rubber components
of the assembly. 4. Install the wheel and bearings. See Steering Axle
Assembly Repair.
Clean the tie rod assembly with warm soapy water.
Rinse with clear warm water, and air dry completely. 5. Repeat Step 1 through Step 4 for the other side.

INSPECT 6. Remove the lift truck from blocks.

Inspect the tie rod assembly for damage (i.e. bent rod
etc.). If found to be damaged, replace the tie rod
assembly.

INSTALL ERP16-20VF (ERP30-40VF)

(A955)
1. Install the tie rod and belleville washers in the
spindle and the steering cylinder rod. See
Figure 39.

Spindle Repair
REMOVE ERC22-35VG (ERC45-70VG) See the Operating Manual or Periodic Maintenance
(A968) AND ERC40-55VH, ERC50VHS section for your lift truck model, for the
procedures to put the lift truck on blocks.
(ERC80-120VH, ERC100VHS) (A938)
1. Put the lift truck on blocks.
WARNING
2. Remove the wheel and bearings. See Steering
PUTTING THE LIFT TRUCK ON BLOCKS
Axle Assembly Repair.
The lift truck must be put on blocks for some types
of maintenance and repair. The removal of the 3. Disconnect the tie rod from the spindle assembly.
mast, drive axle, battery, or counterweight See Tie Rod Replacement.
assemblies will cause large changes in the center
of gravity. When the lift truck is put on blocks, put NOTE: Step 4 through Step 8 are to be performed if
additional blocks in the following positions: the spindle assembly on the right side is being
repaired and the optional steering direction sensor is
• If the mast and drive axle are removed, put
installed.
blocks under the counterweight so the lift
truck cannot fall backward. NOTE: If the optional steering direction sensor is not
• If the counterweight is removed, put blocks installed, go to Step 9.
under the mast so that the lift truck cannot 4. Remove the capscrew and cover from the steer
fall forward. axle. See Figure 40.
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.

38
1600 YRM 1360 Spindle Repair

1. CAPSCREW
2. COVER
3. STEERING DIRECTION SENSOR
4. GREASE CAP
5. MAGNET
6. MAGNET CARRIER
7. STEER AXLE

Figure 40. Steering Direction Sensor for Lift Truck

Model ERC22-35VG (ERC45-70VG) (A968) and
ERC40-55VH, ERC50VHS (ERC80-120VH, 1. SPINDLE LH
2. GREASE CAP
ERC100VHS) (A938) 3. STEERING AXLE
4. BEARING CUP
5. Disconnect the steering direction sensor wiring 5. BEARING CONE
harness from the main wiring harness. 6. SEAL
7. WEAR RING
6. Remove two capscrews and steering direction 8. SHIMS
9. O-RING
sensor from the grease cap. 10. BEARING CAP
11. LUBRICATION FITTING
7. Remove the grease cap from the steer axle. 12. CAPSCREWS

8. Remove the two magnets and magnet carrier Figure 41. Spindle Repair ERC22-35VG
from the steering axle. (ERC45-70VG) (A968) and ERC40-55VH,
ERC50VHS (ERC80-120VH, ERC100VHS) (A938)
9. Remove grease cap from top of steering axle.
See Figure 41. NOTE: Note the thickness of the shims during
removal to aid in installation.
10. Remove three capscrews, bearing cap, and
shims from the bottom of the steering axle. See
Figure 41.

11. Tilt the spindle and lift from the steering axle.

12. Remove the wear sleeve from the steering axle.

39
Spindle Repair 1600 YRM 1360

13. Repeat Step 2, Step 3 and Step 9 through INSPECT

Step 12 for the other spindle.
1. Inspect for loose, missing, cracked, burned or
damaged hardware.
DISASSEMBLE ERC22-35VG
(ERC45-70VG) (A968) AND ERC40-55VH, 2. If upper bearing is found to be damaged, remove
ERC50VHS (ERC80-120VH, ERC100VHS) the bearing cup from the axle using a hammer
(A938) and brass drift pin.
1. Remove and discard O-ring from the bearing cap. 3. If lower bearing is found to be damaged, remove
See Figure 41. the bearing cup from the bearing cap as shown in
Figure 42.
2. Remove bearing cone, and seal from top of the
spindle. Discard seal.

3. Remove bearing cone, and seal from bottom of

the spindle. Discard seal.

CLEAN

WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufacturer’s
recommended safety procedures.

WARNING
Compressed air is used for cleaning or drying
purposes, or for clearing restrictions. Wear
protective clothing (goggles/shield, gloves, etc.) to
avoid injury to personnel.

1. Clean bearings by placing them in a wire basket

and immersing in a container of fresh solvent.
Agitate the bearings in the solvent to remove all
traces of old lubricant.

2. After cleaning the bearings, dry them with clean

compressed air. Take care to prevent spinning the 1. PRY BAR
bearings when using a compressed air jet. 2. BEARING CUP
3. BEARING CAP
3. Immediately wrap bearings in a lint-free cloth to 4. O-RING
protect them from dust and other foreign matter.
Figure 42. Bearing Removal
4. Clean the spindle with solvent and air dry with
compressed air. 4. Inspect all parts for dents, holes, bends, burrs,
rust, corrosion, or marred finish.
5. Clean the wear ring using warm soapy water and
dry with a lint free cloth. 5. Replace any damaged parts.

40
1600 YRM 1360 Spindle Repair

ASSEMBLE ERC22-35VG (ERC45-70VG) NOTE: Step 7 through Step 15 are to be performed if

(A968) AND ERC40-55VH, ERC50VHS the spindle assembly on the left side is being repaired
and the optional steering direction sensor is installed.
(ERC80-120VH, ERC100VHS) (A938)
6. Install grease cap on the top of the steering axle.
1. If upper bearing cup was removed, using a press See Figure 41.
install new bearing cup into the axle.
7. Install magnet carrier and two magnets into the
2. If lower bearing was removed, using a press steering axle. See Figure 43.
install new bearing cup in the bearing cap.

NOTE: Coat all seals and O-rings with multipurpose

grease prior to installation.
3. Install new seals on the top and bottom of
spindle.

4. Pack each bearing cone with multipurpose

grease, and install the bearing cones on top and
bottom of spindle.

INSTALL ERC22-35VG (ERC45-70VG)

(A968) AND ERC40-55VH, ERC50VHS
(ERC80-120VH, ERC100VHS) (A938)
1. Install wear sleeve into steering axle. See
Figure 41.

2. Tilt the spindle and install the spindle in the

steering axle.

3. Install the bearing cap without the shims. See

Figure 41. Install capscrews and tighten to 1. CAPSCREW
22 to 27.5 N•m (16 to 20 lbf ft). Measure the 2. COVER
clearance between the bearing cap and the axle. 3. STEERING DIRECTION SENSOR
Remove the bearing cap and install enough 4. GREASE CAP
shims to give a preload of 5. MAGNET
6. MAGNET CARRIER
0.00 to 0.13 mm (0.000 to 0.005 in.). 7. STEER AXLE
NOTE: Perform Step 4 for lift truck models Figure 43. Steering Direction Sensor for Lift Truck
ERC22-35VG (ERC45-70VG) (A968) . Model ERC22-35VG (ERC045-070VG) (A968)
4. Install bearing cap and capscrews. Tighten the
capscrews to 44 to 55 N•m (32 to 41 lbf ft). 8. Install grease cap in the steer axle with the notch
toward the grease fitting ±5°.
NOTE: Perform Step 5 for lift truck models
ERC40-55VH, ERC50VHS (ERC80-120VH, 9. Using two capscrews, install steering direction
ERC100VHS) (A938) . sensor on grease cap.

5. Coat capscrew threads with Loctite® 242 or 10. Connect steering direction sensor wiring harness
equivalent. Install bearing cap and capscrews. to main wiring harness.
Tighten capscrews to 52 N•m (38 lbf ft).
11. Install cover and capscrew on steer axle.
NOTE: If the optional steering direction sensor is not
installed, perform Step 6, and Step 12 through 12. Connect the tie rod to the spindle assembly. See
Step 15. Tie Rod Replacement.

41
Spindle Repair 1600 YRM 1360

13. Install bearings and wheel. See Steering Axle

Assembly Repair.

14. If required, repeat the procedure for the other

spindle.

15. Remove the lift truck from the blocks.

REMOVE ERC16-20VA (ERC030-040VA)

(A969)

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 1. SPINDLE ASSEMBLY
fall forward. 2. SEAL
3. BEARING CONE
Put the lift truck on blocks on a solid, even, and 4. BEARING CUP
level surface. Verify the blocks or stands have 5. SPACER
enough capacity to hold the lift truck. Use 6. SLEEVE
7. SLOTTED NUT
additional blocks next to the tires as necessary to 8. COTTER PIN
prevent movement of the lift truck. Verify the lifting 9. PIN
devices used during repairs can lift the weight of 10. STEERING AXLE
the parts and assemblies. 11. KINGPIN
See the Operating Manual or Periodic Maintenance Figure 44. Spindle Repair ERC16-20VA
section for your lift truck model, for the (ERC030-040VA) (A969)
procedures to put the lift truck on blocks.
5. Remove pin from kingpin. See Figure 44.
1. Put the lift truck on blocks.
6. Tilt the spindle assembly and lift from the steering
2. Remove the wheel and bearings. See Steering axle. See Figure 44.
Axle Assembly Repair.
7. Repeat Step 2 through Step 6 for the other
3. Disconnect the tie rod from the spindle assembly. spindle.
See Tie Rod Replacement.
DISASSEMBLE ERC16-20VA
4. Remove cotter pin, slotted nut, and sleeve from
spindle. Figure 44. (ERC030-040VA) (A969)
1. Remove and discard seal from bottom of spindle.
See Figure 44.

2. Remove and discard seal from top of spindle. See

Figure 44.

42
1600 YRM 1360 Spindle Repair

3. Remove spacer from top of spindle. See

Figure 44.

4. Remove upper and lower bearing cones from

spindle. See Figure 44.

5. Remove kingpin from spindle. See Figure 44.

CLEAN

WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufacturer’s
recommended safety procedures.

WARNING
Compressed air is used for cleaning or drying
purposes, or for clearing restrictions. Wear
protective clothing (goggles/shield, gloves, etc.) to
avoid injury to personnel.

1. Clean bearings by placing them in a wire basket

and immersing in a container of fresh solvent.
Agitate the bearings in the solvent to remove all
traces of old lubricant. 1. PRY BAR
2. BEARING CUP
2. After cleaning the bearings, dry them with clean 3. BEARING CAP
compressed air. Take care to prevent spinning the 4. O-RING
bearings when using a compressed air jet.
Figure 45. Bearing Removal
3. Immediately wrap bearings in a lint-free cloth to
protect them from dust and other foreign matter. 4. Inspect all parts for dents, holes, bends, burrs,
rust, corrosion, or marred finish.
4. Clean the spindle with solvent and air dry with
compressed air. 5. Replace any damaged parts.

5. Clean the wear ring using warm soapy water and ASSEMBLE ERC16-20VA (ERC030-040VA)
dry with a lint free cloth. (A969)
1. If upper bearing cup was removed, using a press
INSPECT install the new bearing cup in spindle.
1. Inspect for loose, missing, cracked, burned or
damaged hardware. 2. If lower bearing cup was removed, using a press
install new bearing cup in spindle.
2. If upper bearing is found to be damaged, remove
the bearing cup from the axle using a hammer 3. Install kingpin in spindle. See Figure 44.
and brass drift pin.
4. Install upper and lower bearing cones on spindle.
3. If lower bearing is found to be damaged, remove See Figure 44.
the bearing cup from the bearing cap as shown in
Figure 45. 5. Install spacer on spindle. See Figure 44.

43
Spindle Repair 1600 YRM 1360

NOTE: Coat all seals and O-rings with multipurpose prevent movement of the lift truck. Verify the lifting
grease prior to installation. devices used during repairs can lift the weight of
the parts and assemblies.
6. Install new seals on the top and bottom of the
spindle. See Figure 44. See the Operating Manual or Periodic Maintenance
section for your lift truck model, for the
7. If necessary, repeat Step 1 through Step 6 for procedures to put the lift truck on blocks.
opposite side.
1. Put the lift truck on blocks.
INSTALL ERC16-20VA (ERC030-040VA)
(A969) 2. Remove the wheel and bearings. See Steering
Axle Assembly Repair.
1. Tilt the spindle assembly and install the spindle in
the steering axle. 3. Disconnect the tie rod from the spindle assembly.
See Tie Rod Replacement.
2. Install pin on kingpin. See Figure 44.
NOTE: Step 4 through Step 9 are to be performed if
3. Install sleeve, slotted nut, and cotter pin on the kingpin assembly on the left side is being repaired.
spindle. See Figure 44.
4. Remove capscrew and cover from the steer axle.
4. Connect the tie rod to the spindle assembly. See
5. Disconnect the wiring harness from the steering
Tie Rod Replacement.
direction sensor.
5. Install bearings and wheel. See Steering Axle
6. Remove two capscrews and steering direction
Assembly Repair.
sensor from the steer axle. See Figure 46.
6. If required, repeat the procedure for the other
spindle.

7. Remove the lift truck from the blocks.

REMOVE ERP22-35VL (ERP45-70VL)

(A976) AND ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985)

WARNING
PUTTING THE LIFT TRUCK ON BLOCKS
The lift truck must be put on blocks for some types
of maintenance and repair. The removal of the
mast, drive axle, battery, or counterweight
assemblies will cause large changes in the center
of gravity. When the lift truck is put on blocks, put
additional blocks in the following positions:
• If the mast and drive axle are removed, put
blocks under the counterweight so the lift
truck cannot fall backward.
• If the counterweight is removed, put blocks
under the mast so that the lift truck cannot
fall forward.
Put the lift truck on blocks on a solid, even, and
level surface. Verify the blocks or stands have
enough capacity to hold the lift truck. Use
additional blocks next to the tires as necessary to

44
1600 YRM 1360 Spindle Repair

NOTE: STEERING DIRECTION SENSOR FOR LIFT

TRUCK MODELS ERP22-35VL (ERP045-070VL)
(A976) SHOWN. STEERING DIRECTION SENSOR
FOR LIFT TRUCK MODELS ERP40-50VM,
ERP50-55MV6 (ERP080-120VM, ERP100VML)
(A985) IS SIMILAR.

1. CAPSCREW
2. COVER
3. STEERING DIRECTION SENSOR NOTE: SPINDLE ASSEMBLY FOR LIFT TRUCK
4. INSERT
5. GREASE CAP MODELS ERP22-35VL (ERP045-070VL) (A976)
6. MAGNET SHOWN. SPINDLE ASSEMBLY FOR LIFT TRUCK
7. MAGNET CARRIER MODELS ERP40-50VM, ERP50-55MV6
8. STEER AXLE (ERP080-120VM, ERP100VML) (A985) IS SIMILAR.
Figure 46. Steering Direction Sensor for Lift Truck 1. SPINDLE LH
Models ERP22-35VL (ERP045-070VL) (A976) and 2. GREASE CAP
ERP40-50VM, ERP50-55VM6 (ERP080-120VM, 3. STEERING AXLE
ERP100VML) (A985) 4. BEARING CUP
5. BEARING CONE
7. Remove the insert from the steering direction 6. SEAL
7. WEAR RING
sensor. 8. SHIMS
9. O-RING
8. Remove the grease cap from the steer axle. 10. BEARING CAP
11. LUBRICATION FITTING
9. Remove the magnets and magnet carrier from the 12. CAPSCREWS
steer axle.
Figure 47. Spindle Repair for Lift Truck Models
10. Remove grease cap from top of steer axle above ERP22-35VL (ERP045-070VL) (A976) and
spindle. See Figure 47. ERP40-50VM, ERP50-55VM6 (ERP080-120VM,
ERP100VML) (A985)

45
Spindle Repair 1600 YRM 1360

NOTE: Note the thickness of the shims during 4. Clean the spindle with solvent and air dry with
removal to aid in installation. compressed air
11. Remove three capscrews, bearing cap, and
5. Clean the wear ring using warm soapy water and
shims from the bottom of the steering axle. See
dry with a lint free cloth.
Figure 47.

12. Tilt the spindle and lift from the steering axle. INSPECT
1. Inspect for loose, missing, cracked, burned or
13. Remove the wear sleeve from the steering axle. damaged hardware.

14. Repeat Step 2 through Step 13 for the other 2. If upper bearing is found to be damaged, remove
spindle. the bearing cup from the axle using a hammer
and brass drift pin.
DISASSEMBLE ERP22-35VL (ERP45-70VL)
(A976) AND ERP40-50VM, ERP50-55VM6 3. If lower bearing is found to be damaged, remove
(ERP080-120VM, ERP100VML) (A985) the bearing cup from the bearing cap as shown in
Figure 48.
1. Remove and discard the O-ring from the bearing
cap. See Figure 47.

2. Remove bearing cone and seal from the top of

the spindle. Discard seal.

3. Remove bearing cone and seal from the bottom

of the spindle. Discard seal.

CLEAN

WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufacturer’s
recommended safety procedures.

WARNING
Compressed air is used for cleaning or drying
purposes, or for clearing restrictions. Wear
protective clothing (goggles/shield, gloves, etc.) to
avoid injury to personnel.

1. Clean bearings by placing them in a wire basket

and immersing in a container of fresh solvent.
Agitate the bearings in the solvent to remove all
traces of old lubricant. 1. PRY BAR
2. BEARING CUP
2. After cleaning the bearings, dry them with clean 3. BEARING CAP
compressed air. Take care to prevent spinning the 4. O-RING
bearings when using a compressed air jet.
Figure 48. Bearing Removal
3. Immediately wrap bearings in a lint-free cloth to
4. Inspect all parts for dents, holes, bends, burrs,
protect them from dust and other foreign matter.
rust, corrosion, or marred finish.

46
1600 YRM 1360 Spindle Repair

5. Replace any damaged parts. 9. Install magnet carrier and magnets into the steer
axle. See Figure 46.
ASSEMBLE ERP22-35VL (ERP45-70VL)
(A976) 10. Install grease cap into steer axle with the notch
toward grease fitting within ±5°.
NOTE: Pack bearing cone with multipurpose grease
prior to installing. 11. Install insert into steering direction sensor.
1. If upper bearing cup was removed, using a press
12. Install steering direction sensor and two
install new bearing cup into the axle.
capscrews into steer axle.
NOTE: Coat all seals and O-rings with multipurpose
13. Connect wiring harness to steering direction
grease prior to installation.
sensor.
2. Install new seal on top of spindle.
14. Install cover and capscrew on steer axle
NOTE: Pack bearing cone with multipurpose grease
prior to installing. 15. Connect tie rod to spindle assembly. See Tie Rod
3. If lower bearing cup was removed, using a press Replacement.
install new bearing cone and bearing cup on the
16. Install bearings and wheel. See Steering Axle
spindle.
Assembly Repair.
INSTALL ERP22-35VL (ERP45-70VL) 17. If required, repeat procedure for the other spindle.
(A976)
1. Install wear sleeve into steering axle. See 18. Remove lift truck from the blocks.
Figure 47.
ASSEMBLE ERP40-50VM, ERP50-55VM6
2. Tilt spindle and install spindle in the steering axle. (ERP080-120VM, ERP100VML) (A985)
1. If upper bearing cup was removed, using a press
3. Apply multipurpose grease to bearing's rollers
install new bearing cup into the axle.
and cup.
2. If lower bearing cup was removed, using a press
4. Install bearing cap into steering axle without
install new bearing cup in the bearing cap.
shims. Install and tighten capscrews to
5 to 8 N•m (3.7 to 5.9 lbf ft).
NOTE: Coat all seals and O-rings with multipurpose
grease prior to installation.
5. Strike bearing cap with rubber mallet to ensure
bearing races are seated.Re-tighten capscrews to 3. Install new seals on top and bottom of spindle.
5 to 8 N•m (3.7 to 5.9 lbf ft).
4. Pack each bearing cone with multipurpose
6. Measure clearance between bearing cap and grease, and install bearing cones on top and
axle. Prepare shims to match lowest clearance bottom of spindle.
gap (±0.07 mm (0.003 in.)).
INSTALL ERP22-35VL (ERP45-70VL)
7. Loosen capscrews completely and install shims. (A976) AND ERP40-50VM, ERP50-55VM6
Re-install and tighten capscrews to
(ERP080-120VM, ERP100VML) (A985)
44 to 55 N•m (32 to 41 lbf ft).
1. Install wear sleeve into steering axle. See
NOTE: If performing install procedures on the right Figure 47.
side of steer axle, go to Step 11; otherwise perform
Step 10 and then go to Step 17. 2. Tilt spindle and install spindle in the steering axle.
8. Install grease cap on the top of the steering axle.
See Figure 47.

47
Spindle Repair 1600 YRM 1360

3. Install the bearing cap without shims. See assemblies will cause large changes in the center
Figure 47. Install capscrews and tighten of gravity. When the lift truck is put on blocks, put
22 to 27.5 N•m (16 to 20 lbf ft). Measure additional blocks in the following positions:
clearance between bearing cap and axle. If the mast and drive axle are removed, put
•
Remove bearing cap and install enough shims to blocks under the counterweight so the lift
give a preload of truck cannot fall backward.
0.00 to 0.13 mm (0.000 to 0.005 in.).
• If the counterweight is removed, put blocks
under the mast so that the lift truck cannot
4. Install bearing cap and capscrews. Tighten fall forward.
capscrews 44 to 55 N•m (32 to 41 lbf ft).
Put the lift truck on blocks on a solid, even, and
NOTE: If performing install procedures on the right level surface. Verify the blocks or stands have
side of steer axle, go to ; otherwise perform Step 5 and enough capacity to hold the lift truck. Use
then go to Step 12. additional blocks next to the tires as necessary to
prevent movement of the lift truck. Verify the lifting
5. Install grease cap on the top of the steering axle.
devices used during repairs can lift the weight of
See Figure 47.
the parts and assemblies.
6. Install magnet carrier and magnets into the steer See the Operating Manual or Periodic Maintenance
axle. See Figure 46. section for your lift truck model, for the
procedures to put the lift truck on blocks.
7. Install grease cap into steer axle with the notch
toward grease fitting within ±5°. 1. Put the lift truck on blocks.

8. Install insert into steering direction sensor. 2. Remove the wheel and bearings. See Steering
Axle Assembly Repair.
9. Install steering direction sensor and two
capscrews into steer axle. 3. Disconnect the tie rod from the spindle. See Tie
Rod Replacement.
10. Connect wiring harness to steering direction
sensor. NOTE: Step 4 and Step 6 are to be performed if the
kingpin assembly on the right side is being repaired.
11. Install cover and capscrew on steer axle 4. Remove capscrew and two plates from steering
axle. See Figure 49.
12. Connect tie rod to spindle assembly. See Tie Rod
Replacement. 5. Disconnect steering axle wiring harness from the
steering direction sensor. See Figure 49.
13. Install bearings and wheel. See Steering Axle
Assembly Repair. 6. Remove two capscrews and steering direction
sensor from kingpin cover. See Figure 49.
14. If required, repeat procedure for the other spindle.

15. Remove lift truck from the blocks.

REMOVE ERP16-20VF (ERP30-40VF)

(A955)

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

48
1600 YRM 1360 Spindle Repair

NOTE: RIGHT HAND SPINDLE SHOWN.

1. CAPSCREW
1. CAPSCREW 2. WASHER
2. PLATE 3. UPPER KINGPIN COVER
3. STEERING AXLE WIRING HARNESS 4. NEEDLE BEARING
4. STEERING DIRECTION SENSOR 5. STEERING AXLE
5. KIN PIN COVER 6. KINGPIN SEAL
6. STEERING AXLE 7. THRUST BEARING
8. SPINDLE
Figure 49. Steering Direction Sensor for Lift Truck 9. GRUB SCREW.
Model ERP16-20VF (ERP30-40VF) (A955) 10. KINGPIN
11. LOWER KINGPIN COVER
DISASSEMBLE ERP16-20VF (ERP30-40VF) Figure 50. Spindle Repair ERP16-20VF
(A955) (ERP30-40VF) (A955)
1. Remove three capscrews, three washers and the
2. Remove three capscrews, washers, and the lower
upper kingpin cover from the steering axle. See
kingpin cover from the steering axle.
Figure 50.
3. Remove the grub screw and kingpin from the
spindle.

4. Remove the thrust bearing from between the

steering axle and spindle.

5. Remove the spindle from the steering axle.

49
Spindle Repair 1600 YRM 1360

6. Remove the needle bearings from the steering 5. If removed, inspect the steering direction sensor
axle. and its attaching parts for damage. If damaged,
replace either the steering direction sensor or the
7. Remove and discard the kingpin seals from the damaged parts.
steering axle.
ASSEMBLE ERP16-20VF (ERP30-40VF)
CLEAN (A955)
NOTE: Coat kingpin seals with multipurpose grease
WARNING prior to installation.
Cleaning solvents can be flammable and toxic and
1. Install new kingpin seals into steering axle. See
can cause skin irritation. When using cleaning
Figure 50
solvents, always follow the solvent manufacturer’s
recommended safety procedures. 2. Coat needle bearings with multipurpose grease
and install needle bearings into steering axle.

WARNING 3. Install the spindle into steering axle.

Compressed air is used for cleaning or drying
purposes, or for clearing restrictions. Wear 4. Fill thrust bearing with multipurpose grease, and
protective clothing (goggles/shield, gloves, etc.) to install thrust bearing between the steering axle
avoid injury to personnel. and spindle.

1. Clean bearings by placing them in a wire basket NOTE: There is an indentation in the kingpin for the
and immersing in a container of fresh solvent. installation of the grub screw. While performing Step 5,
Agitate the bearings in the solvent to remove all ensure that the indentation is lined up on the grub
traces of old lubricant. screw hole in the spindle.
5. Coat the kingpin with multipurpose grease, and
2. After cleaning the bearings, dry them with clean install the kingpin in the steering axle and spindle
compressed air. assembly.
3. Immediately wrap bearings in a lint-free cloth to 6. Install and tighten the grub screw in the spindle.
protect them from dust and other foreign matter. Check the kingpin to ensure there is no vertical
movement.
4. Clean the spindle and kingpin with solvent and air
dry with compressed air. 7. Install the lower kingpin cover, three capscrews,
and washers on the steering axle.
INSPECT
1. Inspect bearings for any damage. (i.e. burned or 8. Install the upper kingpin cover, three capscrews,
corroded bearings). If any damage is found, and washers on the steering axle.
replace the bearings.
INSTALL ERP16-20VF (ERP30-40VF)
2. Inspect the kingpin for straightness by placing a (A955)
ruler or other known true straight edge along the
NOTE: Step 1 and Step 3 are to be performed if the
length of the kingpin. Replace the kingpin if found
kingpin assembly on the right side is being repaired.
to be bent.
1. Install the steering direction sensor and two
3. Inspect all other parts for, burrs, rust, corrosion, or capscrews in kingpin cover. See Figure 49.
marred finish.
2. Connect steering axle wiring harness to steering
4. Replace any damaged parts. direction sensor. See Figure 49.

3. Install two plates and capscrew to steering axle.

See Figure 49.

50
1600 YRM 1360 Steering Cylinder Repair

4. Connect the tie rod to the spindle assembly. See 6. If required, repeat the procedure for the other
Tie Rod Replacement. spindle.

5. Install the wheel. See Steering Axle Assembly

Repair.

Steering Cylinder Repair

REMOVE ERC22-35VG (ERC045-070VG)
(A968) AND ERP22-35VL (ERP045-070VL)
(A976)
NOTE: The end caps of the steering cylinder are held
in the shell by the installation of cylinder mount
capscrews into the axle frame. To prevent oil leaks at
the caps, hold the caps on the shell during removal.
1. Disconnect and tag hydraulic lines at steering
cylinder. Install plugs in fittings on steering
cylinder and put caps on hydraulic lines.
See Figure 51 for lift truck models
• ERC22-35VG (ERC045-070VG) (A968)
See Figure 52 for lift truck models
• ERP22-35VL (ERP045-070VL) (A976)

1. HYDRAULIC HOSE

Figure 52. Steering Cylinder Hoses for Lift Truck

Model ERP22-35VL (ERP045-070VL) (A976)

NOTE: Perform Step 2 for lift trucks manufactured

prior to November, 2015.
2. Loosen four clamps and move two boots from the
tie rods to the steering cylinder rod. See
Figure 53.

1. HYDRAULIC HOSE

Figure 51. Steering Cylinder Hoses for Lift Truck

Model ERC22-35VG (ERC045-070VG) (A968)

51
Steering Cylinder Repair 1600 YRM 1360

1. CLAMP 6. TIE ROD

2. BOOT 7. STEERING CYLINDER
3. STEERING AXLE 8. CAPSCREW
4. SNAP RING 9. STEERING CYLINDER ROD
5. PIN

Figure 53. Steering Cylinder Removal for Lift Truck Models ERP22-35VL (ERP045-070VL) (A976)
Manufactured Prior to November, 2015 and ERC22-35VG (ERC045-070VG) (A968)

52
1600 YRM 1360 Steering Cylinder Repair

1. STEERING AXLE 5. STEERING CYLINDER

2. SNAP RING 6. CAPSCREW
3. PIN 7. STEERING CYLINDER ROD
4. TIE ROD

Figure 54. Steering Cylinder Removal for Lift Truck Models ERP22-35VL (ERP045-070VL) (A976)
Manufactured After November, 2015 and ERC22-35VG (ERC045-070VG) (A968)

NOTE: Perform Step 4 for lift trucks manufactured

WARNING after November, 2015.
The steering cylinder weighs 13.7 kg (30 lb), and to 4. Remove two snap rings, two pins, eight
prevent possible injury, may require two people to capscrews, and steering cylinder from the
remove the steering cylinder from the steering steering axle and tie rods. See Figure 54.
axle.
NOTE: Perform Step 5 for lift trucks manufactured
NOTE: Perform Step 3 for lift trucks manufactured prior to November, 2015.
prior to November, 2015.
5. Remove two boots and four clamps from the
3. Remove two snap rings, two pins, four steering cylinder rod.
capscrews, and steering cylinder from the
steering axle and tie rods. See Figure 53.
CAUTION
Disposal of lubricants and fluids must meet local
WARNING environmental regulations.
The steering cylinder weighs 13.7 kg (30 lb), and to
prevent possible injury, may require two people to 6. Hold end of steering cylinder over a container.
remove the steering cylinder from the steering Remove plug for hydraulic fitting from each end
axle. cap. Push rod toward end of shell that is over
container. Oil will drain from cylinder. Repeat
procedure for other end.

53
Steering Cylinder Repair 1600 YRM 1360

DISASSEMBLE ERC22-35VG 2. Remove the rod wiper, seal, O-ring, backup ring,
(ERC045-070VG) (A968) AND ERP22-35VL and O-ring from the end cap. Discard rod wiper,
seal, and O-rings. See Figure 55.
(ERP045-070VL) (A976)
1. Remove one end cap from cylinder shell and slide
off of cylinder rod. See Figure 55.

1. ROD WIPER 6. PISTON SEAL

2. SEAL 7. PISTON
3. END CAP 8. CYLINDER ROD
4. O-RING 9. CYLINDER SHELL
5. BACKUP RING

Figure 55. Steering Cylinder Disassembly

54
1600 YRM 1360 Steering Cylinder Repair

3. Pull cylinder rod out of cylinder shell, to prevent 3. Install one end cap on cylinder shell. See
possible damage to the cylinder shell, keep Figure 55.
cylinder rod centered in cylinder shell during
removal. See Figure 55. 4. Install new piston seal on piston. See Figure 55.

4. Remove and discard piston seal from the piston. 5. Carefully slide cylinder rod into cylinder shell and
See Figure 55. end cap. Keep cylinder rod aligned in center of
shell during installation so the parts are not
5. Repeat Step 1 and Step 2 for the opposite end damaged.
cap.
6. Install remaining end cap into cylinder shell.
CLEAN Install plugs in hydraulic fittings on end caps.

INSTALL ERC22-35VG (ERC045-070VG)

WARNING (A968) AND ERP22-35VL (ERP045-070VL)
Cleaning solvents can be flammable and toxic and (A976)
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufacturer's NOTE: Perform Step 1 for lift trucks manufactured
recommended safety procedures. prior November, 2015.
1. Hold end caps and install steering cylinder on
steering axle using four capscrews. Tighten
WARNING capscrews 225 to 280 N•m (166 to 206 lbf ft). See
Compressed air is used for cleaning or drying Figure 53.
purposes, or for clearing restrictions. Wear
protective clothing (goggles/shield, gloves, etc.) to NOTE: Perform Step 2 for lift trucks manufactured
avoid injury to personnel. after November, 2015.
2. Hold end caps and install steering cylinder on
Clean all metal parts in solvent. Dry with compressed steering axle using eight capscrews. Tighten
air. capscrews 225 to 280 N•m (166 to 206 lbf ft). See
Figure 54.
INSPECT
1. Inspect cylinder rod for grooves or damage. 3. Install two clamps and one boot on each end of
Remove small scratches with fine emery cloth. the cylinder rod. See Figure 53.

2. Inspect cylinder bore for damage. 4. Install tie rods into the steering cylinder ends.

3. Inspect end caps for cracks. 5. Install two pins into the steering cylinder rod/tie
rod combination and install a snap ring on each
ASSEMBLE ERC22-35VG (ERC045-070VG) pin. Move the rubber covers over each tie rod/
steering cylinder rod combination and tighten
(A968) AND ERP22-35VL (ERP045-070VL) clamps.
(A976)
1. Coat seals, rod wipers, and O-rings with packing 6. Remove plugs and caps and connect hydraulic
lubricant Yale P/N 504234269 prior to lines as tagged during removal, to steering
installation. cylinder. Operate steering system to remove air
from cylinders and system. Turn steering wheel
several times from one stop to the other. Check
that the steer cylinder operates lock to lock.
CAUTION
DO NOT damage the O-rings, seals, or wipers
during installation.

2. Install new O-ring, backup ring, O-ring, seal, and

wiper on both end caps. See Figure 55.

55
Steering Cylinder Repair 1600 YRM 1360

REMOVE ERC16-20VA (ERC030-040VA)

(A969) WARNING
The steering cylinder weighs 13.7 kg (30 lb), and to
NOTE: The end caps of the steering cylinder are held
prevent possible injury, may require two people to
in the shell by the installation of cylinder mount
remove the steering cylinder from the steering
capscrews into the axle frame. To prevent oil leaks at
axle.
the caps, hold the caps on the shell during removal.
1. Disconnect and tag hydraulic lines at steering 2. Remove four snap rings, two pins, four
cylinder. Install plugs in fittings on steering capscrews, and steering cylinder from the
cylinder and put caps on hydraulic lines. See steering axle and tie rods. See Figure 57.
Figure 56.

1. HYDRAULIC HOSE

Figure 56. Steering Cylinder Hoses for Lift Truck

Model ERC16-20VA (ERC030-040VA) (A969)

56
1600 YRM 1360 Steering Cylinder Repair

1. STEERING AXLE 5. STEERING CYLINDER

2. SNAP RING 6. CAPSCREW
3. PIN 7. STEERING CYLINDER ROD
4. TIE ROD

Figure 57. Steering Cylinder for Lift Truck Models ERC16-20VA (ERC030-040VA) (A969)

DISASSEMBLE ERC16-20VA
CAUTION (ERC030-040VA) (A969)
Disposal of lubricants and fluids must meet local
1. Remove one end cap from cylinder shell and slide
environmental regulations.
off of cylinder rod. See Figure 58.
3. Hold end of steering cylinder over a container.
Remove plug for hydraulic fitting from each end 2. Remove the rod wiper, seal, O-ring, backup ring,
cap. Push rod toward end of shell that is over and O-ring from the end cap. Discard rod wiper,
container. Oil will drain from cylinder. Repeat seal, and O-rings. See Figure 58.
procedure for other end.

57
Steering Cylinder Repair 1600 YRM 1360

1. ROD WIPER 6. PISTON SEAL

2. SEAL 7. PISTON
3. END CAP 8. CYLINDER ROD
4. O-RING 9. CYLINDER SHELL
5. BACKUP RING

Figure 58. Steering Cylinder Disassembly

3. Pull cylinder rod out of cylinder shell. To prevent CLEAN

possible damage to the cylinder shell, keep
cylinder centered in cylinder shell during removal.
WARNING
4. Remove and discard piston seal from the piston. Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
5. Repeat Step 1 and Step 2 for the opposite end solvents, always follow the solvent manufacturer's
cap. recommended safety procedures.

58
1600 YRM 1360 Steering Cylinder Repair

2. Install tie rods into the steering cylinder ends. See

WARNING Figure 57.
Compressed air is used for cleaning or drying 3. Install two pins into steering cylinder rod and tie
purposes, or for clearing restrictions. Wear rod combination. Install two snap rings on each
protective clothing (goggles/shield, gloves, etc.) to pin.
avoid injury to personnel.
4. Remove plugs and caps and connect hydraulic
Clean all metal parts in solvent. Dry with compressed
lines as tagged during removal, to steering
air.
cylinder. Operate steering system to remove air
from cylinders and system. Turn steering wheel
INSPECT several times from one stop to the other. Check
1. Inspect cylinder rod for grooves or damage. that the steer cylinder operates lock to lock.
Remove small scratches with fine emery cloth.
REMOVE ERP16-20VF (ERP30-40VF)
2. Inspect cylinder bore for damage. (A955)
3. Inspect end caps for cracks. 1. Disconnect and tag hydraulic lines at the steering
cylinder. See Figure 59. Install plugs in the
ASSEMBLE ERC16-20VA (ERC030-040VA) cylinder fittings and caps on the hydraulic lines to
prevent possible contamination.
(A969)
1. Coat seals, rod wipers, and O-rings with packing
lubricant Yale P/N 504234269 prior to
installation.

CAUTION
DO NOT damage the O-rings, seals, or wipers
during installation.

2. Install new O-ring, backup ring, O-ring, seal, and

wiper on both end caps. See Figure 58.

3. Install one end cap on cylinder shell. See

Figure 58.

4. Install new piston seal on piston. See Figure 58.

5. Carefully slide cylinder rod into cylinder shell and

end cap. Keep cylinder rod aligned in center of
shell during installation so the parts are not
damaged. 1. HYDRAULIC HOSE

6. Install remaining end cap into cylinder shell. Figure 59. Steering Cylinder Hose Removal
Install plugs in hydraulic fittings on end caps. ERP16-20VF (ERP30-40VF) (A955)

INSTALL ERC16-20VA (ERC030-040VA) 2. Remove two dowel pins, two snap rings, two pins,
(A969) four socket head screws, and two grub screws. To
remove the steering cylinder, rotate one of the
1. Hold end caps and install steering cylinder on hubs out of the way and pull the steering cylinder
steering axle using four capscrews. Tighten from the steer axle frame. See Figure 60.
capscrews to 225 to 280 N•m (166 to 206 lbf ft).
See Figure 57.

59
Steering Cylinder Repair 1600 YRM 1360

1. SNAP RING 5. DOWEL

2. PIN 6. STEERING CYLINDER
3. STEER AXLE FRAME 7. GRUB SCREW
4. HUB 8. SOCKET HEAD SCREWS

Figure 60. Steering Cylinder Removal ERP16-20VF (ERP30-40VF) (A955)

2. Push the collar into the cylinder shell

CAUTION approximately 25.4 mm (1 in.) and remove the
Disposal of lubricants and fluids must meet local split ring from the cylinder shell.
environmental regulations.
3. To remove the collar from the cylinder shell pull
3. While holding one end of the steering cylinder the cylinder rod until the piston pushes the collar
over a suitable container, remove the plug from from the cylinder shell.
the fitting and push the rod toward the end over
the container. This will push any fluid on that end 4. Repeat Step 1 through Step 3 to remove the
of the cylinder out and into the container. Repeat collar from the opposite end of the steer cylinder.
for the opposite end.
5. Remove and discard the rod wiper, inner seal,
outer seal, and backup ring from each collar. See
DISASSEMBLE ERP16-20VF (ERP30-40VF)
Figure 61.
(A955)
1. Remove the snap ring from the collar. See
Figure 61.

60
1600 YRM 1360 Steering Cylinder Repair

6. Remove the cylinder rod from the cylinder shell 7. Remove and discard two wear rings and the
using care not to allow the cylinder rod end to piston seal from the piston. See Figure 61.
come in contact with the inner surface of the
cylinder shell possibly scoring the inner surface.

1. SNAP RING 7. INNER SEAL

2. CYLINDER ROD 8. BACKUP RING
3. CYLINDER SHELL 9. OUTER SEAL
4. COLLAR 10. PISTON
5. SPLIT RING 11. WEAR RING
6. ROD WIPER 12. PISTON SEAL

Figure 61. Steering Cylinder Repair

CLEAN ASSEMBLE ERP16-20VF (ERP30-40VF)

(A955)
WARNING 1. Coat seals, rod wipers, and O-rings with packing
Cleaning solvents can be flammable and toxic and lubricant Yale P/N 504234269 prior to
can cause skin irritation. When using cleaning installation.
solvents, always follow the solvent manufacturer's
recommended safety procedures.
CAUTION
Do not damage the O-rings, seals, or wipers during
WARNING installation.
Compressed air is used for cleaning or drying 2. Install two new wear rings and a new piston seal
purposes, or for clearing restrictions. Wear on the piston. See Figure 61.
protective clothing (goggles/shield, gloves, etc.) to
avoid injury to personnel. 3. Install the cylinder rod in the cylinder shell using
care not to allow the cylinder rod end to come in
Clean all metal parts in solvent. Dry with compressed contact with the inner surface of the cylinder shell
air. possibly scoring the inner surface.
INSPECT 4. Install a new backup ring, outer seal, inner seal,
1. Inspect cylinder rod for grooves or damage. and rod wiper on each collar. See Figure 61.
Remove small scratches with fine emery cloth.
5. Install the collar on the cylinder rod and push the
2. Inspect cylinder bore for damage. collar about 25.4 mm (1 in.) from the cylinder
shell end and install the split ring in the cylinder
3. Inspect collars for damage. shell.

61
Steering Cylinder Repair 1600 YRM 1360

6. Use the rod to push the collar back to the end of

the cylinder shell enough to allow installation of
the snap ring. Install the snap ring on the collar
with the snap ring plier tabs at the top of the
cylinder shell.

7. Repeat Step 5 and Step 6 to install the collar into

the opposite end of the steering cylinder. See
Figure 61.

INSTALL ERP16-20VF (ERP30-40VF)

(A955)
1. Rotate one of the hubs out of the way and install
the steering cylinder on the steer axle frame. See
Figure 60.

2. Install four socket head screws and two grub

screws in steering cylinder and steer axle frame.
Tighten socket head and grub screws to
130 N•m (95 lbf ft).

3. Connect the tie rod to the steering cylinder rod

with a pin and dowel. Figure 60.

4. Repeat Step 3 for opposite side tie rod.

5. Connect the hydraulic hoses to the steering

cylinder as tagged during removal.

6. Operate the steering system to remove air from

the steering system and steering cylinder. Check
that the steering cylinder operates from stop to
stop by turning the steering wheel several times 1. HYDRAULIC HOSE
from one stop to the other. 2. STEERING AXLE

Figure 62. Steering Cylinder Hoses for Lift Truck

REMOVE ERP40-50VM, ERP50-55VM6
Model ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985) (ERP080-120VM, ERP100VML) (A985)
NOTE: The end caps of the steering cylinder are held
in the shell by the installation of cylinder mount
capscrews into the axle frame. To prevent oil leaks at WARNING
the caps, hold the caps on the shell during removal. The steering cylinder is heavy. To prevent possible
1. Disconnect and tag hydraulic lines at steering injury, two people may be required to remove the
cylinder. Install plugs in fittings on steering steering cylinder from the steering axle.
cylinder and put caps on hydraulic lines. See
2. Remove four snap rings, two pins, eight
Figure 62.
capscrews, and steering cylinder from the
steering axle and tie rods. See Figure 63.

62
1600 YRM 1360 Steering Cylinder Repair

1. SNAP RING 5. STEERING CYLINDER

2. PIN 6. CAPSCREW
3. TIE ROD 7. PIN AND SNAP RINGS
4. STEERING CYLINDER ROD

Figure 63. Steering Cylinder Removal for Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM,
ERP100VML) (A985)

DISASSEMBLE ERP40-50VM,
CAUTION ERP50-55VM6 (ERP080-120VM,
Disposal of lubricants and fluids must meet local ERP100VML) (A985)
environmental regulations.
1. Remove one end cap from cylinder shell and slide
3. Hold end of steering cylinder over a container. off of cylinder rod. See Figure 64.
Remove plug for hydraulic fitting from each end
cap. Push rod toward end of shell that is over 2. Remove the rod wiper, seal, O-ring, backup ring,
container. Oil will drain from cylinder. Repeat and O-ring from the end cap. Discard rod wiper,
procedure for other end. seal, and O-rings. See Figure 64.

63
Steering Cylinder Repair 1600 YRM 1360

1. ROD WIPER 6. PISTON SEAL

2. SEAL 7. CYLINDER SHELL
3. END CAP 8. CYLINDER ROD
4. O-RING 9. PISTON
5. BACKUP RING

Figure 64. Steering Cylinder Disassembly

3. Pull cylinder rod out of cylinder shell, to prevent

possible damage to the cylinder shell, keep WARNING
cylinder rod centered in cylinder shell during
Compressed air is used for cleaning or drying
removal. See Figure 64.
purposes, or for clearing restrictions. Wear
4. Remove and discard piston seal from the piston. protective clothing (goggles/shield, gloves, etc.) to
See Figure 64. avoid injury to personnel.

Clean all metal parts in solvent. Dry with compressed

5. Repeat Step 1 and Step 2 for the opposite end
air.
cap.

CLEAN INSPECT
1. Inspect cylinder rod for grooves or damage.
Remove small scratches with fine emery cloth.
WARNING
Cleaning solvents can be flammable and toxic and 2. Inspect cylinder bore for damage.
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufacturer's 3. Inspect end caps for cracks.
recommended safety procedures.

64
1600 YRM 1360 Steering Cylinder Repair

ASSEMBLE ERP40-50VM, ERP50-55VM6 from cylinders and system. Turn steering wheel
(ERP080-120VM, ERP100VML) (A985) several times from one stop to the other. Check
that the steer cylinder operates lock to lock.
1. Coat seals, rod wipers, and O-rings with packing
lubricant Yale P/N 504234269 prior to REMOVE ERC40-55VH, ERC50VHS
installation.
(ERC80-120VH, ERC100VHS) (A938)
1. The end caps of the steering cylinder are held in
CAUTION the shell by the installation of cylinder mount
DO NOT damage the O-rings, seals, or wipers capscrews into the axle frame. To prevent oil
during installation. leaks at the caps, hold the caps on the shell
during removal.
2. Install new O-ring, backup ring, O-ring, seal, and Disconnect and tag hydraulic lines at steering
wiper on both end caps. See Figure 64. cylinder. Install plugs in fittings on steering
cylinder and put caps on hydraulic lines. See
3. Install one end cap on cylinder shell. See Figure 65.
Figure 64.

4. Install new piston seal on piston. See Figure 64.

5. Carefully slide cylinder rod into cylinder shell and

end cap. Keep cylinder rod aligned in center of
shell during installation so the parts are not
damaged.

6. Install remaining end cap into cylinder shell.

Install plugs in hydraulic fittings on end caps.

INSTALL ERP40-50VM, ERP50-55VM6

(ERP080-120VM, ERP100VML) (A985)
1. Hold end caps and install steering cylinder on
steering axle using eight capscrews. Tighten
capscrews 225 to 280 N•m (166 to 206 lbf ft). See 1. HYDRAULIC HOSE
Figure 63.
Figure 65. Steering Cylinder Hoses for Lift Trucks
2. Install tie rods into the steering cylinder ends. ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938)
3. Install two pins into the steering cylinder rod/tie
rod combination and install two snap rings on 2. Loosen four clamps and move two boots from the
each pin. See Figure 63. tie rods to the steering cylinder rod. See
Figure 66.
4. Remove plugs and caps and connect hydraulic
lines as tagged during removal, to steering
cylinder. Operate steering system to remove air

65
Steering Cylinder Repair 1600 YRM 1360

1. CLAMP 6. TIE ROD

2. BOOT 7. STEERING CYLINDER
3. STEERING AXLE 8. CAPSCREW
4. SNAP RING 9. STEERING CYLINDER ROD
5. PIN

Figure 66. Steering Cylinder Removal, Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938)

WARNING CAUTION
The steering cylinder weighs 17.1 kg (38 lb), To Disposal of lubricants and fluids must meet local
prevent possible injury, two people may be environmental regulations.
required to remove the steering cylinder from the
steering axle. 5. Hold end of steering cylinder over a container.
Remove plug for hydraulic fitting from each end
3. Remove two snap rings, two pins, eight cap. Push rod toward end of shell that is over
capscrews, and steering cylinder from the container. Oil will drain from cylinder. Repeat
steering axle and tie rods. See Figure 66. procedure for other end.

4. Remove two boots and four clamps from the

steering cylinder rod.

66
1600 YRM 1360 Steering Cylinder Repair

DISASSEMBLE ERC40-55VH, ERC50VHS 2. Remove the rod wiper, seal, O-ring, backup ring,
(ERC80-120VH, ERC100VHS) (A938) and O-ring from the end cap. Discard rod wiper,
seal, and O-rings. See Figure 67.
1. Remove one end cap from cylinder shell and slide
off of cylinder rod. See Figure 67.

1. ROD WIPER 6. PISTON SEAL

2. SEAL 7. PISTON
3. END CAP 8. CYLINDER ROD
4. O-RING 9. CYLINDER SHELL
5. BACKUP RING

Figure 67. Steering Cylinder Disassembly

3. Pull cylinder rod out of cylinder shell, to prevent 4. Remove and discard piston seal from the piston.
possible damage to the cylinder shell, keep
cylinder rod centered in cylinder shell during 5. Repeat Step 1 through Step 4 for the opposite
removal. See Figure 67. end cap.

67
Steering Cylinder Repair 1600 YRM 1360

CLEAN 6. Carefully slide cylinder rod into cylinder shell and

end cap. Keep cylinder rod aligned in center of
shell during installation so the parts are not
WARNING damaged.
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning 7. Install remaining end cap into cylinder shell.
solvents, always follow the solvent manufacturer’s
recommended safety procedures. 8. Install plugs in hydraulic fittings on end caps.

INSTALL ERC40-55VH, ERC50VHS

WARNING (ERC80-120VH, ERC100VHS) (A938)
Compressed air can move particles so that they 1. Hold end caps and install steering cylinder on
cause injury to the user or to other personnel. steering axle using eight capscrews.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles 2. Tighten capscrews 225 N•m (166 lbf ft) See
or a face shield to prevent injury to the eyes. Figure 66.

Clean all metal parts in solvent and dry with 3. Install two clamps and one boot on each end of
compressed air. the cylinder rod. See Figure 66.

INSPECT 4. Install tie rods into the steering cylinder ends.

1. Inspect cylinder rod for grooves or damage. 5. Install two pins into the steering cylinder rod/tie
Remove small scratches with fine emery cloth. rod combination and install a snap ring on each
pin. Move the rubber covers over each tie rod/
2. Inspect cylinder bore for damage. steering cylinder rod combination and tighten
clamps.
3. Inspect end caps for cracks.
6. Remove plugs and caps and connect hydraulic
ASSEMBLE ERC40-55VH, ERC50VHS lines as tagged during removal, to steering
(ERC80-120VH, ERC100VHS) (A938) cylinder. Operate steering system to remove air
1. Coat the internal surfaces of the cylinder shell from cylinders and system. Turn steering wheel
with anti-rust compound (Rust Veto 377 or several times from one stop to the other. Check
equivalent). See Figure 67. that the steer cylinder operates lock to lock.

2. Coat seals, rod wipers, and O-rings with packing

lubricant (Yale P/N 504234269 ) prior to
installation.

CAUTION
DO NOT damage the O-rings, seals, or wipers
during installation.

3. Install new O-ring, backup ring, O-ring, seal, and

wiper on both end caps. See Figure 67.

4. Install one end cap on cylinder shell.

5. Install new piston seal on piston. See Figure 67.

68
1600 YRM 1360 10/18 (9/18)(1/16)(9/14)(4/13)(12/12)