Electrical System: Maintenance

Maintenance
ELECTRICAL SYSTEM
ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) [A938];ERC22-35VG (ERC045-070VG) [A
968];ERC16-20VA (ERC030-040VA) [A969];
ERP22-35VL (ERP045-070VL) [A976];ERP40-50VM,
ERP50-55VM6 (ERP080-120VM, ERP100VML) [A985]
PART NO. 524319499 2200 YRM 1369

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
Discharging the Capacitors...................................................................................................................................2
Display Panel and Key or Keyless Switch Replacement........................................................................................ 3
Display Panel, Replace.........................................................................................................................................3
Remove..............................................................................................................................................................3
Install..................................................................................................................................................................6
Electronic and Manual Hydraulic Controls.............................................................................................................. 7
General.................................................................................................................................................................7
Manual Hydraulic Controls....................................................................................................................................8
Upper Front Cover............................................................................................................................................. 8
Direction Control Switch.....................................................................................................................................9
Remove........................................................................................................................................................... 9
Install............................................................................................................................................................. 14
Clamp Button................................................................................................................................................... 14
Remove......................................................................................................................................................... 14
Install............................................................................................................................................................. 15
Return To Set Tilt (RTST) Button..................................................................................................................... 15
Remove......................................................................................................................................................... 15
Install............................................................................................................................................................. 15
Emergency Disconnect Switch.........................................................................................................................16
Remove......................................................................................................................................................... 16
Install............................................................................................................................................................. 16
E-Hydraulic Controls - Test.................................................................................................................................17
Mini-Levers.......................................................................................................................................................17
Full Stroke Test................................................................................................................................................ 17
Function Returns to Neutral Test......................................................................................................................17
Push (Override) Button.................................................................................................................................... 18
E-Hydraulic Controls...........................................................................................................................................18
Mini-levers, Remove and Install.......................................................................................................................18
Armrest Assembly............................................................................................................................................19
Remove......................................................................................................................................................... 19
Install............................................................................................................................................................. 21
Horn Button......................................................................................................................................................21
Remove......................................................................................................................................................... 21
Install............................................................................................................................................................. 22
Direction Control Switch...................................................................................................................................22
Remove......................................................................................................................................................... 22
Install............................................................................................................................................................. 23
Emergency Disconnect Switch.........................................................................................................................23
Remove......................................................................................................................................................... 23
Install............................................................................................................................................................. 24
Push (Override) Buttons and Function Selection Button................................................................................. 24
Remove......................................................................................................................................................... 24
Install............................................................................................................................................................. 26
Electronic-Hydraulic Controls, After January, 2020...............................................................................................26
General...............................................................................................................................................................26
E-Hydraulic Controls - TEST.............................................................................................................................. 28
Mini-Levers.......................................................................................................................................................28
Full Stroke Test................................................................................................................................................ 28
Function Returns to Neutral Test......................................................................................................................28
Push Button (push (override) button)...............................................................................................................29
Mini-levers, Remove and Install..........................................................................................................................29
©2020 Yale Materials Handling Corp. i

Table of Contents
TABLE OF CONTENTS (Continued)

Armrest Assembly...............................................................................................................................................29
Remove............................................................................................................................................................29
Install................................................................................................................................................................32
Horn Button.........................................................................................................................................................32
Remove............................................................................................................................................................32
Install................................................................................................................................................................33
Direction Control Switch..................................................................................................................................... 33
Remove............................................................................................................................................................33
Install................................................................................................................................................................33
Emergency Disconnect Switch........................................................................................................................... 33
Remove............................................................................................................................................................34
Install................................................................................................................................................................34
Push (Override) Buttons .................................................................................................................................... 35
Remove............................................................................................................................................................35
Install................................................................................................................................................................36
Sensors and Switches...........................................................................................................................................37
General...............................................................................................................................................................37
Synchronous Steering Valve...............................................................................................................................37
Steering Axle Sensor..........................................................................................................................................37
Remove............................................................................................................................................................37
Install................................................................................................................................................................42
Hydraulic Motor Speed Sensor...........................................................................................................................43
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968)..............................................................................43
Remove......................................................................................................................................................... 43
Install............................................................................................................................................................. 48
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985).......................................................................................................... 49
Remove......................................................................................................................................................... 49
Install............................................................................................................................................................. 53
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969)............................................................................... 53
Remove......................................................................................................................................................... 53
Install............................................................................................................................................................. 54
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938)......................................54
Remove......................................................................................................................................................... 54
Install............................................................................................................................................................. 56
Hydraulic Motor Temperature Sensor.................................................................................................................56
Hydraulic Tank Level Sensor.............................................................................................................................. 56
(ERP080-120VM, ERP100VML) (A985).......................................................................................................... 56
Remove......................................................................................................................................................... 56
Install............................................................................................................................................................. 58
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) .......58
Remove......................................................................................................................................................... 58
Install............................................................................................................................................................. 59
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938).................................... 59
Remove......................................................................................................................................................... 59
Install............................................................................................................................................................. 60
Hydraulic Filter Sensor....................................................................................................................................... 60
(ERP080-120VM, ERP100VML) (A985).......................................................................................................... 60
Remove......................................................................................................................................................... 60
Install............................................................................................................................................................. 61
ii
Table of Contents

Lift Truck Models ERC22-35VG (ERC045-070VG) (A968,) ERC16-20VA (ERC030-040VA) (A969) and
ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938)................................................................ 62
Remove......................................................................................................................................................... 62
Install............................................................................................................................................................. 63
Hydraulic Oil Temperature Sensor......................................................................................................................64
(ERP080-120VM, ERP100VML) (A985).......................................................................................................... 64
Remove......................................................................................................................................................... 64
Install............................................................................................................................................................. 64
Remove......................................................................................................................................................... 64
Install............................................................................................................................................................. 65
Traction Speed Sensor....................................................................................................................................... 65
(ERP080-120VM, ERP100VML) (A985).......................................................................................................... 65
Remove......................................................................................................................................................... 65
Install............................................................................................................................................................. 67
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969)........68
Remove......................................................................................................................................................... 68
Install............................................................................................................................................................. 70
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938)......................................70
Remove......................................................................................................................................................... 70
Install............................................................................................................................................................. 71
Traction Motor Temperature Sensor ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL
(ERP045-070VL) (A976).....................................................................................................................................72
Traction Motor Temperature Sensor ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985).. 72
Remove............................................................................................................................................................72
Install................................................................................................................................................................73
Tilt Position Sensor ERC22-35VG (ERC045-070VG) (A968), ERP22-35VL (ERP045-070VL) (A976), and
ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)............................................................73
Remove............................................................................................................................................................73
Install................................................................................................................................................................75
Tilt Position Sensor ERC16-20VA (ERC030-040VA) (A969).............................................................................. 76
Remove............................................................................................................................................................76
Install................................................................................................................................................................76
Tilt Position Sensor ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938)................................... 77
Remove............................................................................................................................................................77
Install................................................................................................................................................................78
Low Level Brake Fluid Switch for Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA
(ERC030-040VA) (A969), ERP22-35VL (ERP045-070VL) (A976), and ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985).............................................................................................................79
Remove............................................................................................................................................................79
Install................................................................................................................................................................82
Low Level Brake Fluid Switch for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS)
(A938).................................................................................................................................................................83
Remove............................................................................................................................................................83
Install................................................................................................................................................................84
Service Brake Pressure Sensor for Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA
(ERC030-040VA) (A969), ERP22-35VL (ERP045-070VL) (A976), and ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985).............................................................................................................85
Remove............................................................................................................................................................85
Install................................................................................................................................................................85
iii
Table of Contents

Service Brake Pressure Sensor for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS)
(A938).................................................................................................................................................................86
Remove............................................................................................................................................................86
Install................................................................................................................................................................86
Accelerator Pedal Position Sensor..................................................................................................................... 86
Remove............................................................................................................................................................86
Install................................................................................................................................................................87
Seat Belt Sequence Module............................................................................................................................... 87
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985).............................87
Remove......................................................................................................................................................... 87
Install............................................................................................................................................................. 87
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976)................................................................................88
Remove......................................................................................................................................................... 88
Install............................................................................................................................................................. 88
Remove......................................................................................................................................................... 88
Install............................................................................................................................................................. 89
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938)....................................................................................................................................... 89
Remove......................................................................................................................................................... 89
Install............................................................................................................................................................. 90
Seat Sensor (Operator Presence System)......................................................................................................... 90
Non-Suspension Seat...................................................................................................................................... 90
Remove......................................................................................................................................................... 90
Install............................................................................................................................................................. 92
Full Suspension and Swivel Seats...................................................................................................................92
Remove......................................................................................................................................................... 92
Install............................................................................................................................................................. 93
Steering Direction Sensor...................................................................................................................................93
Remove............................................................................................................................................................93
Install................................................................................................................................................................94
Load Weight Sensor........................................................................................................................................... 94
Remove............................................................................................................................................................94
Install................................................................................................................................................................96
Battery Gate Switch............................................................................................................................................96
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and
ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938)................................................................ 96
Remove......................................................................................................................................................... 96
Install............................................................................................................................................................. 98
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976)................................................................................98
Remove......................................................................................................................................................... 98
Install........................................................................................................................................................... 100
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)...........................101
Remove....................................................................................................................................................... 101
Install........................................................................................................................................................... 102
Horn Switch...................................................................................................................................................... 102
Fixed Steering Column...................................................................................................................................102
Remove....................................................................................................................................................... 102
Install........................................................................................................................................................... 103
Telescopic Steering Column...........................................................................................................................103
Remove....................................................................................................................................................... 103
Install........................................................................................................................................................... 104
iv
Table of Contents

Impact Sensor...................................................................................................................................................104
(ERP080-120VM, ERP100VML) (A985)........................................................................................................ 104
Remove....................................................................................................................................................... 104
Install........................................................................................................................................................... 106
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969)......106
Remove....................................................................................................................................................... 106
Install........................................................................................................................................................... 107
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938)....................................108
Remove....................................................................................................................................................... 108
Install........................................................................................................................................................... 109
Rear and Hood Horn Button Switches..............................................................................................................109
Rear Horn Button Switch................................................................................................................................109
Remove....................................................................................................................................................... 109
Install........................................................................................................................................................... 110
Hood Horn Button Switch............................................................................................................................... 110
Remove....................................................................................................................................................... 110
Install............................................................................................................................................................111
Motor Controllers Replacement...........................................................................................................................112
General............................................................................................................................................................. 112
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969)........ 126
Traction Motor and Hydraulic Pump and Motor Controllers........................................................................... 126
Remove....................................................................................................................................................... 126
Install........................................................................................................................................................... 133
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM,
ERP100VML) (A985)........................................................................................................................................134
Hydraulic Pump and Motor Controller............................................................................................................134
Remove....................................................................................................................................................... 134
Install........................................................................................................................................................... 140
Traction Motor Controllers..............................................................................................................................141
Remove....................................................................................................................................................... 141
Install........................................................................................................................................................... 148
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938)...................................... 149
Traction Motor and Hydraulic Pump and Motor Controllers........................................................................... 149
Remove....................................................................................................................................................... 149
Install........................................................................................................................................................... 151
Line Contactor.................................................................................................................................................. 152
Remove..........................................................................................................................................................152
Install..............................................................................................................................................................160
Fans for Lift Truck Models Manufactured Before November 2014ERC22-35VG (ERC045-070VG) (A968),
ERC16-20VA (ERC030-040VA) (A969), ERP22-25VL (ERP045-070VL) (A976), and ERP40-50VM
(ERP080-100VM) (A985)..................................................................................................................................161
Remove..........................................................................................................................................................161
Install..............................................................................................................................................................163
Fans for Lift Truck Model Manufactured Before November 2014ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938)........................................................................................................................................164
Remove..........................................................................................................................................................164
Install..............................................................................................................................................................164
Fans for Lift Truck Models Manufactured After November 2014ERC045-070VG (A968), ERC030-040VA
(A969), ERC80-120VH, ERC100VHS (A938), ERP22-25VL (ERP045-070VL) (A976), and ERP40-50VM,
ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)..................................................................................164
Remove..........................................................................................................................................................171
v
Table of Contents

Install..............................................................................................................................................................175
Vehicle System Manager.................................................................................................................................... 175
General.............................................................................................................................................................175
Remove............................................................................................................................................................ 176
Install................................................................................................................................................................ 180
Programming a New VSM and/or Display Panel..............................................................................................181
PC Service Tool Software.................................................................................................................................181
Fuses and Relays............................................................................................................................................... 182
Fuses............................................................................................................................................................. 182
Relays............................................................................................................................................................ 188
Backup Alarm......................................................................................................................................................196
Battery Connection..............................................................................................................................................199
Inspect.............................................................................................................................................................. 199
Replacing Cables..............................................................................................................................................199
Cab Heater..........................................................................................................................................................201
Lights...................................................................................................................................................................201
General.............................................................................................................................................................201
Work Lights (Front and Rear)........................................................................................................................... 205
Halogen Bulb Lights.......................................................................................................................................205
Remove....................................................................................................................................................... 205
Install........................................................................................................................................................... 205
LED Lights......................................................................................................................................................205
Remove....................................................................................................................................................... 205
Install........................................................................................................................................................... 206
Strobe Light...................................................................................................................................................... 206
Remove..........................................................................................................................................................206
Install..............................................................................................................................................................206
LED Tail, Backup, and Brake Lights................................................................................................................. 207
Remove..........................................................................................................................................................207
Install..............................................................................................................................................................208
Front Marker/Turn Signal Lights....................................................................................................................... 208
Remove..........................................................................................................................................................208
Install..............................................................................................................................................................208
Dome Light....................................................................................................................................................... 208
Remove..........................................................................................................................................................208
Install..............................................................................................................................................................209
Converter..........................................................................................................................................................209
Remove..........................................................................................................................................................210
Install..............................................................................................................................................................218
vi
2200 YRM 1369 General
General
The removal and replacement procedures for the For information on servicing and maintaining transaxle
following electrical components are covered in this motors:
service manual:
See Transaxle 1300YRM1370 for lift truck models
• Display panel
• ERP22-35VL (ERP045-070VL) (A976)
• Electronic and manual hydraulic control
components See Transaxle 1300YRM1539 for lift truck models
• Motor controllers • ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985)
• Sensors and switches
See Drive Axle, Speed Reducer, and Differential
• Lights
1300YRM1366 for lift truck models
• Fuses, alarm and horn
• ERC22-35VG (ERC045-070VG) (A968)
• Battery
• ERC16-20VA (ERC030-040VA) (A969)
• Vehicle System Manger (VSM)
• ERC40-55VH, ERC50VHS (ERC80-120VH,
For adjustment procedure for switches located on ERC100VHS) (A938)
linkage for manual control valve, see Main Control
If any of wire harnesses need to be repaired, see Wire
Valves 2000YRM1334 for lift truck models
Harness Repair 2200YRM1128 for repair procedures.
• ERC22-35VG (ERC045-070VG) (A968)
Some components used are made of plastic. When
• ERP22-35VL (ERP045-070VL) (A976) using screws to replace and install plastic
• ERP40-50VM, ERP50-55VM6 components, screws should be rotated
(ERP080-120VM, ERP100VML) (A985) counterclockwise until screw thread turns over the last
• ERC40-55VH, ERC50VHS (ERC80-120VH, thread in the plastic part. The screw can then be
ERC100VHS) (A938) turned clockwise to make a connection. This prevents
"cutting" new threads and damaging existing thread in
See Main Control Valves 2000YRM1439 for lift truck
plastic components.
models
If any welding must be done, obtain proper
• ERC16-20VA (ERC030-040VA) (A969)
authorization from a Resident Service Engineer. If
If lift truck is equipped with an E-Hydraulic control authorization is given, be sure to follow procedures in
valve, see Main Control Valves 2000YRM1334 for lift WARNING and CAUTIONS below.
truck models
• ERC22-35VG (ERC045-070VG) (A968)
WARNING
• ERP22-35VL (ERP045-070VL) (A976) Forklift frames and components may be painted
• ERP40-50VM, ERP50-55VM6 with a catalyzed paint such as polyurethane or a
(ERP080-120VM, ERP100VML) (A985) two-part primer. Welding, burning, or other heat
• ERC40-55VH, ERC50VHS (ERC80-120VH, sufficient to cause thermal decomposition of the
ERC100VHS) (A938) paint may release isocyanates. These chemicals
are allergic sensitizers to the skin and respiratory
See Main Control Valves 2000YRM1439 for lift truck
tract and overexposure may occur without odor
models
warning. Should work be performed, utilize good
• ERC16-20VA (ERC030-040VA) (A969) industrial hygiene practices including removal of
For information on servicing and maintaining AC all paint (prime and finish coats) to the metal
hydraulic pump motor for all lift truck models covered around the area to be welded, local ventilation,
in this manual and for traction motor on lift truck and/or supplied-air respiratory protection.
models ERC22-35VG (ERC045-070VG) (A968) , see
AC Motor Repair 0620YRM1385.
For information on battery for all lift truck models
covered in this manual see Industrial Battery
2240YRM0001.
1
General 2200 YRM 1369
Before performing any tests or adjustment, block

CAUTION the lift truck to prevent unexpected movement.
When an arc welder is used, always disconnect the The capacitor in the transistor controller(s) can
battery connector on the lift truck. This action will hold an electrical charge for about 10 seconds
prevent damage to the motor controllers. after the battery is disconnected. To prevent an
electrical shock and personal injury, discharge the
Connect the ground clamp for the arc welder as
capacitor(s) before inspecting or repairing any
close as possible to the weld area. This action will
component in the drive unit compartment. Make
prevent damage to a bearing from the large current
certain that the battery has been disconnected.
from the welder.
DO NOT short across the motor controller
Before performing arc welding repairs, disconnect terminals with a screwdriver or jumper wire.
motor controller and VSM connections to prevent
Make certain the Emergency-Disconnect switch
damage to motor controllers and VSM. See sections
has not been activated. This will isolate the
Motor Controllers Replacement and Vehicle Systems
controllers and prevent the capacitors from
Manager for procedures.
discharging properly. The proper way to
disconnect the battery is by separating the battery
DISCHARGING THE CAPACITORS
connectors.
WARNING 1. Ensure capacitors are discharged by performing

Step 2 through Step 6 below.
DO NOT make repairs or adjustments unless you
have been properly trained and authorized to do
2. Turn key or keyless switch to OFF position.
so. Improper repairs and adjustments can create
dangerous operating conditions. DO NOT operate 3. Disconnect battery by separating connectors.
a lift truck that needs repairs. Report the need for
repairs to your supervisor immediately. If repair is 4. Block drive wheels to prevent lift truck from
necessary, attach a DO NOT OPERATE tag on the moving.
steering wheel and disconnect the battery.
Disconnect the battery and allow the capacitors to 5. Make sure Emergency-Disconnect switch HAS
discharge before opening any compartment NOT been activated. If Emergency-Disconnect
covers or inspecting or repairing the electrical switch is activated, rotate switch to the right until it
system. DO NOT place tool on top of the battery. If pops up.
a tool causes a short circuit, the high current flow
from the battery can cause personal injury and 6. Press horn button. Wait 30 seconds to be sure
property damage. capacitors are fully discharged.
Some checks and adjustments are performed with If a torque value is not specified, go to Metric and
the battery connected. DO NOT connect the Inch (SAE) Fasteners 8000YRM0231 for torque
battery until the procedure instructs you to do so. values.
Never wear any metallic items on your fingers,
arms, or neck. Metal items can accidentally make
an electrical connection and cause injury.
2
2200 YRM 1369 Display Panel and Key or Keyless Switch Replacement
Display Panel and Key or Keyless Switch Replacement

DISPLAY PANEL, REPLACE mounted to a bracket on upper right corner of
overhead guard. See Figure 1.
Remove
The optional low mount display panel is mounted
inside of a display panel cover. The display panel
WARNING cover is mounted on a bracket which is mounted in the
Before replacing the display panel, fully lower all middle of the right front leg of the overhead guard. See
parts of the mast and tilt it forward until the tips of Figure 2.
the forks touch the ground. This action will
prevent the mast from lowering suddenly if the
control lever is accidently moved.
WARNING
Disconnect the battery before doing any work on
the electrical system. Serious injury to personnel
and/or damage to lift truck components can occur
if battery is not disconnected.
Discharge capacitors as directed in Discharging
the Capacitors in General section of this manual.
CAUTION
A short circuit and damage can occur if wires are
not installed correctly. Make sure wire connectors
do not touch the other meter terminals or wire
connectors, metal brackets, or the bracket
mounting nuts. Make sure the wires are not pulled
tight and are not touching other parts to damage
the insulation. NOTE: STANDARD KEY SWITCH SHOWN.
NOTE: The display panel cannot be repaired and 1. OVERHEAD GUARD
must be replaced as a unit, if it has a malfunction. See 2. DISPLAY PANEL
Parts Manual for replacement part number. The key 3. DISPLAY PANEL COVER
or keyless switch can be replaced without replacing 4. KEY OR KEYLESS SWITCH
the whole display panel. 5. SLOT
The high mount display panel is mounted inside of a Figure 1. High Mount Display Panel Arrangement
display panel cover. The display panel cover is
3
Display Panel and Key or Keyless Switch Replacement 2200 YRM 1369
Legend for Figure 2.
1. MOUNTING BRACKET
2. OVERHEAD GUARD
3. DISPLAY PANEL COVER
4. DISPLAY PANEL
5. KEY OR KEYLESS SWITCH
6. SLOT
1. Read and follow WARNING and CAUTION

above.
2. Insert a flat head screwdriver in slot on the bottom

of display panel.
See Figure 1 for high mount display panel.
See Figure 2 for low mount display panel.
3. Pull screwdriver down to loosen display panel

from slot. When display panel is loose from slot,
Figure 2. Low Mount Display Panel Arrangement pull display panel out of display panel cover. See
Figure 3 .
NOTE: HIGH MOUNT DISPLAY PANEL SHOWN. LOW MOUNT IS SIMILAR.
1. TOP NOTCHES 4. BOTTOM NOTCH

2. TOP SLOTS 5. BOTTOM SLOT
3. DISPLAY PANEL COVER 6. DISPLAY PANEL
Figure 3. Display Panel Removal
4
2200 YRM 1369 Display Panel and Key or Keyless Switch Replacement
4. When display panel is pulled from display panel

cover, the warning buzzer will disconnect from the
rear of display panel. See Figure 4.
1. PIN CONNECTOR
2. KEY SWITCH
NOTE: REAR OF DISPLAY PANEL AND DISPLAY
PANEL COVER SHOWN. SOME ELECTRICAL COM- Figure 5. Disconnecting Display Panel
PONENTS AND CONNECTIONS OMITTED FOR
CLARITY. 6. Remove key or keyless switch from display panel
by pinching in on the pinch points and pulling key
1. WARNING BUZZER or keyless switch from display panel. See
2. DISPLAY PANEL Figure 6.
3. DISPLAY PANEL COVER
4. DISPLAY WIRE HARNESS
5. WARNING BUZZER ELECTRICAL
CONNECTION
Figure 4. Warning Buzzer
5. Disconnect display wire harness from pin

connector on the back of display panel. Remove
display panel from lift truck. See Figure 5.
5
Display Panel and Key or Keyless Switch Replacement 2200 YRM 1369
NOTE: BACK SIDE OF DISPLAY PANEL SHOWN.
1. PIN CONNECTOR NOTE: KEY SWITCH SHOWN.

2. PINCH POINTS
3. KEY OR KEYLESS SWITCH COVER 1. KEY SWITCH
2. DISPLAY PANEL
Figure 6. Key or Keyless Switch Removal 3. NOTCH
Install Figure 7. Key or Keyless Switch Installation
NOTE: Perform Step 2 for lift truck models

WARNING ERP22-35VL (ERP045-070VL) (A976) and
The ignition switch is a reed switch which uses an ERP40-50VM, ERP50-55VM6 (ERP080-120VM,
applied magnetic field. If a strong magnet is placed ERP100VML) (A985) , equipped with Outdoor
near the ignition switch, it may not function Protection/Wash-down Package.
properly (such as not shutting off power). To
2. Apply dielectric grease to display wire harness
ensure ignition switch functions properly, do not
connector.
place a magnet near the ignition switch.
3. Connect display wire harness to pin connector on
NOTE: If switch being installed uses a key, insert key
the back of display panel. See Figure 5.
into switch first. This will help install switch into display
panel. If switch is keyless, use knob to help install 4. Connect warning buzzer to the back of display
switch into display panel. panel. See Figure 4.
NOTE: For lift truck models ERP22-35VL
(ERP045-070VL) (A976) and ERP40-50VM, 5. Insert notches on top of display panel into slots
ERP50-55VM6 (ERP080-120VM, ERP100VML) on top of display panel cover. See Figure 3 .
(A985) , equipped with Outdoor Protection/ Wash-
down Package, apply dielectric grease to the key 6. Push in bottom of display panel until notch on the
switch terminals. bottom slides into slot on the bottom and display
panel locks into place inside cover. See Figure 3 .
1. Take new key or keyless switch and install into
display panel. Match notches on the switch with
holes on the switch cover. See Figure 6 and
Figure 7. Switch will snap into place.
6
2200 YRM 1369 Electronic and Manual Hydraulic Controls
Electronic and Manual Hydraulic Controls

NOTE: In this section, the information that covers the • Direction Control Switch - The direction
electronic hydraulic controls, applies to lift truck control switch is an optional feature and is used
manufactured before January, 2020. For information to select the direction of travel when lift truck is
on how to service E-Hydraulic controls on lift trucks equipped with a standard accelerator pedal.
manufactured after January, 2020, go to Electronic- • Emergency Disconnect Switch - The
Hydraulic Controls, After January, 2020 . emergency disconnect switch is used to
disconnect all electrical power to lift truck. The
GENERAL switch is operated by pushing the button down
until it clicks. To reset (re-connect) emergency
disconnect switch and energize electrical
circuits, turn switch clockwise until button pops
WARNING up.
Before replacing any part of the electronic or
• Horn Button - These buttons are used to sound
manual hydraulic control assembly, fully lower all
the horn. On lift trucks equipped with E-
parts of the mast and tilt it forward until the tips of Hydraulic mini-levers, there is an optional horn
the forks touch the ground. This action will button on the armrest.
To replace horn switch on steering wheel or
control lever is accidently moved. optional rear horn button on rear right overhead
guard leg or on hood, see Sensors and
Switches section in this manual.
WARNING • Clamp Button - The lift trucks covered in this
Discharge capacitors as directed in Discharging service manual may be equipped with a clamp
the Capacitors in General section of this manual. function. On lift trucks equipped with manual
hydraulic control levers, if lift truck is equipped
Disconnect the battery before doing any work on with three levers, the button for clamp function
the electrical system. Serious injury to personnel is located on top of the third lever. If lift truck has
and/or damage to lift truck components can occur four levers, the clamp button is on top of the
if battery is not disconnected. fourth lever.
For lift trucks equipped with E-Hydraulic mini-
levers, if lift truck is equipped with three mini-
WARNING levers, the push (override) button for clamp
Never wear any metallic items on your fingers, function is located behind third lever on the
palm rest. If lift truck has four levers, the push
arms, or neck. Metal items can accidently make an
(override) button is located behind fourth lever
electrical connection and cause an injury. on the palm rest.
• Return To Set Tilt (RTST) - The Return To Set
Tilt (RTST) is an optional feature on all lift truck
CAUTION models covered in this manual that are
A short circuit and damage can occur if wires are equipped with E-Hydraulic mini-levers. The
not installed correctly. Make sure wire connectors RTST feature can also be on lift truck models
do not touch the other metal terminals or wire ERC045-070VG (A968) manufactured after
connectors, metal brackets, or the bracket November 2014 and equipped with manual
mounting nuts. Make sure the wires are not pulled hydraulic control levers.
tight and are not touching other parts to damage The RTST option automatically stops the tilt
the insulation. function at a set point. To override the RTST
option, press the override button, located
The lift trucks covered in this service manual come directly behind the tilt mini-lever, for lift trucks
standard with manual hydraulic control levers, but equipped with E-Hydraulic mini-levers, or press
have the option of using electronic-hydraulic (E- the override button located on the top of the tilt
Hydraulic) mini-lever controls. In each hydraulic control lever, for lift trucks equipped with manual
hydraulic control levers, and push the mini-lever
arrangement, there are several electronic component
or manual tilt lever forward or pull it backward.
parts that can be replaced if they are no longer
working properly. These components are:
7
Electronic and Manual Hydraulic Controls 2200 YRM 1369
When removing and replacing sensors or switches, be

sure to tag connectors to aid in correct installation.
MANUAL HYDRAULIC CONTROLS

Upper Front Cover
NOTE: To replace direction control switch, emergency
disconnect switch, and the RTST and clamp buttons (if
equipped), the upper front cover must be removed first
from manual hydraulic control lever assembly as
described below.

section in General section above.
2. Remove four capscrews and front cover from

hydraulic lever assembly.
See Figure 8 for lift truck models
• ERC22-35VG (ERC045-070VG) (A968)
• ERP22-35VL (ERP045-070VL) (A976)
• ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985)
ERC100VHS) (A938)
• ERC16-20VA (ERC030-040VA) (A969)
NOTE: OPTIONAL DIRECTION CONTROL SWITCH

AND CLAMP BUTTON SHOWN. FOUR LEVERS
SHOWN. IF LIFT TRUCK IS EQUIPPED WITH
THREE LEVERS, CLAMP BUTTON IS ON THE TOP
OF THIRD LEVER.
NOTE: OPTIONAL RTST BUTTON FOR LIFT
TRUCK MODELS ERC045-070VG (A968) MANU-
FACTURED AFTER NOVEMBER 2014 SHOWN
1. UPPER FRONT COVER

2. CAPSCREWS
3. LOWER COVER
4. UPPER REAR COVER
5. DIRECTION CONTROL SWITCH
6. CLAMP BUTTON
7. EMERGENCY DISCONNECT SWITCH
8. RETURN TO SET TILT BUTTON
Figure 8. Manual Hydraulic Control Lever

Assemble for Lift Truck Models , and ERC22-35VG
(ERC045-070VG) (A968), ERP22-35VL
(ERP045-070VL) (A976), ERP40-50VM,
ERP50-55VM6 (ERP080-120VM, ERP100VML)
(A985) ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938)
8

• ERC16-20VA (ERC030-040VA) (A969)
Direction Control Switch

Remove
2. Remove upper front cover. See section Upper

Front Cover for procedures. Disconnect manual
control valve wire harness from direction control
switch. See Figure 10.
NOTE: OPTIONAL DIRECTION CONTROL SWITCH

AND CLAMP BUTTON SHOWN. FOUR LEVERS
SHOWN. IF LIFT TRUCK IS EQUIPPED WITH
THREE LEVERS, CLAMP BUTTON IS ON THE TOP
OF THIRD LEVER.
1. UPPER FRONT COVER

2. CAPSCREWS
3. LOWER COVER
4. UPPER REAR COVER
6. CLAMP BUTTON
NOTE: RETURN TO SET TILT BUTTON USED ON-
Figure 9. Manual Hydraulic Control Lever LY ON LIFT TRUCK MODELS ERC045-070VG (A968)
Assembly for Lift Truck Model ERC16-20VA MANUFACTURED AFTER NOVEMBER 2014.
(ERC030-040VA) (A969)
1. CLAMP BUTTON CONNECTOR
3. Using four capscrews, install front cover on CONNECTOR
hydraulic lever assembly. 3. RETURN TO SET TILT BUTTON CONNECTOR
See Figure 8 for lift truck models 4. DIRECTION CONTROL SWITCH CONNECTOR
5. MANUAL CONTROL VALVE WIRE HARNESS
• ERC22-35VG (ERC045-070VG) (A968)
Figure 10. Manual Control Levers Assembly
• ERP22-35VL (ERP045-070VL) (A976)
Electrical Components
(ERP080-120VM, ERP100VML) (A985)
ERC100VHS) (A938)
9
3. Remove two outer capscrews and lift/lower with • ERP40-50VM, ERP50-55VM6

direction control switch handle from manual lift/ (ERP080-120VM, ERP100VML) (A985)
lower lever. • ERC40-55VH, ERC50VHS (ERC80-120VH,
See Figure 11 for lift truck models ERC100VHS) (A938)
ERC22-35VG (ERC045-070VG) (A968) See Figure 12 for lift truck models

•
• ERP22-35VL (ERP045-070VL) (A976) • ERC16-20VA (ERC030-040VA) (A969)
Figure 11. Manual Hydraulic Control Handles for Lift Truck Models ERC22-35VG (ERC045-070VG) (A968),
ERP22-35VL (ERP045-070VL) (A976), ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985),
and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938)
10
A. AUX HANDLE WITH DUAL FUNCTION AND B. LIFT/LOWER WITH DIRECTION CONTROL
TILT HANDLE WITH RTST SWITCH
1. PALM SIDE GRIP HANDLE 9. OUTER CAPSCREW

2. CLAMP/RTST SWITCH HANDLE 10. CABLE TRACK
3. LIFT/LOWER WITH DIRECTION CONTROL 11. SCREW
SWITCH HANDLE 12. DIRECTION CONTROL SWITCH RETAINER
4. MANUAL AUX 2 LEVER/TILT LEVER WITH 13. DIRECTION CONTROL SWITCH CUP
RTST 14. PUSH-BUTTON CABLE
5. MANUAL LIFT LEVER 15. DIRECTION CONTROL SWITCH CABLE
7. CLAMPING/RTST PUSH-BUTTON
8. INNER CAPSCREW
11
Figure 12. Manual Hydraulic Control Lever Assembly for Lift Truck Models ERC16-20VA (ERC030-040VA)
(A969)
12
A. AUX HANDLE WITH DUAL FUNCTION C. DTR HANDLE WITH DUAL FUNCTION
B. LIFT/LOWER WITH DIRECTION CONTROL
SWITCH
1. PALM SIDE GRIP HANDLE 10. CABLE TRACK

2. CLAMP SWITCH HANDLE 11. SCREW
3. LIFT/LOWER WITH DIRECTION CONTROL 12. DIRECTION CONTROL SWITCH RETAINER
SWITCH HANDLE 13. DIRECTION CONTROL SWITCH CUP
4. MANUAL AUX 2 LEVER 14. PUSH-BUTTON CABLE
5. MANUAL LIFT LEVER 15. DIRECTION CONTROL SWITCH CABLE
6. DIRECTION CONTROL SWITCH 16. DRIVE-THRU RACK (DTR) CLAMPING HANDLE
7. CLAMPING PUSH-BUTTON 17. DRIVE-THRU RACK (DTR) PALMSIDE HANDLE
8. INNER CAPSCREW 18. LEVER ASSEMBLY
9. OUTER CAPSCREW
4. Remove one inner capscrew and palm side grip

handle from manual lift lever.
• ERC22-35VG (ERC045-070VG) (A968)
• ERP22-35VL (ERP045-070VL) (A976)
(ERP080-120VM, ERP100VML) (A985)
ERC100VHS) (A938)
• ERC16-20VA (ERC030-040VA) (A969)
5. Remove direction control switch cable from cable

track.
• ERC22-35VG (ERC045-070VG) (A968)
• ERP22-35VL (ERP045-070VL) (A976)
(ERP080-120VM, ERP100VML) (A985)
ERC100VHS) (A938)
• ERC16-20VA (ERC030-040VA) (A969)
6. Remove two screws, direction control switch

retainer, direction control switch cup, and
direction control switch from lift/lower lever with
direction control switch handle. See Figure 13. 1. SCREW
2. DIRECTION CONTROL SWITCH RETAINER
3. DIRECTION CONTROL SWITCH CUP
4. DIRECTION CONTROL SWITCH CABLE
Figure 13. Direction Control Switch
13
Install • ERP40-50VM, ERP50-55VM6

(ERP080-120VM, ERP100VML) (A985)
1. Install direction control switch into direction
control switch cup. See Figure 13. ERC100VHS) (A938)
2. Install direction control switch cup and direction See Figure 12 for lift truck models
control switch into lift/lower direction control • ERC16-20VA (ERC030-040VA) (A969)
switch handle. See Figure 13.
8. Install upper front cover. See section Upper Front
3. Install direction control switch retainer onto back Cover for procedures.
side of direction control switch cup, inside lift/
lower with direction control switch handle. See Clamp Button
Figure 13.
Remove
4. Install two screws through retainer and direction
control switch cup into direction control switch.
See Figure 13.
5. Route direction control switch cable through cable
Front Cover for procedures. Disconnect manual
track on manual lift/lower lever.
control valve wire harness from clamp button.
See Figure 11 for lift truck models See Figure 10.
• ERC22-35VG (ERC045-070VG) (A968)
3. Remove two outer capscrews and clamp switch
• ERP22-35VL (ERP045-070VL) (A976) handle from manual aux 2 lever.
(ERP080-120VM, ERP100VML) (A985)
• ERC40-55VH, ERC50VHS (ERC80-120VH, • ERC22-35VG (ERC045-070VG) (A968)
ERC100VHS) (A938) • ERP22-35VL (ERP045-070VL) (A976)
See Figure 12 for lift truck models • ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985)
• ERC16-20VA (ERC030-040VA) (A969)
6. Install palm side handle and one capscrew on ERC100VHS) (A938)
manual lift/lower lever.
See Figure 11 for lift truck models handle from manual aux 2 lever.
• ERC22-35VG (ERC045-070VG) (A968) See Figure 11 for lift truck models
• ERP22-35VL (ERP045-070VL) (A976) • ERC22-35VG (ERC045-070VG) (A968)
• ERP40-50VM, ERP50-55VM6 • ERP22-35VL (ERP045-070VL) (A976)
(ERP080-120VM, ERP100VML) (A985)
• ERC40-55VH, ERC50VHS (ERC80-120VH, (ERP080-120VM, ERP100VML) (A985)
ERC100VHS) (A938)
See Figure 12 for lift truck models ERC100VHS) (A938)
• ERC16-20VA (ERC030-040VA) (A969)
NOTE: Perform Step 5 and Step 6 for lift truck models
7. Install lift/lower with direction control switch ERC16-20VA (ERC030-040VA) (A969) .
handle and two outer capscrews on manual lift/ 5. Remove one outer capscrew and Drive-Thru
lower lever. Tighten outer capscrews Rack (DTR) clamping handle from lever
1.35 to 1.65 N•m (11.9 to 14.6 lbf in). assembly. See Figure 12.
6. Remove one inner capscrew and DTR Palmside
• ERC22-35VG (ERC045-070VG) (A968) handle from lever assembly. See Figure 12.
• ERP22-35VL (ERP045-070VL) (A976)
14
7. Remove push-button cable from cable track. • ERP40-50VM, ERP50-55VM6

(ERP080-120VM, ERP100VML) (A985)
• ERC22-35VG (ERC045-070VG) (A968) ERC100VHS) (A938)
• ERP22-35VL (ERP045-070VL) (A976) See Figure 12 for lift truck models
• ERP40-50VM, ERP50-55VM6 • ERC16-20VA (ERC030-040VA) (A969)
(ERP080-120VM, ERP100VML) (A985)
• ERC40-55VH, ERC50VHS (ERC80-120VH, NOTE: Perform Step 4 and Step 5 for lift truck models
ERC100VHS) (A938) ERC16-20VA (ERC030-040VA) (A969) .
See Figure 12 for lift truck models 4. Install DTR palmside handle and one inner
• ERC16-20VA (ERC030-040VA) (A969) capscrew on lever assembly. See Figure 12.
Install 5. Install DTR clamping handle and one outer

capscrew on lever assembly. See Figure 12.
1. Route push-button cable through cable track on
manual aux 2 lever. 6. Install upper front cover. See section Upper Front
See Figure 11 for lift truck models Cover for procedures.
• ERC22-35VG (ERC045-070VG) (A968) Return To Set Tilt (RTST) Button

• ERP22-35VL (ERP045-070VL) (A976)
Remove
(ERP080-120VM, ERP100VML) (A985) NOTE: The Return To Set Tilt button is an optional
• ERC40-55VH, ERC50VHS (ERC80-120VH, feature on lift truck models ERC045-070VG (A968)
ERC100VHS) (A938) manufactured after November 2014
See Figure 12 for lift truck models 1. Read the following WARNING and CAUTION
• ERC16-20VA (ERC030-040VA) (A969) section in General section above.
2. Install palm side handle and one inner capscrew 2. Remove upper front cover. See section Upper
on manual aux 2 lever. Front Cover for procedures. Disconnect manual
control valve wire harness from RTST button. See
Figure 10.
• ERC22-35VG (ERC045-070VG) (A968)
• ERP22-35VL (ERP045-070VL) (A976) 3. Remove two outer capscrews and RTST switch
handle from manual tilt lever. See Figure 11.
(ERP080-120VM, ERP100VML) (A985)
• ERC40-55VH, ERC50VHS (ERC80-120VH, handle from tilt lever. See Figure 11.
ERC100VHS) (A938)
See Figure 12 for lift truck models 5. Remove push-button cable from cable track. See
Figure 11.
• ERC16-20VA (ERC030-040VA) (A969)
NOTE: Ensure clamping push-button is in correct

Install
position on clamp switch handle by aligning notches 1. Route push-button cable through cable track on
and flats during assembly. tilt lever. See Figure 11.
3. Install clamp switch handle and two outer
2. Install palm side handle and one inner capscrew
capscrews on manual aux 2 lever. Tighten outer
on tilt handle.
capscrews 1.35 to 1.65 N•m (11.9 to 14.6 lbf in).
See Figure 11 for lift truck models NOTE: Ensure RTST push-button is in correct
ERC22-35VG (ERC045-070VG) (A968) position on RTST switch handle by aligning notches
•
and flats during assembly.
• ERP22-35VL (ERP045-070VL) (A976)
15
3. Install RTST switch handle and two outer 5. Insert screwdriver or other flat tipped tool into slot
capscrews on tilt lever. Tighten outer capscrews on side of switch. Pull tool up to remove
to 1.35 to 1.65 N•m (11.9 to 14.6 lbf in). See emergency disconnect switch, switch adapter,
Figure 11. and lock from upper rear cover. See Figure 15.
4. Install upper front cover. See section Upper Front 6. Remove nut from upper rear cover. Remove
Cover for procedures. emergency disconnect button and bushing from
hole in upper rear cover. See Figure 15.
Emergency Disconnect Switch
Remove

Front Cover above for procedures.
3. Remove five socket head capscrews from upper

rear cover. See Figure 14. Pull cover rearward to
generate enough space to disconnect emergency
disconnect switch wires. See Figure 10.
NOTE: THE EMERGENCY DISCONNECT SWITCH

SHOWN IN FIGURE 15 IS ALSO USED ON LIFT
TRUCKS EQUIPPED WITH E-HYDRAULIC CON-
TROLS.
A. INSERT SCREWDRIVER HERE

2. SWITCH ADAPTER
3. LOCK
4. NUT
5. EMERGENCY DISCONNECT BUTTON
6. BUSHING
7. UPPER REAR COVER HOLE
Figure 15. Emergency Disconnect Switch

Replacement
Install
1. SOCKET HEAD SCREWS 1. Insert emergency disconnect button and bushing
2. UPPER REAR COVER into hole in upper rear cover. See Figure 15.
3. LEVER LINKAGE Place nut on button and turn it clockwise to
4. MANUAL HYDRAULICS WIRE HARNESS secure emergency disconnect button and bushing
Figure 14. Upper Rear Cover Removal in hole. Tighten nut to
2.2 ±0.2 N•m (19.5 ±1.8 lbf in).
4. Disconnect clamp function, RTST function, and
direction control switch if lift truck is equipped with NOTE: For lift truck models ERP22-35VL
these features. See Figure 10. (ERP045-070VL) (A976) , equipped with Outdoor
Protection/Wash-down Package, apply dielectric
grease to emergency disconnect switch terminals.
16
2. Connect wires to emergency disconnect switch. 4. Operate each lever to full stroke backward and
Tighten screws to read input.
0.8 to 1.2 N•m (8.55 to 10.7 lbf in). Is lever output = +92%?
•
3. Install switch adapter and lock onto emergency • YES: Mini-lever is supplying full stroke.
disconnect button assembly. Install switches, by • NO: Mini-lever not working properly. See
pushing switches onto switch adapter until switch procedures for each generation of MLM for
clicks into place. Connect main wire harness to repair or replacement. Upon completion, rerun
emergency disconnect switch. See Figure 10. test.
4. Connect clamp function, RTST function, and 5. If mini-lever continues to not function properly,
direction control switch if lift truck is equipped with contact your local YALE dealer or see Yale
these functions. See Figure 10. Axcess Online .
5. Install and tighten five socket head capscrews to Function Returns to Neutral Test
secure upper rear cover to manual lever Check to confirm function returns to neutral (0%). Use
assembly. See Figure 15. DSC or install Service Tool to monitor functions.
6. Install upper front cover. See section Upper Front 1. Stroke each lever to full stroke, forward and
Cover for procedures. backward, and allow lever to snap back to center.
E-HYDRAULIC CONTROLS - TEST 2. Turn key switch to ON position.
NOTE: The information in this section applies to lift
trucks equipped with E-Hydraulic controls and 3. Display electro-hydraulic diagnostics menu on
manufactured before January, 2020. dash display panel.
• Is each lever output = 0%?
Mini-Levers • YES: Go to Step 4.
Perform all of the following test procedures to be sure • NO: Mini-lever is not working properly. See
mini-levers operate properly. procedures for each generation of MLM for
repair or replacement. Upon completion, rerun
See User Interface Service Technician
test.
2200YRM1336 instructions to view Lever output Value.
With Service Password, view Diagnostics – Hydraulic 4. Operate each lever to full stroke forward and
Data Display – Hydraulic Input. slowly release (1-2 seconds from full stroke).
Read output when fully released.
Full Stroke Test
Check for full stroke of mini-lever. Use DSC or install
• YES: Go to Step 5.
the Service Tool to monitor functions.
• NO: Mini-lever is not working properly. See
1. Stroke each lever to full stroke, forward and procedures for each generation of MLM for
backward, and allow lever to snap back to center. repair or replacement. Upon completion, rerun
test.
2. Turn key switch to ON position.
5. Operate each lever to full stroke back and slowly
3. Display electro-hydraulic diagnostics menu on release (1-2 seconds from full stroke). Read
dash display panel. Operate each lever to full output when fully released.
stroke forward and read input. • Is each lever output = 0%?
• Is lever output = -92%? • YES: Mini-lever function is returning to neutral.
• YES: Go to Step 4. • NO: Mini-lever is not working properly. See
NO: Mini-lever not working properly. See procedures for each generation of MLM for
•
procedures for each generation of MLM for repair or replacement. Upon completion, rerun
repair or replacement. Upon completion, rerun test.
test.
17
6. If mini-lever continues to not function, contact

your local YALE dealer or see Yale Axcess
Online .
Push (Override) Button

1. Check that push (override) button operates
properly by operating applicable function.
2. If system does not function, see procedures for

each generation of MLM for repair or
replacement. Upon completion, rerun test.
3. If push (override) button continues to not function

properly, contact your local YALE dealer or see
Yale Axcess Online .
E-HYDRAULIC CONTROLS
1. ARMREST
NOTE: The information in this section applies to lift 2. EMERGENCY DISCONNECT SWITCH
trucks equipped with E-Hydraulic controls and 3. HORN BUTTON
manufactured before January, 2020. For information 4. DIRECTION CONTROL SWITCH
on how to service E-Hydraulic controls on lift trucks 5. MINI-LEVERS
manufactured after January, 2020, go to Electronic- 6. WIRE HARNESS
7. PUSH (OVERRIDE) BUTTONS
Hydraulic Controls, After January, 2020 .
The lift trucks covered in this service manual may be Figure 16. E-Hydraulic Controls Arrangement
equipped with optional E-Hydraulic control mini-levers
(see Figure 16). Each mini-lever can be replaced Mini-levers, Remove and Install
separately if one malfunctions. Like manual control
levers, E-Hydraulic control mini-levers can be
equipped with one or two optional functions: a clamp
CAUTION
function (either the third or fourth mini-lever) and a The following procedure should only be performed
Return To Set Tilt (RTST) function (second mini-lever). by Yale trained certified technicians. The removal
There is a push (override) button behind the mini- and replacement of the mini-levers should be done
levers that engage and disengage clamp and RTST in a clean environment whenever possible and on
functions. If either the clamping or RTST function quits an electrically grounded surface. DO NOT touch
working, mini-lever and push (override) button may any printed circuit board (PCB) surface to prevent
need to be replaced. See sections Mini-levers, damage from electrostatic voltage.
Remove and Install and Push (Override) Buttons and
Function Selection Button for replacement procedures.
2. Remove two capscrews that secure mini-lever to

armrest. Remove mini-lever from armrest. See
Figure 17.
18
Armrest Assembly
Remove
1. Read and follow WARNING and CAUTION in
General section above.
2. Remove two capscrews from seat box cover and

remove cover from seat box. Disconnect main E-
Hydraulic control wire harness from E-Hydraulic
armrest harness. See Figure 18.
NOTE: COMPONENTS PARTS AND ELECTRICAL

CONNECTIONS OMITTED OR MOVED FOR CLARI-
TY.
1. SEAT BOX COVER

2. CAPSCREWS
1. CAPSCREWS 3. SEAT BOX
2. MINI-LEVER 4. E-HYDRAULIC ARMREST HARNESS
3. ARMREST 5. OPERATOR PRESENCE SYSTEM HARNESS
4. PUSH (OVERRIDE) BUTTON 6. ARMREST
Figure 17. Mini-Lever Removal Figure 18. Seat Box Cover Removal
NOTE: Before installing new mini-lever, check Parts 3. Pull up on handle (see Figure 20) and slide
Manual for correct part number to be sure correct armrest all the way forward and remove flange
mini-lever is being installed. capscrew from under armrest mounting bracket
that attaches armrest to mounting bracket. Pull up
3. Install new mini-lever onto armrest using two on handle and slide armrest all the way back and
capscrews. remove other flange capscrew. See Figure 19.
19
A. HANDLE MOVES ARMREST FORWARD OR

BACKWARD
B. HANDLE MOVES ARMREST UP OR DOWN
5. Remove six socket head screws that fasten

bottom and top armrest covers together. See
Figure 21.
1. E-HYDRAULIC CONTROL WIRE HARNESS

2. FLANGE CAPSCREWS
3. ARMREST
4. ARMREST MOUNTING BRACKET
5. HOLES FOR FLANGE CAPSCREWS
Figure 19. E-Hydraulic Armrest and Mounting

Bracket
4. Remove armrest from armrest mounting bracket.
1. SOCKET HEAD SCREWS

2. BOTTOM ARMREST COVER
Figure 21. Bottom Armrest Cover Removal
6. Remove five socket head capscrews from bottom

armrest cover and armrest. Remove bottom
armrest cover.
Figure 20. Armrest Adjustment Handles
20
NOTE: The push (override) buttons and function 2. If lift truck is equipped, connect push (override)
selection button are optional features. If lift truck is not buttons/function selection button connector to
equipped with these features, there will be a plug PCB cassette. See Figure 22.
covering electrical connector on PCB cassette.
3. Install bottom armrest cover to armrest with five
7. Disconnect push (override) buttons/function
socket head screws. See Figure 21.
selection button connector from PCB cassette.
See Figure 22. 4. Install new armrest onto mounting bracket with
flange capscrews. Tighten flange capscrews to
8. Remove three socket screws from PCB cassette
13 to 15 N•m (115 to 132 lbf in).
and remove PCB cassette from armrest. See
Figure 22. 5. Install six socket head screws that fasten bottom
and top armrest covers together. See Figure 21.
6. Connect E-hydraulic wire harness to armrest. See

Figure 19. Install seat box cover to seat box with
two capscrews. See Figure 18. Tighten
capscrews to 1.2 N•m (10.6 lbf in).
7. Connect the battery.
Horn Button
Remove
1. TO E-HYDRAULIC CONTROL WIRE HARNESS 2. Remove armrest from armrest mounting bracket.
2. SOCKET HEAD SCREWS Remove bottom armrest and PCB cassette. See
3. PCB CASSETTE
4. PUSH (OVERRIDE) BUTTONS/FUNCTION section Armrest Assembly for removal
SELECTION BUTTON CONNECTOR procedures.
Figure 22. PCB Cassette Removal 3. Remove two Phillips head screws that attach horn
button to armrest. See Figure 23. Remove horn
Install button from armrest.
1. Install PCB cassette to armrest with three socket

head screws. See Figure 22.
21
NOTE: PUSH (OVERRIDE) BUTTONS AND FUNCTION SELECTION BUTTON CONNECTIONS NOT SHOWN
FOR CLARITY. SEE FIGURE 27 FOR PUSH (OVERRIDE) BUTTONS AND FUNCTION SELECTION BUTTON
CONNECTIONS.
1. PHILLIPS HEAD SCREWS 6. LOCK

2. DIRECTION CONTROL SWITCH ADAPTER 7. HORN SWITCH
3. EMERGENCY DISCONNECT SWITCH 8. ARMREST
4. EMERGENCY DISCONNECT SWITCH 9. DIRECTION CONTROL SWITCH CONNECTOR
ADAPTER
5. NUT
Figure 23. Switch Arrangement and Connections, E-Hydraulic Mini-Levers
Install Direction Control Switch

1. Insert new horn switch into armrest and secure Remove
switch to armrest with two Phillips head screws.
See Figure 23. 1. Read and follow WARNING and CAUTION
2. Install armrest and PCB cassette to armrest and
install armrest to armrest mounting bracket. See 2. Remove armrest from armrest mounting bracket.
section Armrest Assembly for installation Remove bottom armrest cover. See section
procedures. Armrest Assembly for removal procedures.
3. Remove direction control switch assembly from

armrest by compressing clips on either side of
bezel and carefully pulling assembly out.
Disconnect E-Hydraulic control wiring harness
from direction control switch. See Figure 24.
22

2. BEZEL
3. ARMREST
4. E-HYDRAULIC CONTROL VALVE WIRING
HARNESS
Figure 24. Direction Control Switch Replacement
4. Remove direction control switch from bezel. See

Figure 24.
Install
1. Insert new direction control switch into bezel. See
Figure 24.
2. Connect E-Hydraulic control valve wiring harness 1. HORN BUTTON

to direction control switch. Install direction control 2. EMERGENCY DISCONNECT SWITCH
switch assembly into armrest by compressing 3. DIRECTION CONTROL SWITCH
clips on either side of bezel and pushing
assembly into armrest until clips latch. See Figure 25. Emergency Disconnect Switch Location,
Figure 24. E-Hydraulic Controls
3. Install armrest cover to armrest, and install Remove

armrest to armrest mounting bracket. See section 1. Read and follow WARNING and CAUTION
Armrest Assembly for installation procedures. section in General section above.
Emergency Disconnect Switch 2. Remove armrest from armrest mounting bracket.

Both E-Hydraulic controls and manual hydraulic Remove bottom armrest and PCB cassette. See
controls use the same emergency disconnect switch. section Armrest Assembly for removal
See Figure 25. procedures.
3. Disconnect wires from emergency disconnect

switch.
4. Insert screwdriver or other flat tipped tool into slot

on side of switch (see Figure 15). Pull tool up to
remove emergency disconnect switch, switch
adapter, and lock from underneath armrest.
23
5. Remove nut from underneath armrest. Remove If the lift truck is equipped with a clamp attachment,
emergency disconnect button and bushing from the last mini-lever on the right controls the clamp
top part of armrest. See Figure 23. function. Behind this lever will be a push (override)
button. To engage the clamp, move the mini-lever
Install backward. To disengage the clamp, push the push
(override) button behind the mini-lever and move mini-
1. Insert emergency disconnect button and bushing
lever forward.
into hole in top part of armrest.
The different configurations of switches and buttons
2. Place nut on button and turn it clockwise to discussed in this section may not be found on your lift
secure emergency disconnect button and bushing truck.
to armrest. Tighten nut to
2.2 ±0.2 N•m (19.5 ±1.8 lbf in). See Figure 23.
3. Install switch adapter and lock onto emergency

disconnect button assembly. Install switches, by
pushing switches onto switch adapter until
switches clicks into place.
4. Connect wires to emergency disconnect switch.

Tighten screws to
0.8 to 1.2 N•m (8.55 to 10.7 lbf in).

install armrest to armrest mounting bracket. See
section Armrest Assembly for installation
procedures.
Push (Override) Buttons and Function NOTE: ALL POSSIBLE PUSH (OVERRIDE) BUT-
Selection Button TONS AND FUNCTION SELECTION BUTTON CON-
FIGURATIONS SHOWN. NOT ALL LIFT TRUCK MAY
On lift trucks equipped with E-Hydraulic controls, there HAVE ALL SWITCHES AND BUTTONS SHOWN.
may be two optional push (override) buttons (green
buttons) and a function selection button (yellow button) 1. MINI-LEVERS
located behind the second, third, or fourth mini-lever. 2. PUSH (OVERRIDE) BUTTON (RTST)
See Figure 26. The push (override) button located 3. FUNCTION SELECTION BUTTON
behind the second mini-lever is used to override the 4. PUSH (OVERRIDE) BUTTON (CLAMP)
5. ARMREST HOUSING
Return To Set Tilt (RTST) function. By pressing this
switch, the RTST parameters are overridden and the Figure 26. Push (Override) Buttons and Function
mast is allowed to tilt unrestricted. Selection Button Location
If the lift truck is equipped with three mini-levers and a
four function control valve, there will be a function Remove
selection button behind the third mini-lever. Pressing
this button allows the third mini-lever to switch
between the third and fourth functions. If the lift truck is
equipped with four mini-levers and a five function 2. Remove armrest from armrest mounting bracket.
control valve, the function selection button will be Remove bottom armrest and PCB cassette. See
located behind the fourth mini-lever. Pressing the procedures in Armrest Assembly section above.
button allows the fourth mini-lever to switch between
the fourth and fifth functions. NOTE: Tag wires prior to disconnecting them to aid in
reconnecting.
3. Pull push (override) buttons or function selection
button connectors apart to disconnect them from
wire harness. See Figure 27.
24
4. If push (override) button is being replaced, 5. If function selection button is being replaced:
remove lock nut from back of green, round, push
button. Remove push button switch from armrest. a. Remove knurl nut. See Figure 27.
See Figure 27.
b. Rotate red screw to left stop. Remove blue
NOTE: Note the position of the yellow, rectangular, connector by sliding it from black cylinder. See
function button before removal to aid in installation. Figure 27.
See Figure 26.
c. Remove function button from armrest.
Figure 27. Push (Override) Buttons and Function Selection Button Replacement
25
Electronic-Hydraulic Controls, After January, 2020 2200 YRM 1369
1. CLAMP BUTTON CONNECTION 5. LOCK NUT

2. RTST CONNECTION 6. BLUE CONNECTOR
3. FUNCTION SELECTION BUTTON 7. KNURL NUT
CONNECTION 8. BLACK CYLINDER
4. RED SCREW
Install 2. If installing a push (override) button:

1. If installing a new function selection button: a. Install new green, round push (override) button
assembly through armrest housing.
a. Insert black cylinder portion of function
selection button through armrest housing. b. Install and tighten lock nut to secure push
(override) button to armrest. See Figure 27.
b. Slide blue connector onto cylinder. See
Figure 27. c. Push the push (override) button connector to
c. Rotate red screw to right stop.
d. Adjust position of yellow, rectangular function install armrest to armrest mounting bracket. See
selection button. See Figure 26. Install and section Armrest Assembly for installation
tighten knurl nut to secure function selection procedures.
button to armrest.
4. Connect E-hydraulic wire harness to armrest. See
e. Apply Nye 760G grease (supplied in kit) to Figure 19.
function selection button switch connector.
Push function selection button connector to
Electronic-Hydraulic Controls, After January, 2020

NOTE: The information in this section applies to the Disconnect the battery before doing any work on
electronic-hydraulic controls used on lift truck models the electrical system. Serious injury to personnel
manufactured after January, 2020. and/or damage to lift truck components can occur
GENERAL
WARNING
WARNING Never wear any metallic items on your fingers,
Before replacing any part of the electronic or arms, or neck. Metal items can accidently make an
manual hydraulic control assembly, fully lower all electrical connection and cause an injury.
parts of the mast and tilt it forward until the tips of
the forks touch the ground. This action will
CAUTION
not installed correctly. Make sure wire connectors
do not touch the other metal terminals or wire
WARNING connectors, metal brackets, or the bracket
Discharge capacitors as directed in Discharging mounting nuts. Make sure the wires are not pulled
the Capacitors in General section of this manual. tight and are not touching other parts to damage
the insulation.
26
2200 YRM 1369 Electronic-Hydraulic Controls, After January, 2020
The lift trucks covered in this service manual may be • Push (Override) Buttons - On lift trucks
equipped with optional electronic-hydraulic (E- equipped with E-Hydraulic controls, there may
Hydraulic) mini-lever controls. In this arrangement, be two optional push (override) buttons, (green
there are several electronic component parts that can buttons), located behind the second, third, or
be replaced if they are no longer working properly. fourth mini-lever. See Figure 28. The push
(override) button located behind the second
These components are:
mini-lever is used to override the Return To Set
• Direction Control Switch - The direction Tilt (RTST) function. By pressing this switch, the
control switch is an optional feature and is used RTST parameters are overridden and the mast
to select the direction of travel when lift truck is is allowed to tilt unrestricted.
equipped with a standard accelerator pedal. If the lift truck is equipped with a clamp
See Figure 28. attachment, the last mini-lever on the right
• Emergency Disconnect Switch - The controls the clamp function. Behind this lever
emergency disconnect switch is used to will be a push (override) button. To engage the
disconnect all electrical power to lift truck. The clamp, move the mini-lever backward. To
switch is operated by pushing the button down disengage the clamp, push the push (override)
until it clicks. To reset (re-connect) emergency button behind the mini-lever and move mini-
disconnect switch and energize electrical lever forward.
circuits, turn switch clockwise until button pops
up. See Emergency Disconnect Switch and
Figure 37. sure to tag connectors to aid in correct installation.
• Horn Button - These buttons are used to sound
the horn. On lift trucks equipped with E-
Hydraulic mini-levers, there is an optional horn
button on the armrest.
To replace horn switch on steering wheel or
optional rear horn button on rear right overhead
guard leg or on hood, see Sensors and
Switches section in this manual.
• Clamp Button - The lift trucks covered in this
service manual may be equipped with a clamp
function. If lift truck is equipped with three mini-
levers, the push (override) button for clamp
function is located behind third lever on the
palm rest. If lift truck has four levers, the push
(override) button is located behind fourth lever
on the palm rest.
• Return To Set Tilt (RTST) - The Return To Set
Tilt (RTST) is an optional feature on all lift truck
models covered in this manual that are
equipped with E-Hydraulic mini-levers. See
Figure 28. 1. ARMREST
The RTST option automatically stops the tilt 2. TO WIRE HARNESS
function at a set point. To override the RTST 3. HORN BUTTON
option, press the override button, located 5. MINI-LEVERS
directly behind the tilt mini-lever, and push tilt 6. PUSH (OVERRIDE) BUTTONS
mini-lever forward or pull it backward.
Figure 28. E-Hydraulic Controls Arrangement
27
E-HYDRAULIC CONTROLS - TEST Function Returns to Neutral Test

Mini-Levers Check to confirm function returns to neutral (0%). Use
DSC or install the Service Tool to monitor functions.
Perform all of the following test procedures to be sure
mini-levers operate properly. 1. Stroke each lever to full stroke, forward and
See User Interface Service Technician backward, and allow lever to snap back to center.
2200YRM1336 for instructions to view Lever output
Value. With Service Password, view Diagnostics – 2. (DO NOT start). Turn key switch to ON position.
Hydraulic Data Display – Hydraulic Input.
3. Display the electro-hydraulic diagnostics menu on
Full Stroke Test the dash display panel.
Check for full stroke of mini-lever. Use the Display
Switch Cluster (DSC) or install the Service Tool to • YES: Go to Step 4.
monitor functions. • NO: Mini-lever is not working properly. See
procedures below for repair or replacement.
1. Stroke each lever to full stroke, forward and Upon completion, rerun the test.
backward, and allow lever to snap back to center.
4. Operate each lever to full stroke forward and
2. (DO NOT start). Turn key switch to ON position. slowly release (1-2 seconds from full stroke).
Read output when fully released.
3. Display the electro-hydraulic diagnostics menu on
the dash display panel. Operate each lever to full
stroke forward and read input. • YES: Go to Step 5.
• Is lever output ≥ -92%? • NO: Mini-lever is not working properly. See
• YES: Go to Step 4. Upon completion, rerun the test.
procedures below for repair or replacement. 5. Operate each lever to full stroke back and slowly
Upon completion, rerun the test. release (1-2 seconds from full stroke). Read
output when fully released.
4. Operate each lever to full stroke backward and
read input.
• YES: Mini-lever function is returning to neutral.
• Is lever output ≥ +92%?
• YES: Mini-lever is supplying full stroke. procedures below for repair or replacement.
• NO: Mini-lever is not working properly. See Upon completion, rerun the test.
Upon completion, rerun the test. 6. If mini-lever continues to not function properly,
contact your local Yale dealer or see Yale
5. If mini-lever continues to not function properly, Axcess Online.
Axcess Online.
28
Push Button (push (override) button)

1. Validate that push button operates properly by
operating applicable function (push (override)
button).
2. If system does not function, see procedures

below for repair or replacement. Upon
completion, rerun the test.
3. If push button continues to not function properly,

Axcess Online.
MINI-LEVERS, REMOVE AND INSTALL

NOTE: Prior to performing the following procedures,
the E-Hydraulic Controls - TEST must be performed
first.
NOTE: The mini-levers do not need to be calibrated.
1. CAPSCREWS
2. MINI-LEVER
3. ARMREST
CAUTION 4. PUSH (OVERRIDE) BUTTON
The following procedure should only be performed
by Yale trained certified technicians. The removal Figure 29. Mini-Lever Removal
and replacement of the mini-levers should be done
in a clean environment whenever possible and on NOTE: Before installing new mini-lever, check Parts
an electrically grounded surface. Do not touch any Manual for correct part number to be sure correct
printed circuit board (PCB) surface to prevent mini-lever is being installed.
damage from electrostatic voltage. 2. Install new mini-lever onto armrest using two
capscrews. See Figure 29.
1. Remove two capscrews and mini-lever from
armrest. See Figure 29.
ARMREST ASSEMBLY
Remove
1. Disconnect the battery.
2. Remove two capscrews and washers from cover

plate and remove seat box. Disconnect the main
E-Hydraulic control wire harness from E-Hydraulic
armrest harness. See Figure 30.
29
NOTE: SOME COMPONENT PARTS AND ELECTRICAL CONNECTIONS OMITTED FOR CLARITY.
A. FULL SUSPENSION AND SWIVEL SEATS B. NON SUSPENSION SEATS
1. CAPSCREWS 4. E-HYDRAULIC ARMREST HARNESS

2. WASHERS CONNECTOR
3. SEAT BOX 5. COVER PLATE
Figure 30. Seat Box Cover Removal
3. Pull up on handle (see Figure 31) and slide

armrest all the way forward and remove flange
capscrew from under armrest mounting bracket
that attaches armrest to mounting bracket. Pull up
on handle and slide armrest all the way back and
remove the other flange capscrew. See Figure 32.
Figure 31. Armrest Adjustment Handles
30
A. HANDLE MOVES ARMREST FORWARD OR

BACKWARD
B. HANDLE MOVES ARMREST UP OR DOWN
4. Remove armrest from armrest mounting bracket.

2. BOTTOM ARMREST COVER
Figure 33. Bottom Armrest Cover Removal
NOTE: The push (override) button is optional features

and lift truck may be equipped with more than one
1. E-HYDRAULIC CONTROL WIRE HARNESS push (override) button depending of the number of
2. FLANGE CAPSCREWS hydraulic functions on the lift truck. If lift truck is not
3. ARMREST equipped with this feature, there will be a plug
4. ARMREST MOUNTING BRACKET
5. HOLES FOR FLANGE CAPSCREWS covering the electrical connector on the PCB cassette.
6. Disconnect the push (override) button connector
Figure 32. E-Hydraulic Armrest and Mounting from PCB cassette. See Figure 34.
Bracket
7. Remove three socket screws from PCB cassette
5. Remove six socket head screws that fasten the and remove PCB cassette from armrest. See
bottom and top armrest covers together. See Figure 34.
Figure 33. Remove the bottom armrest cover
from armrest.
31
HORN BUTTON
Remove
1. Remove the armrest from armrest mounting
bracket. Remove bottom armrest and PCB
cassette. See section Armrest Assembly for
removal procedures.
2. Remove two Phillips head screws that attach horn

button to armrest. See Figure 35. Remove horn
button from armrest.
1. TO E-HYDRAULIC CONTROL WIRE HARNESS

3. PCB CASSETTE
4. PUSH (OVERRIDE) BUTTON CONNECTOR
Figure 34. PCB Cassette Removal
Install
1. Install PCB cassette to armrest with three socket
head screws. See Figure 34.
2. If lift truck is equipped, connect the push

(override) button connector to PCB cassette. See
Figure 34.
3. Install bottom armrest cover to armrest with six

socket head screws. See Figure 34. NOTE: PUSH (OVERRIDE) BUTTON CONNEC-
TIONS NOT SHOWN FOR CLARITY.
4. Install new armrest onto mounting bracket with
flange capscrews. Tighten flange capscrews to 1. PHILLIPS HEAD SCREWS
13 to 15 N•m (115 to 132 lbf in). 2. DIRECTION CONTROL SWITCH ADAPTER*
3. HORN BUTTON ADAPTER
5. Connect E-hydraulic wire harness to armrest. See 4. PLUG
5. HORN SWITCH
Figure 32. Install seat box to cover plate with two 6. DIRECTION CONTROL SWITCH CONNECTOR
capscrews and washers. See Figure 30. Tighten 7. ARMREST
capscrews to 1.2 N•m (10.6 lbf in). *Direction Control Switch is an optional feature.
6. Connect the battery. Figure 35. Switch Arrangement and Connections,

E-Hydraulic Mini-Levers
32
Install Legend for Figure 36.

1. Install new horn switch and two Phillips head 1. DIRECTION CONTROL SWITCH
screws onto armrest. See Figure 35. 2. BEZEL
3. ARMREST
2. Install armrest and PCB cassette to armrest and 4. E-HYDRAULIC CONTROL VALVE WIRING
install armrest to armrest mounting bracket. See HARNESS
the section Armrest Assembly for installation
procedures. 3. Remove DCS from bezel. See Figure 36.
DIRECTION CONTROL SWITCH Install

NOTE: The Direction Control Switch (DCS) is an 1. Insert new Direction Control Switch into bezel.
optional feature on lift trucks covered in this manual See Figure 36.
that are equipped with electro-hydraulic controls.
2. Connect E-Hydraulic control valve wiring harness
to the DCS. Install DCS assembly into armrest by
Remove compressing clips on either side of the bezel and
1. Remove armrest from armrest mounting bracket. pushing assembly into armrest until the clips
Remove bottom armrest cover. See section latch. See Figure 36.
Armrest Assembly for removal procedures.
3. Install armrest cover to armrest, and install
2. Remove Direction Control Switch (DCS) armrest to armrest mounting bracket. See section
assembly from armrest by compressing the clips Armrest Assembly for installation procedures.
on either side of the bezel and carefully pulling
the assembly out. Disconnect E-Hydraulic control EMERGENCY DISCONNECT SWITCH
wiring harness from the Direction Control Switch.
The emergency disconnect switch is used to
See Figure 36.
disconnect all electrical power to lift truck. The switch
is operated by pushing the button down until it clicks.
To reset (re-connect) emergency disconnect switch
and energize electrical circuits, turn switch clockwise
until button pops up. See Figure 37.
Figure 36. Direction Control Switch Replacement
33
1. HORN BUTTON 5. SLOT

2. EMERGENCY DISCONNECT SWITCH 6. LOCK
3. DIRECTION CONTROL SWITCH 7. NUT
4. SWITCH ADAPTER
Figure 37. Emergency Disconnect Switch Location, E-Hydraulic Controls
Remove Install
1. Read and follow WARNING and CAUTION in 1. Insert emergency disconnect button and bushing
General section above. into hole in top part of armrest.
2. Remove armrest from armrest mounting bracket. 2. Place nut on button and turn it clockwise to
Remove bottom armrest and PCB cassette. See secure emergency disconnect button and bushing
section Armrest Assembly for removal to armrest. Tighten nut to
procedures. 2.2 ±0.2 N•m (19.5 ±1.8 lbf in). See Figure 37.
3. Disconnect wires from emergency disconnect 3. Install switch adapter and lock onto emergency
switch. disconnect button assembly. Install switches, by
pushing switches onto switch adapter until
4. Insert screwdriver or other flat tipped tool into slot switches clicks into place.
on side of switch (see Figure 37). Pull tool up to
remove emergency disconnect switch, switch 4. Connect wires to emergency disconnect switch.
adapter, and lock from underneath armrest. Tighten screws to
0.8 to 1.2 N•m (8.55 to 10.7 lbf in).
5. Remove nut from underneath armrest. Remove
emergency disconnect button and bushing from 5. Install armrest and PCB cassette to armrest and
top part of armrest. See Figure 37. install armrest to armrest mounting bracket. See
Armrest Assembly section for installation
procedures.
34
PUSH (OVERRIDE) BUTTONS Legend for Figure 38.

NOTE: NOT ALL LIFT TRUCK MAY HAVE ALL
On lift trucks equipped with E-Hydraulic controls, there PUSH (OVERRIDE) BUTTONS SHOWN.
may be two optional push (override) buttons (green
buttons) located behind the second, third, or fourth 1. MINI-LEVERS
mini-lever. See Figure 38. The push (override) button 2. PUSH (OVERRIDE) BUTTON (CLAMP)
located behind the second mini-lever is used to 3. PUSH (OVERRIDE) BUTTON (RTST)
override the Return To Set Tilt (RTST) function. By 4. BUTTON PLUG
pressing this switch, the RTST parameters are 5. ARMREST HOUSING
overridden and the mast is allowed to tilt unrestricted.
Remove
If the lift truck is equipped with a clamp attachment,
the last mini-lever on the right controls the clamp 1. Remove the armrest from armrest mounting
function. Behind this lever will be a push (override) bracket. Remove bottom armrest and PCB
button. To engage the clamp, move the mini-lever cassette. See procedures in Armrest Assembly
backward. To disengage the clamp, push the push section above.
(override) button behind the mini-lever and move mini-
lever forward. NOTE: Tag wires prior to disconnecting them to aid in
reconnecting.
The different configurations of push (override) buttons
discussed in this section may not be found on your lift 2. Pull push (override) buttons connectors apart to
truck. disconnect them from wire harness. See
Figure 39.
3. If push (override) button is being replaced,

remove lock nut from back of green, round, push
button. Remove push button switch from armrest.
See Figure 39.
Figure 38. Push (Override) Buttons Location
35
1. CLAMP BUTTON (SWITCH) CONNECTION 3. LOCKNUT

2. RTST BUTTON (SWITCH) CONNECTION 4. PUSH (OVERRIDE) BUTTONS WIRE HARNESS
AND CONNECTOR
Figure 39. Push (Override) Buttons Replacement
Install 4. Install armrest and PCB cassette to armrest and

install armrest to armrest mounting bracket. See
1. Install new green, round push (override) button the section Armrest Assembly for installation
assembly through armrest housing. procedures.
2. Install and tighten lock nut on push (override) 5. Connect the E-hydraulic wire harness to armrest.
button and armrest. See Figure 39. See Figure 32.
3. Push the push (override) button connector to wire
harness. See Figure 39.
36
2200 YRM 1369 Sensors and Switches
Sensors and Switches

GENERAL SYNCHRONOUS STEERING VALVE
On lift trucks equipped with E-Hydraulics and
WARNING Synchronous Steering, refer to Steering System
1600YRM1363 prior to removing Synchronous
Before replacing any sensor or switch, fully lower
Steering Valve Kit.
all parts of the mast and tilt it forward until the tips
of the forks touch the ground. This action will
STEERING AXLE SENSOR
control lever is accidently moved. The steering axle sensor is located on right side of
steering axle.
Never have any metal on your fingers, arms, or
neck. These metal items can accidentally create an The steering axle sensor is an optional feature on lift
electrical connection and cause an injury. truck model ERC22-35VG (ERC045-070VG) (A968) .
• ERC22-35VG (ERC045-070VG) (A968)
WARNING
Discharge capacitors as directed in Discharging See Figure 41 for lift truck models
the Capacitors in General section of this manual. • ERP22-35VL (ERP045-070VL) (A976)
Disconnect the battery before doing any work on • ERP40-80VM (ERP080-100VM) (A985)
the electrical system. Serious injury to personnel manufactured before November 2014
and/or damage to lift truck components can occur
(ERP080-120VM, ERP100VML) (A985)
manufactured after November 2014
CAUTION
A short circuit and damage can occur if wires are See Figure 43 for lift truck model
not installed correctly. Make sure wire connectors • ERC40-55VH, ERC50VHS (ERC80-120VH,
DO NOT touch the other metal terminals or wire ERC100VHS) (A938)
connectors, metal brackets, or the bracket
mounting nuts. Make sure the wires are not pulled Remove
the insulation.
All sensors and switches used on these trucks are
2. Put lift truck on jacks or blocks and remove right
non-repairable parts. Replace with new sensors or
steer tire and wheel.
switches whenever a sensor or switch malfunctions
and is not operating correctly. See Parts Manual for See Periodic Maintenance 8000YRM1364 for lift
replacement part numbers. Before installing new truck models
sensors or switches, use a clean cloth and make sure • ERC22-35VG (ERC045-070VG) (A968)
area around sensor or switch is clean and free of oils
and contaminates. See Periodic Maintenance 8000YRM1372 for lift
truck models
Lift truck models ERP22-35VL (ERP045-070VL)
(A976) and ERP40-50VM, ERP50-55VM6 • ERP22-35VL (ERP045-070VL) (A976)
(ERP080-120VM, ERP100VML) (A985) , equipped See Periodic Maintenance 8000YRM1541 for lift
with Outdoor Protection/ Wash-down Package will truck models
have sealed wiring harnesses as well as light switches
and windshield wiper switches that are fully sealed. • ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985)
sure to tag connectors to aid in correct reconnecting.
37
Sensors and Switches 2200 YRM 1369
See Periodic Maintenance 8000YRM1577 for lift 4. Remove flange capscrew and protective cover
truck model from steering axle.
ERC100VHS) (A938) 5. Remove two socket head screws and sensor from
steering axle.
3. Disconnect steering wire harness from steering See Figure 40 for lift truck models
axle sensor.
• ERC22-35VG (ERC045-070VG) (A968)
• ERC22-35VG (ERC045-070VG) (A968)
• ERP22-35VL (ERP045-070VL) (A976)
• ERP40-80VM (ERP080-100VM) (A985)
• ERP22-35VL (ERP045-070VL) (A976) manufactured before November 2014
• ERP40-80VM (ERP080-100VM) (A985) See Figure 42 for lift truck models
manufactured before November 2014
See Figure 42 for lift truck models (ERP080-120VM, ERP100VML) (A985)
(ERP080-120VM, ERP100VML) (A985) See Figure 43 for lift truck model
See Figure 43 for lift truck model ERC100VHS) (A938)
ERC100VHS) (A938)
38
1. PROTECTIVE COVER 4. STEERING AXLE SENSOR

2. FLANGE CAPSCREW 5. STEERING WIRE HARNESS CONNECTOR
Figure 40. Steering Axle Sensor Replacement, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968)
39

2. FLANGE CAPSCREW 5. STEERING AXLE SENSOR CONNECTOR
Figure 41. Steering Axle Sensor Replacement, Lift Truck Models Manufactured Before November 2014 and
ERP40-80VM (ERP080-100VM) (A985) ERP22-35VL (ERP045-070VL) (A976)
40

Figure 42. Steering Axle Sensor Replacement, Lift Truck Models Manufactured After November
2014ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)
41

Figure 43. Steering Axle Sensor Replacement, Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938)
Install 2. Connect steering wire harness to steering axle

sensor. Install protective cover to steering axle
1. Using two socket head screws, install new sensor with flange capscrew.
onto steering axle.
See Figure 40 for lift truck models 3. Install wheel and tire to steering axle and remove
lift truck from blocks.
• ERC22-35VG (ERC045-070VG) (A968)
See Periodic Maintenance 8000YRM1364 for lift
truck models
• ERP22-35VL (ERP045-070VL) (A976)
• ERC22-35VG (ERC045-070VG) (A968)
• ERP40-80VM (ERP080-100VM) (A985)
manufactured before November 2014 See Periodic Maintenance 8000YRM1372 for lift
truck models
• ERP22-35VL (ERP045-070VL) (A976)
(ERP080-120VM, ERP100VML) (A985) See Periodic Maintenance 8000YRM1541 for lift
manufactured after November 2014 truck models
See Figure 43 for lift truck model • ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985)
ERC100VHS) (A938)
42
See Periodic Maintenance 8000YRM1577 for lift a. Remove floor mat. Remove rear floor plate.
truck model
b. Remove capscrews and washers from front
ERC100VHS) (A938) floor plate and lift front floor plate up enough to
disconnect accelerator pedal or Foot
4. Connect the battery. Directional Control pedal. Remove front floor
plate with accelerator or Foot Directional
HYDRAULIC MOTOR SPEED SENSOR Control pedal still attached. See Figure 44.
Lift Truck Models ERC22-35VG 3. For lift trucks manufactures after June 2012:
(ERC045-070VG) (A968)
a. Remove floor mat. Remove rear floor plate.
Remove
b. Lift front floor plate up enough to disconnect
accelerator pedal or Foot Directional Control
pedal. Remove front floor plate with
2. For lift trucks manufactured before June 2012: accelerator or Foot Directional Control pedal
still attached. See Figure 45.
43
Figure 44. Removing Floor Plate and Accelerator or Pedal, Manufactured Before June 2012Foot
Directional Control
44
A. STANDARD ACCELERATOR PEDAL B. FOOT DIRECTIONAL CONTROL PEDAL
1. FRONT FLOOR PLATE 5. CAPSCREW, WASHER, NUT (FRONT FLOOR

2. CAPSCREW AND NUT (PEDAL BASE) PLATE)
3. PEDAL BASE 6. REAR FLOOR PLATE
4. ACCELERATOR PEDAL POSITION SENSOR 7. FOOT DIRECTIONAL CONTROL PEDAL
CONNECTOR
45
Figure 45. Removing Floor Plate and Accelerator or Pedal, Manufactured After June 2012Foot Directional
Control
46
1. FRONT FLOOR PLATE 4. ACCELERATOR PEDAL POSITION SENSOR

2. CAPSCREW AND NUT (PEDAL BASE) 5. REAR FLOOR PLATE
3. PEDAL BASE 6. FOOT DIRECTIONAL CONTROL PEDAL
CONNECTOR
4. Disconnect main wire harness from hydraulic 6. Remove socket head screw, hydraulic motor
motor speed sensor. speed sensor, and hydraulic motor speed sensor
connector from hydraulic motor. See Figure 47.
5. If lift truck is equipped with an 80 volt hydraulic
pump motor, there is a shroud that covers
hydraulic motor speed sensor that must be
removed first. To remove shroud, perform the
following:
a. Remove three hex nut and hex bolts from

mounting bracket. Remove mounting bracket
from shroud. See Figure 46.
b. Remove two Allen head screws from each side

of shroud. Remove shroud from hydraulic
pump motor. See Figure 46.
1. HEX BOLT
2. HEX NUT
3. MOUNTING BRACKET
4. SHROUD
5. ALLEN HEAD SCREW
6. HYDRAULIC MOTOR SPEED SENSOR WIRE
Figure 46. Shroud Removal
47
1. HYDRAULIC MOTOR SPEED SENSOR 3. HYDRAULIC MOTOR TEMPERATURE SENSOR

2. SOCKET HEAD SCREW CONNECTOR
4. HYDRAULIC MOTOR SPEED SENSOR
CONNECTOR
Figure 47. Hydraulic Motor Speed Sensor, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968)
Install 4. If lift truck is equipped with an 80 volt hydraulic

pump motor, install shroud over the hydraulic
1. Install new hydraulic motor speed sensor and motor speed sensor. To install shroud, perform
hydraulic motor speed sensor connector into the following:
hydraulic motor. See Figure 47.
a. Install shroud to hydraulic pump motor using
2. Attach hydraulic motor speed sensor to hydraulic two Allen head screws. See Figure 46.
motor with socket head screw.
b. Install mounting bracket to bottom of shroud
3. Connect main wire harness to hydraulic motor using three hex bolts and hex nuts. See
speed sensor. Figure 46. Tighten hex nuts and bolts to
60 to 70 N•m (44 to 52 lbf ft).
48
5. Connect accelerator pedal or Foot Directional

Control pedal, (see Figure 44).
Install front floor plate using capscrews and
washers for lift truck models ERC22-35VG
(ERC045-070VG) (A968) manufactured before
June 2012.
No hardware is required to install front floor plate
for lift truck models ERC22-35VG
(ERC045-070VG) (A968) manufactured after
June 2012.
6. Install rear floor plate. Install floor mat and

connect the battery.
Lift Truck Models ERP22-35VL

(ERP045-070VL) (A976) and ERP40-50VM,
ERP50-55VM6 (ERP080-120VM,
ERP100VML) (A985)
Remove
2. Remove tow pin and counterweight cover from

counterweight. See Figure 48 or Figure 49.
NOTE: COUNTERWEIGHT FOR LIFT TRUCK MOD-

ELS ERP22-35VL (ERP045-070VL) (A976) SHOWN.
COUNTERWEIGHT FOR LIFT TRUCK MODELS
ERP40-50VM, ERP50-55VM6 (ERP080-120VM,
ERP100VML) (A985) IS SIMILAR.
1. COUNTERWEIGHT
2. COUNTERWEIGHT COVER
3. WASHER
4. CAPSCREW
5. TOW PIN
Figure 48. Tow Pin and Counterweight Cover

Removal, Lift Truck Models Manufactured Prior to
November, 2015 and ERP22-35VL (ERP045-070VL)
(A976) ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985)
49
1. TOW PIN
2. KNOB SCREW
4. COUNTERWEIGHT
3. Disconnect hydraulic motor speed sensor wire

harness.
• ERP22-35VL (ERP045-070VL) (A976)
• (ERP080-100VM) (A985) manufactured before
November 2014
(ERP080-120VM, ERP100VML) (A985)
4. Remove socket head screw and hydraulic motor

speed sensor from hydraulic motor. See
Figure 50 or Figure 51.
Figure 49. Tow Pin and Counterweight Cover

Remove, Lift Truck Model Manufactured After
November, 2015ERP22-35VL (ERP045-070VL)
(A976)
50
NOTE: ERP22-35VL (ERP045-070VL) (A976) SHOWN. ERP40-50VM, ERP50-55VM6 (ERP080-120VM,


CONNECTOR
Figure 50. Hydraulic Motor Speed Sensor, Lift Truck Models Manufactured Before November 2014 and
Manufactured Prior to November 2015.(ERP080-100VM) (A985) ERP22-35VL (ERP045-070VL) (A976)
51

CONNECTOR
Figure 51. Hydraulic Motor Speed Sensor, Lift Truck Model Manufactured After November,
2015ERP22-35VL (ERP045-070VL) (A976)
52

CONNECTOR
Figure 52. Hydraulic Motor Speed Sensor, Lift Truck Models Manufactured After November
Install 4. Install counterweight cover and tow pin. See

Figure 48 or Figure 49.
1. Install new hydraulic motor speed sensor and
connector into hydraulic motor. 5. Connect the battery.
ERP22-35VL (ERP045-070VL) (A976)
Lift Truck Models ERC16-20VA
•
(ERC030-040VA) (A969)
• (ERP080-100VM) (A985) manufactured before
November 2014 Remove
See Figure 52 for lift truck models 1. Read and follow WARNING and CAUTION
• ERP40-50VM, ERP50-55VM6 section in General section above.
(ERP080-120VM, ERP100VML) (A985)
manufactured after November 2014 2. Disconnect and remove battery. See Periodic
Maintenance 8000YRM1442 for procedures.
2. Attach hydraulic motor speed sensor to hydraulic
motor with socket head screw. 3. Remove battery tray with rollers. See Frame
0100YRM1342 for procedures.
3. Connect main wire harness to hydraulic motor
speed sensor. 4. Disconnect hydraulic motor speed sensor wire
53

CONNECTOR
Figure 53. Hydraulic Motor Speed Sensor for Lift Truck Model ERC16-20VA (ERC030-040VA) (A969)
5. Remove socket head screw and hydraulic motor Lift Truck Model ERC40-55VH, ERC50VHS
speed sensor from hydraulic motor. See (ERC80-120VH, ERC100VHS) (A938)
Figure 53.
Remove
Install 1. Read and follow WARNING and CAUTION
1. Install new hydraulic motor speed sensor and section in General section above.
socket head screw. See Figure 53.
2. Remove floor mat. Remove rear floor plate.
2. Connect hydraulic motor speed sensor wire Lift front floor plate up enough to disconnect
accelerator pedal or Foot Direction® pedal. See
Figure 54. Remove front floor plate with
3. Install battery tray with rollers. See Frame
0100YRM1342 for procedures. accelerator or Foot Direction® pedal still
attached.
4. Install and connect battery. See Periodic
Maintenance 8000YRM1442 for procedures.
54
A. STANDARD ACCELERATOR PEDAL B. FOOT DIRECTION® PEDAL
1. FRONT FLOOR PLATE 4. ACCELERATOR PEDAL POSITION SENSOR

2. CAPSCREW AND NUT (PEDAL BASE) 5. REAR FLOOR PLATE
3. PEDAL BASE 6. FOOT DIRECTION® PEDAL CONNECTOR
Figure 54. Removing Floor Plate and Accelerator or PedalFoot Direction®
55
3. Disconnect main wire harness from hydraulic 4. Connect accelerator pedal or Foot Direction®
motor speed sensor. See Figure 55. pedal (see Figure 54), and install front plate.
Install rear floor plate. Install floor mat and
4. Remove socket head screw, hydraulic motor connect the battery.
speed sensor, and hydraulic motor speed sensor
connector from hydraulic motor. See Figure 55. HYDRAULIC MOTOR TEMPERATURE
SENSOR
The hydraulic motor temperature sensor is heat
welded and sealed onto winding coils in stator housing
in hydraulic motor. It is a non-replaceable part and
cannot be replaced separately from hydraulic motor.
• ERC22-35VG (ERC045-070VG) (A968)
• ERP22-35VL (ERP045-070VL) (A976)
• ERP40-80VM (ERP080-100VM) (A985)
(ERP080-120VM, ERP100VML) (A985)
• ERC16-20VA (ERC030-040VA) (A969)
1. HYDRAULIC MOTOR SPEED SENSOR • ERC40-55VH, ERC50VHS (ERC80-120VH,
2. SOCKET HEAD SCREW ERC100VHS) (A938)
3. HYDRAULIC MOTOR TEMPERATURE SENSOR
CONNECTOR HYDRAULIC TANK LEVEL SENSOR
CONNECTOR Lift Truck Models ERP22-35VL
Figure 55. Hydraulic Motor Speed Sensor, Lift
(ERP045-070VL) (A976) and ERP40-50VM,
Truck Models ERC40-55VH, ERC50VHS ERP50-55VM6 (ERP080-120VM,
(ERC80-120VH, ERC100VHS) (A938) ERP100VML) (A985)
Install Remove
1. Install new hydraulic motor speed sensor and
hydraulic motor speed sensor connector into
hydraulic motor. See Figure 55.
counterweight. See Figure 48.
2. Attach hydraulic motor speed sensor to hydraulic
motor with socket head screw.
3. Disconnect main wire harness from hydraulic tank
level sensor.
3. Connect main wire harness to hydraulic motor
speed sensor. See Figure 56 for lift truck models
• ERP22-35VL (ERP045-070VL) (A976)
manufactured prior to November 2015
• ERP40-50VM (ERP080-100VM) (A985)
56
See Figure 57 for lift truck model

• ERP22-35VL (ERP045-070VL) (A976)
(ERP080-120VM, ERP100VML) (A985)
NOTE: DO NOT twist wires on hydraulic tank level

sensor during removal.
4. Turn hydraulic tank level sensor counterclockwise
to unscrew and remove hydraulic tank level
sensor from hydraulic tank.
1. HYDRAULIC PUMP MOTOR

2. HYDRAULIC TANK
3. COUNTERWEIGHT
4. HYDRAULIC TANK LEVEL SENSOR
5. SENSOR CONNECTOR
6. HYDRAULIC OIL TEMPERATURE SENSOR
Figure 57. Hydraulic Tank Level and Hydraulic Oil

Temperature Sensors, Lift Truck Model
Manufactured After November 2015ERP22-35VL
(ERP045-070VL) (A976)

2. HYDRAULIC TANK
3. COUNTERWEIGHT
5. SENSOR CONNECTOR
6. HYDRAULIC OIL TEMPERATURE SENSOR

Temperature Sensors, Lift Truck Models
Manufactured Before November 2014 and
Manufactured Prior to November 2015ERP40-80VM
(ERP080-100VM) (A985) ERP22-35VL
(ERP045-070VL) (A976)
57
2. Connect main wire harness to hydraulic tank level

sensor.
• ERP22-35VL (ERP045-070VL) (A976)
manufactured prior to November 2015
• ERP40-50VM (ERP080-100VM) (A985)
• ERP22-35VL (ERP045-070VL) (A976)
(ERP080-120VM, ERP100VML) (A985)
3. Install counterweight cover and tow pin onto

2. HYDRAULIC TANK 4. Connect the battery.
3. COUNTERWEIGHT
4. HYDRAULIC TANK LEVEL SENSOR Lift Truck Models ERC22-35VG
5. SENSOR CONNECTOR
6. HYDRAULIC OIL TEMPERATURE SENSOR (ERC045-070VG) (A968) and ERC16-20VA
(ERC030-040VA) (A969)
Temperature Sensors, Lift Truck Models Remove
Manufactured After November 2014ERP40-50VM, 1. Read and follow WARNING and CAUTION
ERP50-55VM6 (ERP080-120VM, ERP100VML) section in General section above.
(A985)
2. Remove three socket head capscrews and
Install foldover nuts and remove step plate from frame
channel. See Figure 59
sensor during installation.
1. Install new hydraulic tank level sensor by turning
it clockwise to screw it into hydraulic tank. Tighten
hydraulic tank level sensor to
4 to 7 N•m (35 to 62 lbf in).
58
Install
sensor during installation
it clockwise to screw it into hydraulic tank. Tighten
hydraulic tank level sensor
4 to 7 N•m (35 to 62 lbf in).
2. Connect main wire harness to hydraulic tank level

sensor. See Figure 59.
3. Install step plate to frame channel using three

socket head capscrews and foldover nuts. See
Figure 59.
Lift Truck Models ERC40-55VH,

ERC50VHS (ERC80-120VH, ERC100VHS)
(A938)
Remove
2. Lift hood to UP position and remove the battery.

See the Operating Manual or Periodic
1. SOCKET HEAD CAPSCREW Maintenance 8000YRM1577 for procedures.
2. LEFT STEP PLATE
3. FOLDOVER NUT 3. Disconnect main wire harness from hydraulic tank
4. SENSOR CONNECTOR level sensor.
6. LEFT FRAME CHANNEL
Figure 59. Hydraulic Tank Level Sensor, Lift Truck sensor during removal.
Models and ERC22-35VG (ERC045-070VG) 4. Remove connector from mounting bracket by
(A968) ERC16-20VA (ERC030-040VA) (A969) pulling mounting clip up. See Figure 60.
3. Disconnect main wire harness from hydraulic tank 5. Remove hydraulic tank level sensor from
level sensor. hydraulic tank by turning sensor
counterclockwise. See Figure 60.
sensor during removal.
4. Remove hydraulic tank level sensor by turning
sensor counterclockwise. See Figure 59.
59
1. HYDRAULIC TANK LEVEL SENSOR 6. FRONT BULKHEAD

2. HYDRAULIC TANK LEVEL SENSOR 7. HYDRAULIC OIL FILTER
CONNECTOR 8. HYDRAULIC TANK BREATHER
3. MOUNTING CLIP 9. SUCTION STRAINER
4. MOUNTING BRACKET
5. HYDRAULIC TANK
Figure 60. Hydraulic Tank Level Sensor, Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938)
Install 4. Install battery into lift truck. Connect battery and

close hood. See the Operating Manual or
NOTE: DO NOT twist wires on hydraulic tank level Periodic Maintenance 8000YRM1577 for
sensor during removal. procedures.
it clockwise to screw it into hydraulic tank. See HYDRAULIC FILTER SENSOR
Figure 60. Tighten hydraulic tank level sensor
4 to 7 N•m (35 to 62 lbf in). Lift Truck Models ERP22-35VL
(ERP045-070VL) (A976) and ERP40-50VM,
2. Install connector to mounting bracket by pushing ERP50-55VM6 (ERP080-120VM,
mounting clip into hole in mounting bracket. ERP100VML) (A985)
3. Connect main wire harness to hydraulic tank level Remove

60
3. Disconnect main wire harness from hydraulic filter

sensor.
4. Remove hydraulic filter sensor from hydraulic

filter by loosening nut on hydraulic filter sensor.
• ERP22-35VL (ERP045-070VL) (A976)
• ERP40-50VM (ERP080-100VM) (A985)
(ERP080-120VM, ERP100VML) (A985)
NOTE: SOME HYDRAULIC SYSTEM COMPO-

NENTS OMITTED FOR CLARITY.
1. COUNTERWEIGHT
2. HYDRAULIC FILTER
3. NUT
4. HYDRAULIC FILTER SENSOR
5. HYDRAULIC TANK
Figure 62. Hydraulic Filter Sensor, Lift Truck

Models Manufactured After November 2014
ERP100VML) (A985)
NOTE: SOME HYDRAULIC SYSTEM COMPO- Install

NENTS OMITTED FOR CLARITY.
NOTE: LIFT TRUCK MODEL ERP22-35VL 1. Install new hydraulic filter sensor into hydraulic
(ERP045-070VL) (A976) MANUFACTURED PRIOR filter by tightening nut on hydraulic filter sensor to
TO NOVEMBER 2015 SHOWN. LIFT TRUCK MODEL 4 to 7 N•m (3 to 5 lbf in).
ERP22-35VL (ERP045-070VL) (A976) MANUFAC- See Figure 61 for lift truck models
TURED AFTER NOVEMBER 2015 SIMILAR.
• ERP22-35VL (ERP045-070VL) (A976)
1. COUNTERWEIGHT • ERP40-50VM (ERP080-100VM) (A985)
2. HYDRAULIC FILTER manufactured before November 2014
3. NUT
4. HYDRAULIC FILTER SENSOR See Figure 62 for lift truck models
5. HYDRAULIC TANK • ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985)
Figure 61. Hydraulic Filter Sensor, Lift Truck manufactured after November 2014
Models Manufactured Before November 2014 and
ERP40-80VM (ERP080-100VM) (A985) ERP22-35VL 2. Connect main wire harness to hydraulic filter
(ERP045-070VL) (A976) sensor.
61
3. Install tow pin and counterweight cover to 7. Remove hydraulic filter sensor from hydraulic
counterweight. See Figure 48 or Figure 49. filter adapter and hydraulic filter by loosening nut
on hydraulic filter sensor.
Lift Truck Models ERC22-35VG • ERC22-35VG (ERC045-070VG) (A968)
(ERC045-070VG) (A968,) ERC16-20VA See Figure 64 for lift truck models
(ERC030-040VA) (A969) and ERC40-55VH, • ERC16-20VA (ERC030-040VA) (A969)
(A938)
Remove ERC100VHS) (A938)

ERC16-20VA (ERC030-040VA) (A969) and
ERC22-35VG (ERC045-070VG) (A968) manufactured
before June 2012
3. Remove capscrews and washers from front floor

plate and lift front floor plate up enough to
disconnect accelerator pedal or Foot Directional
Control pedal. See Figure 44. Remove front floor
plate with the accelerator or Foot Directional
Control pedal still attached.

ERC22-35VG (ERC045-070VG) (A968) manufactured NOTE: SOME HYDRAULIC SYSTEM COMPO-
after June 2012, and lift truck models ERC40-55VH, NENTS OMITTED FOR CLARITY.
ERC50VHS (ERC80-120VH, ERC100VHS) (A938) .
1. HYDRAULIC PUMP AND MOTOR
4. Remove the floor mat and floor plate. 2. HYDRAULIC FILTER
3. HYDRAULIC FILTER ADAPTER
5. Lift front floor plate up enough to disconnect the 4. NUT
accelerator pedal or Foot Directional Control 5. HYDRAULIC FILTER SENSOR
pedal. See Figure 45. Remove front floor plate
with the accelerator or Foot Directional Control Figure 63. Hydraulic Filter Sensor, Lift Truck
pedal still attached. Models ERC22-35VG (ERC045-070VG) (A968)
6. Disconnect main wire harness from hydraulic filter

sensor.
62
1. RIGHT STEP PLATE

2. HYDRAULIC FILTER
Figure 65. Hydraulic Filter Sensor for Lift Truck

Model ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938)
Install
1. Install new hydraulic filter sensor into hydraulic
filter adapter by tightening nut on hydraulic filter
sensor to 25 N•m (18 lbf ft).
1. HYDRAULIC PUMP AND MOTOR See Figure 63 for lift truck models
2. HYDRAULIC FILTER • ERC22-35VG (ERC045-070VG) (A968)
4. NUT See Figure 64 for lift truck models
• ERC16-20VA (ERC030-040VA) (A969)
Figure 64. Hydraulic Filter Sensor for Lift Truck See Figure 65 for lift truck model
Model ERC16-20VA (ERC030-040VA) (A969)
ERC100VHS) (A938)
2. Connect main wire harness to hydraulic filter

sensor.

Control pedal. See Figure 44.

ERC16-20VA (ERC030-040VA) (A969) and
before June 2012.
4. Install front floor plate using capscrews and
washers.
63
NOTE: Perform Step 5 for lift truck models Install

ERC100VHS) (A938) and ERC22-35VG 1. Install new hydraulic oil temperature sensor to
(ERC045-070VG) (A968) manufactured after June hydraulic tank. Tighten hydraulic oil temperature
2012. sensor to 20 N•m (177 lbf in).
5. No hardware is required to install the front floor 2. Connect main wire harness to hydraulic oil
plate. temperature sensor.
6. Install rear floor plate. Install floor mat and 3. Install tow pin and counterweight cover to
connect the battery. counterweight. See Figure 48 or Figure 49.
HYDRAULIC OIL TEMPERATURE SENSOR 4. Connect the battery.

NOTE: Lift truck models ERC16-20VA
(ERC030-040VA) (A969) and ERC40-55VH,
Lift Truck Models ERC22-35VG
ERC50VHS (ERC80-120VH, ERC100VHS) (A938) (ERC045-070VG) (A968)
are not equipped with a Hydraulic Oil Temperature Remove
Sensor.
Lift Truck Models ERP22-35VL section in General section above.
(ERP045-070VL) (A976) and ERP40-50VM, NOTE: Perform Step 2 to Step 4 for lift trucks
ERP50-55VM6 (ERP080-120VM, manufactured before June 2012.
ERP100VML) (A985) 2. Remove floor mat. Remove rear floor plate.
Remove
1. Read and follow WARNING and CAUTION plate and lift front floor plate up enough to
section in General section above. disconnect accelerator pedal or Foot Directional
counterweight. See Figure 48 or Figure 49. 4. Remove front floor plate with accelerator or Foot
Directional Control pedal still attached.
3. Disconnect main wire harness from hydraulic oil
temperature sensor. NOTE: Perform Step 5 to Step 7 for lift trucks
manufactured after June 2012.
4. Unscrew and remove hydraulic oil temperature
sensor from hydraulic tank. 5. Remove floor mat. Remove rear floor plate.
See Figure 56 for lift truck models 6. Lift front floor plate up enough to disconnect
• ERP22-35VL (ERP045-070VL) (A976) accelerator pedal or Foot Directional Control
ERP40-50VM (ERP080-100VM) (A985) pedal. See Figure 45
•
7. Remove front floor plate with accelerator or Foot
See Figure 51 for lift truck model Directional Control pedal still attached.
• ERP22-35VL (ERP045-070VL) (A976)
manufactured after November 2015 8. Disconnect main wire harness from hydraulic oil
temperature sensor.
• ERP40-50VM, ERP50-55VM6 9. Loosen nut on hydraulic oil temperature sensor
(ERP080-120VM, ERP100VML) (A985) and remove sensor from hydraulic tank. See
manufactured after November 2014 Figure 66.
64

after June 2012.
5. No hardware is required to install front floor plate.
6. Install rear floor plate.
7. Install floor mat and connect the battery.
TRACTION SPEED SENSOR

(ERP045-070VL) (A976) and ERP40-50VM,
ERP50-55VM6 (ERP080-120VM,
ERP100VML) (A985)
Remove
NOTE: SOME HYDRAULIC SYSTEM COMPO-
NENTS OMITTED FOR CLARITY NOTE: There are two speed sensors. The procedures
below describe how to replace one sensor. The
1. HYDRAULIC OIL TEMPERATURE SENSOR procedures are the same for both sensors.
2. HYDRAULIC MOTOR 1. Read and follow WARNING and CAUTION
3. HYDRAULIC TANK
Figure 66. Hydraulic Oil Temperature Sensor, Lift
Truck Models ERC22-35VG (ERC045-070VG) 2. Put lift truck on blocks and remove tire and wheel.
(A968) See Operating Manual or section
Periodic Maintenance 8000YRM1372 for lift
Install truck models
1. Install new hydraulic oil temperature sensor to • ERP22-35VL (ERP045-070VL) (A976)
hydraulic tank. Tighten hydraulic oil temperature Periodic Maintenance 8000YRM1541 for lift
sensor to 20 N•m (177 lbf in). truck models
2. Connect main wire harness to hydraulic oil • ERP40-50VM, ERP50-55VM6
temperature sensor. (ERP080-120VM, ERP100VML) (A985)
3. Connect accelerator pedal or Foot Directional 3. Disconnect main wire harness from speed sensor.
Control pedal.
4. Remove socket head screw securing speed
See Figure 44 for lift trucks manufactured before sensor to traction motor. Remove speed sensor
June 2012. and sensor connector from traction motor.
See Figure 45 for lift trucks manufactured after See Figure 67 for lift truck models
June 2012.
• ERP22-35VL (ERP045-070VL) (A976)
NOTE: Perform Step 4 for lift truck models See Figure 68 for lift truck models
before June 2012.
(ERP080-120VM, ERP100VML) (A985)
washers.
65
NOTE: SOME COMPONENT PARTS OMITTED FOR CLARITY. RIGHT SIDE SPEED SENSOR SHOWN. LEFT
SIDE IS THE SAME.
1. SOCKET HEAD SCREW 3. TRANSAXLE ASSEMBLY

2. TRACTION SPEED SENSOR
Figure 67. Speed Sensor Removal, Lift Truck Models ERP22-35VL (ERP045-070VL) (A976)
66
NOTE: SOME COMPONENT PARTS OMITTED FOR CLARITY. RIGHT SIDE SPEED SENSOR SHOWN. LEFT
SIDE IS THE SAME.
1. SOCKET HEAD SCREW 3. TRANSAXLE ASSEMBLY

2. TRACTION SPEED SENSOR
Figure 68. Speed Sensor Removal, Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM,
ERP100VML) (A985)
Install 3. Install tire and wheel. Remove lift truck from

blocks. See Operating Manual or section
1. Install new speed sensor and sensor connector
onto traction motor. Secure speed sensor to Periodic Maintenance 8000YRM1372 for lift
traction motor with socket head screws. truck models
See Figure 67 for lift truck models • ERP22-35VL (ERP045-070VL) (A976)
• ERP22-35VL (ERP045-070VL) (A976) Periodic Maintenance 8000YRM1541 for lift
truck models
• ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)
(ERP080-120VM, ERP100VML) (A985)
2. Connect main wire harness to speed sensor.
67
Lift Truck Models ERC22-35VG • ERC16-20VA (ERC030-040VA) (A969)

(ERC045-070VG) (A968) and ERC16-20VA
3. Remove drip shield for access to speed sensor.
(ERC030-040VA) (A969)
Remove 4. Disconnect main wire harness from speed sensor
connector.
• ERC22-35VG (ERC045-070VG) (A968)
2. Put lift truck on blocks. See Operating Manual or
section
• ERC16-20VA (ERC030-040VA) (A969)
truck models
• ERC22-35VG (ERC045-070VG) (A968) sensor to traction motor. Remove speed sensor
connector from sensor wiring connector mounting
bracket.
truck models
68
NOTE: BOTTOM VIEW SHOWN.
1. TRACTION MOTOR 3. SPEED SENSOR

2. SENSOR MOUNTING BRACKET 4. SPEED SENSOR CONNECTOR
Figure 69. Speed Sensor Removal Lift Truck Models ERC22-35VG (ERC045-070VG) (A968)
69
1. TRACTION MOTOR 4. SPEED SENSOR CONNECTOR

2. SENSOR WIRING BRACKET 5. TRACTION MOTOR TEMPERATURE SENSOR
3. SPEED SENSOR CONNECTOR
Figure 70. Speed Sensor Removal Lift Truck Model ERC16-20VA (ERC030-040VA) (A969)
Install Lift Truck Model ERC40-55VH, ERC50VHS

1. Install new speed sensor to traction motor. (ERC80-120VH, ERC100VHS) (A938)
See Figure 69 for lift truck models Remove
• ERC22-35VG (ERC045-070VG) (A968) 1. Read and follow WARNING and CAUTION
• ERC16-20VA (ERC030-040VA) (A969) 2. Raise hood and seat assembly and remove
batteries and floor plates. See Frame
2. Connect main wire harness to speed sensor. 0100YRM1342 for procedures.
3. Install drip shield. 3. Disconnect wire harness from speed sensor

connector. See Figure 71.
4. Remove lift truck from blocks.
5. Connect the battery. sensor to sensor mounting bracket on traction
motor. See Figure 71.
70
5. Remove sensor mounting bracket. See Figure 71. 7. Remove speed sensor and speed sensor
connector from traction motor. See Figure 71.
sensor to traction motor. See Figure 71.
1. TRACTION MOTOR 4. SOCKET HEAD CAPSCREW

2. SPEED SENSOR CONNECTOR 5. SPEED SENSOR
3. TRACTION MOTOR TEMPERATURE SENSOR 6. SENSOR MOUNTING BRACKET
CONNECTOR
Figure 71. Speed Sensor Removal Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938)
Install 4. Connect wire harness to speed sensor connector.

See Figure 71.
1. Install new speed sensor and speed sensor
connector. See Figure 71. 5. Install floor plates and batteries. See Frame
2. Install socket head capscrew securing speed
sensor to traction motor. See Figure 71. 6. Lower hood and seat assembly.
3. Install sensor mounting bracket and two socket
head capscrews. See Figure 71.
71
TRACTION MOTOR TEMPERATURE 2. Disconnect temperature sensor plug from main

SENSOR ERC22-35VG (ERC045-070VG) wire harness. See Figure 72.
(A968) AND ERP22-35VL (ERP045-070VL) 3. Remove axle from lift truck
(A976)
4. Remove motor terminal cover from failed sensor
The traction motor temperature sensor is heat welded
side.
and sealed onto winding coils in stator housing in
traction motor. It is a non-replaceable part and cannot
5. Cut off and remove existing sensor. Remove
be replaced separately from traction motor.
cable from grommet in motor terminal cover. See
Figure 72.
TRACTION MOTOR TEMPERATURE
SENSOR ERP40-50VM, ERP50-55VM6 6. Clean adhesive from motor terminal cover.
(ERP080-120VM, ERP100VML) (A985)
Remove
1. Locate and note which side of axle has failed.
1. THERMAL SENSOR 4. GROMMET

2. ADHESIVE 5. TEMPERATURE SENSOR CONNECTOR
3. POWER LEAD 6. TRACTION MOTOR
Figure 72. Traction Motor Temperature Sensor
72
Install The tilt position sensor is located on left side of mast. It

1. Route new sensor cable through grommet in is mounted on a bracket on left tilt cylinder rod end.
motor terminal cover before installing new See Figure 73. The tilt position sensor is an optional
temperature sensor. See Figure 72. feature on lift trucks covered in this service manual.
2. Apply a good quantity of adhesive to cleaned Remove

area.
3. Insert temperature sensor into adhesive. See
Figure 72.
2. Disconnect main wire harness from tilt position
sensor. Remove two grommets and wire harness
4. Allow 3-4 hours for adhesive to cure.
from tilt position sensor bracket.
5. Install motor terminal cover.
3. Remove two torx capscrews from tilt position
6. Install axle into lift truck. sensor.
7. Connect temperature sensor plug to main wire
• ERC22-35VG (ERC045-070VG) (A968)
• ERP22-35VL (ERP045-070VL) (A976)
TILT POSITION SENSOR ERC22-35VG • ERP40-50VM (ERP080-100VM) (A985)
(ERC045-070VG) (A968), ERP22-35VL manufactured before November 2014
(ERP045-070VL) (A976), AND See Figure 74 for lift truck models
ERP40-50VM, ERP50-55VM6 • ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985) (ERP080-120VM, ERP100VML) (A985)
WARNING 4. Remove tilt position sensor from tilt position

Before replacing any components installed on the sensor bracket.
mast, fully lower all parts of the mast and tilt it
forward until the tips of the forks touch the
ground. This action will prevent the mast from
lowering suddenly if the control lever is accidently
moved.
73
NOTE: COMPONENTS OF COWL AND MAST OMITTED FOR CLARITY. LEFT SIDE SHOWN.
1. TILT CYLINDER 5. GROMMET

2. TILT POSITION SENSOR MOUNTING 6. TILT POSITION SENSOR WIRE AND
BRACKET CONNECTOR
3. TILT POSITION SENSOR 7. TILT CYLINDER ROD END
4. TORX CAPSCREWS
Figure 73. Tilt Position Sensor Removal for Lift Truck Models Manufactured Before November 2014 and
and ERP40-80VM (ERP080-100VM) (A985) ERC22-35VG (ERC045-070VG) (A968) ERP22-35VL
(ERP045-070VL) (A976)
74
NOTE: COMPONENTS OF COWL AND MAST OMITTED FOR CLARITY. LEFT SIDE SHOWN.
1. TILT CYLINDER 5. GROMMET

2. TILT POSITION SENSOR MOUNTING 6. TILT POSITION SENSOR WIRE AND
BRACKET CONNECTOR
3. TILT POSITION SENSOR 7. TILT CYLINDER ROD END
4. TORX CAPSCREWS
Figure 74. Tilt Position Sensor Removal, Lift Truck Models Manufactured After November
Install • ERC22-35VG (ERC045-070VG) (A968)

1. Install new tilt position sensor on tilt position • ERP22-35VL (ERP045-070VL) (A976)
sensor bracket using two torx head capscrews. • ERP40-50VM (ERP080-100VM) (A985)
See Figure 73. manufactured before November 2014
2. Install grommets and wire harness to tilt position
sensor bracket. • ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985)
3. Connect main wire harness to tilt position sensor manufactured after November 2014
connector.
75
TILT POSITION SENSOR ERC16-20VA

(ERC030-040VA) (A969)
WARNING
Before replacing any components installed on the
mast, fully lower all parts of the mast and tilt it
ground. This action will prevent the mast from
lowering suddenly if the control lever is accidently
moved.
The tilt position sensor is located on left side of mast. It

is mounted on a bracket on left tilt cylinder rod end.
See Figure 75. The tilt position sensor is an optional
feature on lift trucks covered in this service manual.
Perform the following procedures if lift truck is
equipped with tilt position sensor.
Remove
1. TORX CAPSCREWS
2. Disconnect mast harness from cowl harness. 2. RETURN TO SET TILT (TILT ANGLE) SENSOR
3. SENSOR BRACKET
4. COWL
3. Remove two torx capscrews, nuts, and tilt sensor 5. MAST HARNESS (TO COWL HARNESS)
from sensor bracket on mast. See Figure 75. 6. HARNESS BRACKET
4. Remove mast harness from sensor and mast Figure 75. Tilt Position Sensor for Lift Truck Model
brackets. ERC16-20VA (ERC030-040VA) (A969)
Install
1. Install new tilt position sensor on sensor bracket
using two torx head capscrews and two nuts. See
Figure 75.
2. Install mast harness to harness bracket.
3. Connect mast harness to cowl harness. See

Figure 75.
4. Tilt mast completely forward and backward to

ensure tilt sensor is installed and connected
correctly.
76
TILT POSITION SENSOR ERC40-55VH, 2. Disconnect main wire harness from tilt position
ERC50VHS (ERC80-120VH, ERC100VHS) sensor wire connector. Remove tilt sensor wire,
grommets and other tilt sensor wire retainers from
(A938) chassis and set aside. See Figure 76.
3. Remove anchor capscrews from anchor, sensor

WARNING bracket and tilt cylinder rod end. See Figure 76.
Before replacing any components installed on the
mast, fully lower all parts of the mast and tilt it 4. Remove anchor. See Figure 76.
ground. This action will prevent the mast from 5. Remove sensor bracket from tilt cylinder rod end.
lowering suddenly if the control lever is accidently See Figure 76.
moved.
6. Remove two nuts and two torx head capscrews
The tilt position sensor is located on left side of mast. It from tilt position sensor. See Figure 76.
is mounted on a bracket on left tilt cylinder rod end.
See Figure 76. The tilt position sensor is an optional 7. Remove tilt position sensor from sensor bracket.
feature on lift trucks covered in this service manual. See Figure 76.
Remove 8. Remove tilt position sensor and tilt position

sensor wire. See Figure 76.
77
1. ANCHOR CAPSCREW 7. TILT CYLINDER

2. WASHER 8. TILT POSITION SENSOR WIRE CONNECTOR
3. ANCHOR 9. SENSOR BRACKET
4. TILT POSITION SENSOR WIRE 10. TORX CAPSCREW
5. TILT CYLINDER ROD END 11. TILT POSITION SENSOR
6. GROMMET 12. NUT
Figure 76. Tilt Position Sensor Removal for ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938)
Install 4. Install tilt position wire, grommets and other

sensor wire retainers into chassis as shown in
1. Install tilt position sensor in sensor bracket using Figure 76.
two nuts and two torx head capscrews. See
Figure 76. 5. Connect main wire harness to tilt position sensor
wire connector. See Figure 76.
2. Install sensor bracket onto tilt cylinder rod end.
See Figure 76. 6. Connect the battery.
3. Install anchor, washer, and anchor capscrew.
Tighten anchor capscrew to 68 N•m (50 lbf ft).
See Figure 76.
78
LOW LEVEL BRAKE FLUID SWITCH FOR 4. Remove front floor plate with accelerator or Foot
LIFT TRUCK MODELS ERC22-35VG Directional Control pedal still attached.
(ERC045-070VG) (A968), ERC16-20VA NOTE: Perform Step 5 to Step 7 for lift truck models
(ERC030-040VA) (A969), ERP22-35VL ERC22-35VG (ERC045-070VG) (A968) manufactured
(ERP045-070VL) (A976), AND after June 2012.
ERP40-50VM, ERP50-55VM6 5. Remove floor mat and rear floor plate.
(ERP080-120VM, ERP100VML) (A985)
6. Lift front floor plate up enough to disconnect
NOTE: The low level brake fluid switch is a accelerator pedal or Foot Directional Control
component of the master brake cylinder reservoir and pedal. See Figure 45.
is located on bottom of reservoir.
Remove Directional Control pedal still attached.
section in General section above. 8. Disconnect main wire harness from low brake
fluid level switch connector.
NOTE: Perform Step 2 to Step 4 for lift truck models See Figure 77 for lift truck models
• ERC22-35VG (ERC045-070VG) (A968)
before June 2012 and ERC16-20VA (ERC030-040VA)
(A969) , ERP22-35VL (ERP045-070VL) (A976) , and • ERC16-20VA (ERC030-040VA) (A969)
ERP40-50VM, ERP50-55VM6 (ERP080-120VM, • ERP22-35VL (ERP045-070VL) (A976)
ERP100VML) (A985) .
• ERP40-80VM (ERP080-100VM) (A985)
2. Remove floor mat and rear floor plate. manufactured before November 2014
plate and lift front floor plate up enough to • ERP40-50VM, ERP50-55VM6
disconnect accelerator pedal or Foot Directional (ERP080-120VM, ERP100VML) (A985)
Control pedal. See Figure 44. manufactured after November 2014
79
NOTE: SOME COMPONENTS OMITTED FOR CLARITY
1. BRAKE MASTER CYLINDER 4. BRAKE FLUID RESERVOIR

2. BRAKE PRESSURE SENSOR 5. LOW LEVEL BRAKE FLUID SWITCH
3. COWL HARNESS CONNECTOR CONNECTOR
Figure 77. Brake System Switches and Sensors Lift Truck Models Manufactured Before November 2014
and , , and ERP40-80VM (ERP080-100VM) (A985) ERC22-35VG (ERC045-070VG) (A968) ERC16-20VA
(ERC030-040VA) (A969) ERP22-35VL (ERP045-070VL) (A976)
80
NOTE: SOME COMPONENTS OMITTED FOR CLARITY
1. BRAKE MASTER CYLINDER 4. BRAKE FLUID RESERVOIR

2. BRAKE PRESSURE SENSOR 5. LOW LEVEL BRAKE FLUID SWITCH
3. COWL HARNESS CONNECTOR CONNECTOR
Figure 78. Brake System Switches and Sensors Lift Truck Models Manufactured After November
9. Press retaining clip on low level brake fluid switch

and pop low level brake fluid switch out. Remove
switch from brake fluid reservoir. See Figure 79.
81
1. RETAINING CLIP 4. BRAKE FLUID RESERVOIR

2. BRAKE MASTER CYLINDER 5. LOW LEVEL BRAKE FLUID SWITCH
3. BRAKE PRESSURE SENSOR
Figure 79. Low Level Brake Fluid Switch Replacement
Install See Figure 77 for lift truck models

1. Install new low level brake fluid switch into brake • ERC22-35VG (ERC045-070VG) (A968)
fluid reservoir. Switch will snap into position. See • ERC16-20VA (ERC030-040VA) (A969)
Figure 79. • ERP22-35VL (ERP045-070VL) (A976)
2. Connect main wire harness to low brake fluid • ERP40-50VM (ERP080-100VM) (A985)
level switch connector. manufactured before November 2014
82
See Figure 78 for lift truck models LOW LEVEL BRAKE FLUID SWITCH FOR
• ERP40-50VM, ERP50-55VM6 LIFT TRUCK MODEL ERC40-55VH,
(ERP080-120VM, ERP100VML) (A985) ERC50VHS (ERC80-120VH, ERC100VHS)
(A938)
3. Connect accelerator pedal or Foot Directional NOTE: The low level brake fluid switch is a non-
Control pedal. See Figure 44. serviceable component of brake fluid reservoir. If low
level brake fluid switch needs to be replaced, the
NOTE: Perform Step 4 for lift truck models brake fluid reservoir will need to be replaced as well.
ERC16-20VA (ERC030-040VA) (A969) , ERP22-35VL
(ERP045-070VL) (A976) , ERP40-80VM NOTE: Drain fluid from master cylinder prior to
(ERP080-100VM) (A985) , and ERC22-35VG performing this repair procedure. See Drive Axle
(ERC045-070VG) (A968) manufactured before June Repair 1300YRM1575.
2012.
Remove
washers 1. Read and follow WARNING and CAUTION
NOTE: Perform Step 5 for lift truck model
ERC22-35VG (ERC045-070VG) (A968) manufactured 2. Remove three button head capscrews from brake
after June 2012. fluid reservoir cover. See Figure 80.
5. No hardware is required to install the front floor 3. Remove brake fluid reservoir cover. See
plate. Figure 80.
6. Install rear floor plate. Install floor mat and 4. Disconnect main wire harness from low brake
connect the battery. fluid reservoir electrical connector. See Figure 80.
5. Loosen clamp on brake fluid reservoir and press

retaining clip holding brake fluid reservoir to cowl
to remove brake fluid reservoir from lift truck. See
Figure 80.
83
NOTE: SOME COMPONENTS OMITTED FOR CLARITY.
1. BRAKE FLUID RESERVOIR 5. BRAKE FLUID RESERVOIR COVER

2. RETAINING CLIP 6. BUTTON HEAD CAPSCREWS
3. LOW LEVEL BRAKE FLUID SWITCH 7. BRAKE PRESSURE SENSOR
CONNECTOR 8. COWL
4. CLAMP
Figure 80. Brake System Switches and Sensors ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS)
(A938)
Install 4. Connect main wire harness to low level brake

fluid reservoir electrical connector. See Figure 80.
1. Install new brake fluid reservoir onto hose and
tighten clamp. See Figure 80. 5. Bleed brake system as described in Drive Axle
Repair 1300YRM1575.
2. Add correct amount of fluid to reach operating
level. See Operating Manual or Periodic 6. Install brake fluid reservoir cover. See Figure 76.
Maintenance 8000YRM1577 for proper fluid type
and amount. 7. Install three button head capscrews into brake
fluid reservoir cover. See Figure 80.
3. Press brake fluid reservoir into retaining clip.
84
SERVICE BRAKE PRESSURE SENSOR Install

FOR LIFT TRUCK MODELS ERC22-35VG 1. Install a new brake pressure sensor on master
(ERC045-070VG) (A968), ERC16-20VA cylinder. Tighten brake pressure sensor to
(ERC030-040VA) (A969), ERP22-35VL 23 to 28 N•m (204 to 248 lbf in).
(ERP045-070VL) (A976), AND
2. Connect main wire harness to new brake
ERP40-50VM, ERP50-55VM6 pressure sensor. See Figure 77.
(ERP080-120VM, ERP100VML) (A985)
Remove Control pedal, (see Figure 44).
section in General section above. NOTE: Perform Step 4 for lift truck models
NOTE: Perform Step 2 to Step 4 for lift truck models (ERP045-070VL) (A976) , ERP40-80VM
ERC16-20VA (ERC030-040VA) (A969) , ERP22-35VL (ERP080-100VM) (A985) , and ERC22-35VG
(ERP045-070VL) (A976) , ERP40-80VM (ERC045-070VG) (A968) manufactured before June
(ERP080-100VM) (A985) , and ERC22-35VG 2012.
(ERC045-070VG) (A968) manufactured before June 4. Install the front floor plate using capscrews and
2012: washers.
NOTE: Perform Step 5 and Step 6 for lift truck model
3. Remove capscrews and washers from front floor ERC22-35VG (ERC045-070VG) (A968) manufactured
plate and lift front floor plate up enough to after June 2012.
disconnect accelerator pedal or Foot Directional 5. No hardware is required to install front floor plate.
6. Install rear floor plate. Install floor mat and
4. Remove front floor plate with accelerator or Foot connect the battery.
7. Bleed brake system as described in the section
NOTE: Perform Step 5 to Step 7 for lift truck models
ERC22-35VG (ERC045-070VG) (A968) manufactured Brake System 1800YRM1359 for lift truck
after June 2012. models
5. Remove floor mat. Remove rear floor plate. • ERC22-35VG (ERC045-070VG) (A968)
• ERP22-35VL (ERP045-070VL) (A976)
6. Lift front floor plate up enough to disconnect
accelerator pedal or Foot Directional Control Brake System 1800YRM1438 for lift truck
pedal. See Figure 45. models
• ERC16-20VA (ERC030-040VA) (A969)
Transaxle 1300YRM1539 for lift truck models
8. Disconnect main wire harness from brake (ERP080-120VM, ERP100VML) (A985)
pressure sensor and remove it from master
cylinder. See Figure 77.
85
SERVICE BRAKE PRESSURE SENSOR ACCELERATOR PEDAL POSITION

FOR LIFT TRUCK MODEL ERC40-55VH, SENSOR
ERC50VHS (ERC80-120VH, ERC100VHS) Remove
(A938)
NOTE: The accelerator pedal position sensor cannot
Remove be replaced separately from accelerator pedal. If
1. Read and follow WARNING and CAUTION accelerator pedal position sensor malfunctions,
section in General section above. accelerator pedal assembly must be replaced.
NOTE: In the steps and illustrations below, the
2. Remove floor mat. Remove rear floor plate. Lift standard accelerator pedal is used. The procedures to
front floor plate up enough to disconnect the replace a Foot Directional Control pedal are the
accelerator pedal or Foot Directional Control same.
with accelerator or Foot Directional Control pedal 1. Read and follow WARNING and CAUTION
still attached. section in General section above.
3. Install container beneath service brake pressure NOTE: Perform Step 2 to Step 4 for lift truck models
sensor to catch any fluid. Container should have ERC16-20VA (ERC030-040VA) (A969) , ERP22-35VL
a capacity of at least 0.35 liter (0.37 qt). (ERP045-070VL) (A976) , ERP40-80VM
(ERP080-100VM) (A985) and ERC22-35VG
4. Disconnect main wire harness from brake (ERC045-070VG) (A968) manufactured before June
pressure sensor and remove it from master 2012:
cylinder. See Figure 80.
5. Remove container.
Install disconnect accelerator pedal or Foot Directional
1. Install a new brake pressure sensor on master Control pedal. See Figure 44.
cylinder. Tighten brake pressure sensor to
23 to 28 N•m (204 to 248 lbf in). 4. Remove front floor plate with accelerator or Foot
2. Connect main wire harness to new brake
pressure sensor. See Figure 80. NOTE: Perform Step 5 to Step 7 for lift truck models
3. Connect accelerator pedal or Foot Directional after June 2012.
Control pedal, (see Figure 54).
Install the front floor plate. Install rear floor plate.
Install floor mat and connect the battery. 6. Lift front floor plate up enough to disconnect
4. Add brake fluid. See Operating Manual or pedal. See Figure 45.
Periodic Maintenance 8000YRM1577 for proper
fluid type and amount. 7. Remove front floor plate with accelerator or Foot
5. Bleed brake system as described in Drive Axle
Repair 1300YRM1575. 8. Remove three capscrews and nuts that attach the
accelerator pedal and pedal base to accelerator
pedal mounting plate. See Figure 44. Remove
accelerator pedal mounting plate.
86
Install
1. Install new accelerator pedal, pedal base and
accelerator pedal mounting plate to front floor
plate with capscrews and nuts. See Figure 44.

(ERP045-070VL) (A976) , ERP40-80VM
(ERP080-100VM) (A985) , and ERC22-35VG
(ERC045-070VG) (A968) manufactured before June
2012.
washers
NOTE: Perform Step 3 for lift truck model

after June 2012.
3. No hardware is required to install the front floor
plate. 1. HOOD CROSSMEMBER
2. FOAM TAPE
4. Install rear floor plate. Install floor mat and 3. SEAT BELT SEQUENCE MODULE
connect the battery. 4. CONNECTOR
5. CAPSCREW
6. SPACER
SEAT BELT SEQUENCE MODULE 7. LINK
8. WASHER
NOTE: This module is used with Optional Operator 9. NUT
Presence System 10. HINGE
11. CROSSMEMBER PLATE
NOTE: Before performing the procedures below, read 12. REAR COVER
and follow the WARNING and CAUTION in the
General section above. Figure 81. Seat Belt Sequence Module, Lift Truck
Models ERP40-50VM, ERP50-55VM6
Lift Truck Models ERP40-50VM, (ERP080-120VM, ERP100VML) (A985)
ERP50-55VM6 (ERP080-120VM,
ERP100VML) (A985) Install
Remove 1. Install foam tape on back of seat belt sequence
module.
NOTE: Tag connectors to aid in installation.
1. Remove three captive screws and counterweight 2. Install seat belt sequence module on hood
cover from counterweight. crossmember. See Figure 81.
2. Remove four nuts, capscrews, spacers, and 3. Connect wire harness connector to seat belt
washers from hinge, link, and crossmember plate. sequence module.
Remove rear cover. See Figure 81.
4. Install rear cover. Install four washers, spacers,
3. Disconnect wire harness connector from seat belt capscrews, and nuts on crossmember plate, link,
sequence module. and hinge.
4. Remove seat belt sequence module from hood 5. Install counterweight cover and three captive
crossmember. screws on counterweight.
5. Clean foam tape residue from battery connector

bracket.
87
Lift Truck Models ERP22-35VL Install

(ERP045-070VL) (A976) 1. Install foam tape on back of seat belt sequence
Remove module.
NOTE: Tag connectors to aid in installation. 2. Install seat belt sequence module on battery
1. Remove two e-clips, captive screws, nylon connector bracket. See Figure 82.
washers, and counterweight cover from
3. Connect wire harness connector to seat belt
counterweight.
sequence module.
2. Disconnect wire harness connector from seat belt
4. Install counterweight cover, two nylon washers,
sequence module. See Figure 82.
captive screws, and e-clips on counterweight.
3. Remove seat belt sequence module from battery
connector. Lift Truck Models ERC22-35VG
(ERC045-070VG) (A968)
4. Clean foam tape residue from battery connector
bracket. Remove
1. Remove two captive screws and counterweight
cover from counterweight.

3. Remove seat belt sequence module from

controller cover.
4. Clean foam tape residue from controller cover.
1. FOAM TAPE
2. CONNECTOR
3. SEAT BELT SEQUENCE MODULE
4. BATTERY BRACKET
Figure 82. Seat Belt Sequence Module, Lift Truck

Models ERP22-35VL (ERP045-070VL) (A976)
88
Lift Truck Models ERC16-20VA

(ERC030-040VA) (A969) and ERC40-55VH,
(A938)
Remove
1. Remove two captive screws, tow pin, and
counterweight cover from counterweight.

3. Remove seat belt sequence module from rear

bulkhead.
4. Clean foam tape residue from rear bulkhead.
1. CONTROLLER COVER
2. CONNECTOR
4. FOAM TAPE

Models ERC22-35VG (ERC045-070VG) (A968)
Install
1. Install foam tape on back of seat belt sequence
module. 1. REAR BULKHEAD
2. Install seat belt sequence module on controller 3. CONNECTOR
cover. See Figure 83. 4. FOAM TAPE

3. Connect wire harness connector to seat belt
Models ERC16-20VA (ERC030-040VA) (A969) and
sequence module.
4. Install counterweight cover and two captive ERC100VHS) (A938)
screws on counterweight.
89

1. Install foam tape on back of seat belt sequence • ERP22-35VL (ERP045-070VL) (A976)
module. • ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985)
2. Install seat belt sequence module on rear
bulkhead. See Figure 84.
3. Connect wire harness connector to seat belt ERC100VHS) (A938)
sequence module.
4. Install counterweight cover, tow pin, and two

captive screws on counterweight.
SEAT SENSOR (OPERATOR PRESENCE

SYSTEM)
Non-Suspension Seat
Remove
2. Tilt steering column all the way up.
NOTE: Before removing seat from hood, tag or mark

holes that mount the seat to hood. This will aid in
correctly installing seat to hood.
• ERC22-35VG (ERC045-070VG) (A968) NOTE: BOTTOM VIEW OF HOOD SHOWN.
1. HOOD LATCH ASSEMBLY
• ERP22-35VL (ERP045-070VL) (A976) 2. MOUNTING HOLES, NON-SUSPENSION SEAT
• ERP40-50VM, ERP50-55VM6 3. GAS SPRING
(ERP080-120VM, ERP100VML) (A985) 4. HOOD HINGE ASSEMBLY
5. SEAT HARNESS
• ERC40-55VH, ERC50VHS (ERC80-120VH, Figure 85. Seat Removal, Non-Suspension Seat,
ERC100VHS) (A938) Lift Truck Models ERC22-35VG (ERC045-070VG)
(A968)
3. Disconnect chassis harness from seat harness.
Remove four capscrews and washers holding
seat to hood. Remove seat from hood. Remove
spacer bars.
• ERC22-35VG (ERC045-070VG) (A968)
90
NOTE: BOTTOM VIEW OF HOOD SHOWN. NOTE: BOTTOM VIEW OF HOOD SHOWN.
1. HOOD LATCH ASSEMBLY 1. HOOD LATCH ASSEMBLY

2. MOUNTING HOLES, NON-SUSPENSION SEAT 2. MOUNTING HOLES, NON-SUSPENSION SEAT
3. GAS SPRING 3. GAS SPRING
4. HOOD HINGE ASSEMBLY 4. HOOD HINGE ASSEMBLY
5. SEAT HARNESS 5. SEAT HARNESS
Figure 86. Seat Removal, Non-Suspension Seat, Figure 87. Seat Removal, Non-Suspension Seat,
Lift Truck Models and ERP22-35VL Lift Truck Model ERC40-55VH, ERC50VHS
(ERP045-070VL) (A976) ERP40-50VM, (ERC80-120VH, ERC100VHS) (A938)
(A985) 4. Disconnect seat harness from seat sensor. See
Figure 88.
5. Remove two capscrews, washers, and seat

sensor from seat.
91
3. Install seat onto hood using four capscrews,

spacer bars, and washers in correct holes, as
marked during removal. Tighten capscrews to
18 N•m (156 lbf in).
• ERC22-35VG (ERC045-070VG) (A968)
• ERP22-35VL (ERP045-070VL) (A976)
(ERP080-120VM, ERP100VML) (A985)
ERC100VHS) (A938)
4. Connect chassis harness to seat harness.
5. Connect battery and close hood.
Full Suspension and Swivel Seats

1. CAPSCREWS Remove
2. SEAT SENSOR 1. Read and follow WARNING and CAUTION
3. SEAT SENSOR ELECTRICAL CONNECTOR
4. SEAT GROUND WIRE section in General section above.
5. SEAT HARNESS
2. Pull out two pins that secure bottom seat cushion
Figure 88. Seat Sensor, Non- and Semi-Suspension to seat base.
Seat
3. Lift bottom seat cushion up and disconnect seat
Install harness from seat sensor.
1. Using two capscrews and washers, install sensor 4. Use a small, flat-bladed screwdriver and remove
to seat. See Figure 88. seat sensor from seat base. See Figure 89.
2. Connect seat harness to seat sensor.

• ERC22-35VG (ERC045-070VG) (A968)
• ERP22-35VL (ERP045-070VL) (A976)
(ERP080-120VM, ERP100VML) (A985)
ERC100VHS) (A938)
92
STEERING DIRECTION SENSOR

Remove
2. Remove upper steering column cover by pressing

from both sides and pulling cover up and out. See
Figure 96.
3. Disconnect steering wire harness from steering

direction sensor electrical connector. See
Figure 90.
4. Remove two capscrews from steering direction

sensor and remove steering direction sensor from
sensor mounting plate. See Figure 90.
1. SEAT SENSOR
2. CUSHION PINS
3. SEAT HARNESS
4. SEAT BASE
5. TO CHASSIS HARNESS
Figure 89. Seat Sensor, Full Suspension Seat
Install
1. Install new seat sensor into seat base.
2. Connect seat harness to seat sensor. See

Figure 89.
3. Place bottom seat cushion onto seat base and

attach cushion to base with pins.
Figure 90. Steering Direction Sensor
93
Legend for Figure 90. NOTE: Perform Step 2 to Step 4 for lift truck models
1. CAPSCREWS (ERP045-070VL) (A976) , ERP40-80VM
2. STEERING DIRECTION SENSOR (ERP080-100VM) (A985) , and ERC22-35VG
3. LOWER STEERING COLUMN COVER (ERC045-070VG) (A968) manufactured before June
4. SENSOR MOUNTING PLATE
5. STEERING DIRECTION SENSOR ELECTRICAL 2012.
CONNECTOR 2. Remove floor mat. Remove rear floor plate.
Install 3. Remove capscrews and washers from front floor

1. Install new steering direction sensor onto sensor plate and lift front floor plate up enough to
mounting plate. Secure steering direction sensor disconnect accelerator pedal or Foot Directional
to sensor mounting plate with two capscrews. Control pedal. See Figure 44.
See Figure 90.
2. Connect steering wire harness to steering Directional Control pedal still attached.
direction sensor.
NOTE: Perform Step 5 to Step 7 for lift truck models
3. Install steering column upper cover by pressing ERC40-55VH, ERC50VHS (ERC80-120VH,
from both sides and pushing against steering ERC100VHS) (A938) and ERC22-35VG
column lower cover until steering column upper (ERC045-070VG) (A968) manufactured after June
cover snaps into place. See Figure 96. 2012.
4. Connect battery. Adjust steering column for
operator comfort. 6. Lift front floor plate up enough to disconnect
LOAD WEIGHT SENSOR pedal. See Figure 45.
NOTE: The lift trucks covered in this manual may be
equipped with an optional load weight sensor. See
Operating Manual for a more detailed description on
how load weight sensor works. 8. Disconnect harness connector from load weight
sensor.
Remove
1. Read and follow WARNING and CAUTION 9. Remove load weight sensor from T-Fitting on
section in General section above. hydraulic control valve. See Figure 91.
94
NOTE: E-HYDRAULIC CONTROL VALVE SHOWN. RIGHT SIDE SHOWN. LOAD WEIGHT SENSOR IS IN
SAME POSITION ON MANUAL HYDRAULIC CONTROL VALVE.
1. HYDRAULIC CONTROL VALVE 4. HARNESS CONNECTOR

2. T-FITTING 5. FRONT BULKHEAD
3. LOAD WEIGHT SENSOR
Figure 91. Load Weight Sensor
95
Install BATTERY GATE SWITCH

1. Insert new load weight sensor into T-Fitting. NOTE: The lift truck models covered in this manual
Tighten sensor by hand, and then torque sensor may be equipped with a battery restraint system that
to 25 N•m (221 lbf in). may include rollers, a fork lift tray or battery tray, a side
battery lift out gate, or drop-in battery door, or a hinged
2. Connect harness connector to load weight battery gate for horizontal removal of the battery.
sensor. See Figure 91. There is a switch for the side battery gate, located on
right side of lift truck. This switch can be replaced if it
3. Connect accelerator pedal or Foot Directional malfunctions.
NOTE: Read and follow WARNING and CAUTION
NOTE: Perform Step 4 for lift truck models section in General section above.
(ERP045-070VL) (A976) , ERP40-80VM Lift Truck Models ERC22-35VG
(ERP080-100VM) (A985) , and ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA
(ERC045-070VG) (A968) manufactured before June (ERC030-040VA) (A969), and ERC40-55VH,
2012. ERC50VHS (ERC80-120VH, ERC100VHS)
4. Install front floor plate using capscrews and (A938)
washers.
Remove
NOTE: Perform Step 5 and Step 6 for lift truck model 1. Lift up hood and remove battery for access to
ERC40-55VH, ERC50VHS (ERC80-120VH, battery gate switch. See Operating Manual or
ERC100VHS) (A938) and ERC22-35VG service manual Frame 0100YRM1342 for
(ERC045-070VG) (A968) manufactured after June procedures.
2012.
5. No hardware is required to install front floor plate. 2. Remove battery plate that is closest to battery
gate on right side of lift truck frame. See
6. Install rear floor plate. Install floor mat and Figure 92.
7. Re-calibrate load weight sensor. See section

User Interface Service Technician
2200YRM1336 for calibration procedures.
96
Figure 92. Battery Gate Switch Replacement
97

NOTE: LIFT TRUCK MODEL ERC22-35VG (ERC045-070VG) (A968) SHOWN, LIFT TRUCK MODEL
ERC16-20VA (ERC030-040VA) (A969) AND ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938)
SIMILAR.
A. REMOVE BATTERY PLATE B. REPLACE BATTERY GATE SWITCH
1. BATTERY GATE 5. CAPSCREWS

2. BATTERY PLATE 6. BATTERY GATE SWITCH
3. BATTERY ROLLER 7. BRACKET
4. BATTERY GATE SWITCH CONNECTOR AND
WIRE HARNESS
3. Disconnect main wire harness from battery gate 4. Connect the battery.
switch connector and wire harness. See
Figure 92. Remove two capscrews and battery Lift Truck Models ERP22-35VL
gate switch from bracket. (ERP045-070VL) (A976)
Install Remove
1. Install new battery gate switch and two capscrews 1. Lift up hood and remove right side panel. See
on bracket. See Figure 92. Connect main wire Operating Manual or service manual Frame
harness to battery gate connector and wire 0100YRM1342 for procedures.
harness.
2. If lift truck is equipped with hinged door, open
2. Install battery plate into battery compartment. door until it latches in open position. See
Operator Manual or service manual Frame
3. Install battery and close hood. See Operating 0100YRM1342 for procedures.
Manual or service manual Frame 0100YRM1342
for procedures. 3. Disconnect main wire harness from battery gate
switch. See Figure 93 or Figure 94.
98
1. CAPSCREWS 5. BRACKET
2. LIFTOUT BATTERY GATE 6. BATTERY GATE SWITCH CONNECTOR AND
3. BATTERY RETENTION ROD WIRE HARNESS
4. BATTERY GATE SWITCH 7. GROMMET
Figure 93. Liftout Battery Gate Switch Replace, Lift Truck Models ERP22-35VL (ERP045-070VL) (A976)
99
1. CAPSCREWS 5. BATTERY GATE SWITCH

2. WASHER 6. BRACKET
3. HINGED BATTERY GATE 7. BATTERY GATE SWITCH CONNECTOR AND
Figure 94. Hinged Battery Gate Switch Replace, Lift Truck Models ERP22-35VL (ERP045-070VL) (A976)
4. Remove two capscrews and two washers from 3. Install right side panel. See Operating Manual or
battery gate switch. Remove battery gate switch service manual Frame 0100YRM1342 for
from bracket. See Figure 93 or Figure 94. procedures.
Install 4. If lift truck is equipped with hinged door, close

door. See Operating Manual or service manual
1. Install new battery gate switch to bracket with two Frame 0100YRM1342 for procedures.
washers and two capscrews. See Figure 93 or
Figure 94. 5. Connect the battery and close the hood.
2. Connect main wire harness to battery gate switch
connector.
100
Lift Truck Models ERP40-50VM, 2. If lift truck is equipped with hinged door, open
ERP50-55VM6 (ERP080-120VM, door until it latches in open position. See
Operator Manual for procedures.
ERP100VML) (A985)
Remove 3. Disconnect main wire harness from battery gate
switch. See Figure 95.
1. Lift up hood and remove right side panel. See
Operating Manual or service manual Frame
NOTE: LIFT TRUCKS EQUIPPED WITH DROP-IN BATTERY DOOR SHOWN. BATTERY GATE SWITCH ON
LIFT TRUCKS EQUIPPED WITH HINGED BATTERY DOOR IS SIMILAR.
NOTE: ONLY LIFT TRUCK MODELS ERP080-120VM, ERP100VML (A985) CAN BE EQUIPPED WITH DROP-
IN BATTERY DOOR.
1. CAPSCREWS 5. BRACKET
2. DROP-IN BATTERY DOOR 6. BATTERY GATE SWITCH CONNECTOR AND
4. BATTERY GATE SWITCH 7. GROMMET
Figure 95. Battery Gate Switch Replace, Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM,
ERP100VML) (A985)
4. Remove two capscrews and two grommets from 6. If lift truck is equipped with hinged door, close
battery gate switch. Remove battery gate switch door. See Operating Manual.
from bracket. See Figure 95.
7. Connect the battery and close the hood.
5. Install right side panel. See Operating Manual or
service manual Frame 0100YRM1342 for
procedures.
101
Install
1. Install new battery gate switch to bracket with two
grommets and two capscrews. See Figure 95.
2. Connect main wire harness to battery gate switch

connector. See Figure 95.
3. Install right side panel. See Operating Manual or

service manual Frame 0100YRM1342 for
procedures.
4. If lift truck is equipped with hinged door, close

door. See Operating Manual.
5. Connect the battery and close the hood.
HORN SWITCH
NOTE: The procedures below are for replacing horn
switch and horn switch mechanism located on steering
column. If your lift truck is equipped with E-Hydraulic
mini-levers, there is an option for a horn button on the 1. STEERING COLUMN UPPER COVER
armrest. See section Electronic and Manual Hydraulic 2. CLIP
Controls for procedures to replace horn sensor on the 3. STEERING COLUMN LOWER COVER
E-Hydraulic armrest. 4. CAPSCREW
5. STEERING COLUMN TOP COVER
6. DASH PANEL
Fixed Steering Column 7. TILT POSITION LEVER
Remove Figure 96. Steering Column Covers
section in General section above. 3. Disconnect steering wire harness from horn
switch. Remove capscrews, washers, and tapped
2. Remove upper steering column cover by pressing plate from horn switch. Remove horn switch from
from both sides and pulling cover up and out. See horn switch plate. See Figure 97.
Figure 96.
102
Install
1. Install new horn switch, tapped plate, washers,
and capscrews to horn switch plate. See
Figure 97.

ERP22-35VL (ERP045-070VL) (A976) , equipped with
Outdoor Protection/ Wash-down Package.
2. Apply dielectric grease to horn switch terminal.
3. Connect steering wire harness to horn switch.
4. Install steering column upper cover by pressing

from both sides and pushing against steering
column lower cover until steering column upper
cover snaps into place. See Figure 96.
Telescopic Steering Column

Remove
2. Remove horn button, nut, and rod from steering

wheel. See Figure 98.
NOTE: FIXED STEERING COLUMN SHOWN. HORN

SWITCH ON OPTIONAL TELESCOPIC STEERING
COLUMN IS THE SAME.
1. FIXED STEERING COLUMN

2. HORN SWITCH PLATE
3. PIN
4. RETAINING RING
5. SPRING
6. SWITCH CONTACT WASHER
7. SNAP RING
8. CAPSCREW 1. HORN BUTTON
9. WASHER 2. NUT
10. HORN SWITCH 3. ROD
11. TAPPED PLATE 4. STEERING WHEEL
Figure 97. Horn Switch Figure 98. Horn Button Assembly and Electrical
Connections
103
3. Remove hex nut and steering wheel from steering 5. Install steering column upper cover by pressing
column. If necessary, use a puller tool to remove from both sides and pushing against steering
steering wheel. See Figure 99. column lower cover until steering column upper
cover snaps into place. See Figure 96.
6. Install steering wheel and hex nut on steering

column. Tighten nut 40 to 54 N•m (30 to 40 lbf ft).
See Figure 99.
7. Install rod, nut, and horn button in steering wheel.

See Figure 98.
IMPACT SENSOR
(ERP045-070VL) (A976) and ERP40-50VM,
ERP50-55VM6 (ERP080-120VM,
1. HEX NUT
2. STEERING WHEEL ERP100VML) (A985)
3. STEERING COLUMN UPPER COVER
4. STEERING COLUMN LOWER COVER Remove
5. STEERING COLUMN TOP COVER NOTE: The impact sensor is located on right side of
lift truck between right tilt anchor plate and right front
Figure 99. Steering Wheel
overhead guard mounting plate. See Figure 100.
4. Remove upper steering column cover by pressing
from both sides and pulling cover up and out. See
Figure 96.
5. Remove four mounting capscrews and steering

column top cover from steering column plate. See
Figure 99.
6. Disconnect steering wire harness from horn

switch. Remove capscrews, washers, and tapped
plate from horn switch. Remove horn switch from
horn switch plate. See Figure 97.
Install
1. Install new horn switch, tapped plate, washers,
and capscrews to horn switch plate. See
Figure 97. 1. RIGHT FRONT OVERHEAD GUARD MOUNTING
PLATE
NOTE: Perform Step 2 for lift truck models 2. RIGHT TILT ANCHOR PLATE
ERP22-35VL (ERP045-070VL) (A976) , equipped with 3. PLATE
Outdoor Protection/ Wash-down Package. 4. IMPACT SENSOR
2. Apply dielectric grease to horn switch terminal. Figure 100. Impact Sensor Location, Lift Truck
Models and ERP22-35VL (ERP045-070VL)
3. Connect steering wire harness to horn switch. (A976) ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985)
4. Install steering column top cover and four
mounting capscrews on steering column plate.
See Figure 99.
104
NOTE: Read and follow WARNING and CAUTION 3. Going through the opening in right tilt anchor
section in General section above. plate (see Figure 100), disconnect main wire
harness from impact sensor.
NOTE: Note placement and orientation of impact
2. Remove capscrews and washers from front floor sensor prior to removal to aid in installation.
4. Remove two impact sensor mounting capscrews
and impact sensor from impact sensor mounting
Control pedal. See Figure 44. Remove front floor
bracket. See Figure 101.
plate with accelerator or Foot Directional Control
pedal still attached.
NOTE: RIGHT ANCHOR TILT PLATE AND OTHER FRAME COMPONENTS OMITTED FOR CLARITY.
1. RIGHT FRONT OVERHEAD GUARD 4. IMPACT SENSOR MOUNTING CAPSCREW

MOUNTING PLATE 5. IMPACT SENSOR
2. PLATE 6. IMPACT SENSOR CONNECTOR
3. IMPACT SENSOR MOUNTING BRACKET
Figure 101. Impact Sensor Replace, Lift Truck Models and ERP22-35VL (ERP045-070VL)
(A976) ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)
105
Install 2. Remove floor mat. Remove rear floor plate.

1. Install new impact sensor and two impact sensor 3. Remove capscrews and washers from front floor
mounting capscrews on impact sensor mounting plate and lift front floor plate up enough to
bracket as noted during removal. See Figure 101. disconnect accelerator pedal or Foot Directional
2. Connect main wiring harness to impact sensor as
tagged during removal. 4. Remove front floor plate with accelerator or Foot
Control pedal, and install front floor plate using NOTE: Perform Step 5 to Step 7 for lift truck models
capscrews and washers. ERC22-35VG (ERC045-070VG) (A968) manufactured
after June 2012:
4. Install rear floor plate and floor mat. See
Figure 44. 5. Remove floor mat. Remove rear floor plate.
5. Connect the battery. 6. Lift front floor plate up enough to disconnect

Lift Truck Models ERC22-35VG pedal. See Figure 45.
(ERC045-070VG) (A968) and ERC16-20VA 7. Remove front floor plate with accelerator or Foot
(ERC030-040VA) (A969) Directional Control pedal still attached.
NOTE: The impact sensor is located on right side of
lift truck on a mounting plate that is mounted to the 8. Disconnect main wire harness from impact
inside of the right frame channel. sensor. See Figure 102.

Remove
sensor prior to removal to aid in installation.
9. Remove three mounting plate capscrews and
mounting plate with impact sensor from lift truck.
NOTE: Perform Step 2 to Step 4 for lift trucks models
10. Remove two impact sensor capscrews and
ERC16-20VA (ERC030-040VA) (A969) and
impact sensor from mounting plate. See
Figure 102.
before June 2012.
106
NOTE: LIFT TRUCK MODEL ERC22-35VG (ERC045-070VG) (A968) SHOWN, LIFT TRUCK MODEL
ERC16-20VA (ERC030-040VA) (A969) SIMILAR.
1. TILT ANCHOR PLATE 5. MOUNTING PLATE

2. MOUNTING PLATE CAPSCREWS 6. IMPACT SENSOR CONNECTOR
3. IMPACT SENSOR CAPSCREWS 7. MAIN WIRING HARNESS CONNECTOR
4. IMPACT SENSOR
Figure 102. Impact Sensor Replace, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968)
Install 4. Connect accelerator pedal or Foot Directional

1. Install new impact sensor and two impact sensor
capscrew on mounting plate. See Figure 102. NOTE: Perform Step 5 for lift truck models
ERC16-20VA (ERC030-040VA) (A969) and
2. Install mounting plate, with new impact sensor ERC22-35VG (ERC045-070VG) (A968) manufactured
attached, and three mounting plate capscrews on before June 2012.
right frame channel.
3. Connect main wiring harness to impact sensor as washers.
tagged during removal.
107
NOTE: Perform Step 6 and Step 7 for lift truck model Lift Truck Model ERC40-55VH, ERC50VHS
ERC22-35VG (ERC045-070VG) (A968) manufactured (ERC80-120VH, ERC100VHS) (A938)
after June 2012.
6. No hardware is required to install front floor plate.
Remove
NOTE: The impact sensor is located on the left side of
7. Install rear floor plate. Install floor mat. lift truck between the left tilt anchor plate and left front
overhead guard mounting plate. See Figure 103.
1. LEFT TILT ANCHOR PLATE 5. IMPACT SENSOR CONNECTOR

2. MOUNTING PLATE 6. IMPACT SENSOR CAPSCREW
3. MOUNTING PLATE CAPSCREW 7. IMPACT SENSOR
4. MAIN WIRING HARNESS CONNECTOR
Figure 103. Impact Sensor Location, Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938)
1. Read and follow WARNING and CAUTION 3. Lift front floor plate up enough to disconnect
section in General section above. accelerator pedal or Foot Directional Control
pedal. See Figure 45.
108
5. Disconnect main wire harness from impact


sensor prior to removal to aid in installation.
6. Remove two impact sensor capscrews and
remove impact sensor from mounting plate. See
Figure 103.
Install
1. Install new impact sensor to mounting plate with
two impact sensor capscrews. See Figure 103.
2. Connect main wiring harness to impact sensor as

tagged during removal.

Control pedal, and install front floor plate.
4. Install rear floor plate.
5. Install floor mat. See Figure 54.
REAR AND HOOD HORN BUTTON

SWITCHES
NOTE: The procedures below are for replacing the
optional horn switch located in the rear handle on rear
right overhead guard leg or in the handle located on NOTE: RIGHT HOOD MOUNTING BRACKET OMIT-
right side of hood. Lift truck models ERC32-35VG TED FOR CLARITY.
(ERC065-070VG) (A968) and ERP40-80VM
(ERP080-100VM) (A985) are the only trucks that may 1. CAPSCREWS
be equipped with a horn button on hood. 2. REAR HORN BUTTON
3. RIGHT REAR OVERHEAD GUARD LEG
If your lift tucks is equipped with E-Hydraulic mini- 4. REAR HANDLE
levers, there is an optional horn button on armrest. 5. REAR HORN SWITCH CONNECTOR
See section Electronic and Manual Hydraulic Controls 6. HOOD
for procedures to replace horn sensor on E-Hydraulic 7. LEFT HOOD MOUNTING BRACKET
armrest.
Figure 104. Rear Horn Button Switch Arrangement
Rear Horn Button Switch 3. Remove two capscrews that attach rear handle to
Remove right rear overhead guard leg. See Figure 104.
Remove handle from right rear overhead guard
1. Read and follow WARNING and CAUTION leg.
4. Remove rear horn button switch and horn
2. Raise hood, and reach underneath right hood harness from the back of rear handle. See
mounting bracket to disconnect main wiring Figure 105.
harness from rear horn button switch. See
Figure 104.
109
Install
1. Install new rear horn button switch and horn
harness into rear handle.
2. Thread horn harness and connector end through

right overhead guard leg so that connector end
comes out the hole and into right hood mounting
bracket. See Figure 104.
3. Using two capscrews, attach rear handle and new

horn button switch to right rear overhead guard
leg. See Figure 105.
4. Connect main wire harness to rear horn switch

connector. Close and secure hood.
Hood Horn Button Switch

NOTE: The hood horn button switch is an option
found only on lift truck models ERC32-35VG
(ERC065-070VG) (A968) and ERC40-55VH,
Remove
2. Raise hood and disconnect main wire harness

from hood horn switch connector. See Figure 106.
1. RIGHT REAR OVERHEAD GUARD LEG
2. REAR HORN BUTTON SWITCH AND HORN 3. Close hood and remove two capscrews from rear
HARNESS handle. See Figure 106. Remove rear handle
3. REAR HANDLE from hood.
Figure 105. Rear Horn Button Switch Replace
110
1. HOOD HORN SWITCH CONNECTOR 4. HOOD HORN BUTTON SWITCH

2. CAPSCREWS 5. HOOD
3. REAR HANDLE
Figure 106. Hood Horn Button Switch Arrangement
4. Remove hood horn button switch and horn 3. Raise hood and connect hood horn switch
harness from rear handle. See Figure 105. connector to main wiring harness.
Install 4. Close hood after connecting the hood horn switch

to main wiring harness.
1. Install new hood horn button switch and horn
harness into rear handle. See Figure 105. 5. Connect the battery.
2. Thread hood horn switch connector and horn
harness through the hole in hood and using two
capscrews, install rear handle to hood. See
Figure 106.
111
Motor Controllers Replacement 2200 YRM 1369
Motor Controllers Replacement

GENERAL See Figure 109 for lift truck models
• ERC045-070VG (A968) manufactured after
November 2014.
WARNING
Before replacing any of the motor controllers, fully
lower all parts of the mast and tilt it forward until • ERP22-35VL (ERP045-070VL) (A976) ,
the tips of the forks touch the ground. This action manufactured before February, 2009
will prevent the mast from lowering suddenly if the See Figure 111 for lift truck models
• ERP22-35VL (ERP045-070VL) (A976) ,
manufactured after February, 2009
WARNING See Figure 112 for lift truck models

Discharge capacitors as directed in Discharging • ERP22-35VL (ERP045-070VL) (A976) ,
the Capacitors in General section at the beginning manufactured after November 2014
of this manual. See Figure 113 for lift truck model
Disconnect the battery before doing any work on • ERP22-35VL (ERP045-070VL) (A976) ,
the electrical system. Serious injury to personnel manufactured after November 2015
and/or damage to lift truck components can occur See Figure 114 for lift truck models
• ERP40-80VM (ERP080-100VM) (A985)
CAUTION See Figure 115 for lift truck models
A short circuit and damage can occur if wires are • ERP40-50VM, ERP50-55VM6
not installed correctly. Make sure wire connectors (ERP080-120VM, ERP100VML) (A985)
do not touch the other metal terminals or wire manufactured after November 2014
connectors, metal brackets, or the bracket See Figure 116 for lift truck models
mounting nuts. Make sure the wires are not pulled
tight and are not touching other parts to damage • ERC16-20VA (ERC030-040VA) (A969)
the insulation. manufactured before November 2014
• ERC030-040VA (A969) manufactured after
CAUTION November 2014
DO NOT remove the small screws that fasten the
cover of the motor controller.
Make sure there is no dirt between the plate of the ERC100VHS) (A938) manufactured before
motor controller and the mount surface of the lift November 2014
truck frame.
The hydraulic pump and motor controller and traction • ERC80-120VH, ERC100VHS (A938)
motor controller, control and monitor the electrical manufactured after November 2014
function for their respective components.
Before replacing any motor controllers, follow
See Figure 107 for lift truck models capacitor discharge procedure outlined in Discharging
• ERC22-35VG (ERC045-070VG) (A968) the Capacitors in the General section of this manual.
manufactured before September, 2012. Attach a tag to truck battery connector stating DO NOT
CONNECT BATTERY. Remove the key or turn the
See Figure 108 for lift truck models keyless switch OFF.
• ERC22-35VG (ERC045-070VG) (A968)
manufactured after September, 2012.
112
2200 YRM 1369 Motor Controllers Replacement
Make an identification for correct connection of the disconnected prior to removing the controller. This will
power cables on the power terminals of the motor aid in reconnecting during installation.
controller and all electrical connections that are
1. FANS 6. HYDRAULIC PUMP AND MOTOR POWER

2. HYDRAULIC PUMP AND MOTOR CABLES
CONTROLLER 7. VEHICLE SYSTEM MANAGER
3. LINE CONTACTOR 8. TRACTION MOTOR
4. TRACTION MOTOR CONTROLLER 9. HYDRAULIC PUMP AND MOTOR
5. TRACTION MOTOR POWER CABLES 10. HYDRAULIC TANK
Figure 107. Motor Controllers and Electrical Components Arrangement, Lift Truck Models , Manufactured
Before September 2012ERC22-35VG (ERC045-070VG) (A968)
113

After September 2012ERC22-35VG (ERC045-070VG) (A968)
114
NOTE: BULKHEAD REMOVED FOR CLARITY.

After November 2014ERC045-070VG (A968)
115
1. VEHICLE SYSTEM MANAGER MOUNTING 6. HYDRAULIC PUMP AND MOTOR

PLATE 7. LINE CONTACTOR
2. TRACTION MOTOR CONTROLLERS 8. HYDRAULIC TANK
3. HEATSINK 9. HYDRAULIC PUMP AND MOTOR CONTROLLER
4. FANS 10. POWER CABLES
5. DRIVE AXLE ASSEMBLY
Before February 2009
116
A. ELECTRICAL COMPONENTS FOR LIFT TRUCK MODELS ERP22-35VL (ERP045-070VL) (A976) ,

EQUIPPED WITH OUTDOOR PROTECTION/WASH-DOWN PACKAGE, MANUFACTURED AFTER
OCTOBER, 2013

PLATE 7. LINE CONTACTOR
2. TRACTION MOTOR CONTROLLERS 8. HYDRAULIC TANK
3. HEATSINK 9. HYDRAULIC PUMP AND MOTOR CONTROLLER
4. FANS 10. POWER CABLES
5. DRIVE AXLE ASSEMBLY
After February 2009ERP22-35VL (ERP045-070VL) (A976)
117
1. VEHICLE SYSTEM MANAGER MOUNTING 6. LINE CONTACTOR

PLATE 7. HYDRAULIC TANK
2. TRACTION MOTOR CONTROLLERS 8. HYDRAULIC PUMP AND MOTOR CONTROLLER
4. DRIVE AXLE ASSEMBLY CABLES
5. HYDRAULIC PUMP AND MOTOR 10. TRACTION MOTOR POWER CABLES
After November 2014ERP22-35VL (ERP045-070VL) (A976)
118
1. VEHICLE SYSTEM MANAGER MOUNTING 6. LINE CONTACTOR

PLATE 7. HYDRAULIC TANK
2. TRACTION MOTOR CONTROLLERS 8. HYDRAULIC PUMP AND MOTOR CONTROLLER
4. DRIVE AXLE ASSEMBLY CABLES
After November 2015ERP22-35VL (ERP045-070VL) (A976)
119
1. DRIVE AXLE ASSEMBLY 6. POWER CABLES

2. TRACTION MOTOR CONTROLLER 7. LINE CONTACTOR
3. HEAT SINK 8. HYDRAULIC PUMP AND MOTOR CONTROLLER
4. FANS 9. HYDRAULIC TANK
PLATE
Figure 114. Motor Controllers and Electrical Components Arrangement, Lift Truck Models, Manufactured
Before November 2014ERP40-80VM (ERP080-100VM) (A985)
120
1. DRIVE AXLE ASSEMBLY 6. POWER CABLES

2. TRACTION MOTOR CONTROLLER 7. LINE CONTACTOR
3. HEAT SINK 8. HYDRAULIC PUMP AND MOTOR CONTROLLER
4. FANS 9. HYDRAULIC TANK
PLATE
Figure 115. Motor Controllers and Electrical Components Arrangement, Lift Truck Models, Manufactured
After November 2014ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)
121
1. VEHICLE SYSTEM MANAGER 6. FANS

2. HYDRAULIC PUMP AND MOTOR 7. LINE CONTACTOR
CONTROLLER 8. TRACTION MOTOR CONTROLLER
4. HYDRAULIC PUMP AND MOTOR POWER 10. TRACTION MOTOR
CABLES
5. HYDRAULIC TANK
Figure 116. Motor Controllers and Electrical Components Arrangement for Lift Truck Models
Manufactured Before November 2014ERC16-20VA (ERC030-040VA) (A969)
122

CABLES
5. HYDRAULIC TANK
Manufactured After November 2014ERC030-040VA (A969)
123
1. LINE CONTACTOR 6. HYDRAULIC PUMP AND MOTOR POWER

2. FANS CABLES
3. TRACTION MOTOR CONTROLLER 7. HYDRAULIC TANK
4. HYDRAULIC PUMP AND MOTOR 8. VEHICLE SYSTEM MANAGER
CONTROLLER 9. HYDRAULIC PUMP AND MOTOR
5. TRACTION MOTOR POWER CABLES 10. TRACTION MOTOR
Figure 118. Motor Controllers and Electrical Components Arrangement, Lift Truck Model Manufactured
Before November 2014ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938)
124

2. FANS CABLES
Figure 119. Motor Controllers and Electrical Components Arrangement, Lift Truck Model Manufactured
After November 2014ERC80-120VH, ERC100VHS (A938)
125
LIFT TRUCK MODELS ERC22-35VG See Figure 123 for lift truck models
(ERC045-070VG) (A968) AND ERC16-20VA • ERC16-20VA (ERC030-040VA) (A969)
(ERC030-040VA) (A969) manufactured before November 2014
Traction Motor and Hydraulic Pump and
Motor Controllers • ERC030-040VA (A969) manufactured after
November 2014.
Remove
1. Read and follow the WARNING and CAUTION ERC22-35VG (ERC045-070VG) (A968) ,
section in the General section above. manufactured before September, 2012, and lift truck
models ERC16-20VA (ERC030-040VA) (A969)
2. Remove the battery for access to the motor
manufactured before November 2014.
controllers. See the Operating Manual or service
manual 5. Remove eight flange capscrews from motor
controllers. Remove motor controllers from
heatsink.
truck models
• ERC22-35VG (ERC045-070VG) (A968)
• ERC22-35VG (ERC045-070VG) (A968)
Periodic Maintenance 8000YRM1442 for lift manufactured before September, 2012
truck models
• ERC16-20VA (ERC030-040VA) (A969)
• ERC16-20VA (ERC030-040VA) (A969)
3. Remove the plate that is in front of the motor manufactured before November 2014
controllers.
NOTE: Make sure all power cables and electrical ERC22-35VG (ERC045-070VG) (A968) ,
connections are clearly marked before disconnecting manufactured after September, 2012 and lift truck
them to help in reconnecting. models ERC045-070VG (A968) and ERC030-040VA
(A969) manufactured after November 2014.
4. Disconnect the power cables and all electrical
connections from the motor controllers. 6. Remove eight flange capscrews from motor
controllers and heatsink. Remove motor
See Figure 120 for lift truck models controllers and heatsink from mounting bracket.
manufactured before September, 2012.
• ERC22-35VG (ERC045-070VG) (A968)
See Figure 121 for lift truck models manufactured after September, 2012
manufactured after September, 2012.
See Figure 122 for lift truck models November 2014
• ERC045-070VG (A968) manufactured after See Figure 124 for lift truck models
November 2014.
November 2014
126
NOTE: STANDARD PERFORMANCE MOTOR CONTROLLER PANELS SHOWN. ENHANCED PERFORM-

ANCE MOTOR CONTROLLER PANELS ARE SIMILAR.
1. FLANGE CAPSCREW 8. FAN CONNECTORS

2. HYDRAULIC PUMP DRIVE MOTOR 9. CONTACTOR
CONTROLLER 10. FUSE COVER
3. TRACTION MOTOR CONTROLLER 11. CONTROLLER ELECTRICAL CONNECTORS
4. POWER CABLE U 12. AIR DUCT
5. POWER CABLE V 13. FAN TO AIR DUCT
6. POWER CABLE W
7. FANS
Figure 120. Motor Controllers Replace for Lift Truck Models , Manufactured Before September,
2012ERC22-35VG (ERC045-070VG) (A968)
127


4. POWER CABLE U 12. HEATSINK
5. POWER CABLE V 13. FAN AIR DUCT
6. POWER CABLE W 14. MOTOR CONTROLLERS MOUNTING BRACKET
7. FANS
Figure 121. Motor Controllers Replace for Lift Truck Models , Manufactured After September,
2012ERC22-35VG (ERC045-070VG) (A968)
128
Figure 122. Motor Controllers Replace for Lift Truck Models , Manufactured After November
2014ERC045-070VG (A968)
129


4. POWER CABLE U 12. MOTOR CONTROLLERS MOUNTING BRACKET
6. POWER CABLE W
7. FANS
130


2. HYDRAULIC PUMP AND MOTOR 9. CONTACTOR
4. POWER CABLE U 12. HEATSINK
5. POWER CABLE V 13. FAN SPACER
6. POWER CABLE W
7. FANS
Figure 123. Motor Controllers Replace for Lift Truck Models Manufactured Before November
2014ERC16-20VA (ERC030-040VA) (A969)
131
Figure 124. Motor Controllers Replace for Lift Truck Models Manufactured After November
2014ERC030-040VA (A969)
132

1. FLANGE CAPSCREW 7. FANS

2. HYDRAULIC PUMP AND MOTOR 8. FAN CONNECTORS
CONTROLLER 9. CONTACTOR
3. TRACTION MOTOR CONTROLLER 10. FUSE COVER
4. POWER CABLE U 11. CONTROLLER ELECTRICAL CONNECTORS
6. POWER CABLE W

NOTE: The information in Step 1 and Step 2 applies • ERC22-35VG (ERC045-070VG) (A968)
to lift truck models ERC22-35VG (ERC045-070VG) manufactured after September, 2012
(A968) , manufactured before September, 2012, and See Figure 122 for lift truck models
lift truck models ERC16-20VA (ERC030-040VA)
(A969) manufactured before November 2014. November 2014
1. Before installing new motor controllers to See Figure 124 for lift truck models
heatsink, clean motor controllers and heatsink
mating surfaces to ensure they are clean and free • ERC030-040VA (A969) manufactured after
of any debris or paint. Apply 1.5 mm (0.06 in.) November 2014
coat of silicon grease (Yale Part No. 580076898)
4. Connect the fans and other electrical connections
to baseplate of motor controllers and heatsink
as noted during removal. Connect power cables
mating surface. The silicon grease should cover
at the power terminals of the motor controllers as
at least 90% of controller baseplate.
identified during removal. Tighten power cables to
18 to 21 N•m (159 to 186 lbf in).
2. Install new motor controllers to heatsink using
eight flange capscrews. Tighten flange capscrews
5. Install the plate in front of the motor controllers
to 13.5 to 17.5 N•m (119. to 155 lbf in).
using four capscrews.
6. Install the battery in lift truck. See the Operating
• ERC22-35VG (ERC045-070VG) (A968)
manufactured before September, 2012 Manual or service manual
See Figure 123 for lift truck models Periodic Maintenance 8000YRM1364 for lift
truck models
• ERC16-20VA (ERC030-040VA) (A969)
manufactured before November 2014 • ERC22-35VG (ERC045-070VG) (A968)
NOTE: The information in Step 3 applies to lift truck truck models
models ERC22-35VG (ERC045-070VG) (A968) ,
manufactured after September, 2012 and lift truck • ERC16-20VA (ERC030-040VA) (A969)
models ERC045-070VG (A968) and ERC030-040VA
(A969) manufactured after November 2014. 7. Connect the battery.
3. Install new motor controllers and heatsink to

motor controllers mounting bracket using eight
flange capscrews. Tighten flange capscrews to
5.5 to 8.5 N•m (49 to 75 lbf in).
133
LIFT TRUCK MODELS ERP22-35VL

(ERP045-070VL) (A976) AND ERP40-50VM,
ERP50-55VM6 (ERP080-120VM,
ERP100VML) (A985)
Hydraulic Pump and Motor Controller
Remove
1. Read and follow the WARNING and CAUTION
section in the General section above.
2. Remove the battery for access to the hydraulic

pump and motor controller. See the Operating
Manual or service manual below for battery
removal procedures.
truck models
• ERP22-35VL (ERP045-070VL) (A976)
truck models
(ERP080-120VM, ERP100VML) (A985)
3. Remove the counterweight cover and tow pin for

access to the hydraulic pump and motor
controller. See Figure 125 or Figure 126.
NOTE: COUNTERWEIGHT FOR LIFT TRUCK MOD-

COUNTERWEIGHT FOR LIFT TRUCK MODELS
1. COUNTERWEIGHT
3. WASHER
4. CAPSCREWS
5. TOW PIN
Figure 125. Counterweight Cover Removal
134
NOTE: Make sure all power cables and electrical

connections are clearly marked before disconnecting
them to help aid in reconnecting.
4. Disconnect the power cables and all electrical
connections from hydraulic pump and motor
controller.
• ERP22-35VL (ERP045-070VL) (A976) ,
manufactured before February, 2009
• ERP22-35VL (ERP045-070VL) (A976) ,
manufactured after February, 2009
• ERP22-35VL (ERP045-070VL) (A976)
• ERP40-80VM (ERP080-100VM) (A985)
(ERP080-120VM, ERP100VML) (A985)
1. TOW PIN 5. For lift truck models manufactured before

2. KNOB SCREWS November 2014, remove four flange capscrews
3. COUNTERWEIGHT COVER from motor controller. Remove motor controller
4. COUNTERWEIGHT from heatsink and lift truck frame.
Figure 126. Counterweight Cover Removal for Lift For lift truck models manufactured after
Truck Model Manufactured After November, November 2014, remove four flange capscrews
2015ERP22-35VL (ERP045-070VL) (A976) from motor controller and heatsink. Remove
motor controller and heatsink from lift truck frame.
135
NOTE: STANDARD PERFORMANCE HYDRAULIC PUMP AND MOTOR CONTROLLER PANEL SHOWN. EN-
HANCED PERFORMANCE HYDRAULIC PUMP AND MOTOR CONTROLLER PANEL IS SIMILAR.
1. FANS 8. POWER CABLE W

2. FAN CONNECTORS 9. HYDRAULIC PUMP AND MOTOR
3. AIR DUCT 10. CONTACTOR
4. FLANGE CAPSCREW 11. CONTROLLER ELECTRICAL CONNECTORS
5. HYDRAULIC PUMP AND MOTOR 12. HYDRAULIC TANK
CONTROLLER 13. FAN SPACER
6. POWER CABLE U
7. POWER CABLE V
Figure 127. Hydraulic Pump and Motor Controller Replace, Lift Truck Models , Manufactured Before
February, 2009ERP22-35VL (ERP045-070VL) (A976)
136
A. ELECTRICAL COMPONENTS FOR LIFT TRUCK MODELS ERP22-35VL (ERP045-070VL) (A976) ,

EQUIPPED WITH OUTDOOR PROTECTION/WASH-DOWN PACKAGE, MANUFACTURED AFTER
OCTOBER, 2013
1. FANS 7. POWER CABLE V

2. FAN CONNECTORS 8. POWER CABLE W
3. AIR DUCT 9. HYDRAULIC PUMP AND MOTOR
4. FLANGE CAPSCREW 10. LINE CONTACTOR
5. HYDRAULIC PUMP AND MOTOR 11. CONTROLLER ELECTRICAL CONNECTORS
CONTROLLER 12. HYDRAULIC TANK
6. POWER CABLE U
Figure 128. Hydraulic Pump and Motor Controller Replace, Lift Truck Models , Manufactured After
February, 2009ERP22-35VL (ERP045-070VL) (A976)
137
Figure 129. Hydraulic Pump and Motor Controller Replace, Lift Truck Models Manufactured After
November 2014ERP22-35VL (ERP045-070VL) (A976)
138


2. FAN CONNECTORS 8. POWER CABLE U
CONTROLLER
6. POWER CABLE W
1. CONTACTORS 7. CONTROLLER ELECTRICAL CONNECTORS

2. POWER CABLE W 8. FLANGE CAPSCREW
3. FANS 9. AIR DUCT
4. FAN CONNECTOR 10. HYDRAULIC PUMP AND MOTOR CONTROLLER
5. POWER CABLE V 11. HYDRAULIC TANK
6. POWER CABLEU
Figure 130. Hydraulic Pump and Motor Controller Replace, Lift Truck Models Manufactured Before
November 2014ERP40-80VM (ERP080-100VM) (A985)
139

3. FANS 9. AIR DUCT
6. POWER CABLEU
Figure 131. Hydraulic Pump and Motor Controller Replace, Lift Truck Models Manufactured After
November 2014ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)
Install 2. Install new hydraulic pump and motor controller

onto heatsink with four flange capscrews. Tighten
NOTE: Step 1 and Step 2 apply to lift trucks flange capscrews to
manufactured before November 2014. 13.5 to 17.5 N•m (119 to 155 lbf in).
1. Before installing new motor controller to heatsink, See Figure 127 for lift truck models
clean motor controller and heatsink mating
surface to ensure it is clean and free of any debris • ERP22-35VL (ERP045-070VL) (A976) ,
or paint. Apply 1.5 mm (0.06 in.) coat of silicon manufactured before February, 2009
grease (Yale Part No. 580076898) to baseplate See Figure 128 for lift truck models
of motor controller and heatsink mating surface.
• ERP22-35VL (ERP045-070VL) (A976) ,
The silicon grease should cover at least 90% of manufactured after February, 2009
controller baseplate.
140
See Figure 130 for lift truck models Periodic Maintenance 8000YRM1372 for lift
ERP40-80VM (ERP080-100VM) (A985) truck models
•
manufactured before November 2014 • ERP22-35VL (ERP045-070VL) (A976)
NOTE: Step 3 applies to lift trucks manufactured after Periodic Maintenance 8000YRM1541 for lift
November 2014 truck models
3. Install new motor controller and heatsink to motor • ERP40-50VM, ERP50-55VM6

(ERP080-120VM, ERP100VML) (A985)
controller mounting bracket using four flange
capscrews. Tighten flange capscrews to
7. Install the tow pin and counterweight cover using
5.8 to 8.5 N•m (49 to 75 lbf in).
two capscrews. See Figure 125 or Figure 126.
• ERP22-35VL (ERP045-070VL) (A976) ,
9. For lift truck models ERP22-35VL
See Figure 131 for lift truck models (ERP045-070VL) (A976) , equipped with Outdoor
• ERP40-50VM, ERP50-55VM6 Protection/Wash-down package, spray battery
(ERP080-120VM, ERP100VML) (A985) connectors terminals with rust inhibitor-ignition
manufactured after November 2014 sealer, after tightening terminals.
NOTE: Apply dielectric grease to the controller wiring 10. After install complete, perform ground test. See
harness connector for lift truck models ERP22-35VL Frame 0100YRM1342, Ground Test section.
(ERP045-070VL) (A976) , equipped with Outdoor
Protection/ Wash-down Package. See Figure 128. Traction Motor Controllers
4. Connect the fans and other electrical connections Remove
at the power terminals of the hydraulic pump and 1. Read and follow the WARNING and CAUTION
motor controller as identified during removal. section in the General section above.
Tighten power cables to
2. Remove two bolts and belly pan from underside
18 to 21 N•m (159 to 186 lbf in).
of lift truck.
3. Disconnect motor controller connector from main
wiring harness.
Protection/ Wash-down Package, spray power
cable terminals on controller with rust inhibitor-
4. Remove the floor mat. Remove rear floor plate.
ignition sealer.
Remove capscrews and washers from front floor
6. Install the battery into the lift truck. See the
disconnect the accelerator pedal or Foot
Operating Manual or service manual section
Directional Control pedal. See Figure 132.
below for battery installation procedures.
Remove front floor plate with the accelerator or
Foot Directional Control pedal still attached.
141
Figure 132. Removing Floor Plate and Accelerator or PedalFoot Directional Control
142

CONNECTOR
5. Remove the brake pedal assembly for access to See Figure 135 for lift trucks models
the traction motor controllers. ERP22-35VL (ERP045-070VL) (A976) ,
•
See Transaxle 1300YRM1370 for lift truck manufactured after November 2014
models See Figure 136 for lift truck models
• ERP22-35VL (ERP045-070VL) (A976) • ERP40-80VM (ERP080-100VM) (A985)
See Transaxle 1300YRM1539 for lift truck manufactured before November 2014
models See Figure 137 for lift truck models
• ERP40-50VM, ERP50-55VM6 • ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985) (ERP080-120VM, ERP100VML) (A985)
NOTE: Make sure all power cables and electrical
connections are clearly marked before disconnecting 7. For lift truck models ERP22-35VL
them to help aid in reconnecting. (ERP045-070VL) (A976) manufactured before
6. Disconnect the power cables and all electrical November 2014 and lift truck models
connections from traction motor controllers. ERP40-50VM, ERP50-55VM6 (ERP080-120VM,
ERP100VML) (A985) , remove eight flange
See Figure 133 for lift truck models capscrews securing the traction motor controllers
• ERP22-35VL (ERP045-070VL) (A976) , to the air duct and remove traction motor
manufactured before February, 2009 controllers.
See Figure 134 for lift trucks models 8. For lift truck models ERP22-35VL
• ERP22-35VL (ERP045-070VL) (A976) , (ERP045-070VL) (A976) manufactured after
manufactured after February, 2009 November 2014, remove eight socket head
capscrews and traction motor controller from
mounting bracket.
143
1. TRACTION MOTOR CONTROLLER 8. RIGHT POWER CABLE U

2. FLANGE CAPSCREW 9. RIGHT POWER CABLE V
3. AIR DUCT 10. LEFT POWER CABLE W
4. FRONT BULKHEAD 11. LEFT POWER CABLE U
5. FAN 12. LEFT POWER CABLE V
6. FAN CONNECTORS 13. TRACTION MOTOR CONTROLLER
7. RIGHT POWER CABLE W CONNECTORS TO MAIN WIRE HARNESS
14. FAN SPACER
Figure 133. Traction Motor Controllers, Replace, Lift Truck Models , Manufactured Before February,
2009ERP22-35VL (ERP045-070VL) (A976)
144
1. RIGHT TRACTION MOTOR CONTROLLER

2. LEFT TRACTION MOTOR CONTROLLER
3. FLANGE CAPSCREW
4. FANS
5. FAN CONNECTIONS
6. TRACTION MOTOR CONTROLLER
CONNECTORS TO MAIN WIRE HARNESS
7. RIGHT POWER CABLE U TERMINAL
8. LEFT POWER CABLE U TERMINAL
9. RIGHT POWER CABLE V TERMINAL
10. RIGHT POWER CABLE W TERMINAL
11. LEFT POWER CABLE V TERMINAL
12. LEFT POWER CABLE W TERMINAL
13. FRONT BULKHEAD
Figure 134. Traction Motor Controllers, Replace,

Lift Truck Models , Manufactured After February,
2009ERP22-35VL (ERP045-070VL) (A976)
145
1. RIGHT TRACTION MOTOR CONTROLLER 8. LEFT POWER CABLE U TERMINAL

2. LEFT TRACTION MOTOR CONTROLLER 9. RIGHT POWER CABLE V TERMINAL
3. SOCKET HEAD CAPSCREW 10. RIGHT POWER CABLE W TERMINAL
4. FANS 11. LEFT POWER CABLE V TERMINAL
5. FAN CONNECTIONS 12. LEFT POWER CABLE W TERMINAL
6. TRACTION MOTOR CONTROLLER 13. FRONT BULKHEAD
CONNECTORS TO MAIN WIRE HARNESS 14. MOUNTING BRACKET
Figure 135. Traction Motor Controllers, Replace, Lift Truck Models , Manufactured After November
2014ERP22-35VL (ERP045-070VL) (A976)
146
1. FRONT BULKHEAD 7. RIGHT POWER CABLE U

3. FAN CONNECTORS TO MAIN WIRE HARNESS
4. TRACTION MOTOR CONTROLLER 9. LEFT POWER CABLE W
5. RIGHT POWER CABLE W 10. LEFT POWER CABLE V
6. RIGHT POWER CABLE V 11. LEFT POWER CABLE U
Figure 136. Traction Motor Controller, Replace, Manufactured Before November 2014ERP40-80VM
(ERP080-100VM) (A985)
147

Figure 137. Traction Motor Controller, Replace, Manufactured After November 2014ERP40-50VM,
ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)
Install For lift truck models ERP22-35VL

(ERP045-070VL) (A976) manufactured after
1. Before installing new motor controllers to November 2014, install new traction motor
heatsink, clean motor controllers and heatsink controllers onto mounting bracket using eight
mating surface to ensure they are clean and free socket head capscrews.
of any debris or paint.
NOTE: Apply dielectric grease to the controller wiring
2. For lift truck models ERP22-35VL harness connector for lift truck models ERP22-35VL
(ERP045-070VL) (A976) manufactured before (ERP045-070VL) (A976) , equipped with Outdoor
November 2014 and lift truck models Protection/ Wash-down Package.
ERP100VML) (A985) , install new traction motor 3. Connect the fans and other electrical connections
controllers into air duct using eight flange as noted during removal. Connect power cables
capscrews. at the power terminals of the traction motor
controllers as identified during removal. Tighten
power cables to 18 to 21 N•m (159 to 186 lbf in).
148
4. For lift truck models ERP22-35VL LIFT TRUCK MODEL ERC40-55VH,

(ERP045-070VL) (A976) , equipped with Outdoor ERC50VHS (ERC80-120VH, ERC100VHS)
Protection/ Wash-down Package, spray power
cable terminals on controller with rust inhibitor-
(A938)
ignition sealer. Traction Motor and Hydraulic Pump and
Motor Controllers
5. Install the brake pedal assembly. For installation
procedure Remove
See Transaxle 1300YRM1370 for lift truck 1. Read and follow the WARNING and CAUTION
models section in the General section above.
• ERP22-35VL (ERP045-070VL) (A976)
2. Remove the battery for access to the motor
See Transaxle 1300YRM1539 for lift truck controllers. See the Operating Manual or service
models manual Periodic Maintenance 8000YRM1577.
(ERP080-120VM, ERP100VML) (A985) NOTE: Make sure all power cables and electrical
connections are clearly marked before disconnecting
6. Connect the accelerator pedal or Foot Directional them to help in reconnecting.
Control pedal, (see Figure 132) and install the 3. Disconnect the power cables and all electrical
front floor plate using capscrews and washers. connections from the motor controllers. See
Install rear floor plate. Figure 138.
7. Connect motor controller connector to main wiring See Figure 138 for lift truck models
harness. • ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938) manufactured before
8. Install belly pan and two bolts onto underside of November 2014
lift truck.
9. Connect the battery. • ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938) manufactured after
10. For lift truck models ERP22-35VL November 2014
Protection/Wash-down Package, spray battery NOTE: Step 4 through Step 6 apply to lift truck
connector terminals with rust inhibitor-ignition models manufactured before November 2014.
sealer, after tightening terminals. 4. Remove 12 flange capscrews from motor
controllers. See Figure 138.
11. After install complete, perform ground test. See
Frame 0100YRM1342, Ground Test section. 5. Remove motor controllers and heatsink from air
duct as an assembly. See Figure 138.
6. Remove 16 screws securing motor controllers to

heatsink. See Figure 138.
NOTE: Step 7 applies to lift trucks manufactured after

November 2014.
7. Remove eight flange capscrews from motor
controllers. Remove motor controllers from
mounting bracket. See Figure 139.
149

1. FUSE COVER 9. HYDRAULIC PUMP AND MOTOR CONTROLLER

2. CONTACTOR 10. POWER CABLE U
3. FAN 11. POWER CABLE V
4. AIR DUCT 12. POWER CABLE W
6. SCREW 14. HEATSINK
7. CONTROLLER ELECTRICAL CONNECTORS 15. LINE CONTACTOR MOUNTING BRACKET
8. TRACTION MOTOR CONTROLLER CAPSCREW
Figure 138. Motor Controllers Replace for Lift Truck Model Manufactured Before November
2014ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938)
150

1. FUSE COVER 9. HYDRAULIC PUMP AND MOTOR CONTROLLER

2. CONTACTOR 10. POWER CABLE U
3. FAN 11. POWER CABLE V
4. AIR DUCT 12. POWER CABLE W
6. MOUNTING BRACKET 14. LINE CONTACTOR MOUNTING BRACKET
7. CONTROLLER ELECTRICAL CONNECTORS CAPSCREW
8. TRACTION MOTOR CONTROLLER 15. SOCKET HEAD CAPSCREWS
Figure 139. Motor Controllers Replace for Lift Truck Model Manufactured After November
2014ERC80-120VH, ERC100VHS (A938)
Install 2. Install 16 screws into motor controller and

heatsink. See Figure 138.
NOTE: Step 1 through Step 4 apply to lift trucks
manufactured before November 2014. 3. Install motor controller and heat sink in air duct.
1. Before installing new motor controllers to
heatsink, clean motor controllers and heatsink 4. Install 12 flange capscrews and tighten to
mating surfaces to ensure they are clean and free 9 to 11 N•m (80 to 97 lbf in).
of any debris or paint. Apply 1.5 mm (0.06 in.)
coat of silicon grease (Yale Part No. 580076898)
to baseplate of motor controllers and heatsink
mating surface. The silicon grease should cover
at least 90% of controller baseplate.
151
NOTE: Step 5 applies to lift trucks manufactured after See Figure 119 for lift truck model
November 2014. ERC80-120VH, ERC100VHS (A938)
•
5. Install motor controllers to mounting brackets manufactured after November 2014.
using eight flange capscrews and tighten to The line contactor is located just above the hydraulic
9 to 11 N•m (80 to 97 lbf in). See Figure 139. pump and motor for lift truck models ERP22-35VL
(ERP045-070VL) (A976) and ERP40-80VM
6. Connect the fans and other electrical connections (ERP080-100VM) (A985) .
at the power terminals of the motor controllers as For lift truck model ERP22-35VL (ERP045-070VL)
identified during removal. Tighten power cables to (A976) , equipped with Outdoor Protection/Wash-down
18 to 21 N•m (159 to 186 lbf in). Package, the line contactor is enclosed and power
fuse is shrouded.
7. Install the battery in lift truck. See the Operating See Figure 110 for lift truck models
Manual or service manual Periodic
Maintenance 8000YRM1577. • ERP22-35VL (ERP045-070VL) (A976)
manufactured before February, 2009
8. Connect the battery. See Figure 111 for lift truck models
• ERP22-35VL (ERP045-070VL) (A976)
LINE CONTACTOR manufactured after February, 2009
NOTE: The procedures to replace the line contactor See Figure 112 for lift truck models
are the same for all lift truck models covered in this
repair manual. The line contactor is located on the • ERP22-35VL (ERP045-070VL) (A976)
right side of the counterweight, just above the traction
motor controller for lift truck models ERC22-35VG See Figure 113 for lift truck model
(ERC045-070VG) (A968), ERC16-20VA • ERP22-35VL (ERP045-070VL) (A976)
(ERC030-040VA) (A969), and ERC40-55VH, manufactured after November 2014
• ERP40-80VM (ERP080-100VM) (A985)
• ERC22-35VG (ERC045-070VG) (A968) manufactured before November 2014
manufactured before September, 2012.
• ERC22-35VG (ERC045-070VG) (A968) (ERP080-120VM, ERP100VML) (A985)
manufactured after September, 2012. manufactured after November 2014
Remove
November 2014. 1. Read and follow the WARNING and CAUTION
section in the General section above.
• ERC16-20VA (ERC030-040VA) (A969) 2. Remove the counterweight cover for access to
manufactured before November 2014. the line contactor.
See Figure 117 for lift truck models See Figure 140 for lift truck models
• ERC030-040VA (A969) manufactured after • ERC22-35VG (ERC045-070VG) (A968)
November 2014.
• ERC16-20VA (ERC030-040VA) (A969)
• ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938)
See Figure 125 or Figure 126 for lift truck models
November 2014.
• ERP22-35VL (ERP045-070VL) (A976)
(ERP080-120VM, ERP100VML) (A985)
152

November 2014
• ERC22-35VG (ERC045-070VG) (A968)
manufactured after September, 2012
November 2014
• ERP22-35VL (ERP045-070VL) (A976)
• ERP22-35VL (ERP045-070VL) (A976)
• ERP22-35VL (ERP045-070VL) (A976) ,
equipped with Outdoor Protection/Wash-down
Package, manufactured after October, 2013
• ERP40-80VM (ERP080-100VM) (A985)
1. CAPSCREWS
2. COUNTERWEIGHT COVER • ERP40-50VM, ERP50-55VM6
3. COUNTERWEIGHT (ERP080-120VM, ERP100VML) (A985)
Figure 140. Counterweight Cover Removal, Lift
Truck Models and ERC22-35VG (ERC045-070VG) See Figure 150 for lift truck model
(A968), ERC16-20VA (ERC030-040VA) (A969), • ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) manufactured before
ERC100VHS) (A938) November 2014
NOTE: Tag or mark line contactor wire connections
before disconnecting them to aid in reconnecting • ERC80-120VH, ERC100VHS (A938)
during installation. manufactured after November 2014
3. Disconnect all wires from line contactor.

• ERC22-35VG (ERC045-070VG) (A968)
manufactured before September, 2012
• ERC16-20VA (ERC030-040VA) (A969)
153
NOTE: SEVERAL ELECTRICAL COMPONENTS

AND CONNECTIONS OMITTED FOR CLARITY. NOTE: SEVERAL ELECTRICAL COMPONENTS
AND CONNECTIONS OMITTED FOR CLARITY.
1. CAPSCREW
2. MAIN WIRE HARNESS CONNECTIONS 1. CAPSCREW
3. PTC THERMISTOR ASSEMBLY 2. MAIN WIRE HARNESS CONNECTIONS
4. LINE CONTACTOR 3. PTC THERMISTOR ASSEMBLY
5. MOUNTING BRACKET 4. LINE CONTACTOR
6. FUSE COVER 5. MOUNTING BRACKET
6. FUSE COVER
Figure 141. Line Contactor Replacement, Lift Truck
Models and ERC22-35VG (ERC045-070VG) (A968) Figure 142. Line Contactor Replacement, Lift Truck
Manufactured Before September, Models Manufactured After November
2012 ERC16-20VA (ERC030-040VA) (A969) 2014ERC030-040VA (A969)
Manufactured Before November 2014
154

A. LINE CONTACTOR USED ON LIFT TRUCK

MODELS ERC22-35VG (ERC045-070VG) (A968)
B. TWO POLE LINE CONTACTOR OPTION USED
ON LIFT TRUCK MODELS ERC22-35VG (A968)
1. CAPSCREW
2. MAIN WIRE HARNESS CONNECTIONS
3. PTC THERMISTOR ASSEMBLY
4. LINE CONTACTOR
5. MOUNTING BRACKET
6. FUSE COVER

Models Manufactured After September,
2012ERC22-35VG (ERC045-070VG) (A968)

1. CAPSCREW
2. MAIN WIRE HARNESS CONNECTIONS
3. PTC THERMISTOR ASSEMBLY
4. LINE CONTACTOR
5. MOUNTING BRACKET
6. FUSE COVER

Models Manufactured After November
2014ERC045-070VG (A968)
155
NOTE: SOME ELECTRICAL COMPONENTS AND CONNECTIONS OMITTED FOR CLARITY.
A. LIFT TRUCK MODELS ERP22-35VL B. LIFT TRUCK MODELS ERP22-35VL

(ERP045-070VL) (A976) , MANUFACTURED (ERP045-070VL) (A976) , MANUFACTURED
BEFORE FEBRUARY, 2009 AFTER FEBRUARY, 2009
1. CAPSCREWS 6. MOUNTING BRACKET

2. MAIN WIRE HARNESS CONNECTIONS 7. HYDRAULIC PUMP AND MOTOR CONTROLLER
3. PTC THERMISTOR ASSEMBLY 8. HYDRAULIC PUMP AND MOTOR
4. FUSES 9. LINE CONTACTOR FUSE
5. LINE CONTACTOR
Figure 145. Line Contactor Replacement, Lift Truck Models Manufactured Before November
2014ERP22-35VL (ERP045-070VL) (A976)
156
NOTE: SOME ELECTRICAL COMPONENTS AND 1. HYDRAULIC PUMP AND MOTOR CONTROLLER
CONNECTIONS OMITTED FOR CLARITY. 2. HYDRAULIC PUMP AND MOTOR
3. LINE CONTACTOR POWER FUSE SHROUD
1. CAPSCREWS 4. LINE CONTACTOR POWER FUSE
2. MAIN WIRE HARNESS CONNECTIONS 5. FUSES
3. PTC THERMISTOR ASSEMBLY 6. CAPSCREWS
4. FUSES 7. PTC THERMISTOR ASSEMBLY
5. LINE CONTACTOR 8. LINE CONTACTOR
6. MOUNTING BRACKET 9. MAIN WIRE HARNESS CONNECTIONS
7. HYDRAULIC PUMP AND MOTOR CONTROLLER
8. HYDRAULIC PUMP AND MOTOR Figure 147. Line Contactor Replacement for Lift
9. LINE CONTACTOR FUSE Truck Models , Equipped With Outdoor Protection/
Wash-down PackageERP22-35VL (ERP045-070VL)
Figure 146. Line Contactor Replacement, Lift Truck (A976)
Models Manufactured After November
2014ERP22-35VL (ERP045-070VL) (A976)
157
NOTE: SOME ELECTRICAL COMPONENTS AND NOTE: SOME ELECTRICAL COMPONENTS AND
CONNECTIONS OMITTED FOR CLARITY. CONNECTIONS OMITTED FOR CLARITY.
1. CAPSCREWS 1. CAPSCREWS
2. MAIN WIRE HARNESS CONNECTIONS 2. MAIN WIRE HARNESS CONNECTIONS
3. PTC THERMISTOR ASSEMBLY 3. PTC THERMISTOR ASSEMBLY
4. FUSES 4. FUSES
5. LINE CONTACTOR 5. LINE CONTACTOR
6. MOUNTING BRACKET 6. MOUNTING BRACKET
7. HYDRAULIC PUMP AND MOTOR CONTROLLER 7. HYDRAULIC PUMP AND MOTOR CONTROLLER
8. HYDRAULIC PUMP AND MOTOR 8. HYDRAULIC PUMP AND MOTOR
Figure 148. Line Contactor Replacement, Lift Truck Figure 149. Line Contactor Replacement, Lift Truck
Models Manufactured Before November Models Manufactured After November
2014ERP40-80VM (ERP080-100VM) (A985) 2014ERP40-50VM, ERP50-55VM6 (ERP080-120VM,
ERP100VML) (A985)
158
1. LINE CONTACTOR
2. PTC THERMISTOR
3. FUSE COVER 1. LINE CONTACTOR
4. MAIN WIRE HARNESS CONNECTION 2. PTC THERMISTOR
5. MOUNTING BRACKET 3. FUSE COVER
6. CAPSCREW 4. MAIN WIRE HARNESS CONNECTION
5. MAIN WIRE HARNESS
Figure 150. Line Contactor Replacement, Lift Truck 6. LINE CONTACTOR MOUNTING BRACKET
7. LINE CONTACTOR CAPSCREW
Model Manufactured Before November 8. MOUNTING BRACKET CAPSCREWS
2014ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938) Figure 151. Line Contactor Replacement, Lift Truck
Model Manufactured After November
2014ERC80-120VH, ERC100VHS (A938)
4. Remove two capscrews and remove line

contactor from mounting bracket.
NOTE: Perform Step 5 and Step 6 for lift truck model

ERC100VHS) (A938) .
5. Remove two line contactor mounting bracket
capscrews.
November 2014
• ERC80-120VH, ERC100VHS (A938)
159
6. Remove four line contactor capscrews from back See Figure 146 for lift truck models
of mounting bracket and remove line contactors ERP22-35VL (ERP045-070VL) (A976)
•
from mounting bracket. manufactured after November 2014
See Figure 150 for lift truck model See Figure 147 for lift truck models
• ERC40-55VH, ERC50VHS (ERC80-120VH, • ERP22-35VL (ERP045-070VL) (A976) ,
ERC100VHS) (A938) manufactured before equipped with Outdoor Protection/Wash-down
November 2014 Package
See Figure 151 for lift truck model See Figure 148 for lift truck models
• ERC80-120VH, ERC100VHS (A938) • ERP40-80VM (ERP080-100VM) (A985)
manufactured after November 2014 manufactured before November 2014

1. Before installing new line contactor, check to
(ERP080-120VM, ERP100VML) (A985)
ensure the PTC thermistor assembly is on manufactured after November 2014
contactor posts.
NOTE: Perform Step 2 and Step 3 for lift truck model • ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) manufactured before
ERC100VHS) (A938) . November 2014
2. Install new line contactors to mounting bracket See Figure 151 for lift truck model
using four capscrews. Tighten capscrews to ERC80-120VH, ERC100VHS (A938)
•
14 to 15 N•m (123.9 to 132.8 lbf in). See manufactured after November 2014
Figure 150.
5. Connect all wires to line contactor in same
3. Install mounting bracket in lift truck using two line positions as noted during removal.
contactor bracket capscrews and tighten to
66 to 83 N•m (49 to 61 lbf ft). 6. Tighten main contactor terminals as indicated
below:
4. Install new line contactor to mounting bracket
using two capscrews. • Lift truck models ERC030-040VA (A969) -
8 to 10 N•m (70.8 to 88.5 lbf in)
See Figure 141 for lift truck models • Lift truck models ERC22-35VG
• ERC22-35VG (ERC045-070VG) (A968) (ERC045-070VG) (A968) -
manufactured before September, 2012 14 to 15 N•m (123.9 to 132.8 lbf in)
• ERC16-20VA (ERC030-040VA) (A969) • Lift truck models ERP22-35VL (ERP045-070VL)
manufactured before November 2014 (A976) -
See Figure 142 for lift truck models stud size M8 -
8 to 10 N•m (70.8 to 88.5 lbf in)
stud size M10 -
November 2014
14 to 15 N•m (123.9 to 132.8 lbf in)
See Figure 143 for lift truck models • Lift truck models ERP40-50VM, ERP50-55VM6
• ERC22-35VG (ERC045-070VG) (A968) (ERP080-120VM, ERP100VML) (A985) -
manufactured after September, 2012 14 to 15 N•m (123.9 to 132.8 lbf in)
See Figure 144 for lift truck models • Lift truck models ERC40-55VH, ERC50VHS
(ERC80-120VH, ERC100VHS) (A938) -
• ERC045-070VG (A968) manufactured after 14 to 15 N•m (123.9 to 132.8 lbf in)
November 2014
See Figure 145 for lift truck models 7. Install the counterweight cover using two
capscrews.
• ERP22-35VL (ERP045-070VL) (A976)
160
See Figure 140 for lift truck models For lift truck models ERP22-35VL (ERP045-070VL)
ERC22-35VG (ERC045-070VG) (A968) (A976) and ERP40-80VM (ERP080-100VM) (A985)
•
there are two sets of fans. One set is located on the
• ERC16-20VA (ERC030-040VA) (A969) right side of the counterweight mounted on two fan
• ERC40-55VH, ERC50VHS (ERC80-120VH, spacers, mounted to the heatsink, just above the
ERC100VHS) (A938) hydraulic pump and motor controller. The other fan set
See Figure 125 or Figure 126 for lift truck models is located under the floor plate and mounted to two fan
spacers on the heatsink above the traction motor
• ERP22-35VL (ERP045-070VL) (A976) controller.
(ERP080-120VM, ERP100VML) (A985)
• ERP22-35VL (ERP045-070VL) (A976) ,
8. For lift truck models ERP22-35VL manufactured before February, 2009
(ERP045-070VL) (A976) , equipped with Outdoor See Figure 111 for lift truck model
Protection/ Wash-down Package, spray rust
inhibitor-ignition sealer on line contactor fuse • ERP22-35VL (ERP045-070VL) (A976) ,
power cable terminals, after tightening nuts manufactured after February, 2009
retaining line contactor fuse. See Figure 145. See Figure 112 for lift truck model
• ERP22-35VL (ERP045-070VL) (A976) ,
manufactured after November, 2014
10. For lift truck models ERP22-35VL See Figure 113 for lift truck model
(ERP045-070VL) (A976) , equipped with Outdoor • ERP22-35VL (ERP045-070VL) (A976) ,
Protection/Wash-down Package, spray battery manufactured after November, 2015
connector terminals with rust inhibitor-ignition
sealer, after tightening terminals. See Figure 114 for lift truck model
• ERP40-80VM (ERP080-100VM) (A985)
FANS FOR LIFT TRUCK MODELS For lift truck models ERC22-35VG (ERC045-070VG)
MANUFACTURED BEFORE NOVEMBER (A968) manufactured after September, 2012 three fan
2014ERC22-35VG (ERC045-070VG) (A968), assemblies are mounted to an air duct, which is
ERC16-20VA (ERC030-040VA) (A969), mounted to the motor controllers mounting bracket just
above the traction motor controller and hydraulic pump
ERP22-25VL (ERP045-070VL) (A976), AND
and motor controller. See Figure 153.
ERP40-50VM (ERP080-100VM) (A985)
NOTE: For all lift truck models except ERC22-35VG Remove
1. Read and follow the WARNING and CAUTION in
September, 2012, the same style of fan assembly is
the General section above.
used and the procedures to install a new fan assembly
are the same. 2. Remove the counterweight cover for lift truck
For lift truck models ERC22-35VG (ERC045-070VG) models ERC22-35VG (ERC045-070VG) (A968) ,
(A968) manufactured before September, 2012, and lift ERC16-20VA (ERC030-040VA) (A969) , , and
truck models ERC16-20VA (ERC030-040VA) (A969). ERP22-35VL (ERP045-070VL)
the fan assembly is located on two fan spacers (A976) ERP40-80VM (ERP080-100VM) (A985) if
mounted to the heatsink on the counterweight, just the fans for the hydraulic pump and motor
above the hydraulic pump and motor controller. controller will be replaced.
See Figure 107 for lift truck models See Figure 140 for lift truck models
• ERC22-35VG (ERC045-070VG) (A968) • ERC22-35VG (ERC045-070VG) (A968)
manufactured before September, 2012 • ERC16-20VA (ERC030-040VA) (A969)
See Figure 116 for lift truck models See Figure 125 or Figure 126 for lift truck models
• ERC16-20VA (ERC030-040VA) (A969), • ERP22-35VL (ERP045-070VL) (A976)
• ERP40-80VM (ERP080-100VM) (A985)
161
3. On lift truck models ERP22-35VL

(ERP045-070VL) (A976) and ERP40-80VM
(ERP080-100VM) (A985) , if the fans for the
traction motor are being replaced, remove the
floor mat. Remove rear floor plate. Remove
capscrew, washer, and nut from front floor plate.
Remove front floor plate with accelerator or Foot
Directional Control pedal still attached. See
Figure 132.
4. Disconnect main wire harness from fan assembly.

• ERC22-35VG (ERC045-070VG) (A968)
• ERC22-35VG (ERC045-070VG) (A968)
manufactured after September, 2012
• ERC16-20VA (ERC030-040VA) (A969)
See Figure 127, and Figure 133 for lift truck
models
• ERP22-35VL (ERP045-070VL) (A976)
• ERP40-80VM (ERP080-100VM) (A985)
NOTE: DO NOT discard finger guard removed in

Step 5 and Step 6. It will be used with new fan
assembly.
5. For all lift truck models, except ERC22-35VG NOTE: FAN FOR ERC16-20VA (ERC030-040VA)
(ERC045-070VG) (A968) manufactured after (A969) SHOWN. OTHER FANS SIMILAR.
September, 2012, remove four screws that attach
fan assembly to fan spacer. Remove finger guard 1. FAN SPACER
2. FAN ASSEMBLY
and fan assembly from fan spacer. See 3. FINGER GUARD
Figure 152. 4. SCREWS
6. For lift truck models ERC22-35VG Figure 152. Fan Assembly Replacement, All Lift
(ERC045-070VG) (A968) manufactured after Truck Models Except Manufactured After
September, 2012, remove four capscrews that September, 2012ERC22-35VG (ERC045-070VG)
attach fan assembly to air duct. Remove finger (A968)
guard and connector from clip. Remove fan
assembly from air duct. See Figure 153.
162
1. SCREWS 4. AIR DUCT

2. FINGER GUARD 5. CONNECTOR
3. FAN ASSEMBLY 6. CONNECTOR CLIP
Figure 153. Fan Assembly Replacement, Lift Truck Models Manufactured After September,
2012ERC22-35VG (ERC045-070VG) (A968)
Install See Figure 127 and Figure 133 for lift truck models
NOTE: For all lift truck models, except ERC22-35VG • ERP22-35VL (ERP045-070VL) (A976) ,
(ERC045-070VG) (A968) manufactured after manufactured before February, 2009
September, 2012, when installing new fan assembly, See Figure 128 and Figure 134 for lift truck models
fan connector wire must be on right bottom of fan
• ERP22-35VL (ERP045-070VL) (A976) ,
assembly when viewed from the motor controller side. manufactured after February, 2009
For lift truck models ERC22-35VG (ERC045-070VG) See Figure 130 and Figure 136 for lift truck models
(A968) manufactured after September, 2012, when
installing new fan assembly, fan connector wire must • ERP40-80VM (ERP080-100VM) (A985)
be on center bottom of fan assembly when viewed 1. For all lift truck models, except ERC22-35VG
from the motor controller side. (ERC045-070VG) (A968) manufactured after
See Figure 120 for lift truck models September, 2012, install new fan assembly and
finger guard to fan spacer with four screws. See
• ERC22-35VG (ERC045-070VG) (A968) Figure 152.
See Figure 121 for lift truck models 2. For lift truck models ERC22-35VG
• ERC22-35VG (ERC045-070VG) (A968)
manufactured after September, 2012 September, 2012, install new fan assembly and
finger guard to air duct with four capscrews.
• ERC16-20VA (ERC030-040VA) (A969) 3. Connect main wire harness to fan assembly.
163
4. Install the counterweight cover, if the fans for the 4. Remove four screws that attach fan assembly to
hydraulic pump and motor controller were air duct. Remove finger guard and fan assembly
replaced. from air duct. See Figure 152.
5. Repeat Step 4 for three other fan assemblies.
• ERC22-35VG (ERC045-070VG) (A968)
• ERC16-20VA (ERC030-040VA) (A969) Install
See Figure 125 or Figure 126 for lift truck models NOTE: When installing new fan assembly, fan
connector wire must be on left bottom of fan assembly
• ERP22-35VL (ERP045-070VL) (A976)
when viewed from the motor controller side. See
• ERP40-80VM (ERP080-100VM) (A985) Figure 138.
5. For lift truck models ERP22-35VL 1. Install new fan assembly and finger guard to air
(ERP045-070VL) (A976) and ERP40-80VM duct with four screws. See Figure 152.
(ERP080-100VM) (A985) , if the fans for the
2. Repeat Step 1 for three other fan assemblies.
traction motor were replaced, connect the
3. Connect main wire harness to fan assembly. See
pedal, (see Figure 132) and install the front floor
Figure 138.
plate using capscrews, washers, and nuts. Install
rear floor plate. Install floor mat. 4. Install the counterweight cover. See Figure 140.
6. Connect the battery. 5. Connect the battery.
FANS FOR LIFT TRUCK MODEL FANS FOR LIFT TRUCK MODELS
MANUFACTURED BEFORE NOVEMBER MANUFACTURED AFTER NOVEMBER
2014ERC40-55VH, ERC50VHS 2014ERC045-070VG (A968),
(ERC80-120VH, ERC100VHS) (A938) ERC030-040VA (A969), ERC80-120VH,
NOTE: The same style of fan assembly is used on all ERC100VHS (A938), ERP22-25VL
lift truck models covered in this service manual. The (ERP045-070VL) (A976), AND
procedures to install a new fan assembly are the same
ERP40-50VM, ERP50-55VM6
for all trucks.
(ERP080-120VM, ERP100VML) (A985)
The fan assembly is mounted to the air duct on the
counterweight, just above the traction motor and On lift truck models ERC045-070VG (A968) ,
hydraulic pump and motor controllers for lift truck ERC030-040VA (A969) , and ERC80-120VH,
model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS (A938) , the fan assembly is mounted to
ERC100VHS) (A938) . See Figure 138. the air duct on the counterweight, just above the
traction motor and hydraulic pump and motor
Remove controllers.
1. Read and follow the WARNING and CAUTION in See Figure 154 for lift truck models
the General section above. • ERC045-070VG (A968)
2. Remove the counterweight cover. See
Figure 140. • ERC030-040VA (A969)
3. Disconnect main wire harness from fan assembly.
See Figure 138. • ERC80-120VH, ERC100VHS (A938)
NOTE: DO NOT discard finger guard. It will be used

with new fan assembly.
164

Figure 154. Motor Controllers and Electrical Components Arrangement, Lift Truck Models ERC045-070VG
(A968)
165

CABLES
5. HYDRAULIC TANK
ERC030-040VA (A969)
166

2. FANS CABLES
Figure 156. Motor Controllers and Electrical Components Arrangement, Lift Truck Model ERC80-120VH,
ERC100VHS (A938)
For lift truck models ERP22-25VL (ERP045-070VL) • ERP22-35VL (ERP045-070VL) (A976)

(A976) , and ERP40-50VM (ERP080-100VM) (A985) ,
there are two sets of fan assemblies. One set is
mounted to the air duct on the counterweight, just • ERP40-50VM, ERP50-55VM6
above the hydraulic pump and motor controller. (ERP080-120VM, ERP100VML) (A985)
167
Figure 157. Hydraulic Pump and Motor Controller and Electrical Components Arrangement, Lift Truck
Models ERP22-35VL (ERP045-070VL) (A976)
168


2. FAN CONNECTORS 8. POWER CABLE U
CONTROLLER
6. POWER CABLE W

3. FANS 9. AIR DUCT
6. POWER CABLEU
Figure 158. Hydraulic Pump and Motor Controller and Electrical Components Arrangement, Lift Truck
Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)
169
The other set is mounted to the air duct on the front See Figure 160 for lift truck models
bulkhead for the traction motor controller. ERP40-50VM, ERP50-55VM6
•
See Figure 159 for lift truck models (ERP080-120VM, ERP100VML) (A985)
• ERP22-35VL (ERP045-070VL) (A976)
1. RIGHT TRACTION MOTOR CONTROLLER 8. LEFT POWER CABLE U TERMINAL

2. LEFT TRACTION MOTOR CONTROLLER 9. RIGHT POWER CABLE V TERMINAL
3. SOCKET HEAD CAPSCREW 10. RIGHT POWER CABLE W TERMINAL
4. FANS 11. LEFT POWER CABLE V TERMINAL
5. FAN CONNECTIONS 12. LEFT POWER CABLE W TERMINAL
6. TRACTION MOTOR CONTROLLER 13. FRONT BULKHEAD
CONNECTORS TO MAIN WIRE HARNESS 14. MOUNTING BRACKET
Figure 159. Traction Motor Controllers and Electrical Components Arrangement, Lift Truck Models
ERP22-35VL (ERP045-070VL) (A976)
170

Figure 160. Traction Motor Controller and Electrical Components Arrangement, Lift Truck Models
ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)
For all lift truck models covered in this section, the Remove
same style of fan assembly is used and the
procedures to remove and install a new fan assembly 1. Read and follow the WARNING and CAUTION in
are the same. the General section above.
171
2. Remove counterweight cover for access to both • ERC80-120VH, ERC100VHS (A938)

traction motor and hydraulic pump and motor
controller fans for lift truck NOTE: Perform Step 3 through Step 5 for access to
modelsERC045-070VG (A968) , ERC030-040VA fan on traction motor controller for lift truck models
(A969) , ERC80-120VH, ERC100VHS (A938) ERP22-25VL (ERP045-070VL) (A976) and
and for access to hydraulic pump and motor fans ERP40-50VM, ERP50-55VM6 (ERP080-120VM,
for lift truck models ERP22-25VL ERP100VML) (A985) .
(ERP045-070VL) (A976) , and ERP40-50VM, 3. Remove two bolts and belly pan from underside
ERP50-55VM6 (ERP080-120VM, ERP100VML) of lift truck.
(A985) .
See Figure 125 or Figure 126 for lift truck models 4. Remove floor mat and rear floor plate. Remove
capscrews and washers from front floor plate and
• ERP22-25VL (ERP045-070VL) (A976)
lift front floor plate up enough to disconnect the
• ERP40-50VM, ERP50-55VM6 accelerator or Foot Directional Control pedal.
(ERP080-120VM, ERP100VML) (A985) Remove front floor plate with the accelerator or
See Figure 140 for lift truck models Foot Directional Control pedal still attached. See
Figure 161.
• ERC045-070VG (A968)
• ERC030-040VA (A969)
172
Figure 161. Removing Floor Plate and Accelerator or PedalFoot Directional Control
173

CONNECTOR
5. Remove brake pedal assembly for access to

traction motor controller and fan.
See Transaxle 1300YRM1370 for lift truck
models
• ERP22-25VL (ERP045-070VL) (A976)
See Transaxle 1300YRM1539 for lift truck
models
(ERP080-120VM, ERP100VML) (A985)
6. Disconnect main wire harness from fan electrical

connector.
NOTE: DO NOT discard finger guard. It will be used

with new fan assembly.
7. Remove four screws that attach fan assembly to
air duct. Remove finger guard and fan assembly
from air duct. See Figure 162.
8. Repeat Step 7 for other fan assemblies.
1. SCREWS
2. FINGER GUARD
3. FAN ASSEMBLY
4. FAN ELECTRICAL CONNECTOR
5. AIR DUCT
6. CONNECTOR CLIP
Figure 162. Fan Assembly
174
2200 YRM 1369 Vehicle System Manager
Install 5. Install brake pedal assembly. See one of the

following manuals for procedures.
NOTE: When installing new fan assembly, fan
connector wire must be on the left bottom of fan See Transaxle 1300YRM1370 for lift truck
assembly when viewed from the motor controller side. models
See Figure 162. • ERP22-25VL (ERP045-070VL) (A976)
1. Install new fan assembly and finger guard to air See Transaxle 1300YRM1539 for lift truck
duct with four screws. models
2. Repeat Step 1 for other fan assemblies. (ERP080-120VM, ERP100VML) (A985)
3. Connect wire harness to fan electrical connector. 6. Connect the accelerator or Foot Directional
See Figure 162. Control pedal (see Figure 161) and install front
floor plate using capscrews and washers. Install
4. Install counterweight cover. rear floor plate.
NOTE: Perform Step 5 through Step 7 if fan on 7. Install belly pan and two bolts onto underside of
traction motor controller for lift truck models lift truck.
ERP22-25VL (ERP045-070VL) (A976) and
ERP40-50VM (ERP080-100VM) (A985) was 8. Connect the battery.
replaced.
Vehicle System Manager

GENERAL
CAUTION
WARNING not installed correctly. Make sure wire connectors
Before replacing the Vehicle System Manager DO NOT touch the other metal terminals or wire
(VSM), fully lower all parts of the mast and tilt it connectors, metal brackets, or the bracket
forward until the tips of the forks touch the mounting nuts. Make sure the wires are not pulled
ground. This action will prevent the mast from tight and are not touching other parts to damage
lowering suddenly if the control lever is accidently the insulation.
moved.
Never have any metal on your fingers, arms, or
neck. These metal items can accidentally create an CAUTION
electrical connection and cause an injury. Make sure there is no dirt between the plate of the
VSM and the mount surface of the lift truck frame.
WARNING The Vehicle System Manager (VSM) is a

Discharge capacitors as directed in Discharging microprocessor-powered controller which controls or
the Capacitors in the General section at the monitors directly or indirectly, every electrical device
beginning of this manual. on the lift truck.
Disconnect the battery before doing any work on For lift truck models ERC22-35VG (ERC045-070VG)
the electrical system. Serious injury to personnel (A968), ERP22-35VL (ERP045-070VL)
and/or damage to lift truck components can occur (A976),ERP40-50VM, ERP50-55VM6
if battery is not disconnected. (ERP080-120VM, ERP100VML) (A985) and
ERC100VHS) (A938) the VSM is located on a
mounting bracket under the floor mat and floor plate
and to the left of the front bulkhead. See Figure 163.
175
Vehicle System Manager 2200 YRM 1369
See Figure 163 for the following lift truck models 5. Remove front floor plate with accelerator or Foot
manufactured before November 2014 Directional Control pedal still attached.
• ERC22-35VG (ERC045-070VG) (A968)
NOTE: Be sure to tag all connectors to aid correct
• ERP22-35VL (ERP045-070VL) (A976) installation.
• ERP40-80VM (ERP080-100VM) (A985) 6. Disconnect two main harness electrical
• ERC40-55VH, ERC50VHS (ERC80-120VH, connectors from VSM.
ERC100VHS) (A938)
See Figure 164 for the following lift truck models 7. Remove bolts securing VSM to VSM mounting
manufactured after November 2014 bracket on front bulkhead. Remove VSM from lift
truck.
• ERC045-070VG (A968)
See Figure 163 for lift truck models manufactured
• ERP22-35VL (ERP045-070VL) (A976) before November 2014
• ERC80-120VH, ERC100VHS (A938)
• ERC22-35VG (ERC045-070VG) (A968)
See Figure 165 for the following lift truck models • ERP22-35VL (ERP045-070VL) (A976)
• ERP40-80VM (ERP080-100VM) (A985)
(ERP080-120VM, ERP100VML) (A985) • ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938)
For lift truck models ERC16-20VA (ERC030-040VA)
See Figure 164 for the following lift truck models
(A969) the VSM is mounted to a bracket that is
attached to the center of the front bulkhead. See
Figure 166. • ERC045-070VG (A968)
• ERP22-35VL (ERP045-070VL) (A976)
REMOVE • ERC80-120VH, ERC100VHS (A938)
NOTE: The VSM is not a serviceable part. If it
malfunctions, replace with a new VSM. See Parts
Manual for replacement part number.
1. Read and follow WARNING and CAUTION (ERP080-120VM, ERP100VML) (A985)
section above in General section. See Figure 166 for lift truck models
2. Remove floor mat. • ERC16-20VA (ERC030-040VA) (A969)
3. Remove rear floor plate.

176
NOTE: VEHICLE SYSTEM MANAGER FOR LIFT TRUCK MODELS ERP22-35VL (ERP045-070VL) (A976)
WITH E-HYDRAULIC CONTROLS SHOWN.
1. FRONT BULKHEAD 4. VEHICLE SYSTEM MANAGER

2. VSM MOUNTING BRACKET 5. MAIN HARNESS ELECTRICAL CONNECTORS
3. BOLTS
Figure 163. Vehicle System Manager Removal, Lift Truck Models Manufactured Before November
2014ERC22-35VG (ERC045-070VG) (A968), ERP22-35VL (ERP045-070VL) (A976), ERP40-80VM
(ERP080-100VM) (A985) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938)
177
NOTE: VEHICLE SYSTEM MANAGER FOR LIFT TRUCK MODELS EQUIPPED WITH E-HYDRAULIC CON-
TROLS SHOWN.
A. VSM ARRANGEMENT, LIFT TRUCK MODELS C. VSM ARRANGEMENT, LIFT TRUCK MODELS AND
ERC045-070VG (A968) ERC80-120VH, ERC100VHS (A938)
B. VSM ARRANGEMENT, LIFT TRUCK MODELS
ERP22-35VL (ERP045-070VL) (A976)

3. BOLTS
Figure 164. Vehicle System Manager Removal, Lift Truck Models Manufactured After November
2014ERC045-070VG (A968), ERP22-35VL (ERP045-070VL) (A976), and ERC80-120VH, ERC100VHS (A938)
178
1. FRONT BULKHEAD
2. VSM MOUNTING BRACKET
3. BOLTS
4. VEHICLE SYSTEM MANAGER
5. MAIN HARNESS ELECTRICAL CONNECTORS
Figure 165. Vehicle System Manager Removal, Lift

Truck Models Manufactured After November
2014ERP40-50VM, ERP50-55VM6 (ERP080-120VM,
ERP100VML) (A985)
179

3. BOLTS
Figure 166. Vehicle Systems Manager Removal, Lift Truck Models ERC16-20VA (ERC030-040VA) (A969)
INSTALL See Figure 164 for the following lift truck models
1. Install new VSM onto mounting bracket. Tighten
bolts to 19 N•m (168 lbf in). • ERC045-070VG (A968)
• ERP22-35VL (ERP045-070VL) (A976)
NOTE: On lift truck models ERP22-35VL
• ERC80-120VH, ERC100VHS (A938)
Protection/ Wash-down Package, apply dielectric See Figure 165 for the following lift truck models
grease to VSM electrical connectors before performing manufactured after November 2014
Step 2. • ERP40-50VM, ERP50-55VM6
2. Connect all electrical connections, as noted, to (ERP080-120VM, ERP100VML) (A985)
VSM. See Figure 166 for lift truck models
See Figure 163 for lift truck models manufactured • ERC16-20VA (ERC030-040VA) (A969)
before November 2014
• ERC22-35VG (ERC045-070VG) (A968) 3. Connect accelerator pedal or Foot Directional
Control pedal, and install front floor plate using
• ERP22-35VL (ERP045-070VL) (A976) capscrews and washers.
• ERP40-80VM (ERP080-100VM) (A985)
ERC100VHS) (A938)
180
4. Install rear floor plate. A non-blank VSM or display panel is one that has
been used previously. A non-blank VSM or display
5. Install floor mat and connect the battery. See panel is not usable outside of the system it was
Figure 132. originally connected to. In other words, a VSM or
display panel cannot be removed from one lift truck
PROGRAMMING A NEW VSM AND/OR and installed onto another lift truck. If a VSM or display
DISPLAY PANEL panel must be replaced, a new part (blank) must be
used. See the Parts Manual for part numbers for
NOTE: See section Diagnostic Troubleshooting replacement parts.
Manual 9000YRM1377 for information on how delete
and reset fault codes to the VSM, how to use the PC
PC SERVICE TOOL SOFTWARE
Service Tool software, and for the procedures to
troubleshoot the VSM, display panel, and other To perform diagnostic service, the PC Service Tool
electrical components used on these trucks. software can be used. To connect the PC Service Tool,
remove the dust cover that covers the PC service tool
NOTE: When installing a new VSM or Display use PC
diagnostic connector on the right side of the steering
Service Tool to upload Application Code and the
column and connect the interface cable (Yale Part No.
correct Configuration Data File.
580039670) to the PC service tool diagnostic
Two file types are required to operate the VSM; connector. See Figure 167. All transfers will create a
Application Code File and Configuration Data File transfer log on the PC's hard drive and can be
(CDF). New VSMs will have the Application Code accessed by service personnel. The file transfer log
loaded but you will need to upload a truck specific will include all serial number transfers and other
CDF. configuration information related to a specific truck.
• Application Code File - These are operating For minimum PC requirements to run the software,
files for the VSM and Display. refer to the PC Service Tool Installation and Use
Guide, Systems Requirements section.
• Configuration Data File (CDF) - This file
contains a unique set of data values that
represent how a truck is equipped, how systems
are controlled, and what options are enabled.
The CDF is also linked and unique to the truck
serial number. An example of a lift truck serial
number is K160V12345A001. The first 11
characters (K160V12345A) represent the truck’s
serial number and the last 3 digits (001)
represent the CDF revision loaded on the truck.
The serial number of a lift truck is stored in the
display panel. See User Interface Service
Technician 2200YRM1336 for the procedures
to find the serial number. The CDF can be found
online at Axcess Online® using the serial
number.
The CDF revision will change every time a new
version is ordered and transferred to Axcess
Online® . The CDF cannot be modified by a
service technician. However, a replacement file
(with alternate options [SEF]) can be loaded into
a truck VSM by a service technician.
1. DUST COVER
2. TILT MEMORY LEVER
Figure 167. Connecting PC Service Tool
181
Fuses and Relays 2200 YRM 1369
Fuses and Relays

Fuses The fuse panel for lift trucks covered in this service
manual are located in the counterweight. For lift truck
models ERC22-35VG (ERC045-070VG) (A968) and
WARNING ERC16-20VA (ERC030-040VA) (A969) , fuses are
Disconnect the battery and separate the connector located on back wall and right side of counterweight,
before opening the compartment cover or just above traction motor controller. See Figure 168.
inspecting/repairing the electrical system. If a tool For lift truck models ERP22-35VL (ERP045-070VL)
causes a short circuit, the high-current flow from (A976) and ERP40-50VM, ERP50-55VM6
the battery can cause an injury or parts damage. (ERP080-120VM, ERP100VML) (A985) , fuses are
mounted on same bracket as line contactor. The fuses
and line contactor assembly bracket is mounted to a
WARNING crossmember in the center of counterweight.
Use only fuses of the same type and rating as See Figure 169 for lift truck models
specified in Figure 168, Figure 169, and Figure 170.
Replacing fuses of a different type or with higher • ERP22-35VL (ERP045-070VL) (A976)
or lower amperage ratings than specified may See Figure 170 for lift truck models
cause injury or parts damage.
• ERP40-80VM (ERP080-100VM) (A985)
WARNING
Discharge capacitors as directed in Discharging • ERP40-50VM, ERP50-55VM6
the Capacitors in the General section at the (ERP080-120VM, ERP100VML) (A985)
beginning of this manual. manufactured after November 2014
The fuse panel for lift truck model ERC40-55VH,
ERC50VHS (ERC80-120VH, ERC100VHS) (A938) is
located under counterweight cover above and
centered between motor controllers. See Figure 170.
182
2200 YRM 1369 Fuses and Relays
NOTE: STANDARD PERFORMANCE CONTROLLER SHOWN. ENHANCED PERFORMANCE IS SIMILAR.
A. FUSE LOCATION FOR LIFT TRUCK MODELS ERC22-35VG (ERC045-070VG) (A968) MANUFACTURED
BEFORE SEPTEMBER, 2011
B. FUSE LOCATION FOR LIFT TRUCK MODELS ERC22-35VG (ERC045-070VG) (A968) MANUFACTURED
AFTER SEPTEMBER, 2011
C. FUSE LOCATION FOR LIFT TRUCK MODEL ERC16-20VA (ERC030-040VA) (A969) MANUFACTURED
BEFORE NOVEMBER 2014 SHOWN. FUSE LOCATION FOR LIFT TRUCK MODEL ERC030-040VA (A969)
MANUFACTURED AFTER NOVEMBER 2014 IS THE SAME.
1. LINE CONTACTOR 5. FUSE WIRES

2. COUNTERWEIGHT 6. FUSE COVER
3. FUSES (5 AMPS AND 15 AMPS) 7. HYDRAULIC PUMP AND MOTOR CONTROLLER
4. TRACTION MOTOR CONTROLLER
Figure 168. Fuse Location for Lift Truck Models and ERC22-35VG (ERC045-070VG) (A968) ERC16-20VA
(ERC030-040VA) (A969)
183
A. FUSE LOCATION ON LIFT TRUCK MODELS MANUFACTURED BEFORE SEPTEMBER, 2009 (STANDARD
APPLICATION)
B. FUSE LOCATION ON LIFT TRUCK MODELS MANUFACTURED AFTER NOVEMBER, 2013 (OUTDOOR
APPLICATION)
C. FUSE LOCATION ON LIFT TRUCK MODELS MANUFACTURED AFTER SEPTEMBER, 2009 (STANDARD
APPLICATION)

3. FUSES (5 AMPS AND 15 AMPS) 6. CROSSMEMBER
Figure 169. Fuse Locations for Lift Truck Models ERP22-35VL (ERP045-070VL) (A976)
184
A. FUSE LOCATION ON LIFT TRUCK MODELS ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS)

(A938)
B. FUSE LOCATION ON LIFT TRUCK MODELS ERP40-80VM (ERP080-100VM) (A985)

3. FUSES (5 AMPS AND 15 AMPS) 6. CROSSMEMBER
Figure 170. Fuse Locations for Lift Truck Models Manufactured Before November 2014 and ERP40-80VM
(ERP080-100VM) (A985) ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938)
185
NOTE: STANDARD PERFORMANCE CONTROLLER

SHOWN. ENHANCED PERFORMANCE IS SIMILAR.
1. LINE CONTACTOR
2. COUNTERWEIGHT
3. FUSES (5 AMPS AND 15 AMPS)
4. FUSE COVER
5. CROSSMEMBER
Figure 171. Fuse Locations for Lift Truck Models

Manufactured After November 2014ERP40-50VM, 1. CAPSCREWS
ERP50-55VM6 (ERP080-120VM, ERP100VML) 2. COUNTERWEIGHT COVER
(A985) 3. COUNTERWEIGHT
Remove the counterweight cover for access to the Figure 172. Counterweight Cover Removal, Lift
fuses. Truck Models and ERC22-35VG (ERC045-070VG)
(A968), ERC16-20VA (ERC030-040VA) (A969),
• ERC22-35VG (ERC045-070VG) (A968) ERC100VHS) (A938)
• ERC16-20VA (ERC030-040VA) (A969)
ERC100VHS) (A938)
See Figure 173or Figure 174 for lift truck models
• ERP22-35VL (ERP045-070VL) (A976)
(ERP080-120VM, ERP100VML) (A985)
Fuses must be checked with a multimeter. Discharge
capacitors as specified in Discharging the Capacitors
in General section at the beginning of this service
manual.
186
1. TOW PIN
2. KNOB SCREWS
NOTE: COUNTERWEIGHT FOR LIFT TRUCK MOD- 4. COUNTERWEIGHT
COUNTERWEIGHT FOR LIFT TRUCK MODELS Figure 174. Counterweight Cover Removal, Lift
ERP40-50VM, ERP50-55VM6 (ERP080-120VM, Truck Models Manufactured After November,
ERP100VML) (A985) IS SIMILAR. 2015ERP22-35VL (ERP045-070VL) (A976)
1. COUNTERWEIGHT Before replacing any failed fuses, check to see what

2. COUNTERWEIGHT COVER caused the fuse to open before connecting the battery.
3. WASHER
4. CAPSCREWS Make certain to replace any failed fuse with one of the
5. TOW PIN same type and amperage.
For lift truck models ERP22-35VL (ERP045-070VL)
Figure 173. Counterweight Cover Removal, Lift
(A976) , equipped with Outdoor Protection/Wash-down
Truck Models and ERP22-35VL (ERP045-070VL)
Package, spray fuse connection with rust inhibitor-
(A976) ERP40-50VM, ERP50-55VM6
ignition sealer.
(ERP080-120VM, ERP100VML) (A985)
187
Relays See Figure 178 for the following lift truck models
• ERC80-120VH, ERC100VHS (A938)
WARNING
Disconnect the battery and separate the connector See Figure 179 for the following lift truck models
before opening the compartment cover or manufactured after November 2014
inspecting/repairing the electrical system. If a tool • ERC030-040VA (A969)
causes a short circuit, the high-current flow from
the battery can cause an injury or parts damage.
(ERP080-120VM, ERP100VML) (A985)
WARNING
Discharge capacitors as directed in Discharging 1. Remove floor mat and floor plate for access to
the Capacitors in the General section at the relays.
beginning of this manual.
2. Remove relay from receptacle.
NOTE: When replacing relays, use only Yale
approved relays. See Figure 175 for the following lift truck models
On lift truck models ERC22-35VG (ERC045-070VG)
(A968) and ERC16-20VA (ERC030-040VA) (A969) , • ERC22-35VG (ERC045-070VG) (A968)
relays and receptacles are mounted in the center of • ERP22-35VL (ERP045-070VL) (A976)
front bulkhead. • ERP40-80VM (ERP080-100VM) (A985)
On lift truck models ERP22-35VL (ERP045-070VL) • ERC40-55VH, ERC50VHS (ERC80-120VH,
(A976), ERP40-50VM, ERP50-55VM6 ERC100VHS) (A938)
(ERP080-120VM, ERP100VML) (A985), and
ERC100VHS) (A938) , relays and receptacles are
mounted on left side of front bulkhead, near Vehicle • ERC16-20VA (ERC030-040VA) (A969)
Systems Manager (VSM). See Figure 177 for the following lift truck models
For lift truck models ERP22-35VL (ERP045-070VL) manufactured after November 2014
(A976) , equipped with Outdoor Protection/Wash-down • ERC045-070VG (A968)
Package, control circuit relays are sealed relays with
sealed connectors or fitted with individual • ERP22-35VL (ERP045-070VL) (A976)
weatherproof covers. See Figure 178 for the following lift truck models
See Figure 175 for the following lift truck models manufactured after November 2014
manufactured before November 2014 • ERC80-120VH, ERC100VHS (A938)
• ERC22-35VG (ERC045-070VG) (A968) See Figure 179 for the following lift truck models
• ERP22-35VL (ERP045-070VL) (A976) manufactured after November 2014
• ERP40-80VM (ERP080-100VM) (A985) • ERC030-040VA (A969)
• ERC40-55VH, ERC50VHS (ERC80-120VH, See Figure 180 for the following lift truck models
ERC100VHS) (A938) manufactured after November 2014
See Figure 176 for the following lift truck models • ERP40-50VM, ERP50-55VM6
manufactured before November 2014 (ERP080-120VM, ERP100VML) (A985)
• ERC16-20VA (ERC030-040VA) (A969)
See Figure 177 for the following lift truck models (ERP045-070VL) (A976) , equipped with Outdoor
manufactured after November 2014 Protection/Wash-down Package, apply dielectric
• ERC045-070VG (A968) grease to flasher relay terminal connections.
• ERP22-35VL (ERP045-070VL) (A976)
188
4. Replace with new relay by aligning the relay with 5. Install floor plate and floor mat.
mounting holes in receptacle.
NOTE: RELAYS FOR LIFT TRUCK MODELS ERC22-35VG (ERC045-070VG) (A968) SHOWN. RELAYS FOR
TRUCKS EQUIPPED WITH OPTIONAL E-HYDRAULICS, OPTIONAL SYNCHRONOUS STEERING, AND OTH-
ER OPTIONS SHOWN.
1. KEYSWITCH RELAY (12 VOLTS) 6. TURN SIGNAL RELAY (24 VOLTS)

2. E-HYDRAULIC RELAY (24 VOLTS) 7. FRONT BULKHEAD
3. SYNCHRONOUS STEER VALVE RELAY (24 8. RECEPTACLE
VOLTS) 9. WIRE HARNESS
4. BRAKE LIGHT RELAY (24 VOLTS)
5. REVERSE RELAY (24 VOLTS)
Figure 175. Relay Replacement for Lift Truck Models Manufactured Before November 2014ERC22-35VG
(ERC045-070VG) (A968), ERP22-35VL (ERP045-070VL) (A976), ERP40-80VM (ERP080-100VM) (A985), and
ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938)
189
Figure 176. Relay Replacement for Lift Truck Model Manufactured Before November 2014ERC16-20VA
(ERC030-040VA) (A969)
190
A. MANUAL HYDRAULICS B. E-HYDRAULICS
1. KEY SWITCH RELAY 5. RECEPTACLE

2. FLASHER (TURN SIGNAL OPTION) RELAY 6. WIRE HARNESS
3. BRAKE LIGHT RELAY 7. E-HYDRAULIC ENABLE RELAY
4. REVERSE RELAY 8. FRONT BULKHEAD
191
A. RELAY ARRANGEMENT, LIFT TRUCK MODELS B. RELAY ARRANGEMENT, LIFT TRUCK MODELS
ERP22-35VL (ERP045-070VL) (A976) ERC045-070VG (A968)
1. PUMP FAN (12VOLTS) 7. MOUNTING BRACKET

2. KEY SWITCH (12 VOLTS) 8. FRONT BULKHEAD
3. E-HYDRAULIC RELAY (24 VOLTS) 9. WIRE HARNESS
4. TURN SIGNAL (24 VOLTS) 10. RECEPTACLE
5. REVERSE RELAY (24 VOLTS) 11. VEHICLE SYSTEMS MANAGER
6. BRAKE LIGHT (24 VOLTS) 12. SYNCHRONOUS STEERING (24 VOLTS)
Figure 177. Relay Replacement for Lift Truck Models Manufactured After November 2014ERC045-070VG
(A968) and ERP22-35VL (ERP045-070VL) (A976)
192
1. KEY SWITCH (12VOLTS) 7. TURN SIGNAL FLASHER (24 VOLTS)

2. TRACTION MOTOR FAN (12 VOLTS) 8. FRONT BULKHEAD
3. HYDRAULIC PUMP AND MOTOR FAN RELAY 9. MOUNTING BRACKET
(12 VOLTS) 10. RECEPTACLE
4. REVERSE RELAY (24 VOLTS) 11. WIRE HARNESS
5. BRAKE LIGHT (24 VOLTS) 12. VEHICLE SYSTEMS MANAGER
6. E-HYDRAULIC RELAY (24 VOLTS)
Figure 178. Relay Replacement for Lift Truck Models Manufactured After November 2014ERC80-120VH,
ERC100VHS (A938)
193
Figure 179. Relay Replacement for Lift Truck Model Manufactured After November 2014ERC030-040VA
(A969)
194
A. MANUAL HYDRAULICS B. E-HYDRAULICS
1. KEY SWITCH RELAY 5. RECEPTACLE

2. FLASHER (TURN SIGNAL OPTION) RELAY 6. WIRE HARNESS
3. BRAKE LIGHT RELAY 7. E-HYDRAULIC ENABLE RELAY
4. REVERSE RELAY 8. FRONT BULKHEAD
1. FRONT BULKHEAD 5. FAN RELAY (24 VOLTS)

2. E-HYDRAULIC RELAY (24 VOLTS) 6. RECEPTACLE
3. REVERSE RELAY (24 VOLTS) 7. WIRE HARNESS
4. BRAKE LIGHT RELAY (24 VOLTS)
Figure 180. Relay Replacement for Lift Truck Models Manufactured After November 2014ERP40-50VM,
ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)
195
Backup Alarm 2200 YRM 1369
Backup Alarm
If backup alarm is not functioning properly, remove
WARNING counterweight cover for access.
DO NOT operate a truck if the backup alarm does See Figure 172 for lift truck models
not function properly. Injury to personnel may • ERC22-35VG (ERC045-070VG) (A968)
occur.
• ERC16-20VA (ERC030-040VA) (A969)
A backup alarm is used to indicate backwards travel. • ERC40-55VH, ERC50VHS (ERC80-120VH,
When backing up, the operator may be preoccupied ERC100VHS) (A938)
with the position of the mast or carriage or have a See Figure 173 or Figure 174 for lift truck models
restricted range of visibility. The backup alarm sounds
when the lift truck is moved backwards to alert nearby • ERP22-35VL (ERP045-070VL) (A976)
traffic to pay close attention when near the lift truck. • ERP40-50VM, ERP50-55VM6
The alarm is located inside of the counterweight. (ERP080-120VM, ERP100VML) (A985)
See Figure 181 for lift truck models Test voltage to backup alarm by sitting in seat and
moving Direction Control Switch (DCS) to reverse
• ERC22-35VG (ERC045-070VG) (A968)
position. When proper voltage (12 to 48 volts) is
• ERP22-35VL (ERP045-070VL) (A976) reaching the assembly yet no sound is produced, the
• ERP40-50VM, ERP50-55VM6 assembly must be replaced. Disconnect alarm
(ERP080-120VM, ERP100VML) (A985) connector from lighting wiring harness. Remove two
See Figure 182 for lift truck models capscrews attaching alarm to mounting plate. Position
new backup alarm as removed and secure using two
• ERC16-20VA (ERC030-040VA) (A969) capscrews. Tighten capscrews to
See Figure 183 for lift truck model 3.5 to 4 N•m (31 to 35 lbf in). Connect alarm connector
as removed and test for proper operation. Install
• ERC40-55VH, ERC50VHS (ERC80-120VH, counterweight cover and return to service.
ERC100VHS) (A938)
196
2200 YRM 1369 Backup Alarm
Figure 181. Backup Alarm for Lift Truck Models , , and ERC22-35VG (ERC045-070VG) (A968) ERP22-35VL
(ERP045-070VL) (A976) ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)
197
Backup Alarm 2200 YRM 1369

NOTE: SEVERAL COMPONENTS OMITTED FOR CLARITY.
A. BACKUP ALARM LOCATION FOR LIFT TRUCK B. BACKUP ALARM LOCATION FOR LIFT TRUCK
MODELS ERC22-35VG (ERC045-070VG) (A968) MODELS ERP22-35VL (ERP045-070VL) (A976)
AND ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985)
1. MOUNTING PLATE 4. BACKUP ALARM

2. ALARM CONNECTOR 5. COUNTERWEIGHT
3. CAPSCREW 6. CROSSMEMBER
1. MOUNTING PLATE 4. BACKUP ALARM

2. ALARM CONNECTOR 5. COUNTERWEIGHT
3. CAPSCREW
Figure 182. Backup Alarm for Lift Truck Model ERC16-20VA (ERC030-040VA) (A969)
198
2200 YRM 1369 Battery Connection
1. MOUNTING PLATE
2. ALARM CONNECTOR
3. CAPSCREW
4. BACKUP ALARM
5. COUNTERWEIGHT
Figure 183. Backup Alarm for Lift Truck Model

ERC100VHS) (A938)
Battery Connection
The battery cables supply power from the battery REPLACING CABLES
terminals through the battery cable connectors and
then to the connections of the motor controllers and
main contactor in the truck. WARNING
Making repairs with the battery connected can
INSPECT cause a short circuit. Disconnect the battery by
separating the connectors before inspecting or
Inspect battery cables for cuts or damage to insulation. repairing the electrical system.
Inspect for abrasions of insulation or burned insulation
or connector ends. Inspect battery connectors for worn Be careful using tools near the battery terminals.
or damaged cable ends or cracked housings. Contact between terminals can cause a short
Overheated cables or heat affected terminal lug ends circuit. High current flow during a short circuit can
are signs of cable damage, loose connections, or result in injury or parts damage.
improper battery charging or maintenance. Replace
any damaged cables and repair or replace damaged 1. Move lift truck to a safe, level area and
battery connectors. completely lower mast. Turn key switch to OFF
position and attach a DO NOT OPERATE tag to
control handle. Block drive wheel to prevent
unexpected movement.
199
Battery Connection 2200 YRM 1369
2. Pull connector (battery side) from fixed connector 4. If power cables or connector (truck side) are
(truck side) to separate battery cable connectors. damaged, replace cables:
See Figure 184.
a. For lift trucks manufactured before June 2012:
Remove floor mat. Remove rear floor plate.
Remove capscrews and washers from front
floor plate and lift front floor plate up enough to
disconnect accelerator pedal or Foot
Directional Control pedal. See Figure 132.
Remove front floor plate with accelerator or
Foot Directional Control pedal still attached for
access to main contactor.
For lift trucks manufactured after June 2012:
Remove floor mat. Remove rear floor plate. Lift
front floor plate up enough to disconnect
with accelerator or Foot Directional Control
pedal still attached for access to main
contactor.
b. Discharge capacitors. See Discharging the

Capacitors in General section of this manual
for procedures.
NOTE: Make note of position of cables for proper

reinstallation.
c. Remove nuts securing cables to terminals of
main contactor. Remove cables from terminals.
d. Remove two clamps securing cables to frame

Figure 184. Battery Connector and Cables inside electrical compartment. One cable is on
top of hydraulic filter and the other is under
3. If power cables or connector (battery side) are
hydraulic motor.
damaged, replace cables:
e. Remove hardware securing connector (truck
a. Remove battery from lift truck. See Operating
side) to mounting bracket.
Manual or Periodic Maintenance for
procedures to remove battery from lift truck. f. Remove power cables from lift truck.
b. Disconnect cables from battery terminals. g. Route new cables into electrical compartment.
c. Install new cables. h. Secure connector to mounting bracket using
capscrews and attaching hardware.
d. Reinstall battery to lift truck. See Operating
Manual or Periodic Maintenance for i. Position power cables onto terminals as
procedures to install battery in lift truck. removed. Secure cables to terminals of main
contactor and hoist controller using attaching
e. Connect battery connectors.
hardware. Tighten hardware to
18 to 21 N•m (159 to 186 lbf in).
200
2200 YRM 1369 Cab Heater
j. Install two clamps securing power cables to k. Connect accelerator pedal or Foot Directional
frame inside electrical compartment as Control pedal, (see Figure 132) and install
removed. front floor plate using capscrews and washers.
Install rear floor plate. Install floor mat and
Cab Heater
For repair procedures on the cab heater refer to
section Operator's Cab 0100YRM1446.
Lights
GENERAL Lift truck models ERC045-070VG (A968),
ERP045-070VL (A976), ERP080-120VM,
ERP100VML (A985), ERC80-120VH, ERC100VHS
WARNING (A938), and ERC030-040VA (A969) manufactured
Before replacing any of the lights, fully lower all after November 2014 may be equipped with an option
parts of the mast and tilt it forward until the tips of that automatically turns the front lights on whenever
the forks touch the ground. This action will the key or keyless switch is turned on and go off when
prevent the mast from lowering suddenly if the the key or keyless switch is turned off.
control lever is accidently moved. In addition, these lift truck models may also be
Never have any metal on your fingers, arms, or equipped with a rear drive light that is activated
neck. These metal items can accidentally create an whenever the lift truck travels in the reverse direction
electrical connection and cause an injury. or reverse is selected with either the Foot Directional
Control pedal or direction control switch.
There are no switches on the dash panel if lift truck is
WARNING equipped with these light options. See the Operating
Discharge capacitors as directed in Discharging Manual for procedures to check the operation of these
the Capacitors in General section of this manual. light options.
Disconnect the battery before doing any work on There are several different options for lights used on
the electrical system. Serious injury to personnel lift trucks covered in this service manual. Your lift truck
and/or damage to lift truck components can occur may not be equipped with all lights discussed in this
if battery is not disconnected. section.
• ERC22-35VG (ERC045-070VG) (A968)
CAUTION
A short circuit and damage can occur if wires are • ERP22-35VL (ERP045-070VL) (A976)
not installed correctly. Make sure wire connectors • ERP40-50VM, ERP50-55VM6
do not touch the other metal terminals or wire (ERP080-120VM, ERP100VML) (A985)
connectors, metal brackets, or the bracket • ERC40-55VH, ERC50VHS (ERC80-120VH,
mounting nuts. Make sure the wires are not pulled ERC100VHS) (A938)
the insulation.
• ERC16-20VA (ERC030-040VA) (A969)
201
Lights 2200 YRM 1369
Figure 185. Lights Arrangement for Lift Truck Models and ERC22-35VG (ERC045-070VG) (A968),
ERP22-35VL (ERP045-070VL) (A976), ERP40-50VM, ERP50-55VM6 (ERP080-120VM,
ERP100VML) ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938)
202
2200 YRM 1369 Lights

NOTE: LIFT TRUCK MODELS ERC22-35VG (ERC045-070VG) (A968) SHOWN. LIGHTS ARRANGEMENT
FOR LIFT TRUCK MODELS ERP22-35VL (ERP045-070VL) (A976) , ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985) , AND ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938)
IS THE SAME.
NOTE: FRONT AND REAR HALOGEN WORK LIGHTS SHOWN. FOR FRONT AND REAR LED LIGHTS, SEE
LED LIGHTS.
A. FRONT VIEW C. REAR VIEW AFTER JUNE 2012

B. REAR VIEW BEFORE JUNE 2012
1. FRONT WORK LIGHTS 4. LED TAIL, BACKUP, AND BRAKE LIGHTS

2. FRONT MARKER/TURN SIGNAL LIGHTS 5. REAR WORK LIGHTS
3. STROBE LIGHT
203
NOTE: FRONT AND REAR HALOGEN WORK LIGHTS SHOWN. FOR FRONT AND REAR LED LIGHTS, SEE
LED LIGHTS.
A. FRONT VIEW C. REAR VIEW AFTER JUNE 2012

B. REAR VIEW BEFORE JUNE 2012
1. FRONT WORK LIGHT 4. STROBE LIGHT

2. FRONT MARKER/TURN SIGNAL LIGHT 5. TAIL, BACKUP, AND BRAKE LIGHT
3. DOME LIGHT 6. REAR WORK LIGHT
Figure 186. Lights Arrangement for Lift Truck Model ERC16-20VA (ERC030-040VA) (A969)
204
WORK LIGHTS (FRONT AND REAR)

Halogen Bulb Lights
Remove
2. Disconnect negative battery cable from terminal.
CAUTION
DO NOT touch the Halogen bulb surface or inside
reflectors with your bare hands. Oils from skin can
lead to breakage or shorten the life of the lamp.
Use clean gloves or lint free cloth for installation
and removal.
Clean any dirt or oil, from the lamp surface with
alcohol and a lint free cloth or tissue. Any foreign NOTE: REAR WORK LIGHT SHOWN, FRONT
particles or materials on the bulb surface can WORK LIGHT IS SIMILAR.
cause hot spots on the bulb and result in lamp
failure. 1. CAPSCREWS (LENS ASSEMBLY)
2. LENS ASSEMBLY
3. To replace bulb, remove lens assembly by 3. NUT (ATTACHES LIGHT TO OVERHEAD
GUARD)
removing four capscrews. See Figure 187.
Replace bulb and reinstall lens assembly. Figure 187. Halogen Bulb Work Lights
4. To replace work light assembly, disconnect
overhead guard harness from light and remove
LED Lights
capscrew, washer, and nut attaching work light to NOTE: LED work lights are an optional feature on lift
overhead guard for front work lights, or to trucks covered in this service manual. If LED work light
mounting bracket for rear work lights. malfunctions, the whole LED work light assembly must
be replaced.
Install
1. Install work light on overhead guard using
Remove
capscrew, washer, and nut. See Figure 187. 1. Read and follow WARNING and CAUTION
Tighten nut to 20 N•m (177 lbf in). Connect section in General section above.
overhead guard harness to work light.
2. Connect negative battery cable to terminal.
3. Disconnect overhead guard harness from work
light.
4. Remove locknut, washer, and capscrew and

remove LED work light from overhead guard. See
Figure 188.
205
A. LED WORK LIGHT FOR LIFT TRUCK MODELS B. LED WORK LIGHT FOR LIFT TRUCK MODELS
MANUFACTURED BEFORE APRIL, 2017 MANUFACTURED AFTER APRIL, 2017
1. LOCKNUT 4. MOUNTING BRACKET

2. WASHER 5. LED LIGHT ASSEMBLY
3. CAPSCREW
Figure 188. LED Work Lights
Install 2. Disconnect negative battery cable from terminal.

1. Install new LED work light assembly by using 3. Disconnect overhead guard harness from strobe
capscrew, washer, and locknut. For lift truck light electrical connector.
models manufactured before April, 2017, tighten
locknut to 20 N•m (177 lbf in). For lift truck models 4. Remove capscrews, washers, lockwasher, and
manufactured after April, 2017, tighten locknut to nuts securing strobe light and light guard to
5 to 6 N•m (44 to 53 lbf in). See Figure 188. strobe light mounting bracket. See Figure 189.
Remove strobe light and guard from lift truck.
2. Connect overhead guard harness to work light.
NOTE: If strobe light on your lift truck is equipped with
3. Connect negative battery cable to terminal. a replaceable halogen bulb, go to Step 5. If strobe light
is equipped with LED lights, the whole light assembly
STROBE LIGHT must be replaced. Go to Step 2 in the Install section.
NOTE: The strobe light may either be mounted above
the top of overhead guard (high-mounted) or below the 5. If strobe light bulb needs to be replaced, remove
top of overhead guard (low-mounted). The removal strobe light lens from base and remove bulb.
and installation procedures are the same for both
options. Install
1. If bulb is being replaced, install new bulb into
Remove strobe light base. Install strobe light lens onto
1. Read and follow WARNING and CAUTION base.
206
2. Place strobe light assembly and strobe light guard LED TAIL, BACKUP, AND BRAKE LIGHTS
onto mounting bracket. Secure assembly to
mounting bracket with capscrews, washers, NOTE: These light assemblies are non-repairable and
lockwasher, and nuts. See Figure 189. must be replaced as an assembly. See Parts Manual
for replacement LED lights.
3. Connect overhead guard harness to strobe light
electrical connector. Remove
4. Connect negative battery cable to terminal. section in General section above.
2. Remove key, or turn keyless switch OFF, if truck

is equipped with this switch.
4. Remove torx head screw securing LED light

assembly to LED light housing. See Figure 190.
5. Disconnect chassis light harness from LED light

assembly.
6. If LED light housing must be removed from

overhead guard leg, remove two capscrews and
LED light housing from overhead guard leg. The
inserts should remain attached to housing. See
Figure 190.
1. CAPSCREW
2. MOUNTING BRACKET
3. STROBE LIGHT BULB
4. STROBE LIGHT GUARD
5. NUT
6. STROBE LIGHT LENS
7. LIGHT BASE
Figure 189. Strobe Light Assembly

Figure 190. LED Tail, Backup, and Brake Lights
Replacement
207
1. TORX HEAD SCREW

2. LED LIGHT ASSEMBLY
3. CAPSCREW
4. LED LIGHT HOUSING
5. INSERT
Install
1. If LED light housing was removed, install housing
on overhead guard leg with two capscrews and
inserts.
2. Connect chassis light harness to LED light

assembly.
3. Insert torx head screw and install LED light

assembly to LED light housing. See Figure 190.
NOTE: RIGHT FRONT MARKER/TURN SIGNAL
4. Connect negative battery cable to terminal. LIGHT ASSEMBLY SHOWN. PROCEDURES TO RE-
MOVE AND REPLACE LEFT FRONT MARKER/
FRONT MARKER/TURN SIGNAL LIGHTS TURN SIGNAL LIGHT ASSEMBLY ARE THE SAME.
Remove 1. FRONT MARKER/TURN SIGNAL LIGHT

ASSEMBLY
1. Read and follow WARNING and CAUTION in 2. CONNECTOR
General section above. 3. BOLT
4. OVERHEAD GUARD
2. Disconnect negative battery cable from terminal. 5. TRIM
3. Disconnect light wire harness from front marker/ Figure 191. Front Marker/Turn Signal Light
turn signal light connector. Assembly Removal
4. Remove two bolts located at top of the front Install

marker/turn signal light assembly and inside
1. Install new front marker/turn signal light assembly
corner of overhead guard. See Figure 191.
to overhead guard and trim using two bolts. See
5. Remove front marker/turn signal light assembly Figure 191.
from overhead guard and trim. See Figure 191.
2. Connect light wire harness to front marker/turn
signal light connector.
3. Connect negative battery cable to terminal.
DOME LIGHT
Remove
2. Disconnect negative battery terminal.
3. Disconnect light wire harness from dome light

connector.
208
4. Remove two screws and dome light from On lift truck models ERC030-040VA (A969)
overhead guard. See Figure 192. manufactured after November 2014, the standard
converter is mounted on a mounting bracket attached
to the front bulkhead and to the left of the Vehicle
Systems Manager (VSM). These lift trucks may be
equipped with an optional converter that is mounted on
a mounting bracket on the right wall of the frame.
On lift truck models ERC045-070VG (A968)
manufactured after November 2014, the converter is
mounted on a mounting bracket on the right wall of the
frame.
On lift truck models ERP22-35VL (ERP045-070VL)
(A976) and ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985) , the converter
is mounted on the rear bulkhead, in front of the
hydraulic tank.
1. SCREWS
2. DOME LIGHT • ERC22-35VG (ERC045-070VG) (A968)
3. OVERHEAD GUARD • ERC16-20VA (ERC030-040VA) (A969)
Figure 192. Dome Light See Figure 194 for the following lift truck models
Install • ERC045-070VG (A968)
1. Install new dome light and two screws on • ERC030-040VA (A969)
overhead guard. See Figure 192. See Figure 195 for lift truck models
2. Connect light wire harness to dome light • ERP22-35VL (ERP045-070VL) (A976)
connector. • ERP40-80VM (ERP080-100VM) (A985)
3. Connect negative battery terminal.
CONVERTER
The LED tail, backup, and brake Lights operate at 12 (ERP080-120VM, ERP100VML) (A985)
volts with a DC/DC converter. On lift truck models
ERC22-35VG (ERC045-070VG) (A968), See Figure 197 for the following lift truck models
ERC16-20VA (ERC030-040VA) (A969), and manufactured before November 2014
ERC40-55VH, ERC50VHS (ERC80-120VH, • ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938) manufactured before November ERC100VHS) (A938)
2014, the standard converter is mounted to the front See Figure 198 for the following lift truck models
bulkhead, behind the hydraulic pump and motor. Lift manufactured after November 2014
truck models manufactured before November 2014
ERC22-35VG (ERC045-070VG) (A968) and • ERC80-120VH, ERC100VHS (A938)
ERC16-20VA (ERC030-040VA) (A969) may also be
equipped with an optional converter that is mounted on
the right wall of the frame.
209
Remove See Figure 193 for the following lift truck models
1. Read and follow the WARNING and CAUTION
section in the General section above. • ERC22-35VG (ERC045-070VG) (A968) and
ERC16-20VA (ERC030-040VA) (A969)
2. Disconnect negative battery cable from terminal. See Figure 194 for the following lift truck models
3. For lift truck models ERC22-35VG
(ERC045-070VG) (A968) and ERC16-20VA • ERC22-35VG (ERC045-070VG) (A968) and
ERC16-20VA (ERC030-040VA) (A969)
(ERC030-040VA) (A969) , remove the floor mat.
Remove rear floor plate. Remove capscrews and 7. For lift truck models ERP22-35VL
washers from front floor plate and lift front floor (ERP045-070VL) (A976) and ERP40-80VM
plate up enough to disconnect the accelerator (ERP080-100VM) (A985) , remove four
pedal or Foot Directional Control pedal. Remove capscrews from converter and remove converter
front floor plate with the accelerator or Foot from rear bulkhead.
Directional Control pedal still attached for access
to the converter. See Figure 132. See Figure 195 for lift truck models
• ERP22-35VL (ERP045-070VL) (A976)
(ERP045-070VL) (A976) and ERP40-50VM, • ERP40-80VM (ERP080-100VM) (A985)
(A985) , remove the tow pin and counterweight See Figure 196 for the following lift truck models
cover for access to the converter. See Figure 125. manufactured after November 2014
5. Disconnect main wire harness from electrical (ERP080-120VM, ERP100VML) (A985)
connector. manufactured after November 2014
6. For lift truck models ERC22-35VG 8. For lift truck model ERC40-55VH, ERC50VHS
(ERC045-070VG) (A968) and ERC16-20VA (ERC80-120VH, ERC100VHS) (A938) remove
(ERC030-040VA) (A969) , remove four two capscrews from converter and remove
capscrews from converter and remove converter converter from front bulkhead.
from front bulkhead. If lift truck is equipped with
an optional converter, remove two capscrews See Figure 197 for the following lift trucks
from converter and remove converter from manufactured before November 2014
mounting plate. • ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938)
See Figure 198 for following lift trucks
• ERC80-120VH, ERC100VHS (A938)
210
Figure 193. Converter, Lift Truck Models and Manufactured Before November 2014ERC22-35VG
(ERC045-070VG) (A968) ERC16-20VA (ERC030-040VA) (A969)
211
A. STANDARD CONVERTER LOCATION B. OPTIONAL CONVERTER LOCATION
1. CAPSCREW 5. MOUNTING PLATE

2. CONVERTER 6. IMPACT SENSOR
3. ELECTRICAL CONNECTION 7. HYDRAULIC PUMP AND MOTOR
4. FRONT BULKHEAD
212
Figure 194. Converter, Lift Truck Models Manufactured After November 2014ERC045-070VG (A968) and
ERC030-040VA (A969)
213
A. STANDARD CONVERTER LOCATION, LIFT C. STANDARD CONVERTER LOCATION, LIFT

TRUCK MODELS ERC030-040VA (A969) TRUCK MODELS ERC045-070VG (A968)
B. OPTIONAL CONVERTER LOCATION, LIFT
TRUCK MODELS ERC030-040VA (A969)
1. CAPSCREW 4. FRONT BULKHEAD

2. CONVERTER 5. MOUNTING PLATE
3. ELECTRICAL CONNECTION 6. IMPACT SENSOR
1. CAPSCREW 4. HYDRAULIC TANK

2. CONVERTER 5. REAR BULKHEAD
3. ELECTRICAL CONNECTION
Figure 195. Converter, Lift Truck Models Manufactured before November 2014 and ERP40-80VM
(ERP080-100VM) (A985) ERP22-35VL (ERP045-070VL) (A976)
214
1. CAPSCREW 4. HYDRAULIC TANK

2. CONVERTER 5. REAR BULKHEAD
3. ELECTRICAL CONNECTION
Figure 196. Converter, Lift Truck Models Manufactured After November 2014 ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985)
215
1. FRONT BULKHEAD 4. CONVERTER

2. MOUNTING PLATE 5. HYDRAULIC PUMP AND MOTOR
3. CAPSCREW
Figure 197. Converter, Lift Truck Model Manufactured Before November 2014ERC40-55VH, ERC50VHS
(ERC80-120VH, ERC100VHS) (A938)
216
Figure 198. Converter, Lift Truck Model Manufactured After November 2014ERC80-120VH, ERC100VHS
(A938)
217
A. STANDARD CONVERTER LOCATION B. OPTIONAL CONVERTER LOCATION
1. FRONT BULKHEAD 4. CONVERTER

2. MOUNTING PLATE 5. HYDRAULIC PUMP AND MOTOR
3. CAPSCREW
Install 5. Connect converter to main wiring harness.

1. For lift truck model ERC40-55VH, ERC50VHS 6. Connect negative battery cable to terminal.
(ERC80-120VH, ERC100VHS) (A938) install
new standard converter on front bulkhead using 7. For lift truck models ERP22-35VL
two capscrews. (ERP045-070VL) (A976), ERP40-50VM,
2. For lift truck models ERC22-35VG (A985), ERC40-55VH, ERC50VHS
(ERC045-070VG) (A968) and ERC16-20VA (ERC80-120VH, ERC100VHS) (A938) , install the
(ERC030-040VA) (A969) , install new, standard tow pin and counterweight cover. See Figure 125.
converter on the front bulkhead using four
capscrews. If lift truck is equipped with optional 8. For lift truck models ERC22-35VG
converter, install new, optional converter to (ERC045-070VG) (A968) and ERC16-20VA
mounting plate using two capscrews. . (ERC030-040VA) (A969) , connect the
3. For lift truck models ERP22-35VL pedal, and install the front floor plate using
(ERP045-070VL) (A976) and ERP40-50VM, capscrews and washers. Install rear floor plate.
ERP50-55VM6 (ERP080-120VM, ERP100VML) Install floor mat and connect the battery. See
(A985) , install new converter on the rear Figure 132.
bulkhead using four capscrews.
4. Apply 3 mm (0.12 in.) of lubricating grease, (Yale

P/N 580011639 ) to each terminal opening on
electrical connector plug on main wire harness.
218
2200 YRM 1369 1/20 (11/17)(5/17)(1/17)(11/16)(1/16)

Electrical System: Maintenance

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Maintenance

PART NO. 524319499 2200 YRM 1369

©2020 Yale Materials Handling Corp. i

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

Before performing any tests or adjustment, block

WARNING 1. Ensure capacitors are discharged by performing

Display Panel and Key or Keyless Switch Replacement

Legend for Figure 2.

1. Read and follow WARNING and CAUTION

2. Insert a flat head screwdriver in slot on the bottom

3. Pull screwdriver down to loosen display panel

NOTE: HIGH MOUNT DISPLAY PANEL SHOWN. LOW MOUNT IS SIMILAR.

1. TOP NOTCHES 4. BOTTOM NOTCH

Figure 3. Display Panel Removal

4. When display panel is pulled from display panel

Figure 4. Warning Buzzer

5. Disconnect display wire harness from pin

NOTE: BACK SIDE OF DISPLAY PANEL SHOWN.

1. PIN CONNECTOR NOTE: KEY SWITCH SHOWN.

Install Figure 7. Key or Keyless Switch Installation

NOTE: Perform Step 2 for lift truck models

Electronic and Manual Hydraulic Controls

When removing and replacing sensors or switches, be

MANUAL HYDRAULIC CONTROLS

1. Read and follow WARNING and CAUTION

2. Remove four capscrews and front cover from

NOTE: OPTIONAL DIRECTION CONTROL SWITCH

1. UPPER FRONT COVER

Figure 8. Manual Hydraulic Control Lever

See Figure 9 for lift truck models

Direction Control Switch

2. Remove upper front cover. See section Upper

NOTE: OPTIONAL DIRECTION CONTROL SWITCH

1. UPPER FRONT COVER

3. Remove two outer capscrews and lift/lower with • ERP40-50VM, ERP50-55VM6

ERC22-35VG (ERC045-070VG) (A968) See Figure 12 for lift truck models

Legend for Figure 11.

1. PALM SIDE GRIP HANDLE 9. OUTER CAPSCREW

Legend for Figure 12.

1. PALM SIDE GRIP HANDLE 10. CABLE TRACK

4. Remove one inner capscrew and palm side grip

5. Remove direction control switch cable from cable

6. Remove two screws, direction control switch

Figure 13. Direction Control Switch

Install • ERP40-50VM, ERP50-55VM6

7. Remove push-button cable from cable track. • ERP40-50VM, ERP50-55VM6

Install 5. Install DTR clamping handle and one outer

• ERC22-35VG (ERC045-070VG) (A968) Return To Set Tilt (RTST) Button

NOTE: Ensure clamping push-button is in correct

2. Remove upper front cover. See section Upper

3. Remove five socket head capscrews from upper

NOTE: THE EMERGENCY DISCONNECT SWITCH

A. INSERT SCREWDRIVER HERE

1. EMERGENCY DISCONNECT SWITCH

Figure 15. Emergency Disconnect Switch