Yale Forklift A410 (ERP170-190VNL) Service Manual – PDF DOWNLOAD

Yale Forklift A410 (ERP170-190VNL) Service Manual – PDF DOWNLOAD 

FILE DETAILS:

Yale Forklift A410 (ERP170-190VNL) Service Manual – PDF DOWNLOAD

Language : English
Pages : 2551
Downloadable : Yes
File Type : PDF

PART NO. 524150797

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TABLE OF CONTENTS:

Yale Forklift A410 (ERP170-190VNL) 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-(07-2020)-UK-EN 97
Series Code / Model Designation Reference Table 103
General 106
Deutsch Crimping Tool 106
How to Strip a Wire for Use With Deutsch Crimping Tool 106
How to Crimp With the Deutsch Crimping Tool 107
Calibration Test for the Deutsch Crimping Tool 109
Deutsch Connectors 111
DT, DTM, and DTP Series Connectors 111
HD Series Connectors 153
Metri-Pack Connectors 176
Remove and Install 176
Micro-Pack Connectors 178
Weather-Pack Connectors 179
AMPSEAL Crimping Tools 181
AMP Hand Crimping Tool With Certi-Crimp 181
Description 181
Stripping Wire for Use with AMP Hand Crimping Tool 181
Insulation Crimp Adjustment 182
Maintenance and Inspection for AMP Hand Crimping Tool 182
AMP Hand Crimping Tool 182
Crimp Height Inspection 182
How to use AMP Hand Crimping Tool 183
AMP Pro-Crimper II Tool 183
Description 183
Remove and Install Die Set and Locator Assembly 184
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 185
Contact Support Adjustment 185
Crimp Height Adjustment 186
Maintenance and Inspection Procedures 186
PRO-CRIMPER II Tool 186
Crimp Height Inspection 186
How to Use AMP PRO-CRIMPER II Tool 187
AMPSEAL Connector Assemblies 188
Description for Plug Connector Assembly 188
Seal Plug 189
Contact Crimping 189
Description for Plug Connector and Header Assembly 194
Voltage Reading 196
Seal Plug 196
Contact Crimping 196
AMP Superseal 1 5 Crimping Tools 203
Mini Mic Receptacle and Tab Contacts 203
Description 203
Crimping Conditions and Measurements 203
Insertion of Rubber Seal on Cable 205
AMP Hand Application Tool 210
Description 210
Maintenance and Inspection 210
Crimp Height Inspection 210
Crimp Height Adjustment 211
How to Use AMP Hand Application Tool 211
AMP Pro-Crimper II Tool 212
Description 212
Remove and Install Die Set and Locator Assembly 213
Adjustments 213
Contact Support 213
Crimp Height 214
Inspections and Maintenance 215
Crimp Height Inspection 215
Visual Inspection 215
Maintenance 216
How to Use Pro-Crimper II Tool 216
AMP Superseal 1 5 Connector Assemblies 217
Description 217
Repair and Maintenance 224
Panel Mount Option 224
AMP Fastin-Faston Hand Tools 225
Description – AMP Double Action Hand Tool 225
Maintenance and Inspection Procedures 225
Daily Maintenance 225
Periodic Tool Inspection 226
Lubrication 226
Visual Inspection 226
Crimp Height Inspection 226
Certi-Crimp Ratchet Inspection 227
How to Use AMP Double Action Hand Tool 228
Description – AMP Extraction Tool 229
Maintenance and Inspection 229
How to Use AMP Extraction Tool 230
AMP Fastin-Faston Receptacles and Housings 231
Description 231
Wire Repair 238
Wire Splicing Requirements 238
Deutsch Jiffy Splice 239
Twisted/Shielded Cable and Leads Repair 244
Special Tools 247
524319497-2200YRM1335-(01-2023)-UK-EN 255
General 263
Description 263
Display Panel Menu Access 263
Menu Flowchart 264
Supervisor Menu Flowchart 264
Menu Navigation 270
Icon Glossary 274
Introduction 274
Soft Key Icons 274
Overlay Icons 275
Icons on System Off Screen and Alert Screens 275
Main Menu Title Screens 279
Submenu Icons Grouped by Menu 281
Operating Screen Icons 281
Password Screen Icons 282
Activity Log Submenu Icons 282
Calibration Submenu Icons 284
Display Submenu Icons 286
Status Submenu Icons 288
Truck Setup Submenu Icons 291
Operating Screen 298
Introduction 298
Performance Mode Controls 299
Status and Warning Icons 299
Battery Discharge Indicator 300
Direction and Parking Brake Indicators 301
Hazard Flashers and Lighting Controls 301
Steer Angle Indicator 301
System Time 301
Load Weight Indicator 301
System Off/Alert Screens 302
Introduction 302
System Off Screen 302
Alert Screens 302
Password Screen 304
Introduction 304
Password Screen 304
Service Technician Password Setup 304
Adding/Removing/Changing Passwords 305
Password Log 308
Activity Log Menu 309
Introduction 309
Operator Checklist Log 310
Password Log 313
Impact Events Log 315
Calibration Menu 317
Introduction 317
Load Weight Calibration 317
Return to Set Tilt Stop Point Calibration 318
E-Hydraulic and Manual Valve Threshold Calibration 318
Steering Wheel Center Point Calibration 319
Steer Axle Position Calibration 319
Steer Axle Center Point Calibration 320
Manual Hydraulics Calibration 321
Display Menu 322
Introduction 322
Set Date and Time Format Menu 322
Set Daylight Saving Time Menu 323
Procedure for Setting Up Automatic Daylight Savings Time 324
Set Time and Date Menu 326
Procedure for Setting Time and Date 326
Set Units Menu 327
Status Menu 328
Introduction 328
VSM Versions 328
Display Versions 329
Truck Serial Number 329
Hour Meters 329
E-Hydraulic Controller Versions 329
Pump Motor Controller Versions 329
Traction Motor Controller 1 Versions 329
Traction Motor Controller 2 Versions 330
Light Controller Versions 330
Impact Sensor Versions 330
Truck Setup Menu 331
Introduction 331
Add/Remove Password 331
Battery Settings 331
Restore Default Settings 332
Motion Alarm 332
Impact Monitor Settings 333
Impact Detection 333
Setting Adjustments 333
Initial Adjustment of Soft and Hard Impact Settings 333
Readjustment of Soft and Hard Impact Settings 333
Auto Power-Off Time Delay 334
Return to Set Tilt 334
Traction Speed Limit 334
Scheduled Maintenance Reminder 335
Minimum Pump Standby Flow Rate 336
Operator Checklist 336
Impact Monitor Shutdown 337
Motor Braking 338
Changing the Motor Braking Settings 338
Steering Wheel Friction and Steering Turns Adjustment 339
How to Adjust Settings 339
Steering Friction Setting 339
Steering Wheel Number of Turns 340
524319497-2200YRM1335-(07-2020)-UK-EN 343
General 349
Description 349
Display Panel Menu Access 349
Menu Flowchart 350
Supervisor Menu Flowchart 350
Menu Navigation 356
Icon Glossary 360
Introduction 360
Soft Key Icons 360
Overlay Icons 361
Icons on System Off Screen and Alert Screens 361
Main Menu Title Screens 365
Submenu Icons Grouped by Menu 367
Operating Screen Icons 367
Password Screen Icons 368
Activity Log Submenu Icons 368
Calibration Submenu Icons 370
Display Submenu Icons 372
Status Submenu Icons 374
Truck Setup Submenu Icons 377
Operating Screen 384
Introduction 384
Performance Mode Controls 384
Status and Warning Icons 385
Battery Discharge Indicator 386
Direction and Parking Brake Indicators 386
Hazard Flashers and Lighting Controls 387
Steer Angle Indicator 387
System Time 387
Load Weight Indicator 387
System Off/Alert Screens 388
Introduction 388
System Off Screen 388
Alert Screens 388
Password Screen 390
Introduction 390
Password Screen 390
Service Technician Password Setup 390
Adding/Removing/Changing Passwords 391
Password Log 394
Activity Log Menu 395
Introduction 395
Operator Checklist Log 395
Password Log 397
Impact Events Log 399
Calibration Menu 401
Introduction 401
Load Weight Calibration 401
Return to Set Tilt Stop Point Calibration 402
E-Hydraulic and Manual Valve Threshold Calibration 402
Steering Wheel Center Point Calibration 403
Steer Axle Position Calibration 403
Steer Axle Center Point Calibration 404
Manual Hydraulics Calibration 405
Display Menu 406
Introduction 406
Set Date and Time Format Menu 406
Set Daylight Saving Time Menu 407
Procedure for Setting Up Automatic Daylight Savings Time 408
Set Time and Date Menu 410
Procedure for Setting Time and Date 410
Set Units Menu 411
Status Menu 412
Introduction 412
VSM Versions 412
Display Versions 413
Truck Serial Number 413
Hour Meters 413
E-Hydraulic Controller Versions 413
Pump Motor Controller Versions 413
Traction Motor Controller 1 Versions 413
Traction Motor Controller 2 Versions 414
Light Controller Versions 414
Impact Sensor Versions 414
Truck Setup Menu 415
Introduction 415
Add/Remove Password 415
Battery Settings 415
Restore Default Settings 416
Motion Alarm 416
Impact Monitor Settings 416
Impact Detection 417
Setting Adjustments 417
Initial Adjustment of Soft and Hard Impact Settings 417
Readjustment of Soft and Hard Impact Settings 417
Auto Power-Off Time Delay 418
Return to Set Tilt 418
Traction Speed Limit 418
Scheduled Maintenance Reminder 419
Minimum Pump Standby Flow Rate 420
Operator Checklist 420
Impact Monitor Shutdown 421
Motor Braking 422
Changing the Motor Braking Settings 422
Steering Wheel Friction and Steering Turns Adjustment 423
How to Adjust Settings 423
Steering Friction Setting 423
Steering Wheel Number of Turns 424
524319498-2200YRM1336-(02-2023)-UK-EN 427
General 435
Description 435
Display Panel Menu Access 435
Menu Flowchart 436
Technician Menu Flowchart 436
Menu Navigation 442
Icon Glossary 446
Introduction 446
Soft Key Icons 446
Overlay Icons 447
Heat Exchange Module Warning Indicator Screen 447
System Off Screen and Alert Screens 448
Main Menu Title Screens 454
Submenu Icons Grouped by Menu 455
Operating Screen Icons 455
Password Screen Icons 457
Activity Log Submenu Icons 457
Calibration Submenu Icons 458
Display Submenu Icons 462
Status Submenu Icons 464
Truck Setup Submenu Icons 467
Diagnostics Submenu Icons 479
Operating Screen 489
Introduction 489
Performance Mode Controls 489
Status and Warning Icons 490
Battery Discharge Indicator 491
Direction and Parking Brake Indicators 491
Hazard Flashers and Lighting Controls 492
Steer Angle Indicator 492
System Time 492
Load Weight Indicator 492
System Off/Alert Screens 493
Introduction 493
System Off Screen 493
Alert Screens 493
Password Screen 495
Introduction 495
Password Screen 495
Service Technician Password Setup 495
Adding/Removing/Changing Passwords 496
Password Log 499
Activity Log Menu 500
Introduction 500
Operator Checklist Log 500
Password Log 502
Impact Events Log 504
Calibration Menu 506
Introduction 506
Load Weight Calibration 506
Return to Set Tilt Stop Point Calibration 507
E-Hydraulic and Manual Valve Threshold Calibration 507
Steering Wheel Center Point Calibration 508
Steer Axle Position Calibration 509
Steer Axle Center Point Calibration 510
Manual Hydraulics Calibration 510
Display Menu 511
Introduction 511
Set Date and Time Format Menu 511
Set Daylight Saving Time Menu 512
Procedure for Setting Up Automatic Daylight Savings Time 513
Set Time and Date Menu 515
Procedure for Setting Time and Date 515
Set Units Menu 516
Status Menu 517
Introduction 517
VSM Versions 517
Display Versions 518
Truck Serial Number 518
Hour Meters 518
E-Hydraulic Controller Versions 518
Pump Motor Controller Versions 518
Traction Motor Controller 1 Versions 518
Traction Motor Controller 2 Versions 519
Light Controller Versions 519
Impact Sensor Versions 519
E-Steer Controller 1 Versions 519
E-Steer Controller 2 Versions 519
Truck Setup Menu 520
Introduction 520
Add/Remove Password 521
Battery Settings 521
Motor Braking 521
Changing the Motor Braking Settings 522
Battery Mode 522
Battery Setup 523
BDI Adjustment Setting 524
Acceleration Rates 525
Hour Meter Initialization 526
Impact Monitor Shutdown 526
Operator Checklist 528
Minimum Pump Standby Flow Rate 528
Scheduled Maintenance Reminder 529
Traction Speed Limit 530
Return to Set Tilt 530
Auto Power-Off Time Delay 531
Impact Monitor Settings 531
Impact Detection 532
Setting Adjustments 532
Initial Adjustment of Soft and Hard Impact Settings 532
Readjustment of Soft and Hard Impact Settings 532
Motion Alarm 532
Lift Hydraulic Function Maximum Speed and Ramp Times 533
Lower Hydraulic Function Maximum Speed and Ramp Times 533
Tilt Forward Hydraulic Function Maximum Speed and Ramp Times 534
Tilt Backward Hydraulic Function Maximum Speed and Ramp Times 534
Auxiliary 1A Hydraulic Function Maximum Speed and Ramp Times 534
Auxiliary 1B Hydraulic Function Maximum Speed and Ramp Times 534
Auxiliary 2A Hydraulic Function Maximum Speed and Ramp Times 534
Auxiliary 2B Hydraulic Function Maximum Speed and Ramp Times 534
Optional Hydraulic Functions 534
Rear Lights Control 535
Restore Default Settings 535
Steering Wheel Friction and Steering Turns Adjustment 536
Navigation 537
How to Adjust Settings 537
Steering Friction 537
Steering Wheel Number of Turns 538
Diagnostics Menu 540
Introduction 540
Fault Code Log 540
Fault Log Details 541
Speedometer 542
Direction Switch 542
Traction Motor 1 Status 543
Traction Motor 2 Status 543
Occupancy Sensor 543
Brake System Sensors 543
Pump Status 544
Hydraulic Control Inputs 545
E-Hydraulic Valves 545
Hydraulic Sensors 546
System Voltages 546
Steering Position Sensors 548
E-Steering Position Sensors 548
Electric Brake 549
Navigation 550
ESS Diagnostics Menus A, B, and C 551
Menu A 551
Menu B 552
Menu C 554
524319498-2200YRM1336-(07-2020)-UK-EN 557
General 563
Description 563
Display Panel Menu Access 563
Menu Flowchart 564
Technician Menu Flowchart 564
Menu Navigation 570
Icon Glossary 574
Introduction 574
Soft Key Icons 574
Overlay Icons 575
Heat Exchange Module Warning Indicator Screen 575
System Off Screen and Alert Screens 576
Main Menu Title Screens 581
Submenu Icons Grouped by Menu 583
Operating Screen Icons 583
Password Screen Icons 584
Activity Log Submenu Icons 584
Calibration Submenu Icons 586
Display Submenu Icons 589
Status Submenu Icons 591
Truck Setup Submenu Icons 595
Diagnostics Submenu Icons 606
Operating Screen 616
Introduction 616
Performance Mode Controls 616
Status and Warning Icons 617
Battery Discharge Indicator 618
Direction and Parking Brake Indicators 619
Hazard Flashers and Lighting Controls 619
Steer Angle Indicator 619
System Time 619
Load Weight Indicator 619
System Off/Alert Screens 620
Introduction 620
System Off Screen 620
Alert Screens 620
Password Screen 622
Introduction 622
Password Screen 622
Service Technician Password Setup 622
Adding/Removing/Changing Passwords 623
Password Log 625
Activity Log Menu 626
Introduction 626
Operator Checklist Log 626
Password Log 628
Impact Events Log 630
Calibration Menu 632
Introduction 632
Load Weight Calibration 632
Return to Set Tilt Stop Point Calibration 633
E-Hydraulic and Manual Valve Threshold Calibration 633
Steering Wheel Center Point Calibration 634
Steer Axle Position Calibration 635
Steer Axle Center Point Calibration 635
Manual Hydraulics Calibration 636
Display Menu 637
Introduction 637
Set Date and Time Format Menu 637
Set Daylight Saving Time Menu 638
Procedure for Setting Up Automatic Daylight Savings Time 639
Set Time and Date Menu 641
Procedure for Setting Time and Date 641
Set Units Menu 642
Status Menu 643
Introduction 643
VSM Versions 643
Display Versions 644
Truck Serial Number 644
Hour Meters 644
E-Hydraulic Controller Versions 644
Pump Motor Controller Versions 644
Traction Motor Controller 1 Versions 644
Traction Motor Controller 2 Versions 645
Light Controller Versions 645
Impact Sensor Versions 645
E-Steer Controller 1 Versions 645
E-Steer Controller 2 Versions 645
Truck Setup Menu 646
Introduction 646
Add/Remove Password 647
Battery Settings 647
Motor Braking 647
Changing the Motor Braking Settings 648
Battery Mode 648
Battery Setup 649
BDI Adjustment Setting 650
Acceleration Rates 651
Hour Meter Initialization 652
Impact Monitor Shutdown 652
Operator Checklist 653
Minimum Pump Standby Flow Rate 654
Scheduled Maintenance Reminder 654
Traction Speed Limit 656
Return to Set Tilt 656
Auto Power-Off Time Delay 656
Impact Monitor Settings 657
Impact Detection 657
Setting Adjustments 657
Initial Adjustment of Soft and Hard Impact Settings 657
Readjustment of Soft and Hard Impact Settings 658
Motion Alarm 658
Lift Hydraulic Function Maximum Speed and Ramp Times 658
Lower Hydraulic Function Maximum Speed and Ramp Times 659
Tilt Forward Hydraulic Function Maximum Speed and Ramp Times 659
Tilt Backward Hydraulic Function Maximum Speed and Ramp Times 659
Auxiliary 1A Hydraulic Function Maximum Speed and Ramp Times 659
Auxiliary 1B Hydraulic Function Maximum Speed and Ramp Times 660
Auxiliary 2A Hydraulic Function Maximum Speed and Ramp Times 660
Auxiliary 2B Hydraulic Function Maximum Speed and Ramp Times 660
Optional Hydraulic Functions 660
Rear Lights Control 660
Restore Default Settings 661
Steering Wheel Friction and Steering Turns Adjustment 661
Navigation 662
How to Adjust Settings 662
Steering Friction 662
Steering Wheel Number of Turns 663
Diagnostics Menu 665
Introduction 665
Fault Code Log 665
Fault Log Details 666
Speedometer 667
Direction Switch 667
Traction Motor 1 Status 667
Traction Motor 2 Status 668
Occupancy Sensor 668
Brake System Sensors 668
Pump Status 669
Hydraulic Control Inputs 669
E-Hydraulic Valves 669
Hydraulic Sensors 670
System Voltages 670
Steering Position Sensors 671
E-Steering Position Sensors 671
Electric Brake 672
Navigation 673
550073240-1900YRM1620-(01-2023)-UK-EN 675
Proper Flushing after Major Hydraulic Repairs 681
Introduction 681
The Phases of Wear 681
Causes of Hydraulic System Failure 681
Progression of Contaminant Caused Hydraulic System Failure 682
Hydraulic System Flushing Techniques 682
Double Oil and Filter Change 682
Mechanical Cleaning 683
Cleaning of Components 683
How to Clean Tubes and Hoses 683
Filter Caddy 683
Start-Up Procedure for Cleaned System 684
Contaminated Oil Coolers 684
Additional Filter Caddy Functions 685
How to Handle Different Fluids 685
Water Removal Filters 685
Fluid Conditioning and System Flushing Procedures 686
Operation of the Filter Caddy 686
Filter Caddy operation 686
Fluid Conditioning Procedure 686
Filter Caddy Start-Up 687
System Flushing Procedure 687
Component Cleaning Procedure 688
Reservoir Cleaning Procedure 688
Cylinder Cleaning Procedure 688
Hose and Tube Cleaning Procedure 688
Valve Cleaning Procedure 689
Front-End Attachment Cleaning Procedure 690
System Flushing Procedure 690
Filter Caddy Start-Up 691
System Start-Up and Flushing 691
Reservoir Fluid Cleaning Times 692
Dealing With Different Fluid Types 693
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 693
Filter Caddy Maintenance 693
Servicing the Strainer 693
DC Motor 693
Hydraulic Oil Sampling Method and Procedure 694
Hydraulic Oil Sampling Method 694
Objective 694
General Guidelines 694
Synopsis 695
Hydraulic Oil Analysis Report Guidelines 696
Sampling Conditions 696
Equipment 696
Sampling Procedure 697
Hydraulic Oil Sampling 697
Sample Labeling 697
Results Documentation 697
550073240-1900YRM1620-(03-2020)-UK-EN 699
Proper Flushing after Major Hydraulic Repairs 703
Introduction 703
The Phases of Wear 703
Causes of Hydraulic System Failure 703
Progression of Contaminant Caused Hydraulic System Failure 704
Hydraulic System Flushing Techniques 704
Double Oil and Filter Change 704
Mechanical Cleaning 705
Cleaning of Components 705
How to Clean Tubes and Hoses 705
Filter Caddy 705
Start-Up Procedure for Cleaned System 706
Contaminated Oil Coolers 706
Additional Filter Caddy Functions 706
How to Handle Different Fluids 706
Water Removal Filters 707
Fluid Conditioning and System Flushing Procedures 707
Operation of the Filter Caddy 707
Filter Caddy operation 707
Fluid Conditioning Procedure 708
Filter Caddy Start-Up 708
System Flushing Procedure 709
Component Cleaning Procedure 709
Reservoir Cleaning Procedure 709
Cylinder Cleaning Procedure 709
Hose and Tube Cleaning Procedure 710
Valve Cleaning Procedure 710
Front-End Attachment Cleaning Procedure 711
System Flushing Procedure 711
Filter Caddy Start-Up 712
System Start-Up and Flushing 712
Reservoir Fluid Cleaning Times 713
Dealing With Different Fluid Types 713
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 713
Filter Caddy Maintenance 714
Servicing the Strainer 714
DC Motor 714
Hydraulic Oil Sampling Method and Procedure 714
Hydraulic Oil Sampling Method 714
Objective 714
General Guidelines 714
Synopsis 715
Hydraulic Oil Analysis Report Guidelines 716
Sampling Conditions 717
Equipment 717
Sampling Procedure 717
Hydraulic Oil Sampling 717
Sample Labeling 718
Results Documentation 718
550156820-0100YRM2014-(01-2023)-UK-EN 721
General 729
Description 729
High Voltage Disable Procedure 731
General 731
Measuring High Voltage Test Points on Lift Truck (DC Volts) 732
Control Panel High Voltage (HV) Test Points 732
High Voltage Verification Complete 734
Ending Steps 736
Battery Capacity Test Procedure 736
Principles of Operation 738
Operator Station 738
General Description and Location 738
Display Panel 739
General Description 739
Display Panel Features 739
Display Panel 740
LCD Screen and Warning and Indicator Lights 742
Programming – Menus 742
Menu 742
Operator Cycle Main Menu 743
Supervisor/Service Cycle Main Menu 743
Activity Log 743
Calibration 743
Diagnostic 743
Truck Set-Up 743
Truck Status 743
Display Adjustment 744
Display Manu Flowchart 744
E-Hydraulic System Interface 744
General Description to E-Hydraulic System Interface 744
Lift/Lower 745
Tilt 745
Return-To-Set-Tilt (RTST) 745
Auxiliary 1 746
Auxiliary 2 746
Emergency Disconnect Switch 746
Abbreviations and Acronyms 747
Side Covers, Step Plates, Seat Assembly, Dash Panel, Steering Column, And Hood Replacement 752
Side Covers 752
Remove 752
Install 753
Step Plates 753
Remove 753
Install 753
Seat and Seat Pan 754
Seat 754
Remove 754
Install 754
Seat Pan 755
Remove 755
Install 757
Operator Restraint System 757
Emergency Locking Retractor (ELR) Seat Belt 757
Seat Pan and Seat Rail Check 757
Steering Column, Dash and Kick Panels, and Seal Plate 757
Remove 757
Install 761
Hood Assembly and Hood Support 761
Remove 761
Install 765
Hood Doors Assembly 765
Remove 765
Install 766
Steering Column 767
Description 767
Steering Column Repair 767
Remove 767
Disassemble 768
Clean 770
Inspect 770
Assemble 770
Install 770
Counterweight Repair 771
Remove 771
Install 773
Tow Pin, Remove and Install 774
Overhead Guard Replacement 775
Remove 775
Install 777
AC Motors Replacement 778
General 778
Removing AC Motors As A Unit 780
Remove 780
Clean and Inspect 784
Install 784
Battery Replacement 785
General 785
Remove Batteries 785
Remove Counterweight 785
Remove Hood 785
Remove 12V Battery 785
Remove 350V Battery 787
Clean and Inspect 788
Installing Batteries 789
Install 350V Battery 789
Install 12V Battery 789
Install Hood 789
Install Counterweight 789
Cab Replacement 789
General 789
Cooling System 789
General 789
Hydraulic Filter Assembly Repair 790
Remove 790
Install 792
Hydraulic Tank Repair 793
Inspect 793
Clean 793
Steam Method of Cleaning 794
Chemical Solution Method of Cleaning 794
Additional Preparations for Repair 795
Small Leaks, Repair 795
Large Leaks, Repair 795
Preparations for Use After Repair 795
Painting Instructions 796
Safety Labels 798
550156820-0100YRM2014-(07-2020)-UK-EN 803
General 809
Description 809
High Voltage Disable Procedure 811
General 811
Measuring High Voltage Test Points on Lift Truck (DC Volts) 812
Control Panel High Voltage (HV) Test Points 812
High Voltage Verification Complete 813
Ending Steps 816
Battery Capacity Test Procedure 816
Principles of Operation 818
Operator Station 818
General Description and Location 818
Display Panel 820
General Description 820
Display Panel Features 820
Display Panel 820
LCD Screen and Warning and Indicator Lights 822
Programming – Menus 823
Menu 823
Operator Cycle Main Menu 823
Supervisor/Service Cycle Main Menu 823
Activity Log 823
Calibration 823
Diagnostic 823
Truck Set-Up 823
Truck Status 823
Display Adjustment 824
Display Manu Flowchart 824
E-Hydraulic System Interface 825
General Description to E-Hydraulic System Interface 825
Lift/Lower 825
Tilt 825
Return-To-Set-Tilt (RTST) 825
Auxiliary 1 826
Auxiliary 2 826
Emergency Disconnect Switch 826
Abbreviations and Acronyms 827
Side Covers, Step Plates, Seat Assembly, Dash Panel, Steering Column, And Hood Replacement 832
Side Covers 832
Remove 832
Install 833
Step Plates 833
Remove 833
Install 833
Seat and Seat Pan 834
Seat 834
Remove 834
Install 835
Seat Pan 835
Remove 835
Install 837
Operator Restraint System 837
Emergency Locking Retractor (ELR) Seat Belt 837
Seat Pan and Seat Rail Check 837
Steering Column, Dash and Kick Panels, and Seal Plate 837
Remove 837
Install 841
Hood Assembly and Hood Support 841
Remove 841
Install 845
Hood Doors Assembly 845
Remove 845
Install 845
Steering Column 846
Description 846
Steering Column Repair 846
Remove 846
Disassemble 847
Clean 848
Inspect 849
Assemble 849
Install 849
Counterweight Repair 850
Remove 850
Install 852
Tow Pin, Remove and Install 853
Overhead Guard Replacement 854
Remove 854
Install 855
AC Motors Replacement 856
General 856
Removing AC Motors As A Unit 857
Remove 857
Clean and Inspect 861
Install 861
Battery Replacement 862
General 862
Remove Batteries 862
Remove Counterweight 862
Remove Hood 862
Remove 12V Battery 862
Remove 350V Battery 864
Clean and Inspect 865
Installing Batteries 865
Install 350V Battery 865
Install 12V Battery 866
Install Hood 866
Install Counterweight 866
Cab Replacement 866
General 866
Cooling System 866
General 866
Hydraulic Filter Assembly Repair 866
Remove 866
Install 867
Hydraulic Tank Repair 868
Inspect 868
Clean 869
Steam Method of Cleaning 869
Chemical Solution Method of Cleaning 869
Additional Preparations for Repair 870
Small Leaks, Repair 870
Large Leaks, Repair 870
Preparations for Use After Repair 870
Painting Instructions 871
Safety Labels 873
550156821-0100YRM2015-(01-2023)-UK-EN 879
General 885
High Voltage Disable Procedure 886
General 886
Measuring High Voltage Test Points on Lift Truck (DC Volts) 887
Control Panel High Voltage (HV) Test Points 887
High Voltage Verification Complete 889
Ending Steps 891
Battery Capacity Test Procedure 892
Cab Replacement 893
Remove 893
Install 900
Door Assemblies 902
Remove 902
Disassemble 902
Door Cover 902
Door Lock Assembly 903
Windows 906
Clean 906
Inspect 906
Assemble 906
Door Lock Assembly 906
Door Cover 906
Install 906
Windows Replacement 907
General 907
Door Windows 907
Remove 907
Clean 909
Inspect 909
Install 909
Front Window 909
Remove 909
Clean 910
Inspect 910
Install 910
Top Window 911
Remove 911
Clean 911
Inspect 911
Install 911
Rear Window 911
Remove 911
Clean 912
Inspect 912
Install 912
Window Wipers Replacement 913
General 913
Front Wiper Assembly and Motor 913
Remove 913
Install 915
Rear Wiper and Motor 915
Remove 915
Install 917
Heater Replacement 918
Remove 918
Install 920
Cab Heater Controls 921
Heater Filter 922
Remove 922
Install 922
Lights 923
Display Panel 923
Electrical Schematics 924
Optional Equipment 924
Fan 924
Remove 924
Install 924
Mirror 924
Remove 924
Install 924
Rear Horn Button and Handle 926
Rear View Camera 926
Monitor Removal 926
Monitor Install 928
Camera removal 928
Camera install 928
Label Replacement 929
550156821-0100YRM2015-(07-2020)-UK-EN 931
General 935
High Voltage Disable Procedure 936
General 936
Measuring High Voltage Test Points on Lift Truck (DC Volts) 937
Control Panel High Voltage (HV) Test Points 937
High Voltage Verification Complete 939
Ending Steps 941
Battery Capacity Test Procedure 941
Cab Replacement 942
Remove 942
Install 949
Door Assemblies 950
Remove 950
Disassemble 951
Door Cover 951
Door Lock Assembly 952
Windows 953
Clean 953
Inspect 953
Assemble 953
Door Lock Assembly 953
Door Cover 954
Install 954
Windows Replacement 954
General 954
Door Windows 954
Remove 954
Clean 956
Inspect 956
Install 956
Front Window 956
Remove 956
Clean 957
Inspect 957
Install 957
Top Window 958
Remove 958
Clean 958
Inspect 958
Install 958
Rear Window 958
Remove 958
Clean 959
Inspect 959
Install 959
Window Wipers Replacement 960
General 960
Front Wiper Assembly and Motor 960
Remove 960
Install 962
Rear Wiper and Motor 962
Remove 962
Install 964
Heater Replacement 964
Remove 964
Install 966
Cab Heater Controls 966
Heater Filter 967
Remove 967
Install 968
Lights 968
Display Panel 969
Electrical Schematics 970
Optional Equipment 970
Fan 970
Remove 970
Install 970
Mirror 970
Remove 970
Install 970
Rear Horn Button and Handle 971
Rear View Camera 971
Monitor Removal 971
Monitor Install 973
Camera removal 973
Camera install 973
Label Replacement 973
550156822-0620YRM2016-(01-2023)-UK-EN 975
General 981
High Voltage Disable Procedure 983
General 983
Measuring High Voltage Test Points on Lift Truck (DC Volts) 984
Control Panel High Voltage (HV) Test Points 984
High Voltage Verification Complete 986
Ending Steps 989
Battery Capacity Test Procedure 989
Principles of Operation 991
Traction Motor 991
Abbreviations and Acronyms 992
AC Motor Replacement 997
Remove 997
Clean 999
Inspect 999
Install 999
Electrical Connector Repair or Replacement 1000
AC Motors Specifications 1001
550156822-0620YRM2016-(07-2020)-UK-EN 1003
General 1007
High Voltage Disable Procedure 1009
General 1009
Measuring High Voltage Test Points on Lift Truck (DC Volts) 1010
Control Panel High Voltage (HV) Test Points 1010
High Voltage Verification Complete 1012
Ending Steps 1014
Battery Capacity Test Procedure 1014
Principles of Operation 1015
Traction Motor 1015
Abbreviations and Acronyms 1016
AC Motor Replacement 1020
Remove 1020
Clean 1022
Inspect 1022
Install 1022
Electrical Connector Repair or Replacement 1023
AC Motors Specifications 1023
550156823-0700YRM2017-(01-2023)-UK-EN 1025
General 1031
Cooling System 1032
Cooling System Controllers 1032
Cooling System Flow 1032
Cooling System Checks 1035
Water Flow Restrictions in Radiator 1035
Radiator Hoses 1035
Flushing The Cooling System 1036
Radiator Repair 1037
Remove 1037
Disassemble 1041
Clean and Inspect 1043
Assemble 1043
Install 1043
Coolant Pumps 1045
General 1045
Remove 1046
Install 1047
550156823-0700YRM2017-(07-2020)-UK-EN 1049
General 1053
Cooling System 1054
Cooling System Controllers 1054
Cooling System Flow 1054
Cooling System Checks 1056
Water Flow Restrictions in Radiator 1056
Radiator Hoses 1056
Flushing The Cooling System 1056
Radiator Repair 1057
Remove 1057
Disassemble 1061
Clean and Inspect 1063
Assemble 1063
Install 1063
Coolant Pumps 1065
General 1065
Remove 1066
Install 1067
550156824-1400YRM2018-(01-2023)-UK-EN 1069
General 1075
Identification Plate 1075
Principles of Operation 1075
Mechanical Overview 1075
Drive Shaft, Differential, Drive Axle, and Brakes 1075
Drive Shaft 1076
Brake System 1077
Description 1077
Brake Adjustment and Service 1078
Parking Brake 1078
Abbreviations and Acronyms 1079
Drive Axle Removal 1084
Planetary Reduction Gear Repair 1088
Clean and Inspect 1096
Brake Repair 1105
Clean and Inspect 1115
Parking Brake Repair 1125
Remove and Disassemble 1125
Assemble and Install 1127
Adjust 1128
Differential Repair 1129
Clean and Inspect 1138
Bevel Pinion 1150
Clean and Inspect 1154
Drive Axle Installation 1165
Boosted Master Cylinder, Accumulator, and Brake Pressure Reducing Valve 1168
Boosted Master Cylinder 1168
Remove 1168
Disassemble 1169
Clean and Inspect 1171
Assemble 1171
Install and Adjust 1171
Accumulator 1172
Pre-Charge Check 1172
Remove 1172
Install 1173
Brake Pressure Reducing Valve 1173
Remove 1173
Disassemble 1173
Clean and Inspect 1174
Assemble 1174
Install 1174
Pressure Checks 1175
Brake Pressure Reducing Valve Check 1175
Accumulator Check 1175
Brake System Air Removal 1176
Using Pressure Bleed System 1176
Using Brake Pedal Pressure 1177
Brake Pedal Adjustment 1178
Free Pedal Adjustment 1179
Torque Specifications 1180
Special Tools 1181
550156824-1400YRM2018-(07-2020)-UK-EN 1183
General 1187
Identification Plate 1187
Principles of Operation 1187
Mechanical Overview 1187
Drive Shaft, Differential, Drive Axle, and Brakes 1187
Drive Shaft 1188
Brake System 1188
Description 1188
Brake Adjustment and Service 1189
Parking Brake 1189
Abbreviations and Acronyms 1190
Drive Axle Removal 1194
Planetary Reduction Gear Repair 1198
Clean and Inspect 1206
Brake Repair 1214
Clean and Inspect 1225
Parking Brake Repair 1235
Remove and Disassemble 1235
Assemble and Install 1237
Adjust 1238
Differential Repair 1239
Clean and Inspect 1248
Bevel Pinion 1259
Clean and Inspect 1264
Drive Axle Installation 1275
Boosted Master Cylinder, Accumulator, and Brake Pressure Reducing Valve 1278
Boosted Master Cylinder 1278
Remove 1278
Disassemble 1279
Clean and Inspect 1280
Assemble 1281
Install and Adjust 1281
Accumulator 1282
Pre-Charge Check 1282
Remove 1282
Install 1283
Brake Pressure Reducing Valve 1283
Remove 1283
Disassemble 1283
Clean and Inspect 1284
Assemble 1284
Install 1284
Pressure Checks 1284
Brake Pressure Reducing Valve Check 1284
Accumulator Check 1285
Brake System Air Removal 1285
Using Pressure Bleed System 1285
Using Brake Pedal Pressure 1286
Brake Pedal Adjustment 1287
Free Pedal Adjustment 1288
Torque Specifications 1289
Special Tools 1290
550156825-1600YRM2019-(01-2023)-UK-EN 1293
General 1299
Steering Axle Assembly Repair 1302
Remove 1302
Disassemble 1303
Clean 1305
Inspect 1305
Assemble 1305
Install 1306
Spindles, Bearings, and Tie Rods Repair 1307
Spindles and Bearings 1307
Remove 1307
Disassemble 1308
Clean 1309
Inspect 1309
Assemble 1309
Install 1310
Tie Rods 1310
Remove 1310
Install 1311
Steering Cylinder Repair 1312
Remove and Disassemble 1312
Clean and Inspect 1312
Assemble and Install 1312
Turn Assist (Lift trucks built after February 2019) 1314
Removal 1314
Install 1317
Torque Specifications 1318
550156825-1600YRM2019-(07-2020)-UK-EN 1321
General 1325
Steering Axle Assembly Repair 1327
Remove 1327
Disassemble 1328
Clean 1329
Inspect 1330
Assemble 1330
Install 1330
Spindles, Bearings, and Tie Rods Repair 1331
Spindles and Bearings 1331
Remove 1331
Disassemble 1332
Clean 1333
Inspect 1333
Assemble 1333
Install 1334
Tie Rods 1334
Remove 1334
Install 1335
Steering Cylinder Repair 1335
Remove and Disassemble 1335
Clean and Inspect 1335
Assemble and Install 1335
Turn Assist (Lift trucks built after February 2019) 1337
Removal 1337
Install 1339
Torque Specifications 1341
550156826-1600YRM2031-(01-2023)-UK-EN 1343
General 1349
Steering Control Unit (SCU) Repair 1350
Remove 1350
Disassemble 1352
Clean 1354
Inspect 1355
Assemble 1355
Install 1355
System Relief Valve 1356
Disassemble 1356
Clean 1356
Inspect 1357
Assemble 1357
Steering Wheel and Steering Column Assembly Repair 1358
Remove 1358
Disassemble 1360
Clean 1362
Inspect 1363
Assemble 1363
Install 1363
Turn Assist (Lift trucks built after February 2019) 1364
Removal 1364
Install 1367
Torque Specifications 1368
Steering Control Unit 1368
Steering Column 1368
550156826-1600YRM2031-(07-2020)-UK-EN 1371
General 1375
Steering Control Unit (SCU) Repair 1375
Remove 1375
Disassemble 1377
Clean 1379
Inspect 1379
Assemble 1380
Install 1380
System Relief Valve 1381
Disassemble 1381
Clean 1381
Inspect 1382
Assemble 1382
Steering Wheel and Steering Column Assembly Repair 1383
Remove 1383
Disassemble 1385
Clean 1387
Inspect 1388
Assemble 1388
Install 1388
Turn Assist (Lift trucks built after February 2019) 1390
Removal 1390
Install 1392
Torque Specifications 1394
Steering Control Unit 1394
Steering Column 1394
550156827-1900YRM2021-(01-2023)-UK-EN 1397
General 1403
Hydraulic Pump and Motor 1404
Remove 1404
Disassemble 1406
Inspect 1408
Clean 1408
Assemble 1408
Install 1408
Hydraulic Tank 1410
Remove 1410
Clean 1411
Steam Method 1411
Chemical Method 1412
Inspect 1412
Small Leaks, Repair 1413
Large Leaks, Repair 1413
Additional Methods for Metal Tank Repair 1413
Preparations for Use After Repair 1413
Hydraulic Filter Replacement 1413
Hydraulic Tank Breather 1415
Add Hydraulic Oil 1417
Specifications 1419
Tank Capacity 1419
Torque Specifications 1420
Hydraulic Pump and Motor 1420
Hydraulic Tank 1420
550156827-1900YRM2021-(07-2020)-UK-EN 1423
General 1427
Hydraulic Pump and Motor 1427
Remove 1427
Disassemble 1429
Inspect 1430
Clean 1431
Assemble 1431
Install 1431
Hydraulic Tank 1432
Remove 1432
Clean 1433
Steam Method 1433
Chemical Method 1434
Inspect 1434
Small Leaks, Repair 1435
Large Leaks, Repair 1435
Additional Methods for Metal Tank Repair 1435
Preparations for Use After Repair 1435
Hydraulic Filter Replacement 1435
Hydraulic Tank Breather 1437
Add Hydraulic Oil 1438
Specifications 1440
Tank Capacity 1440
Torque Specifications 1440
Hydraulic Pump and Motor 1440
Hydraulic Tank 1440
550156828-1900YRM2032-(01-2023)-UK-EN 1443
General 1449
Gear Pump Assembly 1450
Remove 1450
Disassemble 1452
Clean 1454
Inspect 1454
Assemble 1454
Install 1455
Accumulator Replacement 1456
Remove 1456
Install 1457
Specifications 1458
Tank Capacity 1458
Torque Specifications 1459
Hydraulic Pump and Motor 1459
Hydraulic Tank 1459
550156828-1900YRM2032-(07-2020)-UK-EN 1461
General 1465
Gear Pump Assembly 1465
Remove 1465
Disassemble 1467
Clean 1469
Inspect 1469
Assemble 1469
Install 1470
Accumulator Replacement 1471
Remove 1471
Install 1472
Specifications 1472
Tank Capacity 1472
Torque Specifications 1473
Hydraulic Pump and Motor 1473
Hydraulic Tank 1473
550156829-2000YRM2033-(01-2023)-UK-EN 1475
General 1481
Electro-Hydraulic Main Control Valve 1482
Description 1482
Remove 1484
Electro-Hydraulic Control Valve Sections 1487
General 1487
Outlet Control Valve Section 1487
Remove 1487
Disassemble 1487
Clean 1488
Inspect 1488
Assemble 1488
Install 1488
Auxiliary Control Valve Sections 1489
Remove 1489
Disassemble 1493
Clean 1494
Inspect 1494
Assemble 1494
Install 1495
Tilt Control Valve Section 1495
Remove 1495
Disassemble 1495
Clean 1497
Inspect 1497
Assemble 1497
Install 1497
Lift/Lower Control Valve Section 1497
Remove 1497
Disassemble 1497
Clean 1499
Inspect 1500
Assemble 1500
Install 1501
Mid-Inlet Section 1501
Remove 1501
Clean 1501
Inspect 1501
Install 1502
Install 1502
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 1505
Lift Pilot Pin 1505
Lower Pilot Pin 1507
Abnormal/Erroneous EHPV Adjustment 1509
Pressure Relief Valve Check and Adjustment 1510
Primary Relief Valve 1510
Secondary Relief Valve 1511
Steering Control Unit Repair 1512
Steering Control Unit 1512
Remove 1512
Disassemble 1513
Clean 1515
Inspect 1515
Assemble 1515
Install 1516
Relief Valve 1517
Disassemble 1517
Clean 1517
Inspect 1517
Assemble 1517
550156829-2000YRM2033-(07-2020)-UK-EN 1519
General 1523
Electro-Hydraulic Main Control Valve 1524
Description 1524
Remove 1525
Electro-Hydraulic Control Valve Sections 1529
General 1529
Outlet Control Valve Section 1529
Remove 1529
Disassemble 1529
Clean 1530
Inspect 1530
Assemble 1530
Install 1530
Auxiliary Control Valve Sections 1531
Remove 1531
Disassemble 1535
Clean 1536
Inspect 1536
Assemble 1536
Install 1537
Tilt Control Valve Section 1537
Remove 1537
Disassemble 1537
Clean 1538
Inspect 1539
Assemble 1539
Install 1539
Lift/Lower Control Valve Section 1539
Remove 1539
Disassemble 1539
Clean 1541
Inspect 1542
Assemble 1542
Install 1543
Mid-Inlet Section 1543
Remove 1543
Clean 1543
Inspect 1543
Install 1544
Install 1544
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 1547
Lift Pilot Pin 1547
Lower Pilot Pin 1549
Abnormal/Erroneous EHPV Adjustment 1550
Pressure Relief Valve Check and Adjustment 1551
Primary Relief Valve 1551
Secondary Relief Valve 1551
Steering Control Unit Repair 1552
Steering Control Unit 1552
Remove 1552
Disassemble 1553
Clean 1555
Inspect 1555
Assemble 1555
Install 1556
Relief Valve 1556
Disassemble 1556
Clean 1557
Inspect 1557
Assemble 1557
550156831-2200YRM2035-(01-2023)-UK-EN 1559
General 1567
General 1567
Discharging the Capacitors 1568
High Voltage Disable Procedure 1569
General 1569
Measuring High Voltage Test Points on Lift Truck (DC Volts) 1570
Control Panel High Voltage (HV) Test Points 1570
High Voltage Verification Complete 1572
Ending Steps 1574
Battery Capacity Test Procedure 1575
Principles of Operation 1576
Battery Cables 1576
Inspect 1576
Replacing Cables 1576
Vehicle System Manager (VSM) 1577
General 1577
Motor Controllers 1577
General 1577
Cooling System 1578
Cooling System Flow 1579
Cooling System Controller 1579
Controller Fans 1579
Converters 1580
350V to 12V Converter 1580
12V to 24V Converter 1580
Abbreviations and Acronyms 1580
Display Panel and Key or Keyless Switch Replacement 1585
Display Panel, Replace 1585
Remove 1585
Install 1587
Electronic Hydraulic Controls – Before January, 2020 1589
General 1589
E-Hydraulic Controls – Test 1589
Mini-Levers 1589
Full Stroke Test 1590
Function Returns to Neutral Test 1590
Push (Override) Button 1590
E-Hydraulic Controls 1590
Mini-levers, Remove and Install 1591
Armrest Assembly 1592
Remove 1592
Install 1593
Horn Button 1594
Remove 1594
Install 1595
Direction Control Switch 1595
Remove 1595
Install 1595
Emergency Disconnect Switch 1596
Remove 1596
Install 1596
Push (Override) Buttons and Function Selection Button 1596
Remove 1597
Install 1599
Electronic-Hydraulic Controls, After January, 2020 1600
General 1600
E-Hydraulic Controls – TEST 1601
Mini-Levers 1601
Full Stroke Test 1601
Function Returns to Neutral Test 1601
Push (Override) Button 1602
Mini-levers, Remove and Install 1602
Armrest Assembly 1602
Remove 1602
Install 1605
Horn Button 1605
Remove 1605
Install 1605
Direction Control Switch 1605
Remove 1605
Install 1606
Emergency Disconnect Switch 1606
Remove 1606
Install 1607
Push (Override) Buttons 1607
Remove 1607
Install 1608
Sensors and Switches 1609
General 1609
Hydraulic Filter Switch 1609
Remove 1609
Install 1609
Tilt Position Sensor 1610
Remove 1610
Install 1611
Low Level Brake Fluid Switch 1611
Remove 1611
Install 1612
Service Brake Pressure Sensor 1612
Remove 1612
Install 1613
Accelerator Pedal Position Sensor 1613
Remove 1613
Install 1613
Parking Brake Sensor 1614
Remove 1614
Install 1614
Sensor Microswitch (Foot Directional Control) 1614
Remove 1614
Install 1616
Low Coolant Level Sensor and Coolant Temperature Sensor 1616
Remove 1616
Install 1617
Seat Sensor (Operator Presence System) 1617
Full Suspension 1617
Remove 1617
Install 1617
Steering Direction Sensor 1618
Remove 1618
Install 1618
Load Weight Sensor 1618
Remove 1618
Install 1619
Battery Charger Connector Microswitch 1620
Remove 1620
Install 1621
Hood Switch – Lift Trucks Built Before January, 2020 1621
Remove 1621
Install 1621
Horn Switch 1621
Steering Column 1621
Remove 1621
Install 1623
Impact Sensor 1624
Remove 1624
Install 1624
Remote Key Switch 1624
Remove 1624
Install 1624
Motor Controllers Replacement 1626
General 1626
Traction Motor and Hydraulic Motor Controllers 1627
Remove 1627
Install 1628
Cooling System Controller 1628
Remove 1628
Install 1629
Fans 1629
Remove 1629
Install 1630
Vehicle System Manager 1631
General 1631
Remove 1631
Install 1631
Programming a New VSM and/or Display Panel 1632
PC Service Tool Software 1632
Fuses and Relays 1633
Backup Alarm 1637
Battery Connection 1638
General 1638
Inspect 1638
Replacing Cables 1638
350V Battery Connections 1638
12V Battery Connections 1640
Remove 1640
Install 1641
Converter 1642
350V Converter 1642
Remove 1642
Install 1643
12V Converter 1643
Remove 1643
Install 1644
Cab Heater 1644
Lights 1645
General 1645
Work Lights (Front and Rear) 1646
LED Lights 1646
Remove 1646
Install 1647
Strobe Light 1647
Remove 1647
Install 1647
LED Tail, Backup, and Brake Lights 1648
Remove 1648
Install 1648
Front Marker/Turn Signal Lights 1649
Remove 1649
Install 1649
550156831-2200YRM2035-(07-2020)-UK-EN 1651
General 1657
General 1657
Discharging the Capacitors 1658
High Voltage Disable Procedure 1658
General 1658
Measuring High Voltage Test Points on Lift Truck (DC Volts) 1659
Control Panel High Voltage (HV) Test Points 1660
High Voltage Verification Complete 1661
Ending Steps 1663
Battery Capacity Test Procedure 1663
Principles of Operation 1665
Battery Cables 1665
Inspect 1665
Replacing Cables 1665
Vehicle System Manager (VSM) 1666
General 1666
Motor Controllers 1666
General 1666
Cooling System 1667
Cooling System Flow 1668
Cooling System Controller 1669
Controller Fans 1669
Converters 1669
350V to 12V Converter 1669
12V to 24V Converter 1669
Abbreviations and Acronyms 1670
Display Panel and Key or Keyless Switch Replacement 1674
Display Panel, Replace 1674
Remove 1674
Install 1676
Electronic Hydraulic Controls – Before January, 2020 1677
General 1677
E-Hydraulic Controls – Test 1678
Mini-Levers 1678
Full Stroke Test 1678
Function Returns to Neutral Test 1678
Push (Override) Button 1679
E-Hydraulic Controls 1679
Mini-levers, Remove and Install 1679
Armrest Assembly 1680
Remove 1680
Install 1682
Horn Button 1682
Remove 1682
Install 1683
Direction Control Switch 1683
Remove 1683
Install 1684
Emergency Disconnect Switch 1684
Remove 1684
Install 1685
Push (Override) Buttons and Function Selection Button 1685
Remove 1685
Install 1687
Electronic-Hydraulic Controls, After January, 2020 1688
General 1688
E-Hydraulic Controls – TEST 1689
Mini-Levers 1689
Full Stroke Test 1689
Function Returns to Neutral Test 1689
Push (Override) Button 1690
Mini-levers, Remove and Install 1690
Armrest Assembly 1690
Remove 1690
Install 1693
Horn Button 1693
Remove 1693
Install 1693
Direction Control Switch 1694
Remove 1694
Install 1694
Emergency Disconnect Switch 1694
Remove 1695
Install 1695
Push (Override) Buttons 1695
Remove 1695
Install 1696
Sensors and Switches 1697
General 1697
Hydraulic Filter Switch 1697
Remove 1697
Install 1697
Tilt Position Sensor 1698
Remove 1698
Install 1699
Low Level Brake Fluid Switch 1699
Remove 1699
Install 1700
Service Brake Pressure Sensor 1700
Remove 1700
Install 1701
Accelerator Pedal Position Sensor 1701
Remove 1701
Install 1701
Parking Brake Sensor 1702
Remove 1702
Install 1702
Sensor Microswitch (Foot Directional Control) 1702
Remove 1702
Install 1704
Low Coolant Level Sensor and Coolant Temperature Sensor 1704
Remove 1704
Install 1705
Seat Sensor (Operator Presence System) 1705
Full Suspension 1705
Remove 1705
Install 1705
Steering Direction Sensor 1706
Remove 1706
Install 1706
Load Weight Sensor 1706
Remove 1706
Install 1707
Battery Charger Connector Microswitch 1707
Remove 1708
Install 1708
Hood Switch – Lift Trucks Built Before January, 2020 1709
Remove 1709
Install 1709
Horn Switch 1709
Steering Column 1709
Remove 1709
Install 1711
Impact Sensor 1711
Remove 1711
Install 1712
Remote Key Switch 1712
Remove 1712
Install 1712
Motor Controllers Replacement 1713
General 1713
Traction Motor and Hydraulic Motor Controllers 1714
Remove 1714
Install 1715
Cooling System Controller 1715
Remove 1715
Install 1716
Fans 1716
Remove 1716
Install 1717
Vehicle System Manager 1718
General 1718
Remove 1718
Install 1718
Programming a New VSM and/or Display Panel 1719
PC Service Tool Software 1719
Fuses and Relays 1720
Backup Alarm 1723
Battery Connection 1723
General 1723
Inspect 1723
Replacing Cables 1723
350V Battery Connections 1723
12V Battery Connections 1725
Remove 1725
Install 1726
Converter 1727
350V Converter 1727
Remove 1727
Install 1728
12V Converter 1728
Remove 1728
Install 1729
Cab Heater 1730
Lights 1730
General 1730
Work Lights (Front and Rear) 1731
LED Lights 1731
Remove 1731
Install 1732
Strobe Light 1732
Remove 1732
Install 1732
LED Tail, Backup, and Brake Lights 1733
Remove 1733
Install 1733
Front Marker/Turn Signal Lights 1733
Remove 1733
Install 1734
550156832-2240YRM2036-(01-2023)-UK-EN 1737
General 1743
Discharging the Capacitors 1743
Safety Data 1744
Product Type 1744
Manufacturer: 1744
Regulatory Information 1744
USA 1744
Canada 1744
EC Classification for the Substance/Preparation: 1744
Composition and Ingredient Information 1745
Hazard Identification 1745
Fire Fighting Measures 1745
Unusual Fire and Explosion Hazards: 1745
Accidental Release Measures 1745
Handling and Storage 1745
Exposure Controls and Personal Protection 1746
Physical and Chemical Properties 1746
Stability and Reactivity 1746
Toxicological Information 1746
Disposal Considerations 1746
Required Shipping Labels 1747
High Voltage Disable Procedure 1748
General 1748
Measuring High Voltage Test Points on Lift Truck (DC Volts) 1749
Control Panel High Voltage (HV) Test Points 1749
High Voltage Verification Complete 1751
Ending Steps 1753
Battery Capacity Test Procedure 1753
Lithium-Ion Batteries 1754
Multi-Pack Lithium-Ion Configurations 1754
Electrical Terms 1754
Battery Voltage 1755
Charging The Battery 1755
Battery Ratings 1758
Kilowatt-Hours 1758
Battery Maintenance 1758
Safety Procedures 1758
Cleaning Battery 1759
Charging Battery 1759
Troubleshooting Charger 1759
Where to Charge Batteries 1759
Battery Care 1759
Shipping and Handling 1760
Change The Battery 1760
General 1760
Battery Repair 1761
General 1761
Control Panel Assembly 1761
Remove 1761
Clean and Inspect 1767
Install 1767
Service Disconnect Box 1768
Remove 1768
Clean and Inspect 1769
Install 1769
Fan Assembly 1770
Remove 1770
Install 1771
Battery Module 1772
Remove 1772
Install 1774
Battery Connectors 1775
Remove 1775
Install 1776
350V Battery Current Sensor 1776
Remove 1776
Install 1776
550156832-2240YRM2036-(07-2020)-UK-EN 1779
General 1783
Discharging the Capacitors 1783
Safety Data 1784
Product Type 1784
Manufacturer: 1784
Regulatory Information 1784
USA 1784
Canada 1784
EC Classification for the Substance/Preparation: 1784
Composition and Ingredient Information 1784
Hazard Identification 1785
Fire Fighting Measures 1785
Unusual Fire and Explosion Hazards: 1785
Accidental Release Measures 1785
Handling and Storage 1785
Exposure Controls and Personal Protection 1785
Physical and Chemical Properties 1785
Stability and Reactivity 1786
Toxicological Information 1786
Disposal Considerations 1786
Required Shipping Labels 1787
High Voltage Disable Procedure 1788
General 1788
Measuring High Voltage Test Points on Lift Truck (DC Volts) 1789
Control Panel High Voltage (HV) Test Points 1789
High Voltage Verification Complete 1791
Ending Steps 1793
Battery Capacity Test Procedure 1793
Lithium-Ion Batteries 1794
Multi-Pack Lithium-Ion Configurations 1794
Electrical Terms 1794
Battery Voltage 1795
Charging The Battery 1795
Battery Ratings 1798
Kilowatt-Hours 1798
Battery Maintenance 1798
Safety Procedures 1798
Cleaning Battery 1799
Charging Battery 1799
Troubleshooting Charger 1799
Where to Charge Batteries 1799
Battery Care 1799
Shipping and Handling 1800
Change The Battery 1801
General 1801
Battery Repair 1801
General 1801
Control Panel Assembly 1801
Remove 1801
Clean and Inspect 1806
Install 1806
Service Disconnect Box 1808
Remove 1808
Clean and Inspect 1809
Install 1809
Fan Assembly 1809
Remove 1809
Install 1811
Battery Module 1811
Remove 1811
Install 1813
Battery Connectors 1813
Remove 1814
Install 1814
350V Battery Current Sensor 1815
Remove 1815
Install 1815
550156833-4000YRM2037-(02-2023)-UK-EN 1817
Safety Procedures When Working Near Mast 1823
Principles of Operation 1825
Front End, Mast 1825
Description 1825
Carriages 1825
Description 1825
Integral Sideshift Carriage 1825
Mast Mounts 1827
Description 1827
Principles of Operation 1827
Two-Stage Full Free-Lift (FFL) Mast 1827
Description 1827
Principles of Operation 1828
Two-Stage Limited Free-Lift (LFL) Mast 1829
Description 1829
Principles of Operation 1830
Three-Stage Full Free-Lift (FFL) Mast 1832
Description 1832
Principles of Operation 1832
Cylinder Cushion During Lifting Sequence 1834
Description 1834
Principles of Operation 1834
Cylinder Cushion During Lowering Sequence 1834
Description 1834
Principles of Operation 1834
Tilt and Sideshift Cylinders 1835
Description 1835
Tilt Cylinder 1835
Sideshift Cylinder 1835
Lowering Control Valves 1835
Description 1835
Principles of Operation 1835
Chassis 1837
Description 1837
Overhead Guard 1837
Counterweight 1837
Abbreviations and Acronyms 1838
Fork Replacement 1843
Remove 1843
Install 1844
Checks 1844
Carriage Repair 1846
Remove 1846
Clean and Inspect 1849
Install 1849
Integral Sideshift Carriage And Fork Positioners Repair 1850
Integral Sideshift Carriage 1850
Remove 1850
Disassemble 1851
Clean and Inspect 1854
Assemble 1854
Install 1854
Fork Positioners 1855
Remove 1855
Disassemble 1858
Clean and Inspect 1860
Assemble 1860
Install 1860
Two-Stage Mast With Limited Free-Lift Repair 1861
Remove 1861
Disassemble 1864
Clean and Inspect 1867
Assemble 1869
Install 1869
Header Hose Installation 1871
Three-Stage Mast With Full Free-Lift Repair 1874
Remove 1874
Disassemble 1878
Clean and Inspect 1881
Assemble 1883
Install 1883
Header Hose Installation 1885
Mast Operation Check 1887
Tilt Cylinder Adjustment 1887
Main Lift Cylinder Repair 1888
Lift Chain Adjustment 1888
Mast Adjustments 1890
Load Roller Adjustment 1890
Mast Side Kicking Adjustment 1891
Carriage Adjustment 1892
550156833-4000YRM2037-(07-2020)-UK-EN 1895
Safety Procedures When Working Near Mast 1899
Principles of Operation 1901
Front End, Mast 1901
Description 1901
Carriages 1901
Description 1901
Integral Sideshift Carriage 1901
Mast Mounts 1903
Description 1903
Principles of Operation 1903
Two-Stage Full Free-Lift (FFL) Mast 1903
Description 1903
Principles of Operation 1904
Two-Stage Limited Free-Lift (LFL) Mast 1905
Description 1905
Principles of Operation 1906
Three-Stage Full Free-Lift (FFL) Mast 1907
Description 1907
Principles of Operation 1908
Cylinder Cushion During Lifting Sequence 1909
Description 1909
Principles of Operation 1909
Cylinder Cushion During Lowering Sequence 1910
Description 1910
Principles of Operation 1910
Tilt and Sideshift Cylinders 1910
Description 1910
Tilt Cylinder 1910
Sideshift Cylinder 1910
Lowering Control Valves 1911
Description 1911
Principles of Operation 1911
Chassis 1912
Description 1912
Overhead Guard 1912
Counterweight 1912
Abbreviations and Acronyms 1913
Fork Replacement 1918
Remove 1918
Install 1919
Checks 1919
Carriage Repair 1921
Remove 1921
Clean and Inspect 1924
Install 1924
Integral Sideshift Carriage And Fork Positioners Repair 1925
Integral Sideshift Carriage 1925
Remove 1925
Disassemble 1926
Clean and Inspect 1928
Assemble 1929
Install 1929
Fork Positioners 1930
Remove 1930
Disassemble 1932
Clean and Inspect 1934
Assemble 1934
Install 1934
Two-Stage Mast With Limited Free-Lift Repair 1935
Remove 1935
Disassemble 1938
Clean and Inspect 1941
Assemble 1943
Install 1943
Header Hose Installation 1944
Three-Stage Mast With Full Free-Lift Repair 1947
Remove 1947
Disassemble 1951
Clean and Inspect 1954
Assemble 1956
Install 1956
Header Hose Installation 1957
Mast Operation Check 1960
Tilt Cylinder Adjustment 1961
Main Lift Cylinder Repair 1961
Lift Chain Adjustment 1961
Mast Adjustments 1963
Load Roller Adjustment 1963
Mast Side Kicking Adjustment 1964
Carriage Adjustment 1964
550156835-8000YRM2029-(02-2023)-UK-EN 1967
Lift Truck Lifting Capacity 1973
Counterweight Weights 1973
Tire Sizes 1973
Capacities 1974
Hydraulic System 1974
Steering System 1975
AC Motors Specifications 1975
Tilt Angles 1976
Front End Equipment – Mast Creep 1976
Mast Creep 1976
Mast Speeds 1977
Torque Specifications 1978
Frame 1978
Operator Cab 1978
Drive Axle Assembly 1978
Steering Axle 1979
Masts 1979
Hydraulic Pump and Motor 1979
Hydraulic System 1979
Tilt Cylinders 1979
AC Motors 1979
Adhesives and Sealants 1980
550156835-8000YRM2029-(07-2020)-UK-EN 1983
Lift Truck Lifting Capacity 1987
Counterweight Weights 1987
Tire Sizes 1987
Capacities 1988
Hydraulic System 1988
Steering System 1989
AC Motors Specifications 1989
Tilt Angles 1990
Front End Equipment – Mast Creep 1990
Mast Creep 1990
Mast Speeds 1991
Torque Specifications 1992
Frame 1992
Operator Cab 1992
Drive Axle Assembly 1992
Steering Axle 1993
Masts 1993
Hydraulic Pump and Motor 1993
Hydraulic System 1993
Tilt Cylinders 1993
AC Motors 1993
Adhesives and Sealants 1994
550162872-9000YRM2039-(01-2018)-UK-EN 1997
SECTION 9010 OPERATIONAL DIAGNOSTIC PROCEDURES 2005
Group 05 – Operational Checkout 2007
SECTION 9025 TRACTION MOTOR 2019
Group 10 – Principles of Operation 2021
Group 30 – Observed Symptoms 2023
SECTION 9030 ELECTRICAL SYSTEM 2025
Group 10 – Principles of Operation 2029
Group 20 – Diagnostic Trouble Codes 2045
SECTION 9035 DRIVE AXLE / UNIT 2159
Group 10 – Principles of Operation 2161
Group 30 – Observed Symptoms 2165
SECTION 9050 HYDRAULIC SYSTEMS 2177
Group 33 – Observed Symptoms-Gear Pump 2179
Group 43 – Tests and Adjustments-Gear Pump 2243
Group 45 – Tests and Adjustments-Variable Displacement Pump (VDP) 2264
SECTION 9060 OPERATORS STATION 2267
Group 10 – Principles of Operation 2269
SECTION 9070 FRONT END (MAST) AND CHASSIS 2281
Group 10 – Principles of Operation 2283
Group 30 – Observed Symptoms 2299
SECTION 9080 SUPPLEMENTARY DATA 2337
Group 50 – Abbreviations and Acronyms 2339
550180936-8000YRM2038-(03-2023)-UK-EN 2347
General 2355
Discharging the Capacitors 2355
Serial Number Data 2356
How to Move Disabled Lift Truck 2356
How to Tow Lift Truck 2356
How to Put Lift Truck on Blocks 2357
How to Raise Drive Tires 2357
How to Raise Steering Tires 2357
How to Clean a Lift Truck 2359
Safety Procedures When Working Near Mast 2360
WHEN WORKING NEAR THE MAST ALWAYS: 2360
Maintenance Schedule 2363
Maintenance Procedures Every 8 Hours or Daily 2370
How to Make Checks With Key or Keyless Switch OFF 2370
Tires and Wheels 2370
Forks 2370
General 2370
Inspect 2370
Remove 2372
Install 2372
Integral Sideshift Carriage 2372
Inspection of Mast, Carriage, Header Hoses, Lift Chains, and Attachments 2373
Safety Labels 2374
Steering Column Gas Cylinder 2374
Tilt Adjust Feature 2374
Operator Restraint System 2374
Emergency Locking Retractor (ELR) 2375
Adjust Seat – Full Suspension 2375
Adjust Seat – Internal Suspension 2376
Seal Plate and Seat Rails 2377
350V Battery 2377
350V Battery Restraint System 2377
Oil and Coolant Leaks, Check 2378
Coolant Hoses 2378
Hydraulic Hoses 2378
Hydraulic System 2378
350V Charge Receptacle and Plug 2380
How to Make Checks With Key or Keyless Switch ON 2380
Horn, Lights, Backup Alarm, Fuses and Relays 2380
Steering System 2382
Service Brakes 2382
Parking Brake 2382
Cooling System 2382
Hydraulic Control Levers and Pedals 2383
Direction and Speed Control Pedals 2383
Lift System Operation 2383
Oil Leaks 2383
Maintenance Procedures Every 500 Hours or Three Months 2384
Parking Brake 2384
Hydraulic Oil 2384
Hydraulic Tank Breather 2385
Battery and Cable Terminals (12V Battery) 2387
Clean Debris From Radiator Core 2387
Forks 2388
Inspect 2388
Remove 2388
Install 2389
Adjustment 2390
Header Hose Checks 2390
Operator Presence System Check 2391
Brake Actuation Valve Rod End 2391
Tilt Cylinder Lubrication 2392
Steering Axle Spindle Bearings 2395
Other Lubrication 2395
Controllers 2395
350V Battery Module Retention Strap 2397
Cab Heater Air Filter 2397
Maintenance Procedures Every 1000 Hours or 6 months 2399
Wet Brake Oil Level Check 2399
Other Lubrication 2401
Steering Axle Tie Rods 2401
Mast and Carriage Lubrication 2402
Lift Chain Lubrication 2406
Tilt Cylinder Lubrication 2407
Fork Pins and Guides 2409
Maintenance Procedures Every 2000 Hours or Yearly 2410
Hydraulic System 2410
Hydraulic Oil Change – Cooler/Freezer and Sub-Zero Construction 2410
Hydraulic Filter Element, Replace 2411
Hydraulic Tank Breather, Replace 2414
Service Brakes 2414
Master Cylinder Oil, Change 2414
Forks, Inspect 2416
Wheel Bearings, Lubricate 2417
Steer Wheel Bearings, Lubrication 2417
Drive Wheel Bearings, Lubrication 2417
Maintenance Procedures Every 4000 Hours Or Two Years 2418
Hydraulic Oil Change – Standard Construction 2418
Battery Procedures 2420
How to Charge 350V Battery 2420
Battery Charging Station 2420
Charging the Battery 2420
12V Battery Replacement 2420
350V Battery Removal and Installation 2420
350V Battery Maintenance 2420
Lift and Tilt System Leak Check 2421
Lift Cylinders Leak Check 2421
Tilt Cylinder Leak Check 2421
Lift Chain Adjustments 2422
Welding Repairs 2424
Overhead Guard Changes 2425
Wheel and Tire Replacement 2426
General 2426
Pneumatic Tire With Tube, Repair 2426
Remove Wheels From Lift Truck 2426
Remove Tire From Wheel 2426
Install Wheel in Tire 2429
Install Tire on Two-Piece Wheel 2431
Add Air to Pneumatic Tires With Tube 2432
Install the Wheels 2433
Dual Drive Wheels, Install 2433
Pneumatic Tubeless Tire, Repair 2433
Remove Wheels From Lift Truck 2433
Add Air to Pneumatic Tubeless Tire 2439
Wheels, Install 2439
Solid Rubber Tires on Pneumatic Wheels, Change 2439
Adhesives and Sealants 2444
550180936-8000YRM2038-(07-2020)-UK-EN 2447
General 2453
Discharging the Capacitors 2453
Serial Number Data 2454
How to Move Disabled Lift Truck 2454
How to Tow Lift Truck 2454
How to Put Lift Truck on Blocks 2455
How to Raise Drive Tires 2455
How to Raise Steering Tires 2455
How to Clean a Lift Truck 2456
Safety Procedures When Working Near Mast 2458
WHEN WORKING NEAR THE MAST ALWAYS: 2458
Maintenance Schedule 2460
Maintenance Procedures Every 8 Hours or Daily 2466
How to Make Checks With Key or Keyless Switch OFF 2466
Tires and Wheels 2466
Forks 2466
General 2466
Inspect 2466
Remove 2468
Install 2468
Integral Sideshift Carriage 2468
Inspection of Mast, Carriage, Header Hoses, Lift Chains, and Attachments 2468
Safety Labels 2469
Steering Column Gas Cylinder 2470
Tilt Adjust Feature 2470
Operator Restraint System 2470
Emergency Locking Retractor (ELR) 2470
Adjust Seat – Full Suspension 2471
Adjust Seat – Internal Suspension 2472
Seal Plate and Seat Rails 2472
350V Battery 2472
350V Battery Restraint System 2473
Oil and Coolant Leaks, Check 2473
Coolant Hoses 2473
Hydraulic Hoses 2473
Hydraulic System 2474
350V Charge Receptacle and Plug 2475
How to Make Checks With Key or Keyless Switch ON 2476
Horn, Lights, Backup Alarm, Fuses and Relays 2476
Steering System 2478
Service Brakes 2478
Parking Brake 2478
Cooling System 2478
Hydraulic Control Levers and Pedals 2479
Direction and Speed Control Pedals 2479
Lift System Operation 2479
Oil Leaks 2479
Maintenance Procedures Every 500 Hours or Three Months 2480
Parking Brake 2480
Hydraulic Oil 2480
Hydraulic Tank Breather 2481
Battery and Cable Terminals (12V Battery) 2483
Clean Debris From Radiator Core 2483
Forks 2484
Inspect 2484
Remove 2484
Install 2485
Adjustment 2486
Mast Lubrication 2486
Header Hose Checks 2489
Operator Presence System Check 2490
Wet Brake Oil Level Check 2490
Lift Chain Lubrication 2492
Brake Actuation Valve Rod End 2493
Tilt Cylinder Lubrication 2494
Steering Axle Tie Rods and Spindle Bearings 2496
Other Lubrication 2497
Controllers 2497
350V Battery Module Retention Strap 2498
Cab Heater Air Filter 2498
Maintenance Procedures Every 2000 Hours or Yearly 2500
Hydraulic System 2500
Hydraulic Filter Element, Replace 2500
Hydraulic Tank Breather, Replace 2502
Service Brakes 2502
Master Cylinder Oil, Change 2502
Forks, Inspect 2504
Wheel Bearings, Lubricate 2505
Steer Wheel Bearings, Lubrication 2505
Drive Wheel Bearings, Lubrication 2505
Maintenance Procedures Every 4000 Hours Or Two Years 2506
Hydraulic Oil, Change 2506
Battery Procedures 2508
How to Charge 350V Battery 2508
Battery Charging Station 2508
Charging the Battery 2508
12V Battery Replacement 2508
350V Battery Removal and Installation 2508
350V Battery Maintenance 2508
Lift and Tilt System Leak Check 2509
Lift Cylinders Leak Check 2509
Tilt Cylinder Leak Check 2509
Lift Chain Adjustments 2509
Welding Repairs 2511
Overhead Guard Changes 2511
Wheel and Tire Replacement 2511
General 2511
Pneumatic Tire With Tube, Repair 2511
Remove Wheels From Lift Truck 2511
Remove Tire From Wheel 2512
Install Wheel in Tire 2515
Install Tire on Two-Piece Wheel 2517
Add Air to Pneumatic Tires With Tube 2518
Install the Wheels 2518
Dual Drive Wheels, Install 2519
Pneumatic Tubeless Tire, Repair 2519
Remove Wheels From Lift Truck 2519
Add Air to Pneumatic Tubeless Tire 2525
Wheels, Install 2525
Solid Rubber Tires on Pneumatic Wheels, Change 2525
Adhesives and Sealants 2529
550243798-8000YRM2369-(02-2023)-UK-EN 2531
Schematics/Diagrams 2537
Schematics 2537
New Text Document 2551