Yale A985 (ERP080VM, ERP090VM, ERP100VM, ERP100VML, ERP110VM, ERP120VM) Service Manual PDF

Yale Forklift A985 (ERP080VM, ERP090VM, ERP100VM, ERP100VML, ERP110VM, ERP120VM) Service Manual – PDF DOWNLOAD

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Yale Forklift A985 (ERP080VM, ERP090VM, ERP100VM, ERP100VML, ERP110VM, ERP120VM) Service Manual – PDF DOWNLOAD

Language : English
Pages : 5032
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift A985 (ERP080VM, ERP090VM, ERP100VM, ERP100VML, ERP110VM, ERP120VM) Service Manual – PDF DOWNLOAD

524150797-8000YRM0231-(02-2023)-UK-EN 1
General 7
Threaded Fasteners 7
Nomenclature, Threads 7
Strength Identification 8
Cotter (Split) Pins 9
Fastener Torque Tables 14
Conversion Table 16
524150797-8000YRM0231-(03-2020)-UK-EN 23
General 27
Threaded Fasteners 27
Nomenclature, Threads 27
Strength Identification 28
Cotter (Split) Pins 29
Fastener Torque Tables 34
Conversion Table 36
524158040-2240YRM0001-(01-2023)-UK-EN 43
General 49
Battery Type 49
Lead-Acid Batteries 49
Lithium-Ion Batteries 50
Specific Gravity 50
Chemical Reaction in a Cell 50
Electrical Terms 52
Battery Selection 53
Battery Voltage 54
Battery as a Counterweight 54
Battery Ratings 54
Kilowatt-Hours 54
Battery Maintenance 55
Safety Procedures 55
Maintenance Records 55
New Battery 55
Cleaning Battery 56
Adding Water to Battery 58
Hydrometer 58
Battery Temperature 59
Charging Battery 60
Types of Battery Charges 61
Methods of Charging 62
Troubleshooting Charger 63
Knowing When Battery Is Fully Charged 63
Where to Charge Batteries 63
Equipment Needed 63
Battery Connectors 64
Battery Care 64
Troubleshooting 66
524158040-2240YRM0001-(03-2020)-UK-EN 71
General 75
Battery Type 75
Lead-Acid Batteries 75
Lithium-Ion Batteries 76
Specific Gravity 76
Chemical Reaction in a Cell 76
Electrical Terms 78
Battery Selection 78
Battery Voltage 79
Battery as a Counterweight 80
Battery Ratings 80
Kilowatt-Hours 80
Battery Maintenance 80
Safety Procedures 80
Maintenance Records 81
New Battery 81
Cleaning Battery 81
Adding Water to Battery 83
Hydrometer 84
Battery Temperature 85
Charging Battery 86
Types of Battery Charges 86
Methods of Charging 88
Troubleshooting Charger 88
Knowing When Battery Is Fully Charged 89
Where to Charge Batteries 89
Equipment Needed 89
Battery Connectors 90
Battery Care 90
Troubleshooting 92
524223769-2200YRM1128-(01-2023)-UK-EN – Copy 97
Series Code / Model Designation Reference Table 105
General 107
Deutsch Crimping Tool 108
How to Strip a Wire for Use With Deutsch Crimping Tool 108
How to Crimp With the Deutsch Crimping Tool 109
Calibration Test for the Deutsch Crimping Tool 111
Deutsch Connectors 113
DT, DTM, and DTP Series Connectors 113
HD Series Connectors 156
Metri-Pack Connectors 178
Remove and Install 178
Micro-Pack Connectors 181
Weather-Pack Connectors 182
AMPSEAL Crimping Tools 184
AMP Hand Crimping Tool With Certi-Crimp 184
Description 184
Stripping Wire for Use with AMP Hand Crimping Tool 185
Insulation Crimp Adjustment 186
Maintenance and Inspection for AMP Hand Crimping Tool 186
AMP Hand Crimping Tool 186
Crimp Height Inspection 186
How to use AMP Hand Crimping Tool 187
AMP Pro-Crimper II Tool 187
Description 187
Remove and Install Die Set and Locator Assembly 188
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 188
Contact Support Adjustment 189
Crimp Height Adjustment 190
Maintenance and Inspection Procedures 190
PRO-CRIMPER II Tool 190
Crimp Height Inspection 190
How to Use AMP PRO-CRIMPER II Tool 191
AMPSEAL Connector Assemblies 192
Description for Plug Connector Assembly 192
Seal Plug 193
Contact Crimping 193
Description for Plug Connector and Header Assembly 198
Voltage Reading 201
Seal Plug 201
Contact Crimping 201
AMP Superseal 1 5 Crimping Tools 208
Mini Mic Receptacle and Tab Contacts 208
Description 208
Crimping Conditions and Measurements 208
Insertion of Rubber Seal on Cable 210
AMP Hand Application Tool 215
Description 215
Maintenance and Inspection 215
Crimp Height Inspection 215
Crimp Height Adjustment 216
How to Use AMP Hand Application Tool 216
AMP Pro-Crimper II Tool 217
Description 217
Remove and Install Die Set and Locator Assembly 217
Adjustments 218
Contact Support 218
Crimp Height 219
Inspections and Maintenance 220
Crimp Height Inspection 220
Visual Inspection 220
Maintenance 221
How to Use Pro-Crimper II Tool 221
AMP Superseal 1 5 Connector Assemblies 222
Description 222
Repair and Maintenance 229
Panel Mount Option 229
AMP Fastin-Faston Hand Tools 230
Description – AMP Double Action Hand Tool 230
Maintenance and Inspection Procedures 230
Daily Maintenance 230
Periodic Tool Inspection 231
Lubrication 231
Visual Inspection 231
Crimp Height Inspection 231
Certi-Crimp Ratchet Inspection 232
How to Use AMP Double Action Hand Tool 233
Description – AMP Extraction Tool 234
Maintenance and Inspection 235
How to Use AMP Extraction Tool 235
AMP Fastin-Faston Receptacles and Housings 237
Description 237
Wire Repair 245
Wire Splicing Requirements 245
Deutsch Jiffy Splice 246
Twisted/Shielded Cable and Leads Repair 252
Special Tools 254
524223769-2200YRM1128-(01-2023)-UK-EN 263
Series Code / Model Designation Reference Table 271
General 273
Deutsch Crimping Tool 274
How to Strip a Wire for Use With Deutsch Crimping Tool 274
How to Crimp With the Deutsch Crimping Tool 275
Calibration Test for the Deutsch Crimping Tool 277
Deutsch Connectors 279
DT, DTM, and DTP Series Connectors 279
HD Series Connectors 322
Metri-Pack Connectors 344
Remove and Install 344
Micro-Pack Connectors 347
Weather-Pack Connectors 348
AMPSEAL Crimping Tools 350
AMP Hand Crimping Tool With Certi-Crimp 350
Description 350
Stripping Wire for Use with AMP Hand Crimping Tool 351
Insulation Crimp Adjustment 352
Maintenance and Inspection for AMP Hand Crimping Tool 352
AMP Hand Crimping Tool 352
Crimp Height Inspection 352
How to use AMP Hand Crimping Tool 353
AMP Pro-Crimper II Tool 353
Description 353
Remove and Install Die Set and Locator Assembly 354
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 354
Contact Support Adjustment 355
Crimp Height Adjustment 356
Maintenance and Inspection Procedures 356
PRO-CRIMPER II Tool 356
Crimp Height Inspection 356
How to Use AMP PRO-CRIMPER II Tool 357
AMPSEAL Connector Assemblies 358
Description for Plug Connector Assembly 358
Seal Plug 359
Contact Crimping 359
Description for Plug Connector and Header Assembly 364
Voltage Reading 367
Seal Plug 367
Contact Crimping 367
AMP Superseal 1 5 Crimping Tools 374
Mini Mic Receptacle and Tab Contacts 374
Description 374
Crimping Conditions and Measurements 374
Insertion of Rubber Seal on Cable 376
AMP Hand Application Tool 381
Description 381
Maintenance and Inspection 381
Crimp Height Inspection 381
Crimp Height Adjustment 382
How to Use AMP Hand Application Tool 382
AMP Pro-Crimper II Tool 383
Description 383
Remove and Install Die Set and Locator Assembly 383
Adjustments 384
Contact Support 384
Crimp Height 385
Inspections and Maintenance 386
Crimp Height Inspection 386
Visual Inspection 386
Maintenance 387
How to Use Pro-Crimper II Tool 387
AMP Superseal 1 5 Connector Assemblies 388
Description 388
Repair and Maintenance 395
Panel Mount Option 395
AMP Fastin-Faston Hand Tools 396
Description – AMP Double Action Hand Tool 396
Maintenance and Inspection Procedures 396
Daily Maintenance 396
Periodic Tool Inspection 397
Lubrication 397
Visual Inspection 397
Crimp Height Inspection 397
Certi-Crimp Ratchet Inspection 398
How to Use AMP Double Action Hand Tool 399
Description – AMP Extraction Tool 400
Maintenance and Inspection 401
How to Use AMP Extraction Tool 401
AMP Fastin-Faston Receptacles and Housings 403
Description 403
Wire Repair 411
Wire Splicing Requirements 411
Deutsch Jiffy Splice 412
Twisted/Shielded Cable and Leads Repair 418
Special Tools 420
524223769-2200YRM1128-(07-2020)-UK-EN 429
Series Code / Model Designation Reference Table 435
General 438
Deutsch Crimping Tool 438
How to Strip a Wire for Use With Deutsch Crimping Tool 438
How to Crimp With the Deutsch Crimping Tool 439
Calibration Test for the Deutsch Crimping Tool 441
Deutsch Connectors 443
DT, DTM, and DTP Series Connectors 443
HD Series Connectors 485
Metri-Pack Connectors 508
Remove and Install 508
Micro-Pack Connectors 510
Weather-Pack Connectors 511
AMPSEAL Crimping Tools 513
AMP Hand Crimping Tool With Certi-Crimp 513
Description 513
Stripping Wire for Use with AMP Hand Crimping Tool 513
Insulation Crimp Adjustment 514
Maintenance and Inspection for AMP Hand Crimping Tool 514
AMP Hand Crimping Tool 514
Crimp Height Inspection 514
How to use AMP Hand Crimping Tool 515
AMP Pro-Crimper II Tool 515
Description 515
Remove and Install Die Set and Locator Assembly 516
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 517
Contact Support Adjustment 517
Crimp Height Adjustment 518
Maintenance and Inspection Procedures 518
PRO-CRIMPER II Tool 518
Crimp Height Inspection 518
How to Use AMP PRO-CRIMPER II Tool 519
AMPSEAL Connector Assemblies 520
Description for Plug Connector Assembly 520
Seal Plug 521
Contact Crimping 521
Description for Plug Connector and Header Assembly 526
Voltage Reading 528
Seal Plug 528
Contact Crimping 528
AMP Superseal 1 5 Crimping Tools 535
Mini Mic Receptacle and Tab Contacts 535
Description 535
Crimping Conditions and Measurements 535
Insertion of Rubber Seal on Cable 537
AMP Hand Application Tool 542
Description 542
Maintenance and Inspection 542
Crimp Height Inspection 542
Crimp Height Adjustment 543
How to Use AMP Hand Application Tool 543
AMP Pro-Crimper II Tool 544
Description 544
Remove and Install Die Set and Locator Assembly 545
Adjustments 545
Contact Support 545
Crimp Height 546
Inspections and Maintenance 547
Crimp Height Inspection 547
Visual Inspection 547
Maintenance 548
How to Use Pro-Crimper II Tool 548
AMP Superseal 1 5 Connector Assemblies 549
Description 549
Repair and Maintenance 556
Panel Mount Option 556
AMP Fastin-Faston Hand Tools 557
Description – AMP Double Action Hand Tool 557
Maintenance and Inspection Procedures 557
Daily Maintenance 557
Periodic Tool Inspection 558
Lubrication 558
Visual Inspection 558
Crimp Height Inspection 558
Certi-Crimp Ratchet Inspection 559
How to Use AMP Double Action Hand Tool 560
Description – AMP Extraction Tool 561
Maintenance and Inspection 561
How to Use AMP Extraction Tool 562
AMP Fastin-Faston Receptacles and Housings 563
Description 563
Wire Repair 570
Wire Splicing Requirements 570
Deutsch Jiffy Splice 571
Twisted/Shielded Cable and Leads Repair 576
Special Tools 579
524319489-0100YRM1342-(02-2023)-UK-EN 587
General 595
Description 595
Frame 595
Discharging the Capacitors 602
Rapid Charge 602
Ground Test 604
Mud Guards 606
Covers and Floor Plates 607
For Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 607
For Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 609
For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 610
For Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 611
For Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 615
Overhead Guard Replacement 616
Remove 616
For Lift Trucks ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 616
For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 622
For Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 625
Install 627
For Lift Trucks ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 627
For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 627
For Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 629
Battery and Operator Restraint System Repair 630
General 630
Battery Restraint System 630
Auxiliary Counterweight Support Bracket for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH,ERC100VHS) (A938) 644
Operator Restraint System 645
Emergency Locking Retractor (ELR) 649
E-Hydraulic Armrest Assembly Repair 649
Hood and Seat Assembly Replacement 650
General For Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 650
Hood Assembly 650
Seat Assembly 656
General For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 659
Hood Assembly 659
Seat Assembly 663
Opening and Closing the Hood 667
Manual Hydraulic Control Levers 667
E-Hydraulic Mini-Levers 668
Remove 669
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 669
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 678
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 680
Install 685
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 685
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 686
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 687
Ground Test For Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 689
Ground Test For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 689
Hood and Seat Assembly Replacement for Lift Truck Model ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 690
General 690
Hood Assembly 690
Seat Assembly 693
Opening and Closing the Hood 695
Manual Hydraulic Control Levers 695
E-Hydraulic Mini-Levers 696
Remove 697
Install 701
Ground Test 702
Master Cylinder Repair and Adjustment for 1 5-3 5T Cushion and 2 2-5 5T Pneumatic Lift Trucks 703
Master Cylinder Repair and Adjustment for 4 0-5 5T Cushion Lift Trucks 703
Brake Pedal Components 709
For Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985), and ERP22-35VL (ERP045-070VL) (A976) 709
For Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 709
Remove 709
Disassemble 709
Inspect 710
Assemble 710
Install 710
Brake Pedal Adjustment For Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 711
Brake System Air Removal 712
For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 712
Using Pressure Bleed System 712
Using Brake Pedal Pressure For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 712
For Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 713
Counterweight Replacement for Lift Truck Models ERC22-35VG (ERC045-070) (A968) and ERC16-20VA (ERC030-040VA) (A969) 714
Remove 717
Install 718
Counterweight Replacement for Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 719
Remove 726
Clean and Inspect, Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 730
Install 732
Counterweight Replacement for Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 735
Remove 737
Install 737
Traction Motor Replacement for Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 739
Traction Motor Replacement for Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 746
Traction Motor Replacement for Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 747
Hydraulic Tank Inspection 750
Inspect 750
Clean 754
Painting Instructions 755
Safety Label Replacement 758
Battery Specifications 767
Torque Specifications for Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 774
Overhead Guard 774
Counterweight 774
Traction Motor 774
Torque Specifications for Lift Truck ERP22-35VL (ERP045-070VL) (A976) 774
Overhead Guard 774
Counterweight 774
Torque Specifications for Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 774
Overhead Guard 774
Counterweight 774
Torque Specifications for Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 774
Overhead Guard 774
Counterweight 774
524319489-0100YRM1342-(06-2019)-UK-EN 777
General 783
Description 783
Frame 783
Discharging the Capacitors 790
Rapid Charge 790
Ground Test 792
Mud Guards 793
Covers and Floor Plates 794
For Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 794
For Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 795
For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 797
For Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 798
For Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 802
Overhead Guard Replacement 802
Remove 803
For Lift Trucks ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 803
For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 808
For Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 810
Install 812
For Lift Trucks ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 812
For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 812
For Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 814
Battery and Operator Restraint System Repair 814
General 814
Battery Restraint System 814
Auxiliary Counterweight Support Bracket for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938) 829
Operator Restraint System 830
Emergency Locking Retractor (ELR) 834
E-Hydraulic Armrest Assembly Repair 834
Hood and Seat Assembly Replacement 834
General For Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 835
Hood Assembly 835
Seat Assembly 841
General For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 844
Hood Assembly 844
Seat Assembly 848
Opening and Closing the Hood 852
Manual Hydraulic Control Levers 852
E-Hydraulic Mini-Levers 853
Remove 854
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 854
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 863
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 865
Install 870
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 870
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 871
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 872
Ground Test For Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 873
Ground Test For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 873
Hood and Seat Assembly Replacement for Lift Truck Model ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 874
General 874
Hood Assembly 874
Seat Assembly 877
Opening and Closing the Hood 879
Manual Hydraulic Control Levers 879
E-Hydraulic Mini-Levers 880
Remove 881
Install 885
Ground Test 886
Master Cylinder Repair and Adjustment for 1 5-3 5T Cushion and 2 2-5 5T Pneumatic Lift Trucks 886
Master Cylinder Repair and Adjustment for 4 0-5 5T Cushion Lift Trucks 886
Brake Pedal Components 891
For Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985), and ERP22-35VL (ERP045-070VL) (A976) 891
For Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 892
Remove 892
Disassemble 892
Inspect 893
Assemble 893
Install 893
Brake Pedal Adjustment For Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 894
Brake System Air Removal 894
For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 894
Using Pressure Bleed System 894
Using Brake Pedal Pressure For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 895
For Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 895
Counterweight Replacement for Lift Truck Models ERC22-35VG (ERC045-070) (A968) and ERC16-20VA (ERC030-040VA) (A969) 895
Remove 898
Install 899
Counterweight Replacement for Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 900
Remove 907
Clean and Inspect, Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 911
Install 913
Counterweight Replacement for Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 915
Remove 918
Install 918
Traction Motor Replacement for Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 919
Traction Motor Replacement for Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 925
Traction Motor Replacement for Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 926
Hydraulic Tank Inspection 928
Inspect 928
Clean 934
Painting Instructions 934
Safety Label Replacement 936
Battery Specifications 944
Torque Specifications for Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 951
Overhead Guard 951
Counterweight 951
Traction Motor 951
Torque Specifications for Lift Truck ERP22-35VL (ERP045-070VL) (A976) 951
Overhead Guard 952
Counterweight 952
Torque Specifications for Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 952
Overhead Guard 952
Counterweight 952
Torque Specifications for Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 952
Overhead Guard 952
Counterweight 952
524319491-1600YRM1360-(03-2023)-UK-EN 955
General 963
Steering Axle Assembly Repair 965
Remove ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 965
Disassemble ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 967
Clean 970
Inspect 970
Assemble ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 971
Install ERC22-35VG (ERC045-070VG) (A968) 972
Install ERC16-20VA (ERC030-040VA) (A969) 973
Install ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 974
Remove ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 975
Disassemble ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 980
Clean 981
Inspect 981
Assemble ERP40-50VM, ERP50-55MV6 (ERP080-120VM, ERP100VML) (A985) 981
Assemble ERP22-35VL (ERP045-070VL) (A976) 982
Wheel Bearing Adjustment ERP22-35VL (ERP045-070VL) (A976) 983
Install ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) 984
Remove ERP16-20VF (ERP30-40VF) (A955) 990
Disassemble ERP16-20VF (ERP30-40VF) (A955) 990
Clean 992
Inspect 992
Assemble ERP16-20VF (ERP30-40VF) (A955) 992
Install ERP16-20VF (ERP30-40VF) (A955) 993
Tie Rod Replacement 994
Remove ERC20-35VG (ERC045-070VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 994
Clean 995
Inspect 995
Install ERC20-35VG (ERC045-070VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 995
Remove ERC16-20VA (ERC030-040VA) (A969) 995
Clean 996
Inspect 996
Install ERC16-20VA (ERC030-040VA) (A969) 996
Remove ERP20-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 997
Clean 998
Inspect 998
Install ERP20-35VL (ERP045-070VL) (A976) andERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 998
Remove ERP16-20VF (ERP30-40VF) (A955) 998
Clean 999
Inspect 999
Install ERP16-20VF (ERP30-40VF) (A955) 999
Spindle Repair 1000
Remove ERC22-35VG (ERC45-70VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1000
Disassemble ERC22-35VG (ERC45-70VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1001
Clean 1001
Inspect 1002
Assemble ERC22-35VG (ERC45-70VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1002
Install ERC22-35VG (ERC45-70VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1002
Remove ERC16-20VA (ERC030-040VA) (A969) 1003
Disassemble ERC16-20VA (ERC030-040VA) (A969) 1004
Clean 1004
Inspect 1004
Assemble ERC16-20VA (ERC030-040VA) (A969) 1005
Install ERC16-20VA (ERC030-040VA) (A969) 1005
Remove ERP22-35VL (ERP45-70VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1006
Disassemble ERP22-35VL (ERP45-70VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1007
Clean 1007
Inspect 1008
Assemble ERP22-35VL (ERP45-70VL) (A976) 1008
Install ERP22-35VL (ERP45-70VL) (A976) 1008
Assemble ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1009
Install ERP22-35VL (ERP45-70VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1009
Remove ERP16-20VF (ERP30-40VF) (A955) 1010
Disassemble ERP16-20VF (ERP30-40VF) (A955) 1010
Clean 1011
Inspect 1011
Assemble ERP16-20VF (ERP30-40VF) (A955) 1012
Install ERP16-20VF (ERP30-40VF) (A955) 1012
Steering Cylinder Repair 1013
Remove ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 1013
Disassemble ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 1016
Clean 1017
Inspect 1017
Assemble ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 1017
Install ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 1017
Remove ERC16-20VA (ERC030-040VA) (A969) 1018
Disassemble ERC16-20VA (ERC030-040VA) (A969) 1019
Clean 1020
Inspect 1021
Assemble ERC16-20VA (ERC030-040VA) (A969) 1021
Install ERC16-20VA (ERC030-040VA) (A969) 1021
Remove ERP16-20VF (ERP30-40VF) (A955) 1021
Disassemble ERP16-20VF (ERP30-40VF) (A955) 1022
Clean 1023
Inspect 1023
Assemble ERP16-20VF (ERP30-40VF) (A955) 1023
Install ERP16-20VF (ERP30-40VF) (A955) 1024
Remove ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1024
Disassemble ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1025
Clean 1026
Inspect 1026
Assemble ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1027
Install ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1027
Remove ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1027
Disassemble ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1029
Clean 1029
Inspect 1030
Assemble ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1030
Install ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1030
524319491-1600YRM1360-(10-2018)-UK-EN 1033
General 1039
Steering Axle Assembly Repair 1040
Remove ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1041
Disassemble ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1042
Clean 1046
Inspect 1046
Assemble ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1046
Install ERC22-35VG (ERC045-070VG) (A968) 1048
Install ERC16-20VA (ERC030-040VA) (A969) 1049
Install ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1050
Remove ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1052
Disassemble ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1056
Clean 1058
Inspect 1058
Assemble ERP40-50VM, ERP50-55MV6 (ERP080-120VM, ERP100VML) (A985) 1058
Assemble ERP22-35VL (ERP045-070VL) (A976) 1059
Wheel Bearing Adjustment ERP22-35VL (ERP045-070VL) (A976) 1060
Install ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) 1061
Remove ERP16-20VF (ERP30-40VF) (A955) 1067
Disassemble ERP16-20VF (ERP30-40VF) (A955) 1067
Clean 1069
Inspect 1069
Assemble ERP16-20VF (ERP30-40VF) (A955) 1069
Install ERP16-20VF (ERP30-40VF) (A955) 1070
Tie Rod Replacement 1070
Remove ERC20-35VG (ERC045-070VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1071
Clean 1072
Inspect 1072
Install ERC20-35VG (ERC045-070VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1072
Remove ERC16-20VA (ERC030-040VA) (A969) 1072
Clean 1073
Inspect 1073
Install ERC16-20VA (ERC030-040VA) (A969) 1073
Remove ERP20-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1074
Clean 1074
Inspect 1075
Install ERP20-35VL (ERP045-070VL) (A976) andERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1075
Remove ERP16-20VF (ERP30-40VF) (A955) 1075
Clean 1076
Inspect 1076
Install ERP16-20VF (ERP30-40VF) (A955) 1076
Spindle Repair 1076
Remove ERC22-35VG (ERC45-70VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1076
Disassemble ERC22-35VG (ERC45-70VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1078
Clean 1078
Inspect 1078
Assemble ERC22-35VG (ERC45-70VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1079
Install ERC22-35VG (ERC45-70VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1079
Remove ERC16-20VA (ERC030-040VA) (A969) 1080
Disassemble ERC16-20VA (ERC030-040VA) (A969) 1080
Clean 1081
Inspect 1081
Assemble ERC16-20VA (ERC030-040VA) (A969) 1081
Install ERC16-20VA (ERC030-040VA) (A969) 1082
Remove ERP22-35VL (ERP45-70VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1082
Disassemble ERP22-35VL (ERP45-70VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1084
Clean 1084
Inspect 1084
Assemble ERP22-35VL (ERP45-70VL) (A976) 1085
Install ERP22-35VL (ERP45-70VL) (A976) 1085
Assemble ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1085
Install ERP22-35VL (ERP45-70VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1085
Remove ERP16-20VF (ERP30-40VF) (A955) 1086
Disassemble ERP16-20VF (ERP30-40VF) (A955) 1087
Clean 1088
Inspect 1088
Assemble ERP16-20VF (ERP30-40VF) (A955) 1088
Install ERP16-20VF (ERP30-40VF) (A955) 1088
Steering Cylinder Repair 1089
Remove ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 1089
Disassemble ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 1092
Clean 1093
Inspect 1093
Assemble ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 1093
Install ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 1093
Remove ERC16-20VA (ERC030-040VA) (A969) 1094
Disassemble ERC16-20VA (ERC030-040VA) (A969) 1095
Clean 1096
Inspect 1097
Assemble ERC16-20VA (ERC030-040VA) (A969) 1097
Install ERC16-20VA (ERC030-040VA) (A969) 1097
Remove ERP16-20VF (ERP30-40VF) (A955) 1097
Disassemble ERP16-20VF (ERP30-40VF) (A955) 1098
Clean 1099
Inspect 1099
Assemble ERP16-20VF (ERP30-40VF) (A955) 1099
Install ERP16-20VF (ERP30-40VF) (A955) 1100
Remove ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1100
Disassemble ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1101
Clean 1102
Inspect 1102
Assemble ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1103
Install ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1103
Remove ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1103
Disassemble ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1105
Clean 1106
Inspect 1106
Assemble ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1106
Install ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1106
524319492-1600YRM1363-(03-2023)-UK-EN 1109
General 1115
Discharging The Capacitors 1115
Steering Control Unit (SCU) Repair 1117
Remove 1117
Disassemble 1120
Clean 1126
Inspect 1126
Assemble 1126
Install 1127
Steering Wheel and Fixed Steering Column Assembly Repair 1128
Remove 1128
Disassemble 1131
Clean 1132
Inspect 1133
Assemble 1133
Install 1133
Gear Replacement for Lift Trucks Built Prior to October, 2008 1134
Steering Wheel and Telescopic Column Assembly Repair 1136
Remove 1136
Disassemble 1139
Clean 1142
Inspect 1143
Assemble 1143
Install 1144
Torque Specifications 1151
Steering Control Unit 1151
Steering Column 1151
524319492-1600YRM1363-(09-2014)-UK-EN 1153
524319494-1900YRM1367-(04-2017)-UK-EN 1191
General 1197
Discharging the Capacitors 1197
Hydraulic Pump and Motor 1198
Remove 1198
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1199
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1202
Lift Truck Models ERP22-25VL (ERP045-070VL) (A976) 1205
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1210
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1215
Disassemble 1217
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969)ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1217
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1219
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1221
Inspect 1223
Clean 1223
Assemble 1223
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969)ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1223
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1223
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1224
Install 1224
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1224
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1225
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1226
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1227
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1228
Hydraulic Tank 1229
Remove 1229
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1229
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1232
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1233
Lift Truck Models ERP22-25VL (ERP045-070VL) (A976) 1237
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1239
Disassemble 1241
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1241
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1242
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1242
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1243
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1245
Clean 1247
Steam Method 1247
Chemical Method 1247
Inspect 1248
Small Leaks, Repair 1248
Large Leaks, Repair 1248
Additional Methods for Metal Tank Repair 1248
Assemble 1248
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1248
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1249
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1250
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1250
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1251
Install 1251
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1251
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1252
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1252
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1253
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1253
Hydraulic Filter Replacement 1254
Breather Clean and Inspect 1255
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 1255
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1258
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1258
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1258
Hydraulic Oil Cooler for Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1259
Add Hydraulic Oil 1259
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1259
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1261
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1261
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1261
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1262
Steer Accumulator Replacement 1263
Remove 1263
Install 1270
Specifications for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1270
Tank Capacity 1271
Specifications for Lift Truck ERC16-20VA (ERC030-040VA) (A969) 1271
Tank Capacity 1271
Specifications for Lift Truck ERP22-25VL (ERP045-070VL) (A976) 1271
Tank Capacity 1271
Specifications for Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1271
Tank Capacity 1271
Specifications for Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1271
Tank Capacity 1272
Torque Specifications for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1272
Hydraulic Pump and Motor 1272
Hydraulic Tank 1272
Torque Specifications for Lift Truck ERC16-20VA (ERC030-040VA) (A969) 1273
Hydraulic Pump and Motor 1273
Hydraulic Tank 1273
Torque Specifications for Lift Truck ERP22-35VL (ERP045-070VL) (A976) 1273
Hydraulic Pump and Motor 1273
Hydraulic Tank 1273
Torque Specifications for Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1273
Hydraulic Pump and Motor 1274
Hydraulic Tank 1274
Torque Specifications for Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1275
Hydraulic Pump and Motor 1275
Hydraulic Tank 1275
524319494-1900YRM1367-(08-2023)-UK-EN 1279
General 1285
Discharging the Capacitors 1285
Hydraulic Pump and Motor 1287
Remove 1287
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1287
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1293
Lift Truck Models ERP22-25VL (ERP045-070VL) (A976) 1297
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1302
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1307
Disassemble 1309
Lift Truck Models , ERC22-35VG (ERC045-070VG) (A968)ERC16-20VA (ERC030-040VA) (A969)ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1309
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1311
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1313
Inspect 1315
Clean 1315
Assemble 1315
Lift Truck Models , ERC22-35VG (ERC045-070VG) (A968)ERC16-20VA (ERC030-040VA) (A969)ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1315
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1316
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1316
Install 1316
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1316
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1317
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1318
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1319
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1320
Hydraulic Tank 1321
Remove 1321
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1321
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1324
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1327
Lift Truck Models ERP22-25VL (ERP045-070VL) (A976) 1330
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1332
Disassemble 1334
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1334
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1334
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1335
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1336
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1338
Clean 1340
Steam Method 1341
Chemical Method 1341
Inspect 1341
Small Leaks, Repair 1341
Large Leaks, Repair 1342
Additional Methods for Metal Tank Repair 1342
Assemble 1342
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1342
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1343
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1343
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1344
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1344
Install 1345
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1345
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1345
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1346
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1347
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1347
Hydraulic Filter Replacement 1348
Breather Clean and Inspect 1349
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 1349
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1351
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1351
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1352
Hydraulic Oil Cooler for Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1352
Add Hydraulic Oil 1352
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1352
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1354
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1354
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1354
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1355
Steer Accumulator Replacement 1357
Remove 1357
Install 1365
Specifications for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1366
Tank Capacity 1366
Specifications for Lift Truck ERC16-20VA (ERC030-040VA) (A969) 1366
Tank Capacity 1366
Specifications for Lift Truck ERP22-25VL (ERP045-070VL) (A976) 1366
Tank Capacity 1366
Specifications for Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1367
Tank Capacity 1367
Specifications for Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1367
Tank Capacity 1367
Torque Specifications for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1368
Hydraulic Pump and Motor 1368
Hydraulic Tank 1368
Torque Specifications for Lift Truck ERC16-20VA (ERC030-040VA) (A969) 1368
Hydraulic Pump and Motor 1368
Hydraulic Tank 1368
Torque Specifications for Lift Truck ERP22-35VL (ERP045-070VL) (A976) 1369
Hydraulic Pump and Motor 1369
Hydraulic Tank 1369
Torque Specifications for Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1369
Hydraulic Pump and Motor 1369
Hydraulic Tank 1369
Torque Specifications for Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1370
Hydraulic Pump and Motor 1370
Hydraulic Tank 1370
524319495-2000YRM1334-(03-2023)-UK-EN 1373
General 1381
Lift Trucks ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955) 1381
Lift Trucks ERC22-35VG (ERC045-070VG) (A968), ERP22-35VL (ERP045-070VL) (A976), and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1383
Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1387
Discharging the Capacitors 1389
Manual Hydraulic Control Valve Repair for 1 5-2 0T Trucks 1390
Remove 1390
Beginning Steps 1390
Disassemble Handles and Levers 1403
Disassemble Manual Control Valve 1406
Spool Seal Replacement 1416
Clean 1419
Inspect 1419
Assemble Manual Control Valve 1421
Assemble Handles and Levers 1432
Install 1435
Ending Steps 1447
Manual Hydraulic Control Valve Repair for 2 0-3 5T Trucks and 4 0-5 0T Pneumatic Trucks 1449
Remove 1449
Disassemble Handles and Levers 1465
Disassemble Manual Control Valve 1468
Disassemble Valve 1468
Disassemble Inlet Section 1471
Disassemble Lift, Tilt, and Auxiliary Sections 1471
Spool Seal Replacement 1473
Clean 1474
Inspect 1475
Assemble Manual Control Valve 1475
Assemble Lift, Tilt, and Auxiliary Sections 1475
Assemble Inlet Section 1476
Assemble Valve 1477
Assemble Handles and Levers 1485
Install 1489
Ending Steps 1501
Manual Hydraulic Control Valve Repair for 4 0-5 5T Cushion Trucks 1502
Remove 1502
Disassemble Handles and Levers 1516
Disassemble Manual Control Valve 1518
Disassemble Valve 1518
Disassemble Inlet Section 1521
Disassemble Lift, Tilt, and Auxiliary Sections 1522
Spool Seal Replacement 1524
Clean 1525
Inspect 1525
Assemble Manual Control Valve 1526
Assemble Lift, Tilt, and Auxiliary Sections 1526
Assemble Inlet Section 1527
Assemble Valve 1528
Assemble Handles and Levers 1535
Install 1538
Ending Steps 1550
E-Hydraulic Control Valve Repair for 1 5-2 0T Trucks 1551
Remove 1551
Disassemble 1557
Clean 1564
Inspect 1564
Assemble 1564
Install 1572
E-Hydraulic Controls 1577
Replace E-Hydraulic Control Components 1578
E-Hydraulic Control Valve Repair for 2 0-3 5T Trucks and 4 0-5 0T Pneumatic Trucks 1579
Remove 1579
Initial Steps 1579
Fitting Removal for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1579
Fitting Removal for Lift Truck ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1581
Electrical Disconnect and Control Valve Dismount 1583
Disassemble 1585
Clean 1590
Inspect 1590
Assemble 1590
Install 1598
Electrical Connect and Control Valve Mount 1598
Fitting Installation for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1600
Fitting Installation for Lift Truck ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1602
Ending Steps 1603
E-Hydraulic Controls 1604
Replace E-Hydraulic Control Components 1604
E-Hydraulic Control Valve Repair for 4 0-5 5T Cushion Trucks 1605
Remove 1605
Initial Steps 1605
Fitting Removal 1605
Electrical Disconnect and Control Valve Dismount 1607
Disassemble 1609
Clean 1614
Inspect 1614
Assemble 1614
Install 1622
Electrical Connect and Control Valve Mount 1622
Fitting Installation 1624
Ending Steps 1625
E-Hydraulic Controls 1626
Replace E-Hydraulic Control Components 1626
Checks and Adjustments
for 1 5-2 0T Lift Trucks 1627
Manual Control Valve 1627
Primary Relief Valve 1627
Optional Auxiliary Port Relief Valve 1627
E-Hydraulic Control Valve 1628
Primary Relief Valve 1628
Optional Secondary Port Relief Valve 1629
Hydraulic System Air Removal 1630
Checks and Adjustments
2 0-5 5T Lift Trucks 1631
Manual Control Valve 1631
External Leakage 1631
Primary Relief Cartridge 1631
Secondary Relief Valve 1632
E-Hydraulic Control Valve 1632
Primary Relief Valve 1632
Secondary Relief Valve 1633
PPRV Pilot Pressure Test 1634
Hydraulic System Air Removal 1635
Position Sensor and OPS Check and Adjustment 1636
Position Sensor 1636
(OPS) Operator Presence Solenoid 1636
Manual Control Valve Re-Calibration 1636
Calibration Procedure 1637
Control Valve 1637
Torque Specifications
for 1 5-2 0T Lift Trucks 1638
Manual Hydraulic Control Valve 1638
Manual Control Valve Handles and Levers 1638
E-Hydraulic Control Valve 1638
Torque Specifications
for 2 2-5 5T Lift Trucks 1639
Manual Hydraulic Control Valve 1639
Manual Control Valve Handles and Levers 1639
Manual Control Valve Covers 1639
E-Hydraulic Control Valve 1639
524319495-2000YRM1334-(09-2014)-UK-EN 1641
524319496-2100YRM1382-(02-2018)-UK-EN 1891
Safety Procedures When Working Near Mast 1899
General 1901
Description 1902
Tilt Cylinder Repair for 2 0-5 5T Trucks 1902
Remove 1902
Disassemble 1904
Inspect 1905
Clean 1905
Assemble 1905
Install 1907
Tilt Cylinders, Adjust 1907
Tilt Cylinder Leak Check 1910
Tilt Cylinder Repair
for 1 0-2 0T Trucks 1911
Remove 1911
Disassemble 1913
Inspect 1915
Clean 1915
Assemble 1915
Install 1915
Tilt Cylinders, Adjust 1916
Tilt Cylinders Leak Check 1917
Lift Cylinder Repair
for 2 0-3 5T Trucks 1918
Main Lift Cylinders 1918
Remove 1918
Two-Stage FFL 1918
Three-Stage FFL 1920
Four-Stage FFL 1920
Two-Stage LFL 1921
Disassemble 1921
Two-Stage FFL 1921
Three-Stage FFL 1923
Four-Stage FFL 1923
Two-Stage LFL 1925
Clean 1926
Inspect 1926
Assemble 1926
Two-Stage FFL 1926
Three-Stage FFL 1926
Four-Stage FFL 1927
Two-Stage LFL 1927
Install 1928
Two-Stage FFL 1928
System Air Bleed Procedures 1928
Three-Stage FFL 1928
Four-Stage FFL 1929
Two-Stage LFL 1929
Lift Cylinder Repair for Lift Truck Model ERP15VT (G807) 1930
Main Lift Cylinder 1930
Remove 1930
Main Lift Cylinders – Two-Stage FFL Mast 1930
Left-Hand Main Lift Cylinder – Three-Stage FFL Mast 1932
Right-Hand Main Lift Cylinder – Three-Stage FFL Mast 1936
Main Lift Cylinder – Two-Stage LFL Mast 1936
Disassemble 1939
Main Lift Cylinders – Two-Stage FFL Mast 1939
Main Lift Cylinder – Three-Stage FFL Mast 1941
Main Lift Cylinder – Two-Stage LFL Mast 1941
Clean 1942
Inspect 1942
Assemble 1943
Main Lift Cylinder – Two-Stage FFL Mast 1943
Main Lift Cylinder – Three-Stage FFL Mast 1943
Main Lift Cylinder – Two-Stage LFL Mast 1943
Install 1944
Main Lift Cylinder – Two-Stage FFL Mast 1944
Left-Hand Main Lift Cylinder – Three-Stage FFL Mast 1944
Right-Hand Main Lift Cylinder – Three-Stage FFL Mast 1945
Main Lift Cylinder – Two-Stage LFL Mast 1946
System Air Bleed Procedures 1947
All Main Lift Cylinders 1947
Lift Cylinder Repair for 1 5-2 0T Trucks 1947
Main Lift Cylinder 1947
Remove 1947
Two-Stage FFL 1948
Three-Stage FFL 1948
Two-Stage LFL 1949
Four-Stage FFL 1951
Disassemble 1952
Two-Stage FFL 1952
Three-Stage FFL 1954
Two-Stage LFL 1954
Four-Stage FFL 1955
Clean 1958
Inspect 1958
Assemble 1958
Two-Stage FFL 1958
Three-Stage FFL 1959
Two-Stage LFL 1959
Four-Stage FFL 1960
Install 1961
Two-Stage FFL 1961
System Air Bleed Procedures 1961
Three-Stage FFL Mast 1961
Two-Stage LFL 1962
Four-Stage FFL 1962
Mast and Carriage Install for Two-Stage FFL, Three-Stage FFL, and Two-Stage LFL 1963
Mast and Carriage Installation for Four-Stage FFL 1963
Lift Cylinder Repair
for 4 0-5 5T Trucks 1964
Main Lift Cylinders 1964
Remove 1964
Two-Stage FFL 1964
Three-Stage FFL 1966
Two-Stage LFL 1966
Disassemble 1967
Two-Stage FFL 1967
Three-Stage FFL 1969
Two-Stage LFL 1970
Clean 1971
Inspect 1971
Assemble 1971
Two-Stage FFL 1971
Three-Stage FFL 1972
Two-Stage LFL 1972
Install 1973
Two-Stage FFL 1973
System Air Bleed Procedures 1973
Three-Stage FFL 1973
Two-Stage LFL 1974
Free-Lift Cylinder Repair
for 2 0-3 5T Trucks 1975
Free-Lift Cylinder 1975
Remove 1975
Two and Three-Stage FFL Mast 1975
Four-Stage FFL For Lift Truck ERC22-356VG (ERC045-070VG) (A968) 1976
Disassemble 1978
Two and Three-Stage FFL Mast 1978
Four-Stage FFL Mast for Lift Truck ERC22-356VG (ERC045-070VG) (A968) 1979
Clean 1979
Inspect 1979
Assemble 1980
Two and Three-Stage FFL Mast 1980
Four-Stage FFL Mast for Lift Truck ERC22-356VG (ERC045-070VG) (A968) 1980
Install 1981
Two and Three-Stage FFL Mast 1981
Four-Stage FFL Mast for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1981
Free Lift Cylinder Repair for Lift Truck Model ERP15VT (G807) 1982
Free-Lift Cylinder 1982
Remove 1982
Three-Stage FFL Mast 1982
Disassemble 1984
Clean 1985
Inspect 1985
Assemble 1985
Install 1985
Free Lift Cylinder Repair
for 1 5-2 0T Trucks 1986
Free-Lift Cylinder 1986
Remove 1986
Two and Three-Stage FFL Mast 1986
Four-Stage FFL Mast 1988
Disassemble 1990
Two-Stage and Three-Stage FFL Masts 1990
Four Stage FFL Mast 1991
Clean 1992
Inspect 1992
Assemble 1992
Two-Stage and Three-Stage FFL Masts 1992
Four-Stage FFL Mast 1993
Install 1993
Two-Stage and Three-Stage FFL Masts 1993
Four-Stage FFL Mast 1993
All Masts 1995
Free-Lift Cylinder Repair
for 4 0-5 5T Trucks 1996
Free-Lift Cylinder 1996
Remove 1996
Two and Three-Stage FFL Mast 1996
Disassemble 1997
Two and Three-Stage FFL Mast 1997
Clean 1998
Inspect 1998
Assemble 1998
Two and Three-Stage FFL Mast 1998
Install 1999
Two and Three-Stage FFL Mast 1999
Sideshift Cylinder Repair
for 1 5-3 5T Trucks Prior to December 2016 1999
Remove 1999
Disassemble 2003
Clean and Inspect 2005
Assemble and Install 2005
Sideshift Cylinder Repair
for 1 5-3 5T Trucks After December 2016 2006
Remove 2006
Disassemble 2010
Clean and Inspect 2012
Assemble and Install 2012
Integral Side-Shift Cylinder Gland Leak Checks 2014
Sideshift Cylinder Repair
for 4 0-5 5T Trucks 2015
Remove 2015
Disassemble 2015
Clean and Inspect 2017
Assemble and Install 2017
Fork Positioner Cylinder Repair Prior to December 2016 2017
Remove 2017
Disassemble 2018
Clean 2020
Inspect 2020
Assemble 2021
Install 2021
Fork Positioner Cylinder Adjustment 2021
Fork Positioner Cylinder Repair After December 2016 2022
Remove 2022
Disassemble 2022
Clean 2025
Inspect 2025
Assemble 2026
Install 2026
Fork Positioner Cylinder Adjustment 2026
Lift Cylinder Leak Check 2027
Seal Kit Installation 2027
External Installation (Seal and Back-Up Ring) 2028
Internal Installation (Piston Rod Assembly) 2028
Torque Specifications for Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-25VL (ERP045-070VL) (A976) 2028
Tilt Cylinders 2028
Piston Rod Nut 2028
Gland 2029
Tilt Cylinder Mounting Capscrew 2029
Tilt Cylinder Rod End Capscrew 2029
Main and Free-Lift Cylinder 2029
Sideshift Cylinder 2029
Fork Positioner Cylinder 2029
Torque Specifications for Lift Truck Model ERP15VT (G807) 2029
Tilt Cylinders 2029
Main and Free-Lift Cylinders 2029
Sideshift Cylinder 2030
Torque Specifications for Lift Truck Models ERP16-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), ESC030-40AC (B883),ESC030-40AD (C883) 2030
Tilt Cylinders 2030
Main and Free-Lift Cylinders 2030
Sideshift Cylinder 2031
Fork Positioner Cylinder 2031
Torque Specifications for Lift Truck Model ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2031
Tilt Cylinders 2031
Main and Free-Lift Cylinder 2031
Sideshift Cylinder 2031
Torque Specifications for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2031
Tilt Cylinder 2032
Main and Free Lift Cylinder 2032
Sideshift Cylinder 2032
524319496-2100YRM1382-(07-2023)-UK-EN 2035
Safety Procedures When Working Near Mast 2045
General 2048
Description 2048
Tilt Cylinder Repair for 2 0-5 5T Trucks 2049
Remove 2049
Disassemble 2051
Inspect 2052
Clean 2052
Assemble 2052
Install 2054
Tilt Cylinders, Adjust 2054
Tilt Cylinder Leak Check 2057
Tilt Cylinder Repair
for 1 0-2 0T Trucks 2058
Remove 2058
Disassemble 2061
Inspect 2063
Clean 2063
Assemble 2063
Install 2063
Tilt Cylinders, Adjust 2064
Tilt Cylinders Leak Check 2065
Lift Cylinder Repair
for 2 0-3 5T Trucks 2067
Main Lift Cylinders 2067
Remove 2067
Two-Stage FFL 2067
Three-Stage FFL 2069
Four-Stage FFL 2069
Two-Stage LFL 2070
Disassemble 2070
Two-Stage FFL 2070
Three-Stage FFL 2072
Four-Stage FFL 2074
Two-Stage LFL 2075
Clean 2076
Inspect 2076
Assemble 2076
Two-Stage FFL 2076
Three-Stage FFL 2077
Four-Stage FFL 2077
Two-Stage LFL 2078
Install 2078
Two-Stage FFL 2078
System Air Bleed Procedures 2078
Three-Stage FFL 2079
Four-Stage FFL 2079
Two-Stage LFL 2080
Lift Cylinder Repair for Lift Truck Model ERP15VT (G807) 2081
Main Lift Cylinder 2081
Remove 2081
Main Lift Cylinders – Two-Stage FFL Mast 2081
Left-Hand Main Lift Cylinder – Three-Stage FFL Mast 2083
Right-Hand Main Lift Cylinder – Three-Stage FFL Mast 2087
Main Lift Cylinder – Two-Stage LFL Mast 2087
Disassemble 2090
Main Lift Cylinders – Two-Stage FFL Mast 2090
Main Lift Cylinder – Three-Stage FFL Mast 2092
Main Lift Cylinder – Two-Stage LFL Mast 2093
Clean 2094
Inspect 2094
Assemble 2094
Main Lift Cylinder – Two-Stage FFL Mast 2094
Main Lift Cylinder – Three-Stage FFL Mast 2095
Main Lift Cylinder – Two-Stage LFL Mast 2095
Install 2095
Main Lift Cylinder – Two-Stage FFL Mast 2095
Left-Hand Main Lift Cylinder – Three-Stage FFL Mast 2096
Right-Hand Main Lift Cylinder – Three-Stage FFL Mast 2097
Main Lift Cylinder – Two-Stage LFL Mast 2098
System Air Bleed Procedures 2098
All Main Lift Cylinders 2099
Lift Cylinder Repair for 1 5-2 0T Trucks 2100
Main Lift Cylinder 2100
Remove 2100
Two-Stage FFL 2100
Three-Stage FFL 2100
Two-Stage LFL 2101
Four-Stage FFL 2103
Disassemble 2105
Two-Stage FFL 2105
Three-Stage FFL 2106
Two-Stage LFL 2107
Four-Stage FFL 2108
Clean 2110
Inspect 2111
Assemble 2111
Two-Stage FFL 2111
Three-Stage FFL 2111
Two-Stage LFL 2112
Four-Stage FFL 2112
Install 2113
Two-Stage FFL 2113
System Air Bleed Procedures 2114
Three-Stage FFL Mast 2114
Two-Stage LFL 2114
Four-Stage FFL 2115
Mast and Carriage Install for Two-Stage FFL, Three-Stage FFL, and Two-Stage LFL 2115
Mast and Carriage Installation for Four-Stage FFL 2116
Lift Cylinder Repair for 4 0-5 5T Trucks 2117
Main Lift Cylinders 2117
Remove 2117
Two-Stage FFL 2117
Three-Stage FFL 2119
Two-Stage LFL 2119
Disassemble 2120
Two-Stage FFL 2120
Three-Stage FFL 2122
Two-Stage LFL 2123
Clean 2124
Inspect 2124
Assemble 2124
Two-Stage FFL 2124
Three-Stage FFL 2125
Two-Stage LFL 2125
Install 2126
Two-Stage FFL 2126
System Air Bleed Procedures 2126
Three-Stage FFL 2126
Two-Stage LFL 2127
Free-Lift Cylinder Repair for 2 0-3 5T Trucks 2128
Free-Lift Cylinder 2128
Remove 2128
Two and Three-Stage FFL Mast 2128
Four-Stage FFL For Lift Truck ERC22-356VG (ERC045-070VG) (A968) 2129
Disassemble 2131
Two and Three-Stage FFL Mast 2131
Four-Stage FFL Mast for Lift Truck ERC22-356VG (ERC045-070VG) (A968) 2132
Clean 2132
Inspect 2133
Assemble 2133
Two and Three-Stage FFL Mast 2133
Four-Stage FFL Mast for Lift Truck ERC22-356VG (ERC045-070VG) (A968) 2133
Install 2134
Two and Three-Stage FFL Mast 2134
Four-Stage FFL Mast for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 2134
Free Lift Cylinder Repair for Lift Truck Model ERP15VT (G807) 2136
Free-Lift Cylinder 2136
Remove 2136
Three-Stage FFL Mast 2136
Disassemble 2138
Clean 2139
Inspect 2139
Assemble 2139
Install 2139
Free Lift Cylinder Repair for 1 5-2 0T Trucks 2141
Free-Lift Cylinder 2141
Remove 2141
Two and Three-Stage FFL Mast 2141
Four-Stage FFL Mast 2143
Disassemble 2146
Two-Stage and Three-Stage FFL Masts 2146
Four Stage FFL Mast 2146
Clean 2147
Inspect 2147
Assemble 2147
Two-Stage and Three-Stage FFL Masts 2147
Four-Stage FFL Mast 2148
Install 2148
Two-Stage and Three-Stage FFL Masts 2148
Four-Stage FFL Mast 2149
All Masts 2152
Free-Lift Cylinder Repair
for 4 0-5 5T Trucks 2153
Free-Lift Cylinder 2153
Remove 2153
Two and Three-Stage FFL Mast 2153
Disassemble 2154
Two and Three-Stage FFL Mast 2154
Clean 2155
Inspect 2155
Assemble 2155
Two and Three-Stage FFL Mast 2155
Install 2156
Two and Three-Stage FFL Mast 2156
Sideshift Cylinder Repair
for 1 5-3 5T Trucks Prior to December 2016 2157
Remove 2157
Disassemble 2160
Clean and Inspect 2162
Assemble and Install 2162
Sideshift Cylinder Repair
for 1 5-3 5T Trucks After December 2016 2164
Remove 2164
Disassemble 2167
Clean and Inspect 2168
Assemble and Install 2169
Integral Side-Shift Cylinder Gland Leak Checks 2171
Sideshift Cylinder Repair
for 4 0-5 5T Trucks 2172
Remove 2172
Disassemble 2173
Clean and Inspect 2174
Assemble and Install 2174
Fork Positioner Cylinder Repair Prior to December 2016 2175
Remove 2175
Disassemble 2175
Clean 2178
Inspect 2178
Assemble 2179
Install 2179
Fork Positioner Cylinder Adjustment 2179
Fork Positioner Cylinder Repair After December 2016 2181
Remove 2181
Disassemble 2181
Clean 2184
Inspect 2184
Assemble 2185
Install 2185
Fork Positioner Cylinder Adjustment 2185
Lift Cylinder Leak Check 2187
Seal Kit Installation 2188
External Installation (Seal and Back-Up Ring) 2188
Internal Installation (Piston Rod Assembly) 2188
Torque Specifications for Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-25VL (ERP045-070VL) (A976) 2189
Tilt Cylinders 2189
Piston Rod Nut 2189
Gland 2189
Tilt Cylinder Mounting Capscrew 2189
Tilt Cylinder Rod End Capscrew 2189
Main and Free-Lift Cylinder 2189
Sideshift Cylinder 2189
Fork Positioner Cylinder 2189
Torque Specifications for Lift Truck Model ERP15VT (G807) 2190
Tilt Cylinders 2190
Main and Free-Lift Cylinders 2190
Sideshift Cylinder 2190
Torque Specifications for Lift Truck Models ERP16-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), ESC030-40AC (B883),ESC030-40AD (C883) 2191
Tilt Cylinders 2191
Main and Free-Lift Cylinders 2191
Sideshift Cylinder 2191
Fork Positioner Cylinder 2191
Torque Specifications for Lift Truck Model ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2192
Tilt Cylinders 2192
Main and Free-Lift Cylinder 2192
Sideshift Cylinder 2192
Torque Specifications for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2192
Tilt Cylinder 2192
Main and Free Lift Cylinder 2192
Sideshift Cylinder 2192
524319497-2200YRM1335-(01-2023)-UK-EN 2195
General 2203
Description 2203
Display Panel Menu Access 2203
Menu Flowchart 2204
Supervisor Menu Flowchart 2204
Menu Navigation 2210
Icon Glossary 2214
Introduction 2214
Soft Key Icons 2214
Overlay Icons 2215
Icons on System Off Screen and Alert Screens 2215
Main Menu Title Screens 2219
Submenu Icons Grouped by Menu 2221
Operating Screen Icons 2221
Password Screen Icons 2222
Activity Log Submenu Icons 2222
Calibration Submenu Icons 2224
Display Submenu Icons 2226
Status Submenu Icons 2228
Truck Setup Submenu Icons 2231
Operating Screen 2238
Introduction 2238
Performance Mode Controls 2239
Status and Warning Icons 2239
Battery Discharge Indicator 2240
Direction and Parking Brake Indicators 2241
Hazard Flashers and Lighting Controls 2241
Steer Angle Indicator 2241
System Time 2241
Load Weight Indicator 2241
System Off/Alert Screens 2242
Introduction 2242
System Off Screen 2242
Alert Screens 2242
Password Screen 2244
Introduction 2244
Password Screen 2244
Service Technician Password Setup 2244
Adding/Removing/Changing Passwords 2245
Password Log 2248
Activity Log Menu 2249
Introduction 2249
Operator Checklist Log 2250
Password Log 2253
Impact Events Log 2255
Calibration Menu 2257
Introduction 2257
Load Weight Calibration 2257
Return to Set Tilt Stop Point Calibration 2258
E-Hydraulic and Manual Valve Threshold Calibration 2258
Steering Wheel Center Point Calibration 2259
Steer Axle Position Calibration 2259
Steer Axle Center Point Calibration 2260
Manual Hydraulics Calibration 2261
Display Menu 2262
Introduction 2262
Set Date and Time Format Menu 2262
Set Daylight Saving Time Menu 2263
Procedure for Setting Up Automatic Daylight Savings Time 2264
Set Time and Date Menu 2266
Procedure for Setting Time and Date 2266
Set Units Menu 2267
Status Menu 2268
Introduction 2268
VSM Versions 2268
Display Versions 2269
Truck Serial Number 2269
Hour Meters 2269
E-Hydraulic Controller Versions 2269
Pump Motor Controller Versions 2269
Traction Motor Controller 1 Versions 2269
Traction Motor Controller 2 Versions 2270
Light Controller Versions 2270
Impact Sensor Versions 2270
Truck Setup Menu 2271
Introduction 2271
Add/Remove Password 2271
Battery Settings 2271
Restore Default Settings 2272
Motion Alarm 2272
Impact Monitor Settings 2273
Impact Detection 2273
Setting Adjustments 2273
Initial Adjustment of Soft and Hard Impact Settings 2273
Readjustment of Soft and Hard Impact Settings 2273
Auto Power-Off Time Delay 2274
Return to Set Tilt 2274
Traction Speed Limit 2274
Scheduled Maintenance Reminder 2275
Minimum Pump Standby Flow Rate 2276
Operator Checklist 2276
Impact Monitor Shutdown 2277
Motor Braking 2278
Changing the Motor Braking Settings 2278
Steering Wheel Friction and Steering Turns Adjustment 2279
How to Adjust Settings 2279
Steering Friction Setting 2279
Steering Wheel Number of Turns 2280
524319497-2200YRM1335-(07-2020)-UK-EN 2283
General 2289
Description 2289
Display Panel Menu Access 2289
Menu Flowchart 2290
Supervisor Menu Flowchart 2290
Menu Navigation 2296
Icon Glossary 2300
Introduction 2300
Soft Key Icons 2300
Overlay Icons 2301
Icons on System Off Screen and Alert Screens 2301
Main Menu Title Screens 2305
Submenu Icons Grouped by Menu 2307
Operating Screen Icons 2307
Password Screen Icons 2308
Activity Log Submenu Icons 2308
Calibration Submenu Icons 2310
Display Submenu Icons 2312
Status Submenu Icons 2314
Truck Setup Submenu Icons 2317
Operating Screen 2324
Introduction 2324
Performance Mode Controls 2324
Status and Warning Icons 2325
Battery Discharge Indicator 2326
Direction and Parking Brake Indicators 2326
Hazard Flashers and Lighting Controls 2327
Steer Angle Indicator 2327
System Time 2327
Load Weight Indicator 2327
System Off/Alert Screens 2328
Introduction 2328
System Off Screen 2328
Alert Screens 2328
Password Screen 2330
Introduction 2330
Password Screen 2330
Service Technician Password Setup 2330
Adding/Removing/Changing Passwords 2331
Password Log 2334
Activity Log Menu 2335
Introduction 2335
Operator Checklist Log 2335
Password Log 2337
Impact Events Log 2339
Calibration Menu 2341
Introduction 2341
Load Weight Calibration 2341
Return to Set Tilt Stop Point Calibration 2342
E-Hydraulic and Manual Valve Threshold Calibration 2342
Steering Wheel Center Point Calibration 2343
Steer Axle Position Calibration 2343
Steer Axle Center Point Calibration 2344
Manual Hydraulics Calibration 2345
Display Menu 2346
Introduction 2346
Set Date and Time Format Menu 2346
Set Daylight Saving Time Menu 2347
Procedure for Setting Up Automatic Daylight Savings Time 2348
Set Time and Date Menu 2350
Procedure for Setting Time and Date 2350
Set Units Menu 2351
Status Menu 2352
Introduction 2352
VSM Versions 2352
Display Versions 2353
Truck Serial Number 2353
Hour Meters 2353
E-Hydraulic Controller Versions 2353
Pump Motor Controller Versions 2353
Traction Motor Controller 1 Versions 2353
Traction Motor Controller 2 Versions 2354
Light Controller Versions 2354
Impact Sensor Versions 2354
Truck Setup Menu 2355
Introduction 2355
Add/Remove Password 2355
Battery Settings 2355
Restore Default Settings 2356
Motion Alarm 2356
Impact Monitor Settings 2356
Impact Detection 2357
Setting Adjustments 2357
Initial Adjustment of Soft and Hard Impact Settings 2357
Readjustment of Soft and Hard Impact Settings 2357
Auto Power-Off Time Delay 2358
Return to Set Tilt 2358
Traction Speed Limit 2358
Scheduled Maintenance Reminder 2359
Minimum Pump Standby Flow Rate 2360
Operator Checklist 2360
Impact Monitor Shutdown 2361
Motor Braking 2362
Changing the Motor Braking Settings 2362
Steering Wheel Friction and Steering Turns Adjustment 2363
How to Adjust Settings 2363
Steering Friction Setting 2363
Steering Wheel Number of Turns 2364
524319498-2200YRM1336-(02-2023)-UK-EN 2367
General 2375
Description 2375
Display Panel Menu Access 2375
Menu Flowchart 2376
Technician Menu Flowchart 2376
Menu Navigation 2382
Icon Glossary 2386
Introduction 2386
Soft Key Icons 2386
Overlay Icons 2387
Heat Exchange Module Warning Indicator Screen 2387
System Off Screen and Alert Screens 2388
Main Menu Title Screens 2394
Submenu Icons Grouped by Menu 2395
Operating Screen Icons 2395
Password Screen Icons 2397
Activity Log Submenu Icons 2397
Calibration Submenu Icons 2398
Display Submenu Icons 2402
Status Submenu Icons 2404
Truck Setup Submenu Icons 2407
Diagnostics Submenu Icons 2419
Operating Screen 2429
Introduction 2429
Performance Mode Controls 2429
Status and Warning Icons 2430
Battery Discharge Indicator 2431
Direction and Parking Brake Indicators 2431
Hazard Flashers and Lighting Controls 2432
Steer Angle Indicator 2432
System Time 2432
Load Weight Indicator 2432
System Off/Alert Screens 2433
Introduction 2433
System Off Screen 2433
Alert Screens 2433
Password Screen 2435
Introduction 2435
Password Screen 2435
Service Technician Password Setup 2435
Adding/Removing/Changing Passwords 2436
Password Log 2439
Activity Log Menu 2440
Introduction 2440
Operator Checklist Log 2440
Password Log 2442
Impact Events Log 2444
Calibration Menu 2446
Introduction 2446
Load Weight Calibration 2446
Return to Set Tilt Stop Point Calibration 2447
E-Hydraulic and Manual Valve Threshold Calibration 2447
Steering Wheel Center Point Calibration 2448
Steer Axle Position Calibration 2449
Steer Axle Center Point Calibration 2450
Manual Hydraulics Calibration 2450
Display Menu 2451
Introduction 2451
Set Date and Time Format Menu 2451
Set Daylight Saving Time Menu 2452
Procedure for Setting Up Automatic Daylight Savings Time 2453
Set Time and Date Menu 2455
Procedure for Setting Time and Date 2455
Set Units Menu 2456
Status Menu 2457
Introduction 2457
VSM Versions 2457
Display Versions 2458
Truck Serial Number 2458
Hour Meters 2458
E-Hydraulic Controller Versions 2458
Pump Motor Controller Versions 2458
Traction Motor Controller 1 Versions 2458
Traction Motor Controller 2 Versions 2459
Light Controller Versions 2459
Impact Sensor Versions 2459
E-Steer Controller 1 Versions 2459
E-Steer Controller 2 Versions 2459
Truck Setup Menu 2460
Introduction 2460
Add/Remove Password 2461
Battery Settings 2461
Motor Braking 2461
Changing the Motor Braking Settings 2462
Battery Mode 2462
Battery Setup 2463
BDI Adjustment Setting 2464
Acceleration Rates 2465
Hour Meter Initialization 2466
Impact Monitor Shutdown 2466
Operator Checklist 2468
Minimum Pump Standby Flow Rate 2468
Scheduled Maintenance Reminder 2469
Traction Speed Limit 2470
Return to Set Tilt 2470
Auto Power-Off Time Delay 2471
Impact Monitor Settings 2471
Impact Detection 2472
Setting Adjustments 2472
Initial Adjustment of Soft and Hard Impact Settings 2472
Readjustment of Soft and Hard Impact Settings 2472
Motion Alarm 2472
Lift Hydraulic Function Maximum Speed and Ramp Times 2473
Lower Hydraulic Function Maximum Speed and Ramp Times 2473
Tilt Forward Hydraulic Function Maximum Speed and Ramp Times 2474
Tilt Backward Hydraulic Function Maximum Speed and Ramp Times 2474
Auxiliary 1A Hydraulic Function Maximum Speed and Ramp Times 2474
Auxiliary 1B Hydraulic Function Maximum Speed and Ramp Times 2474
Auxiliary 2A Hydraulic Function Maximum Speed and Ramp Times 2474
Auxiliary 2B Hydraulic Function Maximum Speed and Ramp Times 2474
Optional Hydraulic Functions 2474
Rear Lights Control 2475
Restore Default Settings 2475
Steering Wheel Friction and Steering Turns Adjustment 2476
Navigation 2477
How to Adjust Settings 2477
Steering Friction 2477
Steering Wheel Number of Turns 2478
Diagnostics Menu 2480
Introduction 2480
Fault Code Log 2480
Fault Log Details 2481
Speedometer 2482
Direction Switch 2482
Traction Motor 1 Status 2483
Traction Motor 2 Status 2483
Occupancy Sensor 2483
Brake System Sensors 2483
Pump Status 2484
Hydraulic Control Inputs 2485
E-Hydraulic Valves 2485
Hydraulic Sensors 2486
System Voltages 2486
Steering Position Sensors 2488
E-Steering Position Sensors 2488
Electric Brake 2489
Navigation 2490
ESS Diagnostics Menus A, B, and C 2491
Menu A 2491
Menu B 2492
Menu C 2494
524319498-2200YRM1336-(07-2020)-UK-EN 2497
General 2503
Description 2503
Display Panel Menu Access 2503
Menu Flowchart 2504
Technician Menu Flowchart 2504
Menu Navigation 2510
Icon Glossary 2514
Introduction 2514
Soft Key Icons 2514
Overlay Icons 2515
Heat Exchange Module Warning Indicator Screen 2515
System Off Screen and Alert Screens 2516
Main Menu Title Screens 2521
Submenu Icons Grouped by Menu 2523
Operating Screen Icons 2523
Password Screen Icons 2524
Activity Log Submenu Icons 2524
Calibration Submenu Icons 2526
Display Submenu Icons 2529
Status Submenu Icons 2531
Truck Setup Submenu Icons 2535
Diagnostics Submenu Icons 2546
Operating Screen 2556
Introduction 2556
Performance Mode Controls 2556
Status and Warning Icons 2557
Battery Discharge Indicator 2558
Direction and Parking Brake Indicators 2559
Hazard Flashers and Lighting Controls 2559
Steer Angle Indicator 2559
System Time 2559
Load Weight Indicator 2559
System Off/Alert Screens 2560
Introduction 2560
System Off Screen 2560
Alert Screens 2560
Password Screen 2562
Introduction 2562
Password Screen 2562
Service Technician Password Setup 2562
Adding/Removing/Changing Passwords 2563
Password Log 2565
Activity Log Menu 2566
Introduction 2566
Operator Checklist Log 2566
Password Log 2568
Impact Events Log 2570
Calibration Menu 2572
Introduction 2572
Load Weight Calibration 2572
Return to Set Tilt Stop Point Calibration 2573
E-Hydraulic and Manual Valve Threshold Calibration 2573
Steering Wheel Center Point Calibration 2574
Steer Axle Position Calibration 2575
Steer Axle Center Point Calibration 2575
Manual Hydraulics Calibration 2576
Display Menu 2577
Introduction 2577
Set Date and Time Format Menu 2577
Set Daylight Saving Time Menu 2578
Procedure for Setting Up Automatic Daylight Savings Time 2579
Set Time and Date Menu 2581
Procedure for Setting Time and Date 2581
Set Units Menu 2582
Status Menu 2583
Introduction 2583
VSM Versions 2583
Display Versions 2584
Truck Serial Number 2584
Hour Meters 2584
E-Hydraulic Controller Versions 2584
Pump Motor Controller Versions 2584
Traction Motor Controller 1 Versions 2584
Traction Motor Controller 2 Versions 2585
Light Controller Versions 2585
Impact Sensor Versions 2585
E-Steer Controller 1 Versions 2585
E-Steer Controller 2 Versions 2585
Truck Setup Menu 2586
Introduction 2586
Add/Remove Password 2587
Battery Settings 2587
Motor Braking 2587
Changing the Motor Braking Settings 2588
Battery Mode 2588
Battery Setup 2589
BDI Adjustment Setting 2590
Acceleration Rates 2591
Hour Meter Initialization 2592
Impact Monitor Shutdown 2592
Operator Checklist 2593
Minimum Pump Standby Flow Rate 2594
Scheduled Maintenance Reminder 2594
Traction Speed Limit 2596
Return to Set Tilt 2596
Auto Power-Off Time Delay 2596
Impact Monitor Settings 2597
Impact Detection 2597
Setting Adjustments 2597
Initial Adjustment of Soft and Hard Impact Settings 2597
Readjustment of Soft and Hard Impact Settings 2598
Motion Alarm 2598
Lift Hydraulic Function Maximum Speed and Ramp Times 2598
Lower Hydraulic Function Maximum Speed and Ramp Times 2599
Tilt Forward Hydraulic Function Maximum Speed and Ramp Times 2599
Tilt Backward Hydraulic Function Maximum Speed and Ramp Times 2599
Auxiliary 1A Hydraulic Function Maximum Speed and Ramp Times 2599
Auxiliary 1B Hydraulic Function Maximum Speed and Ramp Times 2600
Auxiliary 2A Hydraulic Function Maximum Speed and Ramp Times 2600
Auxiliary 2B Hydraulic Function Maximum Speed and Ramp Times 2600
Optional Hydraulic Functions 2600
Rear Lights Control 2600
Restore Default Settings 2601
Steering Wheel Friction and Steering Turns Adjustment 2601
Navigation 2602
How to Adjust Settings 2602
Steering Friction 2602
Steering Wheel Number of Turns 2603
Diagnostics Menu 2605
Introduction 2605
Fault Code Log 2605
Fault Log Details 2606
Speedometer 2607
Direction Switch 2607
Traction Motor 1 Status 2607
Traction Motor 2 Status 2608
Occupancy Sensor 2608
Brake System Sensors 2608
Pump Status 2609
Hydraulic Control Inputs 2609
E-Hydraulic Valves 2609
Hydraulic Sensors 2610
System Voltages 2610
Steering Position Sensors 2611
E-Steering Position Sensors 2611
Electric Brake 2612
Navigation 2613
524319499-2200YRM1369-(01-2020)-UK-EN 2615
General 2623
Discharging the Capacitors 2624
Display Panel and Key or Keyless Switch Replacement 2625
Display Panel, Replace 2625
Remove 2625
Install 2628
Electronic and Manual Hydraulic Controls 2629
General 2629
Manual Hydraulic Controls 2630
Upper Front Cover 2630
Direction Control Switch 2631
Remove 2631
Install 2636
Clamp Button 2636
Remove 2636
Install 2637
Return To Set Tilt (RTST) Button 2637
Remove 2637
Install 2637
Emergency Disconnect Switch 2638
Remove 2638
Install 2638
E-Hydraulic Controls – Test 2639
Mini-Levers 2639
Full Stroke Test 2639
Function Returns to Neutral Test 2639
Push (Override) Button 2640
E-Hydraulic Controls 2640
Mini-levers, Remove and Install 2640
Armrest Assembly 2641
Remove 2641
Install 2643
Horn Button 2643
Remove 2643
Install 2644
Direction Control Switch 2644
Remove 2644
Install 2645
Emergency Disconnect Switch 2645
Remove 2645
Install 2646
Push (Override) Buttons and Function Selection Button 2646
Remove 2646
Install 2648
Electronic-Hydraulic Controls, After January, 2020 2648
General 2648
E-Hydraulic Controls – TEST 2650
Mini-Levers 2650
Full Stroke Test 2650
Function Returns to Neutral Test 2650
Push Button (push (override) button) 2651
Mini-levers, Remove and Install 2651
Armrest Assembly 2651
Remove 2651
Install 2654
Horn Button 2654
Remove 2654
Install 2655
Direction Control Switch 2655
Remove 2655
Install 2655
Emergency Disconnect Switch 2655
Remove 2656
Install 2656
Push (Override) Buttons 2657
Remove 2657
Install 2658
Sensors and Switches 2659
General 2659
Synchronous Steering Valve 2659
Steering Axle Sensor 2659
Remove 2659
Install 2664
Hydraulic Motor Speed Sensor 2665
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 2665
Remove 2665
Install 2670
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2671
Remove 2671
Install 2675
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 2675
Remove 2675
Install 2676
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2676
Remove 2676
Install 2678
Hydraulic Motor Temperature Sensor 2678
Hydraulic Tank Level Sensor 2678
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2678
Remove 2678
Install 2680
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 2680
Remove 2680
Install 2681
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2681
Remove 2681
Install 2682
Hydraulic Filter Sensor 2682
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2682
Remove 2682
Install 2683
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968,) ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2684
Remove 2684
Install 2685
Hydraulic Oil Temperature Sensor 2686
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2686
Remove 2686
Install 2686
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 2686
Remove 2686
Install 2687
Traction Speed Sensor 2687
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2687
Remove 2687
Install 2689
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 2690
Remove 2690
Install 2692
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2692
Remove 2692
Install 2693
Traction Motor Temperature Sensor ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 2694
Traction Motor Temperature Sensor ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2694
Remove 2694
Install 2695
Tilt Position Sensor ERC22-35VG (ERC045-070VG) (A968), ERP22-35VL (ERP045-070VL) (A976), and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2695
Remove 2695
Install 2697
Tilt Position Sensor ERC16-20VA (ERC030-040VA) (A969) 2698
Remove 2698
Install 2698
Tilt Position Sensor ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2699
Remove 2699
Install 2700
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) 2701
Remove 2701
Install 2704
Low Level Brake Fluid Switch for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2705
Remove 2705
Install 2706
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) 2707
Remove 2707
Install 2707
Service Brake Pressure Sensor for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2708
Remove 2708
Install 2708
Accelerator Pedal Position Sensor 2708
Remove 2708
Install 2709
Seat Belt Sequence Module 2709
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2709
Remove 2709
Install 2709
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 2710
Remove 2710
Install 2710
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 2710
Remove 2710
Install 2711
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2711
Remove 2711
Install 2712
Seat Sensor (Operator Presence System) 2712
Non-Suspension Seat 2712
Remove 2712
Install 2714
Full Suspension and Swivel Seats 2714
Remove 2714
Install 2715
Steering Direction Sensor 2715
Remove 2715
Install 2716
Load Weight Sensor 2716
Remove 2716
Install 2718
Battery Gate Switch 2718
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2718
Remove 2718
Install 2720
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 2720
Remove 2720
Install 2722
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2723
Remove 2723
Install 2724
Horn Switch 2724
Fixed Steering Column 2724
Remove 2724
Install 2725
Telescopic Steering Column 2725
Remove 2725
Install 2726
Impact Sensor 2726
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2726
Remove 2726
Install 2728
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 2728
Remove 2728
Install 2729
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2730
Remove 2730
Install 2731
Rear and Hood Horn Button Switches 2731
Rear Horn Button Switch 2731
Remove 2731
Install 2732
Hood Horn Button Switch 2732
Remove 2732
Install 2733
Motor Controllers Replacement 2734
General 2734
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 2748
Traction Motor and Hydraulic Pump and Motor Controllers 2748
Remove 2748
Install 2755
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2756
Hydraulic Pump and Motor Controller 2756
Remove 2756
Install 2762
Traction Motor Controllers 2763
Remove 2763
Install 2770
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2771
Traction Motor and Hydraulic Pump and Motor Controllers 2771
Remove 2771
Install 2773
Line Contactor 2774
Remove 2774
Install 2782
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) 2783
Remove 2783
Install 2785
Fans for Lift Truck Model Manufactured Before November 2014ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2786
Remove 2786
Install 2786
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) 2786
Remove 2793
Install 2797
Vehicle System Manager 2797
General 2797
Remove 2798
Install 2802
Programming a New VSM and/or Display Panel 2803
PC Service Tool Software 2803
Fuses and Relays 2804
Backup Alarm 2818
Battery Connection 2821
Inspect 2821
Replacing Cables 2821
Cab Heater 2823
Lights 2823
General 2823
Work Lights (Front and Rear) 2827
Halogen Bulb Lights 2827
Remove 2827
Install 2827
LED Lights 2827
Remove 2827
Install 2828
Strobe Light 2828
Remove 2828
Install 2828
LED Tail, Backup, and Brake Lights 2829
Remove 2829
Install 2830
Front Marker/Turn Signal Lights 2830
Remove 2830
Install 2830
Dome Light 2830
Remove 2830
Install 2831
Converter 2831
Remove 2832
Install 2840
524319499-2200YRM1369-(04-2023)-UK-EN 2843
General 2853
Discharging the Capacitors 2854
Display Panel and Key or Keyless Switch Replacement 2855
Display Panel, Replace 2855
Remove 2855
Install 2858
Electronic and Manual Hydraulic Controls 2859
General 2859
Manual Hydraulic Controls 2860
Upper Front Cover 2860
Direction Control Switch 2861
Remove 2861
Install 2867
Clamp Button 2867
Remove 2867
Install 2868
Return To Set Tilt (RTST) Button 2868
Remove 2868
Install 2868
Emergency Disconnect Switch 2869
Remove 2869
Install 2869
E-Hydraulic Controls – Test 2870
Mini-Levers 2870
Full Stroke Test 2870
Function Returns to Neutral Test 2870
Push (Override) Button 2871
E-Hydraulic Controls 2871
Mini-levers, Remove and Install 2871
Armrest Assembly 2872
Remove 2872
Install 2874
Horn Button 2874
Remove 2874
Install 2875
Direction Control Switch 2875
Remove 2875
Install 2876
Emergency Disconnect Switch 2876
Remove 2876
Install 2877
Push (Override) Buttons and Function Selection Button 2877
Remove 2877
Install 2880
Electronic-Hydraulic Controls, After January, 2020 2881
General 2881
E-Hydraulic Controls – TEST 2882
Mini-Levers 2882
Full Stroke Test 2882
Function Returns to Neutral Test 2882
Push Button (push (override) button) 2883
Mini-levers, Remove and Install 2883
Armrest Assembly 2883
Remove 2883
Install 2886
Horn Button 2886
Remove 2886
Install 2886
Direction Control Switch 2886
Remove 2886
Install 2887
Emergency Disconnect Switch 2887
Remove 2887
Install 2888
Push (Override) Buttons 2888
Remove 2888
Install 2889
Sensors and Switches 2890
General 2890
Synchronous Steering Valve 2890
Steering Axle Sensor 2890
Remove 2890
Install 2895
Hydraulic Motor Speed Sensor 2896
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 2896
Remove 2896
Install 2901
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2902
Remove 2902
Install 2906
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 2906
Remove 2906
Install 2907
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2907
Remove 2907
Install 2909
Hydraulic Motor Temperature Sensor 2909
Hydraulic Tank Level Sensor 2909
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2909
Remove 2909
Install 2911
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 2911
Remove 2911
Install 2912
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2912
Remove 2912
Install 2913
Hydraulic Filter Sensor 2913
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2913
Remove 2913
Install 2914
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968,) ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2915
Remove 2915
Install 2916
Hydraulic Oil Temperature Sensor 2917
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2917
Remove 2917
Install 2917
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 2917
Remove 2917
Install 2918
Traction Speed Sensor 2918
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2918
Remove 2918
Install 2920
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 2921
Remove 2921
Install 2923
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2923
Remove 2923
Install 2924
Traction Motor Temperature Sensor ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 2925
Traction Motor Temperature Sensor ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2925
Remove 2925
Install 2926
Tilt Position Sensor ERC22-35VG (ERC045-070VG) (A968), ERP22-35VL (ERP045-070VL) (A976), and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2926
Remove 2926
Install 2928
Tilt Position Sensor ERC16-20VA (ERC030-040VA) (A969) 2928
Remove 2929
Install 2929
Tilt Position Sensor ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2929
Remove 2929
Install 2930
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) 2931
Remove 2931
Install 2934
Low Level Brake Fluid Switch for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2935
Remove 2935
Install 2936
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) 2937
Remove 2937
Install 2937
Service Brake Pressure Sensor for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2937
Remove 2937
Install 2938
Accelerator Pedal Position Sensor 2938
Remove 2938
Install 2938
Seat Belt Sequence Module 2939
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2939
Remove 2939
Install 2940
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 2940
Remove 2940
Install 2940
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 2940
Remove 2940
Install 2941
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2941
Remove 2941
Install 2941
Seat Sensor (Operator Presence System) 2942
Non-Suspension Seat 2942
Remove 2942
Install 2944
Full Suspension and Swivel Seats 2944
Remove 2944
Install 2945
Steering Direction Sensor 2945
Remove 2945
Install 2945
Load Weight Sensor 2946
Remove 2946
Install 2947
Battery Gate Switch 2948
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2948
Remove 2948
Install 2950
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 2950
Remove 2950
Install 2952
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2952
Remove 2952
Install 2953
Horn Switch 2954
Fixed Steering Column 2954
Remove 2954
Install 2955
Telescopic Steering Column 2955
Remove 2955
Install 2956
Impact Sensor 2956
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2956
Remove 2956
Install 2958
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 2958
Remove 2958
Install 2959
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2960
Remove 2960
Install 2961
Rear and Hood Horn Button Switches 2961
Rear Horn Button Switch 2961
Remove 2961
Install 2962
Hood Horn Button Switch 2962
Remove 2962
Install 2963
Motor Controllers Replacement 2964
General 2964
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 2978
Traction Motor and Hydraulic Pump and Motor Controllers 2978
Remove 2978
Install 2985
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2985
Hydraulic Pump and Motor Controller 2985
Remove 2985
Install 2992
Traction Motor Controllers 2993
Remove 2993
Install 3000
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 3001
Traction Motor and Hydraulic Pump and Motor Controllers 3001
Remove 3001
Install 3003
Line Contactor 3004
Remove 3004
Install 3011
Fans for Lift Truck Models Manufactured Before November 2014 ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), ERP22-25VL (ERP045-070VL) (A976), and ERP40-50VM (ERP080-100VM) (A985) 3013
Remove 3013
Install 3015
Fans for Lift Truck Model Manufactured Before November 2014 ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 3016
Remove 3016
Install 3016
Fans for Lift Truck Models Manufactured After November 2014 ERC045-070VG (A968), ERC030-040VA (A969), ERC80-120VH, ERC100VHS (A938), ERP22-25VL (ERP045-070VL) (A976), and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 3016
Remove 3023
Install 3027
Vehicle System Manager 3028
General 3028
Remove 3028
Install 3033
Programming a New VSM and/or Display Panel 3034
PC Service Tool Software 3034
Fuses and Relays 3035
Backup Alarm 3049
Battery Connection 3053
Inspect 3053
Replacing Cables 3053
Cab Heater 3055
Lights 3055
General 3055
Work Lights (Front and Rear) 3059
Halogen Bulb Lights 3059
Remove 3059
Install 3059
LED Lights 3059
Remove 3059
Install 3060
Strobe Light 3060
Remove 3060
Install 3060
LED Tail, Backup, and Brake Lights 3061
Remove 3061
Install 3062
Front Marker/Turn Signal Lights 3062
Remove 3062
Install 3062
Dome Light 3062
Remove 3062
Install 3063
Converter 3063
Remove 3063
Install 3072
524319504-9000YRM1377-(09-2019)-UK-EN 3075
SECTION 9010 Operational Diagnostic Procedures 3091
Group 05 – Operational Checkout 3093
SECTION 9025 Traction Motor 3103
Group 10 – Principles of Operation 3105
Group 30 – Observed Symptoms 3111
SECTION 9030 Electrical System 3113
Group 03 – General Maintenance and Diagnostic Data 3123
Group 10 – Principles of Operation 3167
Group 20 – Diagnostic Trouble Codes 3199
Group 30 – Observed Symptoms 3811
Group 55 – Icons and Graphics 3855
SECTION 9035 Drive Axle/Unit 3863
Group 10 – Principles of Operation 3865
Group 30 – Observed Symptoms 3875
Group 20 – Diagnostic Trouble Codes 3887
SECTION 9050 Hydraulic Systems 3889
Group 10 – Principles of Operation 3893
Group 33 – Observed Symptoms-Gear Pump 3931
Group 43 – Tests and Adjustments-Gear Pump 4011
SECTION 9060 Operators Station 4041
Group 10 – Principles of Operation 4043
SECTION 9070 Front End (Mast) and Chassis 4083
Group 10 – Principles of Operation 4085
Group 30 – Observed Symptoms 4103
SECTION 9080 Supplementary Data 4147
Group 50 – Abbreviations and Acronyms 4149
524327049-0620YRM1385-(02-2023)-UK-EN 4157
General 4165
Discharging the Capacitors for Lift Truck Models ESC030-040AC (B883), ESC030-040AD (C883) 4171
Discharging the Capacitors (All Other Models) 4173
Traction Motor Repair 4174
For Lift Truck Models , and ERP15-20VT (ERP030-040VT) (G807)ERP16-20VF (ERP30-40VF) (A955), ESC030-040AC (B883) 4174
Remove 4174
Disassemble 4175
Electrical Connector Repair or Replacement 4177
Clean 4177
Inspect 4177
Assemble 4178
Install 4180
For Lift Truck ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 4182
Remove 4182
Disassemble 4182
Electrical Connector Repair or Replacement 4185
Clean 4185
Inspect 4185
Assemble 4186
Install 4186
For Lift Truck ERP2 2-3 5VL (ERP045-070VL) (A976) 4186
Remove 4186
Disassemble 4186
Clean 4188
Inspect 4188
Assemble 4189
Install 4189
For Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080120VM, ERP100VML) (A985) 4189
Remove 4189
Clean 4191
Install 4191
For Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 4191
Remove 4191
Disassemble 4191
Electrical Connector Repair or Replacement 4193
Clean 4193
Inspect 4193
Assemble 4194
Install 4195
Traction Motor Repair for 4-5 5T Lift Trucks 4196
For Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080120VM, ERP100VML) (A985) 4196
Remove 4196
Clean 4198
Install 4198
Hydraulic Motor Repair 4199
For Lift Trucks and ERP15-20VT (ERP030-040VT) (G807)ERP16-20VF (ERP30-40VF) (A955)ESC030-040AC (B883), ESC030-040AD (C883) 4199
Remove 4199
Disassemble 4200
Electrical Connector Repair or Replacement 4202
Clean 4202
Inspect 4202
Assemble 4203
Install 4205
For Lift Truck ERC22-35VG (ERC045-070VG) (A968) 4206
Remove 4206
Disassemble 4208
Standard Motor 4208
Enhanced Motor 4210
Electrical Connector Repair or Replacement 4211
Clean 4212
Inspect 4212
Assemble 4213
Standard Motor 4213
Enhanced Motor 4213
Install 4214
For Lift Truck Models ERP2 2-3 5VL (ERP045-070VL) (A976) and ERC16-20VA (ERC030-040VA) (A969) 4214
Remove 4214
Disassemble 4214
Electrical Connector Repair or Replacement 4220
Clean 4221
Inspect 4221
Assemble 4222
Install 4223
For Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 4223
Remove 4223
Disassemble 4223
Electrical Connector Repair or Replacement 4226
Clean 4226
Inspect 4227
Assemble 4227
Install 4228
Hydraulic Motor Repair For 4 0-5 5T Lift Trucks 4228
Remove 4228
Disassemble 4228
Electrical Connector Repair or Replacement 4230
Clean 4230
Inspect 4231
Assemble 4231
Install 4232
Torque Specifications 4233
Traction Motor for Lift Trucks and ERP15-20VT (ERP030-040VT) (G807)ERP16-20VF (ERP30-40VF) (A955) 4233
Traction Motor for Lift Truck and ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969),ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 4233
Traction Motor for Lift Truck ESC030-040AC (B883), ESC030-040AD (C883) 4233
Hydraulic Motor for Lift Trucks and ERP15-20VT (ERP030-040VT) (G807)ERP16-20VF (ERP30-40VF) (A955) 4233
Hydraulic Motor for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 4233
Hydraulic Motor for Lift Truck ERP22-35VG (ERP045-070VG) (A976) 4233
Hydraulic Motor for Lift Truck ERC16-20VA (ERC030-040VA) (A969) 4233
Hydraulic Motor for Lift Truck ESC030-040AC (B883), ESC030-040AD (C883) 4233
Hydraulic Motor for Lift Truck and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 4234
524327049-0620YRM1385-(06-2015)-UK-EN 4237
General 4241
Discharging the Capacitors for Lift Truck Models ESC030-040AC (B883), ESC030-040AD (C883) 4248
Discharging the Capacitors (All Other Models) 4249
Traction Motor Repair 4249
For Lift Truck Models ERP15-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), and ESC030-040AC (B883) 4250
Remove 4250
Disassemble 4251
Electrical Connector Repair or Replacement 4254
Clean 4254
Inspect 4254
Assemble 4255
Install 4258
For Lift Truck ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 4260
Remove 4260
Disassemble 4260
Electrical Connector Repair or Replacement 4264
Clean 4264
Inspect 4264
Assemble 4265
Install 4265
For Lift Truck ERP2 2-3 5VL (ERP045-070VL) (A976) 4265
Remove 4265
Disassemble 4265
Clean 4267
Inspect 4267
Assemble 4268
Install 4268
For Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 4268
Remove 4268
Disassemble 4269
Electrical Connector Repair or Replacement 4270
Clean 4270
Inspect 4271
Assemble 4271
Install 4272
4272
Traction Motor Repair For Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 4272
Remove 4272
Clean 4274
Install 4274
Hydraulic Motor Repair 4274
For Lift Trucks ERP15-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), and ESC030-040AC (B883), ESC030-040AD (C883) 4274
Remove 4274
Disassemble 4276
Electrical Connector Repair or Replacement 4278
Clean 4278
Inspect 4278
Assemble 4279
Install 4281
For Lift Truck ERC22-35VG (ERC045-070VG) (A968) 4283
Remove 4283
Disassemble 4284
Standard Motor 4284
Enhanced Motor 4285
Electrical Connector Repair or Replacement 4287
Clean 4288
Inspect 4289
Assemble 4289
Standard Motor 4289
Enhanced Motor 4290
Install 4291
For Lift Truck Models ERP2 2-3 5VL (ERP045-070VL) (A976) and ERC16-20VA (ERC030-040VA) (A969) 4292
Remove 4292
Disassemble 4292
Electrical Connector Repair or Replacement 4298
Clean 4299
Inspect 4299
Assemble 4300
Install 4301
4301
Hydraulic Motor Repair For 4 0-5 5T Lift Trucks 4301
Remove 4301
Disassemble 4301
Electrical Connector Repair or Replacement 4304
Clean 4305
Inspect 4305
Assemble 4306
Install 4306
Torque Specifications 4307
Traction Motor for Lift Trucks ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955) 4307
Traction Motor for Lift Truck ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 4307
Traction Motor for Lift Truck ESC030-040AC (B883), ESC030-040AD (C883) 4307
Hydraulic Motor for Lift Trucks ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955) 4307
Hydraulic Motor for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 4307
Hydraulic Motor for Lift Truck ERP22-35VG (ERP045-070VG) (A976) 4307
Hydraulic Motor for Lift Truck ERC16-20VA (ERC030-040VA) (A969) 4307
Hydraulic Motor for Lift Truck ESC030-040AC (B883), ESC030-040AD (C883) 4307
Hydraulic Motor for Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 4308
524332383-8000YRM1384-(01-2020)-UK-EN 4311
524332383-8000YRM1384-(04-2023)-UK-EN 4353
550025937-0100YRM1446-(02-2023)-UK-EN 4397
General 4403
Discharging the Capacitors 4404
Window Replacement 4405
Front Panel 4405
Remove, Lift Truck Models ERP22-35VL (ERP045-070VL) (A976), ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985), ERP15-20VT (ERP030-040VT) (G807), and ERP16-20VF (ERP30-40VF) (A955) 4405
Remove, Lift Truck Models ERP13VC, ERP15VC (B888) 4406
Clean 4408
Inspect 4408
Install, Lift Truck Models ERP22-35VL (ERP045-070VL) (A976), ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985), ERP15-20VT (ERP030-040VT) (G807), and ERP16-20VF (ERP30-40VF) (A955) 4408
Install, Lift Truck Models ERP13VC, ERP15VC (B888) 4408
Rear Panel 4408
Remove 4408
Clean 4412
Inspect 4412
Install 4412
Door Window 4413
Disassemble Window 4413
Clean 4414
Inspect 4414
Assemble Window 4414
Window Wipers Replacement 4415
Front Wiper Assembly 4415
Remove, Lift Truck Models ERP22-35VL (ERP045-070VL) (A976), ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985), ERP15-20VT (ERP030-040VT) (G807), and ERP16-20VF (ERP30-40VF) (A955) 4415
Remove, Lift Truck Models ERP13VC, ERP15VC (B888) 4420
Clean 4421
Inspect 4422
Install, Lift Truck Models ERP22-35VL (ERP045-070VL) (A976), ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985), ERP15-20VT (ERP030-040VT) (G807), and ERP16-20VF (ERP30-40VF) (A955) 4422
Install, Lift Truck Models ERP13VC, ERP15VC (B888) 4423
Cab Component Repair 4424
Roof Liner 4424
Remove 4424
Clean 4425
Inspect 4425
Install 4425
Top Panel 4426
Remove, Lift Truck Models ERP22-35VL (ERP045-070VL) (A976), ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985), ERP15-20VT (ERP030-040VT) (G807), and ERP16-20VF (ERP30-40VF) (A955) 4426
Remove, Lift Truck Models ERP13VC, ERP15VC (B888) 4428
Clean 4429
Inspect 4429
Install, Lift Truck Models ERP22-35VL (ERP045-070VL) (A976), ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985), ERP15-20VT (ERP030-040VT) (G807), and ERP16-20VF (ERP30-40VF) (A955) 4429
Install, Lift Truck Models ERP13VC, ERP15VC (B888) 4429
Cab Door Assembly 4430
Door Assembly 4430
Remove 4430
Lift Truck Models and ERP22-35VL (ERP045-070VL) (A976)ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 4430
Lift Truck Models and ERP15-20VT (ERP030-040VT) (G807)ERP16-20VF (ERP30-40VF) (A955) 4432
Disassemble Left Door 4434
Disassemble Right Door 4436
Clean 4438
Inspect 4438
Assemble Right Door 4438
Assemble Left Door 4438
Install 4439
Lift Truck Models and ERP22-35VL (ERP045-070VL) (A976)ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 4439
Lift Truck Models and ERP15-20VT (ERP030-040VT) (G807)ERP16-20VF (ERP30-40VF) (A955) 4439
Cab Heater 4440
Cab Heater 4440
Remove 4440
Clean 4447
Inspect 4447
Install 4447
Troubleshooting 4449
Weather Panel Replacement 4452
Remove 4452
Roof Panels 4452
Front Screen Panel 4455
Install 4456
Front Screen Panel 4456
Roof Panels 4456
550025937-0100YRM1446-(09-2014)-UK-EN 4459
550041580-1300YRM1539-(02-2023)-UK-EN 4513
General 4519
Discharging the Capacitors 4519
Description 4520
Transaxle Repair 4522
Remove 4522
Install 4527
Maintenance and Repair 4528
Wheel Studs 4528
Remove 4528
Install 4528
Brake Lever 4529
Remove 4529
Install 4529
Brake Piston and Seals 4529
Remove 4529
Clean and Inspect 4530
Install 4530
Transaxle Output Breathers 4531
Remove 4531
Clean and Inspect 4531
Install 4531
Speed Sensor Replacement 4532
Traction Motor 4532
Remove 4532
Traction Motor Repair 4536
Install 4536
Automatic Parking Brake Actuator 4537
Remove 4537
Inspect 4538
Install 4539
Transmission Output Assembly 4540
Remove 4540
Install 4542
Transmission Gearbox Housing 4543
Remove 4543
Install 4543
Service (Wet) Brakes 4544
Remove 4544
Disassemble 4544
Clean and Inspect 4546
Assemble 4546
Install 4546
Brake Pedal and Linkages 4547
General 4547
Master Cylinder 4548
Remove 4548
Disassemble 4549
Clean 4550
Inspect 4551
Assemble 4551
Bench Bleed Master Cylinder 4551
Install and Adjust 4551
Brake Pedal Components 4552
Remove 4552
Disassemble 4552
Inspect 4553
Assemble 4553
Install 4554
Brake Pedal and Master Cylinder Adjustments 4554
Brake Pedal Adjustment 4554
Master Cylinder Adjustment 4555
Automatic Parking Brake Valve Repair 4556
Remove and Install 4556
Solenoid Valve Cartridge 4556
Automatic Park Brake (APB) Valve Handle and Cartridge 4556
Hand Pump Cartridge 4557
550041580-1300YRM1539-(09-2014)-UK-EN 4559
550041581-4000YRM1540-(04-2023)-UK-EN 4597
General 4603
Safety Procedures When Working Near Mast 4603
Fork Replacement 4606
Remove 4606
Install 4607
Checks 4607
Fork Positioner 4609
Remove 4609
Install 4610
Checks 4611
Carriage Replacement 4612
Remove 4612
Install 4614
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 4615
Connecting Attachment Hydraulic Quick Disconnect Hoses 4615
Integral Sideshift Carriage Repair 4616
Remove 4616
Disassemble 4616
Assemble 4619
Install 4619
Fork Positioner 4620
Two-Stage Mast With Limited Free-Lift Repair 4621
Remove 4621
Disassemble 4621
Clean and Inspect 4622
Assemble 4626
Install 4627
Header Hose Alignment 4629
Two-Stage Mast With Full Free-Lift Repair 4634
Remove 4634
Disassemble 4634
Clean and Inspect 4637
Assemble 4638
Install 4639
Header Hose Installation and Adjustment 4641
Installation 4641
Adjustment 4643
Three-Stage Mast With Full Free-Lift Repair 4644
Remove 4644
Disassemble 4644
Clean and Inspect 4648
Assemble 4649
Install 4651
Header Hose Alignment 4653
Mast Operation Check 4660
Tilt Cylinders Adjustment 4660
Lift Chains Adjustment 4660
Mast Adjustments 4662
Load Roller Adjustment 4662
Mast Side Kicking Adjustment 4665
Carriage Adjustments 4666
550041581-4000YRM1540-(11-2017)-UK-EN 4669
General 4673
Safety Procedures When Working Near Mast 4673
Fork Replacement 4676
Remove 4676
Install 4676
Checks 4678
Fork Positioner 4680
Remove 4680
Install 4681
Checks 4681
Carriage Replacement 4681
Remove 4682
Install 4682
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 4684
Connecting Attachment Hydraulic Quick Disconnect Hoses 4684
Integral Sideshift Carriage Repair 4685
Remove 4685
Disassemble 4685
Assemble 4688
Install 4688
Fork Positioner 4688
Two-Stage Mast With Limited Free-Lift Repair 4690
Remove 4690
Disassemble 4690
Clean and Inspect 4690
Assemble 4692
Install 4696
Header Hose Alignment 4698
Two-Stage Mast With Full Free-Lift Repair 4701
Remove 4702
Disassemble 4702
Clean and Inspect 4705
Assemble 4707
Install 4707
Header Hose Installation and Adjustment 4710
Installation 4710
Adjustment 4710
Three-Stage Mast With Full Free-Lift Repair 4712
Remove 4713
Disassemble 4713
Clean and Inspect 4717
Assemble 4718
Install 4720
Header Hose Alignment 4722
Mast Operation Check 4727
Tilt Cylinders Adjustment 4728
Lift Chains Adjustment 4728
Mast Adjustments 4729
Load Roller Adjustment 4730
Mast Side Kicking Adjustment 4730
Carriage Adjustments 4732
550041582-8000YRM1541-(04-2019)-UK-EN 4735
General 4741
Serial Number Data 4741
Discharging the Capacitors 4742
How to Move Disabled Lift Truck 4742
How to Tow Lift Truck 4742
How to Put Lift Truck on Blocks 4743
How to Raise Drive Tires 4743
How to Raise Steering Tires 4743
How to Clean a Lift Truck 4744
Maintenance Schedule 4745
Maintenance Procedures Every 8 Hours or Daily 4750
How to Make Checks With Key or Keyless Switch OFF 4750
Tires and Wheels 4750
Forks, General 4751
Forks, Inspect 4751
Forks, Remove 4752
Forks, Install 4753
Forks, Adjust 4753
Fork Positioner, General 4753
Forks, Inspect 4754
Forks, Remove 4754
Forks, Install 4755
Forks, Adjustments 4756
Inspection of Mast, Carriage, Header Hoses, Lift Chains, and Attachments 4756
Safety Labels 4757
Steering Column Adjustments 4757
Tilt Adjust Feature 4757
Tilt Memory Feature 4757
Telescopic Feature 4758
Operator Restraint System 4758
Emergency Locking Retractor (ELR) 4759
Seat Adjustments 4759
Seat Position Adjustment (Standard Seat) 4759
Seat Position Adjustment (Swivel Seat) 4759
Seat Adjustment for Operator Weight 4759
Battery Restraint System 4760
Hood Latch and Hood Release Handle 4762
Manual Hydraulics 4762
E-Hydraulics 4764
Battery 4765
Hydraulic System 4766
How to Make Checks With Key or Keyless Switch ON 4768
Horn, Lights, and Backup Alarm 4768
Motion Alarm 4769
Emergency Disconnect Switch 4769
Steering System 4770
Service Brakes 4771
Automatic Parking Brake 4771
Hydraulic Control Levers and Pedals 4771
Direction and Speed Control Pedals 4772
Lift System Operation 4772
Oil Leaks 4772
Maintenance Procedures Every 500 Hours or Three Months 4772
Forks, Inspect 4772
Fork Positioner Lubrication 4774
Header Hose Checks 4775
Mast Lubrication 4775
Brake Fluid Check 4777
Master Cylinder Oil Check 4777
Bleeding the Brake System 4779
Operator Presence System Check 4781
Drive Axle Unit Assembly, Gear Oil Level Check 4781
Drive Axle Unit Assembly, Wet Brake Oil Level Check 4783
Tilt Cylinder Rod End Pins 4783
Lift Chains 4784
Wear Check 4784
Lift Chain Lubrication 4785
Fork Pins and Guides 4785
Check Upper and Lower Bearings, Integral Sideshift Carriage 4785
Check Lower Mounting Hook, Integral Sideshift Carriage 4786
Hydraulic Tank Breather, Check 4786
Electrical Inspection 4787
Line Contactor 4787
Steering Axle 4788
King Pins and Tie Rods, Lubricate 4788
Other Lubrication 4789
Hydraulic Control Levers 4789
Cab Heater 4789
Maintenance Procedures Every 2000 Hours or Yearly 4789
Hydraulic System 4790
Hydraulic Filter Element, Replace 4790
Hydraulic Tank Breather, Change 4791
Service Brakes 4792
Master Cylinder Oil, Change 4792
Forks, Inspect 4794
Integral Sideshift Carriage, Replace Upper and Lower Bearings 4796
Lift Chains 4796
Steer Wheel Bearings, Lubricate 4796
Wheel Bearings 4796
Steer Wheels, Lubrication 4796
Maintenance Procedures Every 4000 Hours or Two Years 4796
Hydraulic Oil Change 4796
Steering Direction Sensor Inspection 4798
Fixed Steering Column 4798
Telescopic Steering Column 4800
Telescopic Steering Column Lubrication 4801
Drive Axle Unit Assembly, Gear Oil Change 4802
Drive Axle Unit Assembly, Wet Brake Oil Change 4804
Battery Maintenance 4804
How to Charge Battery 4804
Rapid Charge 4805
How to Change Batteries 4806
General 4806
Remove the Battery, Lift Trucks Equipped With Standard (Vertical) Battery Removal System 4807
Manual Hydraulics 4807
E-Hydraulics 4809
Install the Battery, Lift Trucks Equipped With Standard (Vertical) Battery Removal System 4811
Optional Side (Horizontal) Battery Removal System 4813
Remove the Battery, Lift Trucks Equipped With Battery Tray and Hinged Battery Door 4814
Install the Battery, Lift Trucks Equipped With Battery Tray and Hinged Battery Door 4818
Remove the Battery, Lift Trucks Equipped With Rollers and Drop-In Battery Door 4819
Install the Battery, Lift Trucks Equipped With Rollers and Drop-In Door 4821
Battery Size Specifications 4822
Lift and Tilt System Leak Check 4822
Lift Cylinder Leak Check 4822
Tilt Cylinder Leak Check 4822
Safety Procedures When Working Near Mast 4822
WHEN WORKING NEAR THE MAST ALWAYS: 4823
Lift Chain Adjustments 4825
Welding Repairs 4826
Overhead Guard Changes 4827
Wheels and Tires 4827
General 4827
Pneumatic Tires Repair 4827
Remove Wheels From Lift Truck 4827
Remove Tire From Wheel 4828
Install Wheel in Tire 4831
Add Air to Pneumatic Tires With Tube 4833
Wheels, Install 4834
Solid Rubber Tires on Pneumatic Wheels, Change 4834
Wheels, Install 4838
Dual Drive Wheels, Install 4838
550041582-8000YRM1541-(07-2023)-UK-EN 4841
General 4849
Serial Number Data 4849
Discharging the Capacitors 4850
How to Move Disabled Lift Truck 4850
How to Tow Lift Truck 4850
How to Put Lift Truck on Blocks 4851
How to Raise Drive Tires 4851
How to Raise Steering Tires 4851
How to Clean a Lift Truck 4852
Maintenance Schedule 4854
Maintenance Procedures Every 8 Hours or Daily 4860
How to Make Checks With Key or Keyless Switch OFF 4860
Tires and Wheels 4860
Forks, General 4860
Forks, Inspect 4860
Forks, Remove 4862
Forks, Install 4862
Forks, Adjust 4863
Fork Positioner, General 4863
Forks, Inspect 4863
Forks, Remove 4864
Forks, Install 4865
Forks, Adjustments 4865
Visual Inspection of Mast, Mast hardware, and Tilt Cylinder Hardware 4865
Inspection of Mast, Carriage, Header Hoses, Lift Chains, and Attachments 4865
Safety Labels 4866
Steering Column Adjustments 4866
Tilt Adjust Feature 4867
Tilt Memory Feature 4867
Telescopic Feature 4867
Operator Restraint System 4867
Emergency Locking Retractor (ELR) 4868
Seat Adjustments 4869
Seat Position Adjustment (Standard Seat) 4869
Seat Position Adjustment (Swivel Seat) 4869
Seat Adjustment for Operator Weight 4869
Battery Restraint System 4870
Hood Latch and Hood Release Handle 4872
Manual Hydraulics 4872
E-Hydraulics 4874
Battery 4875
Hydraulic System 4876
How to Make Checks With Key or Keyless Switch ON 4878
Horn, Lights, and Backup Alarm 4878
Motion Alarm 4879
Emergency Disconnect Switch 4879
Steering System 4880
Service Brakes 4881
Automatic Parking Brake 4881
Hydraulic Control Levers and Pedals 4881
Direction and Speed Control Pedals 4882
Lift System Operation 4882
Oil Leaks 4882
Maintenance Procedures Every 500 Hours or Three Months 4883
Forks, Inspect 4883
Fork Positioner Lubrication 4884
Header Hose Checks 4885
Mast Lubrication 4885
Brake Fluid Check 4887
Master Cylinder Oil Check 4887
Bleeding the Brake System 4889
Operator Presence System Check 4891
Drive Axle Unit Assembly, Gear Oil Level Check 4891
Drive Axle Unit Assembly, Wet Brake Oil Level Check 4893
Tilt Cylinder Adjustments 4893
Tilt Cylinder Rod End Pins 4894
Lift Chains 4895
Wear Check 4895
Lift Chain Lubrication 4896
Fork Pins and Guides 4896
Check Upper and Lower Bearings, Integral Sideshift Carriage 4896
Check Lower Mounting Hook, Integral Sideshift Carriage 4897
Hydraulic Tank Breather, Check 4897
Electrical Inspection 4898
Line Contactor 4898
Steering Axle 4899
King Pins and Tie Rods, Lubricate 4899
Other Lubrication 4900
Hydraulic Control Levers 4900
Cab Heater 4900
Maintenance Procedures Every 2000 Hours or Yearly 4901
Hydraulic System 4901
Hydraulic Filter Element, Replace 4901
Hydraulic Tank Breather, Change 4902
Service Brakes 4903
Master Cylinder Oil, Change 4903
Forks, Inspect 4905
Integral Sideshift Carriage, Replace Upper and Lower Bearings 4907
Lift Chains 4907
Steer Wheel Bearings, Lubricate 4907
Wheel Bearings 4907
Steer Wheels, Lubrication 4907
Maintenance Procedures Every 4000 Hours or Two Years 4908
Hydraulic Oil Change 4908
Steering Direction Sensor Inspection 4909
Fixed Steering Column 4909
Telescopic Steering Column 4911
Telescopic Steering Column Lubrication 4912
Drive Axle Unit Assembly, Gear Oil Change 4913
Drive Axle Unit Assembly, Wet Brake Oil Change 4915
Battery Maintenance 4916
How to Charge Battery 4916
Rapid Charge 4917
How to Change Batteries 4919
General 4919
Remove the Battery, Lift Trucks Equipped With Standard (Vertical) Battery Removal System 4919
Manual Hydraulics 4920
E-Hydraulics 4921
Install the Battery, Lift Trucks Equipped With Standard (Vertical) Battery Removal System 4923
Optional Side (Horizontal) Battery Removal System 4924
Remove the Battery, Lift Trucks Equipped With Battery Tray and Hinged Battery Door 4926
Install the Battery, Lift Trucks Equipped With Battery Tray and Hinged Battery Door 4930
Remove the Battery, Lift Trucks Equipped With Rollers and Drop-In Battery Door 4931
Install the Battery, Lift Trucks Equipped With Rollers and Drop-In Door 4933
Battery Size Specifications 4934
Lift and Tilt System Leak Check 4935
Lift Cylinder Leak Check 4935
Tilt Cylinder Leak Check 4935
Safety Procedures When Working Near Mast 4936
WHEN WORKING NEAR THE MAST ALWAYS: 4936
Lift Chain Adjustments 4939
Welding Repairs 4941
Overhead Guard Changes 4942
Wheels and Tires 4943
General 4943
Pneumatic Tires Repair 4943
Remove Wheels From Lift Truck 4943
Remove Tire From Wheel 4943
Install Wheel in Tire 4947
Add Air to Pneumatic Tires With Tube 4950
Wheels, Install 4950
Solid Rubber Tires on Pneumatic Wheels, Change 4950
Wheels, Install 4954
Dual Drive Wheels, Install 4954
550041583-8000YRM1542-(04-2023)-UK-EN 4957
Counterweights 4963
Hydraulic System 4963
Steering System 4964
Specifications 4964
Turning Radius 4964
Wheels and Tires 4964
Battery Specifications 4965
Capacities 4967
Maximum Carriage and Tilt Creep Rates 4968
Tilt Angles 4968
Tilt Speeds 4969
Mast Speeds 4969
Torque Specifications 4970
Frame 4970
Counterweight 4970
Transaxle (Drive Axle) 4970
Steering Axle 4970
Masts 4970
Hydraulic Pump and Motor 4970
Hydraulic System 4970
Adhesives and Sealants 4971
550041583-8000YRM1542-(09-2018)-UK-EN 4973
Counterweights 4977
Hydraulic System 4977
Steering System 4977
Specifications 4977
Turning Radius 4978
Wheels and Tires 4978
Battery Specifications 4978
Capacities 4980
Maximum Carriage and Tilt Creep Rates 4981
Tilt Angles 4982
Tilt Speeds 4982
Mast Speeds 4982
Torque Specifications 4983
Frame 4983
Counterweight 4983
Transaxle (Drive Axle) 4983
Steering Axle 4983
Masts 4983
Hydraulic Pump and Motor 4983
Hydraulic System 4984
Adhesives and Sealants 4984
550073240-1900YRM1620-(01-2023)-UK-EN 4987
Proper Flushing after Major Hydraulic Repairs 4993
Introduction 4993
The Phases of Wear 4993
Causes of Hydraulic System Failure 4993
Progression of Contaminant Caused Hydraulic System Failure 4994
Hydraulic System Flushing Techniques 4994
Double Oil and Filter Change 4994
Mechanical Cleaning 4995
Cleaning of Components 4995
How to Clean Tubes and Hoses 4995
Filter Caddy 4995
Start-Up Procedure for Cleaned System 4996
Contaminated Oil Coolers 4996
Additional Filter Caddy Functions 4997
How to Handle Different Fluids 4997
Water Removal Filters 4997
Fluid Conditioning and System Flushing Procedures 4998
Operation of the Filter Caddy 4998
Filter Caddy operation 4998
Fluid Conditioning Procedure 4998
Filter Caddy Start-Up 4999
System Flushing Procedure 4999
Component Cleaning Procedure 5000
Reservoir Cleaning Procedure 5000
Cylinder Cleaning Procedure 5000
Hose and Tube Cleaning Procedure 5000
Valve Cleaning Procedure 5001
Front-End Attachment Cleaning Procedure 5002
System Flushing Procedure 5002
Filter Caddy Start-Up 5003
System Start-Up and Flushing 5003
Reservoir Fluid Cleaning Times 5004
Dealing With Different Fluid Types 5005
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 5005
Filter Caddy Maintenance 5005
Servicing the Strainer 5005
DC Motor 5005
Hydraulic Oil Sampling Method and Procedure 5006
Hydraulic Oil Sampling Method 5006
Objective 5006
General Guidelines 5006
Synopsis 5007
Hydraulic Oil Analysis Report Guidelines 5008
Sampling Conditions 5008
Equipment 5008
Sampling Procedure 5009
Hydraulic Oil Sampling 5009
Sample Labeling 5009
Results Documentation 5009
550073240-1900YRM1620-(03-2020)-UK-EN 5011
Proper Flushing after Major Hydraulic Repairs 5015
Introduction 5015
The Phases of Wear 5015
Causes of Hydraulic System Failure 5015
Progression of Contaminant Caused Hydraulic System Failure 5016
Hydraulic System Flushing Techniques 5016
Double Oil and Filter Change 5016
Mechanical Cleaning 5017
Cleaning of Components 5017
How to Clean Tubes and Hoses 5017
Filter Caddy 5017
Start-Up Procedure for Cleaned System 5018
Contaminated Oil Coolers 5018
Additional Filter Caddy Functions 5018
How to Handle Different Fluids 5018
Water Removal Filters 5019
Fluid Conditioning and System Flushing Procedures 5019
Operation of the Filter Caddy 5019
Filter Caddy operation 5019
Fluid Conditioning Procedure 5020
Filter Caddy Start-Up 5020
System Flushing Procedure 5021
Component Cleaning Procedure 5021
Reservoir Cleaning Procedure 5021
Cylinder Cleaning Procedure 5021
Hose and Tube Cleaning Procedure 5022
Valve Cleaning Procedure 5022
Front-End Attachment Cleaning Procedure 5023
System Flushing Procedure 5023
Filter Caddy Start-Up 5024
System Start-Up and Flushing 5024
Reservoir Fluid Cleaning Times 5025
Dealing With Different Fluid Types 5025
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 5025
Filter Caddy Maintenance 5026
Servicing the Strainer 5026
DC Motor 5026
Hydraulic Oil Sampling Method and Procedure 5026
Hydraulic Oil Sampling Method 5026
Objective 5026
General Guidelines 5026
Synopsis 5027
Hydraulic Oil Analysis Report Guidelines 5028
Sampling Conditions 5029
Equipment 5029
Sampling Procedure 5029
Hydraulic Oil Sampling 5029
Sample Labeling 5030
Results Documentation 5030