Yale Forklift A968 (ERC045VG-070VG) Service Manual - PDF

Yale Forklift A968 (ERC045VG-070VG) Service Manual – PDF DOWNLOAD

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Yale Forklift A968 (ERC045VG-070VG) Service Manual – PDF DOWNLOAD

Language : English
Pages : 5640
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift A968 (ERC045VG-070VG) 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 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-(07-2020)-UK-EN 263
Series Code / Model Designation Reference Table 269
General 272
Deutsch Crimping Tool 272
How to Strip a Wire for Use With Deutsch Crimping Tool 272
How to Crimp With the Deutsch Crimping Tool 273
Calibration Test for the Deutsch Crimping Tool 275
Deutsch Connectors 277
DT, DTM, and DTP Series Connectors 277
HD Series Connectors 319
Metri-Pack Connectors 342
Remove and Install 342
Micro-Pack Connectors 344
Weather-Pack Connectors 345
AMPSEAL Crimping Tools 347
AMP Hand Crimping Tool With Certi-Crimp 347
Description 347
Stripping Wire for Use with AMP Hand Crimping Tool 347
Insulation Crimp Adjustment 348
Maintenance and Inspection for AMP Hand Crimping Tool 348
AMP Hand Crimping Tool 348
Crimp Height Inspection 348
How to use AMP Hand Crimping Tool 349
AMP Pro-Crimper II Tool 349
Description 349
Remove and Install Die Set and Locator Assembly 350
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 351
Contact Support Adjustment 351
Crimp Height Adjustment 352
Maintenance and Inspection Procedures 352
PRO-CRIMPER II Tool 352
Crimp Height Inspection 352
How to Use AMP PRO-CRIMPER II Tool 353
AMPSEAL Connector Assemblies 354
Description for Plug Connector Assembly 354
Seal Plug 355
Contact Crimping 355
Description for Plug Connector and Header Assembly 360
Voltage Reading 362
Seal Plug 362
Contact Crimping 362
AMP Superseal 1 5 Crimping Tools 369
Mini Mic Receptacle and Tab Contacts 369
Description 369
Crimping Conditions and Measurements 369
Insertion of Rubber Seal on Cable 371
AMP Hand Application Tool 376
Description 376
Maintenance and Inspection 376
Crimp Height Inspection 376
Crimp Height Adjustment 377
How to Use AMP Hand Application Tool 377
AMP Pro-Crimper II Tool 378
Description 378
Remove and Install Die Set and Locator Assembly 379
Adjustments 379
Contact Support 379
Crimp Height 380
Inspections and Maintenance 381
Crimp Height Inspection 381
Visual Inspection 381
Maintenance 382
How to Use Pro-Crimper II Tool 382
AMP Superseal 1 5 Connector Assemblies 383
Description 383
Repair and Maintenance 390
Panel Mount Option 390
AMP Fastin-Faston Hand Tools 391
Description – AMP Double Action Hand Tool 391
Maintenance and Inspection Procedures 391
Daily Maintenance 391
Periodic Tool Inspection 392
Lubrication 392
Visual Inspection 392
Crimp Height Inspection 392
Certi-Crimp Ratchet Inspection 393
How to Use AMP Double Action Hand Tool 394
Description – AMP Extraction Tool 395
Maintenance and Inspection 395
How to Use AMP Extraction Tool 396
AMP Fastin-Faston Receptacles and Housings 397
Description 397
Wire Repair 404
Wire Splicing Requirements 404
Deutsch Jiffy Splice 405
Twisted/Shielded Cable and Leads Repair 410
Special Tools 413
524319489-0100YRM1342-(02-2023)-UK-EN 421
General 429
Description 429
Frame 429
Discharging the Capacitors 436
Rapid Charge 436
Ground Test 438
Mud Guards 440
Covers and Floor Plates 441
For Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 441
For Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 443
For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 444
For Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 445
For Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 449
Overhead Guard Replacement 450
Remove 450
For Lift Trucks ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 450
For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 456
For Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 459
Install 461
For Lift Trucks ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 461
For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 461
For Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 463
Battery and Operator Restraint System Repair 464
General 464
Battery Restraint System 464
Auxiliary Counterweight Support Bracket for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH,ERC100VHS) (A938) 478
Operator Restraint System 479
Emergency Locking Retractor (ELR) 483
E-Hydraulic Armrest Assembly Repair 483
Hood and Seat Assembly Replacement 484
General For Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 484
Hood Assembly 484
Seat Assembly 490
General For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 493
Hood Assembly 493
Seat Assembly 497
Opening and Closing the Hood 501
Manual Hydraulic Control Levers 501
E-Hydraulic Mini-Levers 502
Remove 503
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 503
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 512
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 514
Install 519
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 519
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 520
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 521
Ground Test For Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 523
Ground Test For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 523
Hood and Seat Assembly Replacement for Lift Truck Model ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 524
General 524
Hood Assembly 524
Seat Assembly 527
Opening and Closing the Hood 529
Manual Hydraulic Control Levers 529
E-Hydraulic Mini-Levers 530
Remove 531
Install 535
Ground Test 536
Master Cylinder Repair and Adjustment for 1 5-3 5T Cushion and 2 2-5 5T Pneumatic Lift Trucks 537
Master Cylinder Repair and Adjustment for 4 0-5 5T Cushion Lift Trucks 537
Brake Pedal Components 543
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) 543
For Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 543
Remove 543
Disassemble 543
Inspect 544
Assemble 544
Install 544
Brake Pedal Adjustment For Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 545
Brake System Air Removal 546
For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 546
Using Pressure Bleed System 546
Using Brake Pedal Pressure For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 546
For Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 547
Counterweight Replacement for Lift Truck Models ERC22-35VG (ERC045-070) (A968) and ERC16-20VA (ERC030-040VA) (A969) 548
Remove 551
Install 552
Counterweight Replacement for Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 553
Remove 560
Clean and Inspect, Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 564
Install 566
Counterweight Replacement for Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 569
Remove 571
Install 571
Traction Motor Replacement for Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 573
Traction Motor Replacement for Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 580
Traction Motor Replacement for Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 581
Hydraulic Tank Inspection 584
Inspect 584
Clean 588
Painting Instructions 589
Safety Label Replacement 592
Battery Specifications 601
Torque Specifications for Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 608
Overhead Guard 608
Counterweight 608
Traction Motor 608
Torque Specifications for Lift Truck ERP22-35VL (ERP045-070VL) (A976) 608
Overhead Guard 608
Counterweight 608
Torque Specifications for Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 608
Overhead Guard 608
Counterweight 608
Torque Specifications for Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 608
Overhead Guard 608
Counterweight 608
524319489-0100YRM1342-(06-2019)-UK-EN 611
General 617
Description 617
Frame 617
Discharging the Capacitors 624
Rapid Charge 624
Ground Test 626
Mud Guards 627
Covers and Floor Plates 628
For Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 628
For Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 629
For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 631
For Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 632
For Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 636
Overhead Guard Replacement 636
Remove 637
For Lift Trucks ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 637
For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 642
For Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 644
Install 646
For Lift Trucks ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 646
For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 646
For Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 648
Battery and Operator Restraint System Repair 648
General 648
Battery Restraint System 648
Auxiliary Counterweight Support Bracket for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938) 663
Operator Restraint System 664
Emergency Locking Retractor (ELR) 668
E-Hydraulic Armrest Assembly Repair 668
Hood and Seat Assembly Replacement 668
General For Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 669
Hood Assembly 669
Seat Assembly 675
General For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 678
Hood Assembly 678
Seat Assembly 682
Opening and Closing the Hood 686
Manual Hydraulic Control Levers 686
E-Hydraulic Mini-Levers 687
Remove 688
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 688
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 697
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 699
Install 704
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 704
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 705
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 706
Ground Test For Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 707
Ground Test For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 707
Hood and Seat Assembly Replacement for Lift Truck Model ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 708
General 708
Hood Assembly 708
Seat Assembly 711
Opening and Closing the Hood 713
Manual Hydraulic Control Levers 713
E-Hydraulic Mini-Levers 714
Remove 715
Install 719
Ground Test 720
Master Cylinder Repair and Adjustment for 1 5-3 5T Cushion and 2 2-5 5T Pneumatic Lift Trucks 720
Master Cylinder Repair and Adjustment for 4 0-5 5T Cushion Lift Trucks 720
Brake Pedal Components 725
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) 725
For Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 726
Remove 726
Disassemble 726
Inspect 727
Assemble 727
Install 727
Brake Pedal Adjustment For Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 728
Brake System Air Removal 728
For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 728
Using Pressure Bleed System 728
Using Brake Pedal Pressure For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 729
For Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 729
Counterweight Replacement for Lift Truck Models ERC22-35VG (ERC045-070) (A968) and ERC16-20VA (ERC030-040VA) (A969) 729
Remove 732
Install 733
Counterweight Replacement for Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 734
Remove 741
Clean and Inspect, Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 745
Install 747
Counterweight Replacement for Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 749
Remove 752
Install 752
Traction Motor Replacement for Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 753
Traction Motor Replacement for Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 759
Traction Motor Replacement for Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 760
Hydraulic Tank Inspection 762
Inspect 762
Clean 768
Painting Instructions 768
Safety Label Replacement 770
Battery Specifications 778
Torque Specifications for Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 785
Overhead Guard 785
Counterweight 785
Traction Motor 785
Torque Specifications for Lift Truck ERP22-35VL (ERP045-070VL) (A976) 785
Overhead Guard 786
Counterweight 786
Torque Specifications for Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 786
Overhead Guard 786
Counterweight 786
Torque Specifications for Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 786
Overhead Guard 786
Counterweight 786
524319490-1300YRM1366-(03-2023)-UK-EN 789
General 795
Drive Axle Repair 795
Remove 795
Disassemble 800
Clean 802
Inspect 802
Assemble 802
Install 804
Differential Repair 808
Remove 808
Disassemble 822
Clean and Inspect 828
Install 837
Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion) 837
Ring Gear Backlash, Adjust 853
Ring Gear, Runout Check 854
Gear Set, Tooth Contact Pattern Check 854
Torque Specifications 857
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 857
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 857
524319490-1300YRM1366-(08-2016)-UK-EN 859
General 863
Drive Axle Repair 863
Remove 863
Disassemble 868
Clean 870
Inspect 870
Assemble 870
Install 873
Differential Repair 876
Remove 876
Disassemble 891
Clean and Inspect 897
Assemble 897
Install 904
Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion) 904
Ring Gear Backlash, Adjust 922
Ring Gear, Runout Check 924
Gear Set, Tooth Contact Pattern Check 924
Torque Specifications 927
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 927
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 927
524319491-1600YRM1360-(03-2023)-UK-EN 931
General 939
Steering Axle Assembly Repair 941
Remove ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 941
Disassemble ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 943
Clean 946
Inspect 946
Assemble ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 947
Install ERC22-35VG (ERC045-070VG) (A968) 948
Install ERC16-20VA (ERC030-040VA) (A969) 949
Install ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 950
Remove ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 951
Disassemble ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 956
Clean 957
Inspect 957
Assemble ERP40-50VM, ERP50-55MV6 (ERP080-120VM, ERP100VML) (A985) 957
Assemble ERP22-35VL (ERP045-070VL) (A976) 958
Wheel Bearing Adjustment ERP22-35VL (ERP045-070VL) (A976) 959
Install ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) 960
Remove ERP16-20VF (ERP30-40VF) (A955) 966
Disassemble ERP16-20VF (ERP30-40VF) (A955) 966
Clean 968
Inspect 968
Assemble ERP16-20VF (ERP30-40VF) (A955) 968
Install ERP16-20VF (ERP30-40VF) (A955) 969
Tie Rod Replacement 970
Remove ERC20-35VG (ERC045-070VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 970
Clean 971
Inspect 971
Install ERC20-35VG (ERC045-070VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 971
Remove ERC16-20VA (ERC030-040VA) (A969) 971
Clean 972
Inspect 972
Install ERC16-20VA (ERC030-040VA) (A969) 972
Remove ERP20-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 973
Clean 974
Inspect 974
Install ERP20-35VL (ERP045-070VL) (A976) andERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 974
Remove ERP16-20VF (ERP30-40VF) (A955) 974
Clean 975
Inspect 975
Install ERP16-20VF (ERP30-40VF) (A955) 975
Spindle Repair 976
Remove ERC22-35VG (ERC45-70VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 976
Disassemble ERC22-35VG (ERC45-70VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 977
Clean 977
Inspect 978
Assemble ERC22-35VG (ERC45-70VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 978
Install ERC22-35VG (ERC45-70VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 978
Remove ERC16-20VA (ERC030-040VA) (A969) 979
Disassemble ERC16-20VA (ERC030-040VA) (A969) 980
Clean 980
Inspect 980
Assemble ERC16-20VA (ERC030-040VA) (A969) 981
Install ERC16-20VA (ERC030-040VA) (A969) 981
Remove ERP22-35VL (ERP45-70VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 982
Disassemble ERP22-35VL (ERP45-70VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 983
Clean 983
Inspect 984
Assemble ERP22-35VL (ERP45-70VL) (A976) 984
Install ERP22-35VL (ERP45-70VL) (A976) 984
Assemble ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 985
Install ERP22-35VL (ERP45-70VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 985
Remove ERP16-20VF (ERP30-40VF) (A955) 986
Disassemble ERP16-20VF (ERP30-40VF) (A955) 986
Clean 987
Inspect 987
Assemble ERP16-20VF (ERP30-40VF) (A955) 988
Install ERP16-20VF (ERP30-40VF) (A955) 988
Steering Cylinder Repair 989
Remove ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 989
Disassemble ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 992
Clean 993
Inspect 993
Assemble ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 993
Install ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 993
Remove ERC16-20VA (ERC030-040VA) (A969) 994
Disassemble ERC16-20VA (ERC030-040VA) (A969) 995
Clean 996
Inspect 997
Assemble ERC16-20VA (ERC030-040VA) (A969) 997
Install ERC16-20VA (ERC030-040VA) (A969) 997
Remove ERP16-20VF (ERP30-40VF) (A955) 997
Disassemble ERP16-20VF (ERP30-40VF) (A955) 998
Clean 999
Inspect 999
Assemble ERP16-20VF (ERP30-40VF) (A955) 999
Install ERP16-20VF (ERP30-40VF) (A955) 1000
Remove ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1000
Disassemble ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1001
Clean 1002
Inspect 1002
Assemble ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1003
Install ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1003
Remove ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1003
Disassemble ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1005
Clean 1005
Inspect 1006
Assemble ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1006
Install ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1006
524319491-1600YRM1360-(10-2018)-UK-EN 1009
General 1015
Steering Axle Assembly Repair 1016
Remove ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1017
Disassemble ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1018
Clean 1022
Inspect 1022
Assemble ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1022
Install ERC22-35VG (ERC045-070VG) (A968) 1024
Install ERC16-20VA (ERC030-040VA) (A969) 1025
Install ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1026
Remove ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1028
Disassemble ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1032
Clean 1034
Inspect 1034
Assemble ERP40-50VM, ERP50-55MV6 (ERP080-120VM, ERP100VML) (A985) 1034
Assemble ERP22-35VL (ERP045-070VL) (A976) 1035
Wheel Bearing Adjustment ERP22-35VL (ERP045-070VL) (A976) 1036
Install ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) 1037
Remove ERP16-20VF (ERP30-40VF) (A955) 1043
Disassemble ERP16-20VF (ERP30-40VF) (A955) 1043
Clean 1045
Inspect 1045
Assemble ERP16-20VF (ERP30-40VF) (A955) 1045
Install ERP16-20VF (ERP30-40VF) (A955) 1046
Tie Rod Replacement 1046
Remove ERC20-35VG (ERC045-070VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1047
Clean 1048
Inspect 1048
Install ERC20-35VG (ERC045-070VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1048
Remove ERC16-20VA (ERC030-040VA) (A969) 1048
Clean 1049
Inspect 1049
Install ERC16-20VA (ERC030-040VA) (A969) 1049
Remove ERP20-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1050
Clean 1050
Inspect 1051
Install ERP20-35VL (ERP045-070VL) (A976) andERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1051
Remove ERP16-20VF (ERP30-40VF) (A955) 1051
Clean 1052
Inspect 1052
Install ERP16-20VF (ERP30-40VF) (A955) 1052
Spindle Repair 1052
Remove ERC22-35VG (ERC45-70VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1052
Disassemble ERC22-35VG (ERC45-70VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1054
Clean 1054
Inspect 1054
Assemble ERC22-35VG (ERC45-70VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1055
Install ERC22-35VG (ERC45-70VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1055
Remove ERC16-20VA (ERC030-040VA) (A969) 1056
Disassemble ERC16-20VA (ERC030-040VA) (A969) 1056
Clean 1057
Inspect 1057
Assemble ERC16-20VA (ERC030-040VA) (A969) 1057
Install ERC16-20VA (ERC030-040VA) (A969) 1058
Remove ERP22-35VL (ERP45-70VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1058
Disassemble ERP22-35VL (ERP45-70VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1060
Clean 1060
Inspect 1060
Assemble ERP22-35VL (ERP45-70VL) (A976) 1061
Install ERP22-35VL (ERP45-70VL) (A976) 1061
Assemble ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1061
Install ERP22-35VL (ERP45-70VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1061
Remove ERP16-20VF (ERP30-40VF) (A955) 1062
Disassemble ERP16-20VF (ERP30-40VF) (A955) 1063
Clean 1064
Inspect 1064
Assemble ERP16-20VF (ERP30-40VF) (A955) 1064
Install ERP16-20VF (ERP30-40VF) (A955) 1064
Steering Cylinder Repair 1065
Remove ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 1065
Disassemble ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 1068
Clean 1069
Inspect 1069
Assemble ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 1069
Install ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 1069
Remove ERC16-20VA (ERC030-040VA) (A969) 1070
Disassemble ERC16-20VA (ERC030-040VA) (A969) 1071
Clean 1072
Inspect 1073
Assemble ERC16-20VA (ERC030-040VA) (A969) 1073
Install ERC16-20VA (ERC030-040VA) (A969) 1073
Remove ERP16-20VF (ERP30-40VF) (A955) 1073
Disassemble ERP16-20VF (ERP30-40VF) (A955) 1074
Clean 1075
Inspect 1075
Assemble ERP16-20VF (ERP30-40VF) (A955) 1075
Install ERP16-20VF (ERP30-40VF) (A955) 1076
Remove ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1076
Disassemble ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1077
Clean 1078
Inspect 1078
Assemble ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1079
Install ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1079
Remove ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1079
Disassemble ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1081
Clean 1082
Inspect 1082
Assemble ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1082
Install ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1082
524319492-1600YRM1363-(03-2023)-UK-EN 1085
General 1091
Discharging The Capacitors 1091
Steering Control Unit (SCU) Repair 1093
Remove 1093
Disassemble 1096
Clean 1102
Inspect 1102
Assemble 1102
Install 1103
Steering Wheel and Fixed Steering Column Assembly Repair 1104
Remove 1104
Disassemble 1107
Clean 1108
Inspect 1109
Assemble 1109
Install 1109
Gear Replacement for Lift Trucks Built Prior to October, 2008 1110
Steering Wheel and Telescopic Column Assembly Repair 1112
Remove 1112
Disassemble 1115
Clean 1118
Inspect 1119
Assemble 1119
Install 1120
Torque Specifications 1127
Steering Control Unit 1127
Steering Column 1127
524319492-1600YRM1363-(09-2014)-UK-EN 1129
524319493-1800YRM1359-(03-2012)-UK-EN 1167
toc 1167
Brake System 1167
Safety Precautions Maintenance and Repair 1168
General 1171
Dry Brake System 1171
Service Brakes Repair (Dry Brake) 1172
Remove and Disassemble 1172
Clean 1176
Inspect 1176
Assemble and Install 1176
Adjust 1182
Parking Brake Repair 1182
Remove and Disassemble 1182
Inspect 1185
Assemble and Install 1185
Adjust 1187
Master Cylinder Repair 1188
Remove 1188
Disassemble 1188
Clean 1190
Inspect 1190
Assemble 1190
Bench Bleed Master Cylinder 1190
Install and Adjust 1190
Brake Pedal Components 1192
Remove 1192
Disassemble 1192
Inspect 1192
Assemble 1192
Install 1194
Automatic Park Brake 1195
General 1195
Remove 1195
Manual Release Handle 1195
Automatic Park Brake Assembly 1195
Automatic Park Brake Module 1195
Disassemble 1197
Clean and Inspect 1197
Assemble 1197
Install 1197
Automatic Park Brake Module 1197
Manual Release Handle 1198
Automatic Park Brake Assembly 1198
Adjustments 1198
Service Brakes Adjustment (Dry Brake) 1198
Brake Adjust 1198
Parking Brake Adjustment 1200
Brake System Air Removal 1200
Brake System Air Removal 1200
Using Pressure Bleed System 1200
Using Brake Pedal Pressure 1200
Master Cylinder Adjustment 1201
Adjust Push Rod 1201
Parking Brake Not Applied Switch Test 1201
Torque Specifications 1202
524319493-1800YRM1359-(04-2023)-UK-EN 1205
General 1211
Dry Brake System 1211
Service Brakes Repair (Dry Brake) 1212
Remove and Disassemble 1212
Clean 1216
Inspect 1217
Assemble and Install 1217
Adjust 1223
Parking Brake Repair 1224
Remove and Disassemble 1224
Inspect 1227
Assemble and Install 1227
Adjust 1229
Master Cylinder Repair 1230
Remove 1230
Disassemble 1231
Clean 1232
Inspect 1233
Assemble 1233
Bench Bleed Master Cylinder 1233
Install and Adjust 1233
Brake Pedal Components 1235
Remove 1235
Disassemble 1237
Inspect 1238
Assemble 1238
Install 1238
Automatic Park Brake 1239
General 1239
Remove 1239
Manual Release Handle 1239
Automatic Park Brake Assembly 1241
Automatic Park Brake Module 1241
Disassemble 1241
Clean and Inspect 1242
Assemble 1242
Install 1242
Automatic Park Brake Module 1242
Manual Release Handle 1242
Automatic Park Brake Assembly 1242
Adjustments 1242
Service Brakes Adjustment (Dry Brake) 1243
Brake Adjust 1243
Parking Brake Adjustment 1243
Brake System Air Removal 1246
Brake System Air Removal 1246
Using Pressure Bleed System 1246
Using Brake Pedal Pressure 1246
Brake Pedal Adjustment 1247
Brake Pedal Adjustment 1247
Master Cylinder Adjustment 1248
Adjust Push Rod 1248
Parking Brake Not Applied Switch Test 1248
Torque Specifications 1249
524319494-1900YRM1367-(04-2017)-UK-EN 1251
General 1257
Discharging the Capacitors 1257
Hydraulic Pump and Motor 1258
Remove 1258
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1259
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1262
Lift Truck Models ERP22-25VL (ERP045-070VL) (A976) 1265
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1270
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1275
Disassemble 1277
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969)ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1277
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1279
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1281
Inspect 1283
Clean 1283
Assemble 1283
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969)ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1283
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1283
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1284
Install 1284
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1284
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1285
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1286
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1287
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1288
Hydraulic Tank 1289
Remove 1289
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1289
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1292
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) 1299
Disassemble 1301
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1301
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1302
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1302
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1303
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1305
Clean 1307
Steam Method 1307
Chemical Method 1307
Inspect 1308
Small Leaks, Repair 1308
Large Leaks, Repair 1308
Additional Methods for Metal Tank Repair 1308
Assemble 1308
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1308
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1309
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1310
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1310
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1311
Install 1311
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1311
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1312
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1312
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1313
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1313
Hydraulic Filter Replacement 1314
Breather Clean and Inspect 1315
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 1315
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1318
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1318
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1318
Hydraulic Oil Cooler for Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1319
Add Hydraulic Oil 1319
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1319
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1321
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1321
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1321
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1322
Steer Accumulator Replacement 1323
Remove 1323
Install 1330
Specifications for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1330
Tank Capacity 1331
Specifications for Lift Truck ERC16-20VA (ERC030-040VA) (A969) 1331
Tank Capacity 1331
Specifications for Lift Truck ERP22-25VL (ERP045-070VL) (A976) 1331
Tank Capacity 1331
Specifications for Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1331
Tank Capacity 1331
Specifications for Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1331
Tank Capacity 1332
Torque Specifications for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1332
Hydraulic Pump and Motor 1332
Hydraulic Tank 1332
Torque Specifications for Lift Truck ERC16-20VA (ERC030-040VA) (A969) 1333
Hydraulic Pump and Motor 1333
Hydraulic Tank 1333
Torque Specifications for Lift Truck ERP22-35VL (ERP045-070VL) (A976) 1333
Hydraulic Pump and Motor 1333
Hydraulic Tank 1333
Torque Specifications for Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1333
Hydraulic Pump and Motor 1334
Hydraulic Tank 1334
Torque Specifications for Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1335
Hydraulic Pump and Motor 1335
Hydraulic Tank 1335
524319494-1900YRM1367-(08-2023)-UK-EN 1339
General 1345
Discharging the Capacitors 1345
Hydraulic Pump and Motor 1347
Remove 1347
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1347
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1353
Lift Truck Models ERP22-25VL (ERP045-070VL) (A976) 1357
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1362
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1367
Disassemble 1369
Lift Truck Models , ERC22-35VG (ERC045-070VG) (A968)ERC16-20VA (ERC030-040VA) (A969)ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1369
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1371
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1373
Inspect 1375
Clean 1375
Assemble 1375
Lift Truck Models , ERC22-35VG (ERC045-070VG) (A968)ERC16-20VA (ERC030-040VA) (A969)ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1375
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1376
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1376
Install 1376
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1376
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1377
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1378
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1379
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1380
Hydraulic Tank 1381
Remove 1381
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1381
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1384
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1387
Lift Truck Models ERP22-25VL (ERP045-070VL) (A976) 1390
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1392
Disassemble 1394
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1394
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1394
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1395
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1396
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1398
Clean 1400
Steam Method 1401
Chemical Method 1401
Inspect 1401
Small Leaks, Repair 1401
Large Leaks, Repair 1402
Additional Methods for Metal Tank Repair 1402
Assemble 1402
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1402
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1403
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1403
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1404
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1404
Install 1405
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1405
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1405
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1406
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1407
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1407
Hydraulic Filter Replacement 1408
Breather Clean and Inspect 1409
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 1409
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1411
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1411
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1412
Hydraulic Oil Cooler for Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1412
Add Hydraulic Oil 1412
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1412
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1414
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1414
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1414
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1415
Steer Accumulator Replacement 1417
Remove 1417
Install 1425
Specifications for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1426
Tank Capacity 1426
Specifications for Lift Truck ERC16-20VA (ERC030-040VA) (A969) 1426
Tank Capacity 1426
Specifications for Lift Truck ERP22-25VL (ERP045-070VL) (A976) 1426
Tank Capacity 1426
Specifications for Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1427
Tank Capacity 1427
Specifications for Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1427
Tank Capacity 1427
Torque Specifications for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1428
Hydraulic Pump and Motor 1428
Hydraulic Tank 1428
Torque Specifications for Lift Truck ERC16-20VA (ERC030-040VA) (A969) 1428
Hydraulic Pump and Motor 1428
Hydraulic Tank 1428
Torque Specifications for Lift Truck ERP22-35VL (ERP045-070VL) (A976) 1429
Hydraulic Pump and Motor 1429
Hydraulic Tank 1429
Torque Specifications for Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1429
Hydraulic Pump and Motor 1429
Hydraulic Tank 1429
Torque Specifications for Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1430
Hydraulic Pump and Motor 1430
Hydraulic Tank 1430
524319495-2000YRM1334-(03-2023)-UK-EN 1433
General 1441
Lift Trucks ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955) 1441
Lift Trucks ERC22-35VG (ERC045-070VG) (A968), ERP22-35VL (ERP045-070VL) (A976), and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1443
Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1447
Discharging the Capacitors 1449
Manual Hydraulic Control Valve Repair for 1 5-2 0T Trucks 1450
Remove 1450
Beginning Steps 1450
Disassemble Handles and Levers 1463
Disassemble Manual Control Valve 1466
Spool Seal Replacement 1476
Clean 1479
Inspect 1479
Assemble Manual Control Valve 1481
Assemble Handles and Levers 1492
Install 1495
Ending Steps 1507
Manual Hydraulic Control Valve Repair for 2 0-3 5T Trucks and 4 0-5 0T Pneumatic Trucks 1509
Remove 1509
Disassemble Handles and Levers 1525
Disassemble Manual Control Valve 1528
Disassemble Valve 1528
Disassemble Inlet Section 1531
Disassemble Lift, Tilt, and Auxiliary Sections 1531
Spool Seal Replacement 1533
Clean 1534
Inspect 1535
Assemble Manual Control Valve 1535
Assemble Lift, Tilt, and Auxiliary Sections 1535
Assemble Inlet Section 1536
Assemble Valve 1537
Assemble Handles and Levers 1545
Install 1549
Ending Steps 1561
Manual Hydraulic Control Valve Repair for 4 0-5 5T Cushion Trucks 1562
Remove 1562
Disassemble Handles and Levers 1576
Disassemble Manual Control Valve 1578
Disassemble Valve 1578
Disassemble Inlet Section 1581
Disassemble Lift, Tilt, and Auxiliary Sections 1582
Spool Seal Replacement 1584
Clean 1585
Inspect 1585
Assemble Manual Control Valve 1586
Assemble Lift, Tilt, and Auxiliary Sections 1586
Assemble Inlet Section 1587
Assemble Valve 1588
Assemble Handles and Levers 1595
Install 1598
Ending Steps 1610
E-Hydraulic Control Valve Repair for 1 5-2 0T Trucks 1611
Remove 1611
Disassemble 1617
Clean 1624
Inspect 1624
Assemble 1624
Install 1632
E-Hydraulic Controls 1637
Replace E-Hydraulic Control Components 1638
E-Hydraulic Control Valve Repair for 2 0-3 5T Trucks and 4 0-5 0T Pneumatic Trucks 1639
Remove 1639
Initial Steps 1639
Fitting Removal for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1639
Fitting Removal for Lift Truck ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1641
Electrical Disconnect and Control Valve Dismount 1643
Disassemble 1645
Clean 1650
Inspect 1650
Assemble 1650
Install 1658
Electrical Connect and Control Valve Mount 1658
Fitting Installation for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1660
Fitting Installation for Lift Truck ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1662
Ending Steps 1663
E-Hydraulic Controls 1664
Replace E-Hydraulic Control Components 1664
E-Hydraulic Control Valve Repair for 4 0-5 5T Cushion Trucks 1665
Remove 1665
Initial Steps 1665
Fitting Removal 1665
Electrical Disconnect and Control Valve Dismount 1667
Disassemble 1669
Clean 1674
Inspect 1674
Assemble 1674
Install 1682
Electrical Connect and Control Valve Mount 1682
Fitting Installation 1684
Ending Steps 1685
E-Hydraulic Controls 1686
Replace E-Hydraulic Control Components 1686
Checks and Adjustments
for 1 5-2 0T Lift Trucks 1687
Manual Control Valve 1687
Primary Relief Valve 1687
Optional Auxiliary Port Relief Valve 1687
E-Hydraulic Control Valve 1688
Primary Relief Valve 1688
Optional Secondary Port Relief Valve 1689
Hydraulic System Air Removal 1690
Checks and Adjustments
2 0-5 5T Lift Trucks 1691
Manual Control Valve 1691
External Leakage 1691
Primary Relief Cartridge 1691
Secondary Relief Valve 1692
E-Hydraulic Control Valve 1692
Primary Relief Valve 1692
Secondary Relief Valve 1693
PPRV Pilot Pressure Test 1694
Hydraulic System Air Removal 1695
Position Sensor and OPS Check and Adjustment 1696
Position Sensor 1696
(OPS) Operator Presence Solenoid 1696
Manual Control Valve Re-Calibration 1696
Calibration Procedure 1697
Control Valve 1697
Torque Specifications
for 1 5-2 0T Lift Trucks 1698
Manual Hydraulic Control Valve 1698
Manual Control Valve Handles and Levers 1698
E-Hydraulic Control Valve 1698
Torque Specifications
for 2 2-5 5T Lift Trucks 1699
Manual Hydraulic Control Valve 1699
Manual Control Valve Handles and Levers 1699
Manual Control Valve Covers 1699
E-Hydraulic Control Valve 1699
524319495-2000YRM1334-(09-2014)-UK-EN 1701
524319496-2100YRM1382-(02-2018)-UK-EN 1951
Safety Procedures When Working Near Mast 1959
General 1961
Description 1962
Tilt Cylinder Repair for 2 0-5 5T Trucks 1962
Remove 1962
Disassemble 1964
Inspect 1965
Clean 1965
Assemble 1965
Install 1967
Tilt Cylinders, Adjust 1967
Tilt Cylinder Leak Check 1970
Tilt Cylinder Repair
for 1 0-2 0T Trucks 1971
Remove 1971
Disassemble 1973
Inspect 1975
Clean 1975
Assemble 1975
Install 1975
Tilt Cylinders, Adjust 1976
Tilt Cylinders Leak Check 1977
Lift Cylinder Repair
for 2 0-3 5T Trucks 1978
Main Lift Cylinders 1978
Remove 1978
Two-Stage FFL 1978
Three-Stage FFL 1980
Four-Stage FFL 1980
Two-Stage LFL 1981
Disassemble 1981
Two-Stage FFL 1981
Three-Stage FFL 1983
Four-Stage FFL 1983
Two-Stage LFL 1985
Clean 1986
Inspect 1986
Assemble 1986
Two-Stage FFL 1986
Three-Stage FFL 1986
Four-Stage FFL 1987
Two-Stage LFL 1987
Install 1988
Two-Stage FFL 1988
System Air Bleed Procedures 1988
Three-Stage FFL 1988
Four-Stage FFL 1989
Two-Stage LFL 1989
Lift Cylinder Repair for Lift Truck Model ERP15VT (G807) 1990
Main Lift Cylinder 1990
Remove 1990
Main Lift Cylinders – Two-Stage FFL Mast 1990
Left-Hand Main Lift Cylinder – Three-Stage FFL Mast 1992
Right-Hand Main Lift Cylinder – Three-Stage FFL Mast 1996
Main Lift Cylinder – Two-Stage LFL Mast 1996
Disassemble 1999
Main Lift Cylinders – Two-Stage FFL Mast 1999
Main Lift Cylinder – Three-Stage FFL Mast 2001
Main Lift Cylinder – Two-Stage LFL Mast 2001
Clean 2002
Inspect 2002
Assemble 2003
Main Lift Cylinder – Two-Stage FFL Mast 2003
Main Lift Cylinder – Three-Stage FFL Mast 2003
Main Lift Cylinder – Two-Stage LFL Mast 2003
Install 2004
Main Lift Cylinder – Two-Stage FFL Mast 2004
Left-Hand Main Lift Cylinder – Three-Stage FFL Mast 2004
Right-Hand Main Lift Cylinder – Three-Stage FFL Mast 2005
Main Lift Cylinder – Two-Stage LFL Mast 2006
System Air Bleed Procedures 2007
All Main Lift Cylinders 2007
Lift Cylinder Repair for 1 5-2 0T Trucks 2007
Main Lift Cylinder 2007
Remove 2007
Two-Stage FFL 2008
Three-Stage FFL 2008
Two-Stage LFL 2009
Four-Stage FFL 2011
Disassemble 2012
Two-Stage FFL 2012
Three-Stage FFL 2014
Two-Stage LFL 2014
Four-Stage FFL 2015
Clean 2018
Inspect 2018
Assemble 2018
Two-Stage FFL 2018
Three-Stage FFL 2019
Two-Stage LFL 2019
Four-Stage FFL 2020
Install 2021
Two-Stage FFL 2021
System Air Bleed Procedures 2021
Three-Stage FFL Mast 2021
Two-Stage LFL 2022
Four-Stage FFL 2022
Mast and Carriage Install for Two-Stage FFL, Three-Stage FFL, and Two-Stage LFL 2023
Mast and Carriage Installation for Four-Stage FFL 2023
Lift Cylinder Repair
for 4 0-5 5T Trucks 2024
Main Lift Cylinders 2024
Remove 2024
Two-Stage FFL 2024
Three-Stage FFL 2026
Two-Stage LFL 2026
Disassemble 2027
Two-Stage FFL 2027
Three-Stage FFL 2029
Two-Stage LFL 2030
Clean 2031
Inspect 2031
Assemble 2031
Two-Stage FFL 2031
Three-Stage FFL 2032
Two-Stage LFL 2032
Install 2033
Two-Stage FFL 2033
System Air Bleed Procedures 2033
Three-Stage FFL 2033
Two-Stage LFL 2034
Free-Lift Cylinder Repair
for 2 0-3 5T Trucks 2035
Free-Lift Cylinder 2035
Remove 2035
Two and Three-Stage FFL Mast 2035
Four-Stage FFL For Lift Truck ERC22-356VG (ERC045-070VG) (A968) 2036
Disassemble 2038
Two and Three-Stage FFL Mast 2038
Four-Stage FFL Mast for Lift Truck ERC22-356VG (ERC045-070VG) (A968) 2039
Clean 2039
Inspect 2039
Assemble 2040
Two and Three-Stage FFL Mast 2040
Four-Stage FFL Mast for Lift Truck ERC22-356VG (ERC045-070VG) (A968) 2040
Install 2041
Two and Three-Stage FFL Mast 2041
Four-Stage FFL Mast for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 2041
Free Lift Cylinder Repair for Lift Truck Model ERP15VT (G807) 2042
Free-Lift Cylinder 2042
Remove 2042
Three-Stage FFL Mast 2042
Disassemble 2044
Clean 2045
Inspect 2045
Assemble 2045
Install 2045
Free Lift Cylinder Repair
for 1 5-2 0T Trucks 2046
Free-Lift Cylinder 2046
Remove 2046
Two and Three-Stage FFL Mast 2046
Four-Stage FFL Mast 2048
Disassemble 2050
Two-Stage and Three-Stage FFL Masts 2050
Four Stage FFL Mast 2051
Clean 2052
Inspect 2052
Assemble 2052
Two-Stage and Three-Stage FFL Masts 2052
Four-Stage FFL Mast 2053
Install 2053
Two-Stage and Three-Stage FFL Masts 2053
Four-Stage FFL Mast 2053
All Masts 2055
Free-Lift Cylinder Repair
for 4 0-5 5T Trucks 2056
Free-Lift Cylinder 2056
Remove 2056
Two and Three-Stage FFL Mast 2056
Disassemble 2057
Two and Three-Stage FFL Mast 2057
Clean 2058
Inspect 2058
Assemble 2058
Two and Three-Stage FFL Mast 2058
Install 2059
Two and Three-Stage FFL Mast 2059
Sideshift Cylinder Repair
for 1 5-3 5T Trucks Prior to December 2016 2059
Remove 2059
Disassemble 2063
Clean and Inspect 2065
Assemble and Install 2065
Sideshift Cylinder Repair
for 1 5-3 5T Trucks After December 2016 2066
Remove 2066
Disassemble 2070
Clean and Inspect 2072
Assemble and Install 2072
Integral Side-Shift Cylinder Gland Leak Checks 2074
Sideshift Cylinder Repair
for 4 0-5 5T Trucks 2075
Remove 2075
Disassemble 2075
Clean and Inspect 2077
Assemble and Install 2077
Fork Positioner Cylinder Repair Prior to December 2016 2077
Remove 2077
Disassemble 2078
Clean 2080
Inspect 2080
Assemble 2081
Install 2081
Fork Positioner Cylinder Adjustment 2081
Fork Positioner Cylinder Repair After December 2016 2082
Remove 2082
Disassemble 2082
Clean 2085
Inspect 2085
Assemble 2086
Install 2086
Fork Positioner Cylinder Adjustment 2086
Lift Cylinder Leak Check 2087
Seal Kit Installation 2087
External Installation (Seal and Back-Up Ring) 2088
Internal Installation (Piston Rod Assembly) 2088
Torque Specifications for Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-25VL (ERP045-070VL) (A976) 2088
Tilt Cylinders 2088
Piston Rod Nut 2088
Gland 2089
Tilt Cylinder Mounting Capscrew 2089
Tilt Cylinder Rod End Capscrew 2089
Main and Free-Lift Cylinder 2089
Sideshift Cylinder 2089
Fork Positioner Cylinder 2089
Torque Specifications for Lift Truck Model ERP15VT (G807) 2089
Tilt Cylinders 2089
Main and Free-Lift Cylinders 2089
Sideshift Cylinder 2090
Torque Specifications for Lift Truck Models ERP16-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), ESC030-40AC (B883),ESC030-40AD (C883) 2090
Tilt Cylinders 2090
Main and Free-Lift Cylinders 2090
Sideshift Cylinder 2091
Fork Positioner Cylinder 2091
Torque Specifications for Lift Truck Model ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2091
Tilt Cylinders 2091
Main and Free-Lift Cylinder 2091
Sideshift Cylinder 2091
Torque Specifications for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2091
Tilt Cylinder 2092
Main and Free Lift Cylinder 2092
Sideshift Cylinder 2092
524319496-2100YRM1382-(07-2023)-UK-EN 2095
Safety Procedures When Working Near Mast 2105
General 2108
Description 2108
Tilt Cylinder Repair for 2 0-5 5T Trucks 2109
Remove 2109
Disassemble 2111
Inspect 2112
Clean 2112
Assemble 2112
Install 2114
Tilt Cylinders, Adjust 2114
Tilt Cylinder Leak Check 2117
Tilt Cylinder Repair
for 1 0-2 0T Trucks 2118
Remove 2118
Disassemble 2121
Inspect 2123
Clean 2123
Assemble 2123
Install 2123
Tilt Cylinders, Adjust 2124
Tilt Cylinders Leak Check 2125
Lift Cylinder Repair
for 2 0-3 5T Trucks 2127
Main Lift Cylinders 2127
Remove 2127
Two-Stage FFL 2127
Three-Stage FFL 2129
Four-Stage FFL 2129
Two-Stage LFL 2130
Disassemble 2130
Two-Stage FFL 2130
Three-Stage FFL 2132
Four-Stage FFL 2134
Two-Stage LFL 2135
Clean 2136
Inspect 2136
Assemble 2136
Two-Stage FFL 2136
Three-Stage FFL 2137
Four-Stage FFL 2137
Two-Stage LFL 2138
Install 2138
Two-Stage FFL 2138
System Air Bleed Procedures 2138
Three-Stage FFL 2139
Four-Stage FFL 2139
Two-Stage LFL 2140
Lift Cylinder Repair for Lift Truck Model ERP15VT (G807) 2141
Main Lift Cylinder 2141
Remove 2141
Main Lift Cylinders – Two-Stage FFL Mast 2141
Left-Hand Main Lift Cylinder – Three-Stage FFL Mast 2143
Right-Hand Main Lift Cylinder – Three-Stage FFL Mast 2147
Main Lift Cylinder – Two-Stage LFL Mast 2147
Disassemble 2150
Main Lift Cylinders – Two-Stage FFL Mast 2150
Main Lift Cylinder – Three-Stage FFL Mast 2152
Main Lift Cylinder – Two-Stage LFL Mast 2153
Clean 2154
Inspect 2154
Assemble 2154
Main Lift Cylinder – Two-Stage FFL Mast 2154
Main Lift Cylinder – Three-Stage FFL Mast 2155
Main Lift Cylinder – Two-Stage LFL Mast 2155
Install 2155
Main Lift Cylinder – Two-Stage FFL Mast 2155
Left-Hand Main Lift Cylinder – Three-Stage FFL Mast 2156
Right-Hand Main Lift Cylinder – Three-Stage FFL Mast 2157
Main Lift Cylinder – Two-Stage LFL Mast 2158
System Air Bleed Procedures 2158
All Main Lift Cylinders 2159
Lift Cylinder Repair for 1 5-2 0T Trucks 2160
Main Lift Cylinder 2160
Remove 2160
Two-Stage FFL 2160
Three-Stage FFL 2160
Two-Stage LFL 2161
Four-Stage FFL 2163
Disassemble 2165
Two-Stage FFL 2165
Three-Stage FFL 2166
Two-Stage LFL 2167
Four-Stage FFL 2168
Clean 2170
Inspect 2171
Assemble 2171
Two-Stage FFL 2171
Three-Stage FFL 2171
Two-Stage LFL 2172
Four-Stage FFL 2172
Install 2173
Two-Stage FFL 2173
System Air Bleed Procedures 2174
Three-Stage FFL Mast 2174
Two-Stage LFL 2174
Four-Stage FFL 2175
Mast and Carriage Install for Two-Stage FFL, Three-Stage FFL, and Two-Stage LFL 2175
Mast and Carriage Installation for Four-Stage FFL 2176
Lift Cylinder Repair for 4 0-5 5T Trucks 2177
Main Lift Cylinders 2177
Remove 2177
Two-Stage FFL 2177
Three-Stage FFL 2179
Two-Stage LFL 2179
Disassemble 2180
Two-Stage FFL 2180
Three-Stage FFL 2182
Two-Stage LFL 2183
Clean 2184
Inspect 2184
Assemble 2184
Two-Stage FFL 2184
Three-Stage FFL 2185
Two-Stage LFL 2185
Install 2186
Two-Stage FFL 2186
System Air Bleed Procedures 2186
Three-Stage FFL 2186
Two-Stage LFL 2187
Free-Lift Cylinder Repair for 2 0-3 5T Trucks 2188
Free-Lift Cylinder 2188
Remove 2188
Two and Three-Stage FFL Mast 2188
Four-Stage FFL For Lift Truck ERC22-356VG (ERC045-070VG) (A968) 2189
Disassemble 2191
Two and Three-Stage FFL Mast 2191
Four-Stage FFL Mast for Lift Truck ERC22-356VG (ERC045-070VG) (A968) 2192
Clean 2192
Inspect 2193
Assemble 2193
Two and Three-Stage FFL Mast 2193
Four-Stage FFL Mast for Lift Truck ERC22-356VG (ERC045-070VG) (A968) 2193
Install 2194
Two and Three-Stage FFL Mast 2194
Four-Stage FFL Mast for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 2194
Free Lift Cylinder Repair for Lift Truck Model ERP15VT (G807) 2196
Free-Lift Cylinder 2196
Remove 2196
Three-Stage FFL Mast 2196
Disassemble 2198
Clean 2199
Inspect 2199
Assemble 2199
Install 2199
Free Lift Cylinder Repair for 1 5-2 0T Trucks 2201
Free-Lift Cylinder 2201
Remove 2201
Two and Three-Stage FFL Mast 2201
Four-Stage FFL Mast 2203
Disassemble 2206
Two-Stage and Three-Stage FFL Masts 2206
Four Stage FFL Mast 2206
Clean 2207
Inspect 2207
Assemble 2207
Two-Stage and Three-Stage FFL Masts 2207
Four-Stage FFL Mast 2208
Install 2208
Two-Stage and Three-Stage FFL Masts 2208
Four-Stage FFL Mast 2209
All Masts 2212
Free-Lift Cylinder Repair
for 4 0-5 5T Trucks 2213
Free-Lift Cylinder 2213
Remove 2213
Two and Three-Stage FFL Mast 2213
Disassemble 2214
Two and Three-Stage FFL Mast 2214
Clean 2215
Inspect 2215
Assemble 2215
Two and Three-Stage FFL Mast 2215
Install 2216
Two and Three-Stage FFL Mast 2216
Sideshift Cylinder Repair
for 1 5-3 5T Trucks Prior to December 2016 2217
Remove 2217
Disassemble 2220
Clean and Inspect 2222
Assemble and Install 2222
Sideshift Cylinder Repair
for 1 5-3 5T Trucks After December 2016 2224
Remove 2224
Disassemble 2227
Clean and Inspect 2228
Assemble and Install 2229
Integral Side-Shift Cylinder Gland Leak Checks 2231
Sideshift Cylinder Repair
for 4 0-5 5T Trucks 2232
Remove 2232
Disassemble 2233
Clean and Inspect 2234
Assemble and Install 2234
Fork Positioner Cylinder Repair Prior to December 2016 2235
Remove 2235
Disassemble 2235
Clean 2238
Inspect 2238
Assemble 2239
Install 2239
Fork Positioner Cylinder Adjustment 2239
Fork Positioner Cylinder Repair After December 2016 2241
Remove 2241
Disassemble 2241
Clean 2244
Inspect 2244
Assemble 2245
Install 2245
Fork Positioner Cylinder Adjustment 2245
Lift Cylinder Leak Check 2247
Seal Kit Installation 2248
External Installation (Seal and Back-Up Ring) 2248
Internal Installation (Piston Rod Assembly) 2248
Torque Specifications for Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-25VL (ERP045-070VL) (A976) 2249
Tilt Cylinders 2249
Piston Rod Nut 2249
Gland 2249
Tilt Cylinder Mounting Capscrew 2249
Tilt Cylinder Rod End Capscrew 2249
Main and Free-Lift Cylinder 2249
Sideshift Cylinder 2249
Fork Positioner Cylinder 2249
Torque Specifications for Lift Truck Model ERP15VT (G807) 2250
Tilt Cylinders 2250
Main and Free-Lift Cylinders 2250
Sideshift Cylinder 2250
Torque Specifications for Lift Truck Models ERP16-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), ESC030-40AC (B883),ESC030-40AD (C883) 2251
Tilt Cylinders 2251
Main and Free-Lift Cylinders 2251
Sideshift Cylinder 2251
Fork Positioner Cylinder 2251
Torque Specifications for Lift Truck Model ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2252
Tilt Cylinders 2252
Main and Free-Lift Cylinder 2252
Sideshift Cylinder 2252
Torque Specifications for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2252
Tilt Cylinder 2252
Main and Free Lift Cylinder 2252
Sideshift Cylinder 2252
524319497-2200YRM1335-(01-2023)-UK-EN 2255
General 2263
Description 2263
Display Panel Menu Access 2263
Menu Flowchart 2264
Supervisor Menu Flowchart 2264
Menu Navigation 2270
Icon Glossary 2274
Introduction 2274
Soft Key Icons 2274
Overlay Icons 2275
Icons on System Off Screen and Alert Screens 2275
Main Menu Title Screens 2279
Submenu Icons Grouped by Menu 2281
Operating Screen Icons 2281
Password Screen Icons 2282
Activity Log Submenu Icons 2282
Calibration Submenu Icons 2284
Display Submenu Icons 2286
Status Submenu Icons 2288
Truck Setup Submenu Icons 2291
Operating Screen 2298
Introduction 2298
Performance Mode Controls 2299
Status and Warning Icons 2299
Battery Discharge Indicator 2300
Direction and Parking Brake Indicators 2301
Hazard Flashers and Lighting Controls 2301
Steer Angle Indicator 2301
System Time 2301
Load Weight Indicator 2301
System Off/Alert Screens 2302
Introduction 2302
System Off Screen 2302
Alert Screens 2302
Password Screen 2304
Introduction 2304
Password Screen 2304
Service Technician Password Setup 2304
Adding/Removing/Changing Passwords 2305
Password Log 2308
Activity Log Menu 2309
Introduction 2309
Operator Checklist Log 2310
Password Log 2313
Impact Events Log 2315
Calibration Menu 2317
Introduction 2317
Load Weight Calibration 2317
Return to Set Tilt Stop Point Calibration 2318
E-Hydraulic and Manual Valve Threshold Calibration 2318
Steering Wheel Center Point Calibration 2319
Steer Axle Position Calibration 2319
Steer Axle Center Point Calibration 2320
Manual Hydraulics Calibration 2321
Display Menu 2322
Introduction 2322
Set Date and Time Format Menu 2322
Set Daylight Saving Time Menu 2323
Procedure for Setting Up Automatic Daylight Savings Time 2324
Set Time and Date Menu 2326
Procedure for Setting Time and Date 2326
Set Units Menu 2327
Status Menu 2328
Introduction 2328
VSM Versions 2328
Display Versions 2329
Truck Serial Number 2329
Hour Meters 2329
E-Hydraulic Controller Versions 2329
Pump Motor Controller Versions 2329
Traction Motor Controller 1 Versions 2329
Traction Motor Controller 2 Versions 2330
Light Controller Versions 2330
Impact Sensor Versions 2330
Truck Setup Menu 2331
Introduction 2331
Add/Remove Password 2331
Battery Settings 2331
Restore Default Settings 2332
Motion Alarm 2332
Impact Monitor Settings 2333
Impact Detection 2333
Setting Adjustments 2333
Initial Adjustment of Soft and Hard Impact Settings 2333
Readjustment of Soft and Hard Impact Settings 2333
Auto Power-Off Time Delay 2334
Return to Set Tilt 2334
Traction Speed Limit 2334
Scheduled Maintenance Reminder 2335
Minimum Pump Standby Flow Rate 2336
Operator Checklist 2336
Impact Monitor Shutdown 2337
Motor Braking 2338
Changing the Motor Braking Settings 2338
Steering Wheel Friction and Steering Turns Adjustment 2339
How to Adjust Settings 2339
Steering Friction Setting 2339
Steering Wheel Number of Turns 2340
524319497-2200YRM1335-(07-2020)-UK-EN 2343
General 2349
Description 2349
Display Panel Menu Access 2349
Menu Flowchart 2350
Supervisor Menu Flowchart 2350
Menu Navigation 2356
Icon Glossary 2360
Introduction 2360
Soft Key Icons 2360
Overlay Icons 2361
Icons on System Off Screen and Alert Screens 2361
Main Menu Title Screens 2365
Submenu Icons Grouped by Menu 2367
Operating Screen Icons 2367
Password Screen Icons 2368
Activity Log Submenu Icons 2368
Calibration Submenu Icons 2370
Display Submenu Icons 2372
Status Submenu Icons 2374
Truck Setup Submenu Icons 2377
Operating Screen 2384
Introduction 2384
Performance Mode Controls 2384
Status and Warning Icons 2385
Battery Discharge Indicator 2386
Direction and Parking Brake Indicators 2386
Hazard Flashers and Lighting Controls 2387
Steer Angle Indicator 2387
System Time 2387
Load Weight Indicator 2387
System Off/Alert Screens 2388
Introduction 2388
System Off Screen 2388
Alert Screens 2388
Password Screen 2390
Introduction 2390
Password Screen 2390
Service Technician Password Setup 2390
Adding/Removing/Changing Passwords 2391
Password Log 2394
Activity Log Menu 2395
Introduction 2395
Operator Checklist Log 2395
Password Log 2397
Impact Events Log 2399
Calibration Menu 2401
Introduction 2401
Load Weight Calibration 2401
Return to Set Tilt Stop Point Calibration 2402
E-Hydraulic and Manual Valve Threshold Calibration 2402
Steering Wheel Center Point Calibration 2403
Steer Axle Position Calibration 2403
Steer Axle Center Point Calibration 2404
Manual Hydraulics Calibration 2405
Display Menu 2406
Introduction 2406
Set Date and Time Format Menu 2406
Set Daylight Saving Time Menu 2407
Procedure for Setting Up Automatic Daylight Savings Time 2408
Set Time and Date Menu 2410
Procedure for Setting Time and Date 2410
Set Units Menu 2411
Status Menu 2412
Introduction 2412
VSM Versions 2412
Display Versions 2413
Truck Serial Number 2413
Hour Meters 2413
E-Hydraulic Controller Versions 2413
Pump Motor Controller Versions 2413
Traction Motor Controller 1 Versions 2413
Traction Motor Controller 2 Versions 2414
Light Controller Versions 2414
Impact Sensor Versions 2414
Truck Setup Menu 2415
Introduction 2415
Add/Remove Password 2415
Battery Settings 2415
Restore Default Settings 2416
Motion Alarm 2416
Impact Monitor Settings 2416
Impact Detection 2417
Setting Adjustments 2417
Initial Adjustment of Soft and Hard Impact Settings 2417
Readjustment of Soft and Hard Impact Settings 2417
Auto Power-Off Time Delay 2418
Return to Set Tilt 2418
Traction Speed Limit 2418
Scheduled Maintenance Reminder 2419
Minimum Pump Standby Flow Rate 2420
Operator Checklist 2420
Impact Monitor Shutdown 2421
Motor Braking 2422
Changing the Motor Braking Settings 2422
Steering Wheel Friction and Steering Turns Adjustment 2423
How to Adjust Settings 2423
Steering Friction Setting 2423
Steering Wheel Number of Turns 2424
524319498-2200YRM1336-(02-2023)-UK-EN 2427
General 2435
Description 2435
Display Panel Menu Access 2435
Menu Flowchart 2436
Technician Menu Flowchart 2436
Menu Navigation 2442
Icon Glossary 2446
Introduction 2446
Soft Key Icons 2446
Overlay Icons 2447
Heat Exchange Module Warning Indicator Screen 2447
System Off Screen and Alert Screens 2448
Main Menu Title Screens 2454
Submenu Icons Grouped by Menu 2455
Operating Screen Icons 2455
Password Screen Icons 2457
Activity Log Submenu Icons 2457
Calibration Submenu Icons 2458
Display Submenu Icons 2462
Status Submenu Icons 2464
Truck Setup Submenu Icons 2467
Diagnostics Submenu Icons 2479
Operating Screen 2489
Introduction 2489
Performance Mode Controls 2489
Status and Warning Icons 2490
Battery Discharge Indicator 2491
Direction and Parking Brake Indicators 2491
Hazard Flashers and Lighting Controls 2492
Steer Angle Indicator 2492
System Time 2492
Load Weight Indicator 2492
System Off/Alert Screens 2493
Introduction 2493
System Off Screen 2493
Alert Screens 2493
Password Screen 2495
Introduction 2495
Password Screen 2495
Service Technician Password Setup 2495
Adding/Removing/Changing Passwords 2496
Password Log 2499
Activity Log Menu 2500
Introduction 2500
Operator Checklist Log 2500
Password Log 2502
Impact Events Log 2504
Calibration Menu 2506
Introduction 2506
Load Weight Calibration 2506
Return to Set Tilt Stop Point Calibration 2507
E-Hydraulic and Manual Valve Threshold Calibration 2507
Steering Wheel Center Point Calibration 2508
Steer Axle Position Calibration 2509
Steer Axle Center Point Calibration 2510
Manual Hydraulics Calibration 2510
Display Menu 2511
Introduction 2511
Set Date and Time Format Menu 2511
Set Daylight Saving Time Menu 2512
Procedure for Setting Up Automatic Daylight Savings Time 2513
Set Time and Date Menu 2515
Procedure for Setting Time and Date 2515
Set Units Menu 2516
Status Menu 2517
Introduction 2517
VSM Versions 2517
Display Versions 2518
Truck Serial Number 2518
Hour Meters 2518
E-Hydraulic Controller Versions 2518
Pump Motor Controller Versions 2518
Traction Motor Controller 1 Versions 2518
Traction Motor Controller 2 Versions 2519
Light Controller Versions 2519
Impact Sensor Versions 2519
E-Steer Controller 1 Versions 2519
E-Steer Controller 2 Versions 2519
Truck Setup Menu 2520
Introduction 2520
Add/Remove Password 2521
Battery Settings 2521
Motor Braking 2521
Changing the Motor Braking Settings 2522
Battery Mode 2522
Battery Setup 2523
BDI Adjustment Setting 2524
Acceleration Rates 2525
Hour Meter Initialization 2526
Impact Monitor Shutdown 2526
Operator Checklist 2528
Minimum Pump Standby Flow Rate 2528
Scheduled Maintenance Reminder 2529
Traction Speed Limit 2530
Return to Set Tilt 2530
Auto Power-Off Time Delay 2531
Impact Monitor Settings 2531
Impact Detection 2532
Setting Adjustments 2532
Initial Adjustment of Soft and Hard Impact Settings 2532
Readjustment of Soft and Hard Impact Settings 2532
Motion Alarm 2532
Lift Hydraulic Function Maximum Speed and Ramp Times 2533
Lower Hydraulic Function Maximum Speed and Ramp Times 2533
Tilt Forward Hydraulic Function Maximum Speed and Ramp Times 2534
Tilt Backward Hydraulic Function Maximum Speed and Ramp Times 2534
Auxiliary 1A Hydraulic Function Maximum Speed and Ramp Times 2534
Auxiliary 1B Hydraulic Function Maximum Speed and Ramp Times 2534
Auxiliary 2A Hydraulic Function Maximum Speed and Ramp Times 2534
Auxiliary 2B Hydraulic Function Maximum Speed and Ramp Times 2534
Optional Hydraulic Functions 2534
Rear Lights Control 2535
Restore Default Settings 2535
Steering Wheel Friction and Steering Turns Adjustment 2536
Navigation 2537
How to Adjust Settings 2537
Steering Friction 2537
Steering Wheel Number of Turns 2538
Diagnostics Menu 2540
Introduction 2540
Fault Code Log 2540
Fault Log Details 2541
Speedometer 2542
Direction Switch 2542
Traction Motor 1 Status 2543
Traction Motor 2 Status 2543
Occupancy Sensor 2543
Brake System Sensors 2543
Pump Status 2544
Hydraulic Control Inputs 2545
E-Hydraulic Valves 2545
Hydraulic Sensors 2546
System Voltages 2546
Steering Position Sensors 2548
E-Steering Position Sensors 2548
Electric Brake 2549
Navigation 2550
ESS Diagnostics Menus A, B, and C 2551
Menu A 2551
Menu B 2552
Menu C 2554
524319498-2200YRM1336-(07-2020)-UK-EN 2557
General 2563
Description 2563
Display Panel Menu Access 2563
Menu Flowchart 2564
Technician Menu Flowchart 2564
Menu Navigation 2570
Icon Glossary 2574
Introduction 2574
Soft Key Icons 2574
Overlay Icons 2575
Heat Exchange Module Warning Indicator Screen 2575
System Off Screen and Alert Screens 2576
Main Menu Title Screens 2581
Submenu Icons Grouped by Menu 2583
Operating Screen Icons 2583
Password Screen Icons 2584
Activity Log Submenu Icons 2584
Calibration Submenu Icons 2586
Display Submenu Icons 2589
Status Submenu Icons 2591
Truck Setup Submenu Icons 2595
Diagnostics Submenu Icons 2606
Operating Screen 2616
Introduction 2616
Performance Mode Controls 2616
Status and Warning Icons 2617
Battery Discharge Indicator 2618
Direction and Parking Brake Indicators 2619
Hazard Flashers and Lighting Controls 2619
Steer Angle Indicator 2619
System Time 2619
Load Weight Indicator 2619
System Off/Alert Screens 2620
Introduction 2620
System Off Screen 2620
Alert Screens 2620
Password Screen 2622
Introduction 2622
Password Screen 2622
Service Technician Password Setup 2622
Adding/Removing/Changing Passwords 2623
Password Log 2625
Activity Log Menu 2626
Introduction 2626
Operator Checklist Log 2626
Password Log 2628
Impact Events Log 2630
Calibration Menu 2632
Introduction 2632
Load Weight Calibration 2632
Return to Set Tilt Stop Point Calibration 2633
E-Hydraulic and Manual Valve Threshold Calibration 2633
Steering Wheel Center Point Calibration 2634
Steer Axle Position Calibration 2635
Steer Axle Center Point Calibration 2635
Manual Hydraulics Calibration 2636
Display Menu 2637
Introduction 2637
Set Date and Time Format Menu 2637
Set Daylight Saving Time Menu 2638
Procedure for Setting Up Automatic Daylight Savings Time 2639
Set Time and Date Menu 2641
Procedure for Setting Time and Date 2641
Set Units Menu 2642
Status Menu 2643
Introduction 2643
VSM Versions 2643
Display Versions 2644
Truck Serial Number 2644
Hour Meters 2644
E-Hydraulic Controller Versions 2644
Pump Motor Controller Versions 2644
Traction Motor Controller 1 Versions 2644
Traction Motor Controller 2 Versions 2645
Light Controller Versions 2645
Impact Sensor Versions 2645
E-Steer Controller 1 Versions 2645
E-Steer Controller 2 Versions 2645
Truck Setup Menu 2646
Introduction 2646
Add/Remove Password 2647
Battery Settings 2647
Motor Braking 2647
Changing the Motor Braking Settings 2648
Battery Mode 2648
Battery Setup 2649
BDI Adjustment Setting 2650
Acceleration Rates 2651
Hour Meter Initialization 2652
Impact Monitor Shutdown 2652
Operator Checklist 2653
Minimum Pump Standby Flow Rate 2654
Scheduled Maintenance Reminder 2654
Traction Speed Limit 2656
Return to Set Tilt 2656
Auto Power-Off Time Delay 2656
Impact Monitor Settings 2657
Impact Detection 2657
Setting Adjustments 2657
Initial Adjustment of Soft and Hard Impact Settings 2657
Readjustment of Soft and Hard Impact Settings 2658
Motion Alarm 2658
Lift Hydraulic Function Maximum Speed and Ramp Times 2658
Lower Hydraulic Function Maximum Speed and Ramp Times 2659
Tilt Forward Hydraulic Function Maximum Speed and Ramp Times 2659
Tilt Backward Hydraulic Function Maximum Speed and Ramp Times 2659
Auxiliary 1A Hydraulic Function Maximum Speed and Ramp Times 2659
Auxiliary 1B Hydraulic Function Maximum Speed and Ramp Times 2660
Auxiliary 2A Hydraulic Function Maximum Speed and Ramp Times 2660
Auxiliary 2B Hydraulic Function Maximum Speed and Ramp Times 2660
Optional Hydraulic Functions 2660
Rear Lights Control 2660
Restore Default Settings 2661
Steering Wheel Friction and Steering Turns Adjustment 2661
Navigation 2662
How to Adjust Settings 2662
Steering Friction 2662
Steering Wheel Number of Turns 2663
Diagnostics Menu 2665
Introduction 2665
Fault Code Log 2665
Fault Log Details 2666
Speedometer 2667
Direction Switch 2667
Traction Motor 1 Status 2667
Traction Motor 2 Status 2668
Occupancy Sensor 2668
Brake System Sensors 2668
Pump Status 2669
Hydraulic Control Inputs 2669
E-Hydraulic Valves 2669
Hydraulic Sensors 2670
System Voltages 2670
Steering Position Sensors 2671
E-Steering Position Sensors 2671
Electric Brake 2672
Navigation 2673
524319499-2200YRM1369-(01-2020)-UK-EN 2675
General 2683
Discharging the Capacitors 2684
Display Panel and Key or Keyless Switch Replacement 2685
Display Panel, Replace 2685
Remove 2685
Install 2688
Electronic and Manual Hydraulic Controls 2689
General 2689
Manual Hydraulic Controls 2690
Upper Front Cover 2690
Direction Control Switch 2691
Remove 2691
Install 2696
Clamp Button 2696
Remove 2696
Install 2697
Return To Set Tilt (RTST) Button 2697
Remove 2697
Install 2697
Emergency Disconnect Switch 2698
Remove 2698
Install 2698
E-Hydraulic Controls – Test 2699
Mini-Levers 2699
Full Stroke Test 2699
Function Returns to Neutral Test 2699
Push (Override) Button 2700
E-Hydraulic Controls 2700
Mini-levers, Remove and Install 2700
Armrest Assembly 2701
Remove 2701
Install 2703
Horn Button 2703
Remove 2703
Install 2704
Direction Control Switch 2704
Remove 2704
Install 2705
Emergency Disconnect Switch 2705
Remove 2705
Install 2706
Push (Override) Buttons and Function Selection Button 2706
Remove 2706
Install 2708
Electronic-Hydraulic Controls, After January, 2020 2708
General 2708
E-Hydraulic Controls – TEST 2710
Mini-Levers 2710
Full Stroke Test 2710
Function Returns to Neutral Test 2710
Push Button (push (override) button) 2711
Mini-levers, Remove and Install 2711
Armrest Assembly 2711
Remove 2711
Install 2714
Horn Button 2714
Remove 2714
Install 2715
Direction Control Switch 2715
Remove 2715
Install 2715
Emergency Disconnect Switch 2715
Remove 2716
Install 2716
Push (Override) Buttons 2717
Remove 2717
Install 2718
Sensors and Switches 2719
General 2719
Synchronous Steering Valve 2719
Steering Axle Sensor 2719
Remove 2719
Install 2724
Hydraulic Motor Speed Sensor 2725
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 2725
Remove 2725
Install 2730
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2731
Remove 2731
Install 2735
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 2735
Remove 2735
Install 2736
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2736
Remove 2736
Install 2738
Hydraulic Motor Temperature Sensor 2738
Hydraulic Tank Level Sensor 2738
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2738
Remove 2738
Install 2740
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 2740
Remove 2740
Install 2741
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2741
Remove 2741
Install 2742
Hydraulic Filter Sensor 2742
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2742
Remove 2742
Install 2743
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968,) ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2744
Remove 2744
Install 2745
Hydraulic Oil Temperature Sensor 2746
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2746
Remove 2746
Install 2746
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 2746
Remove 2746
Install 2747
Traction Speed Sensor 2747
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2747
Remove 2747
Install 2749
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 2750
Remove 2750
Install 2752
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2752
Remove 2752
Install 2753
Traction Motor Temperature Sensor ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 2754
Traction Motor Temperature Sensor ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2754
Remove 2754
Install 2755
Tilt Position Sensor ERC22-35VG (ERC045-070VG) (A968), ERP22-35VL (ERP045-070VL) (A976), and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2755
Remove 2755
Install 2757
Tilt Position Sensor ERC16-20VA (ERC030-040VA) (A969) 2758
Remove 2758
Install 2758
Tilt Position Sensor ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2759
Remove 2759
Install 2760
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) 2761
Remove 2761
Install 2764
Low Level Brake Fluid Switch for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2765
Remove 2765
Install 2766
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) 2767
Remove 2767
Install 2767
Service Brake Pressure Sensor for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2768
Remove 2768
Install 2768
Accelerator Pedal Position Sensor 2768
Remove 2768
Install 2769
Seat Belt Sequence Module 2769
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2769
Remove 2769
Install 2769
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 2770
Remove 2770
Install 2770
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 2770
Remove 2770
Install 2771
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2771
Remove 2771
Install 2772
Seat Sensor (Operator Presence System) 2772
Non-Suspension Seat 2772
Remove 2772
Install 2774
Full Suspension and Swivel Seats 2774
Remove 2774
Install 2775
Steering Direction Sensor 2775
Remove 2775
Install 2776
Load Weight Sensor 2776
Remove 2776
Install 2778
Battery Gate Switch 2778
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2778
Remove 2778
Install 2780
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 2780
Remove 2780
Install 2782
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2783
Remove 2783
Install 2784
Horn Switch 2784
Fixed Steering Column 2784
Remove 2784
Install 2785
Telescopic Steering Column 2785
Remove 2785
Install 2786
Impact Sensor 2786
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2786
Remove 2786
Install 2788
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 2788
Remove 2788
Install 2789
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2790
Remove 2790
Install 2791
Rear and Hood Horn Button Switches 2791
Rear Horn Button Switch 2791
Remove 2791
Install 2792
Hood Horn Button Switch 2792
Remove 2792
Install 2793
Motor Controllers Replacement 2794
General 2794
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 2808
Traction Motor and Hydraulic Pump and Motor Controllers 2808
Remove 2808
Install 2815
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2816
Hydraulic Pump and Motor Controller 2816
Remove 2816
Install 2822
Traction Motor Controllers 2823
Remove 2823
Install 2830
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2831
Traction Motor and Hydraulic Pump and Motor Controllers 2831
Remove 2831
Install 2833
Line Contactor 2834
Remove 2834
Install 2842
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) 2843
Remove 2843
Install 2845
Fans for Lift Truck Model Manufactured Before November 2014ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2846
Remove 2846
Install 2846
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) 2846
Remove 2853
Install 2857
Vehicle System Manager 2857
General 2857
Remove 2858
Install 2862
Programming a New VSM and/or Display Panel 2863
PC Service Tool Software 2863
Fuses and Relays 2864
Backup Alarm 2878
Battery Connection 2881
Inspect 2881
Replacing Cables 2881
Cab Heater 2883
Lights 2883
General 2883
Work Lights (Front and Rear) 2887
Halogen Bulb Lights 2887
Remove 2887
Install 2887
LED Lights 2887
Remove 2887
Install 2888
Strobe Light 2888
Remove 2888
Install 2888
LED Tail, Backup, and Brake Lights 2889
Remove 2889
Install 2890
Front Marker/Turn Signal Lights 2890
Remove 2890
Install 2890
Dome Light 2890
Remove 2890
Install 2891
Converter 2891
Remove 2892
Install 2900
524319499-2200YRM1369-(04-2023)-UK-EN 2903
General 2913
Discharging the Capacitors 2914
Display Panel and Key or Keyless Switch Replacement 2915
Display Panel, Replace 2915
Remove 2915
Install 2918
Electronic and Manual Hydraulic Controls 2919
General 2919
Manual Hydraulic Controls 2920
Upper Front Cover 2920
Direction Control Switch 2921
Remove 2921
Install 2927
Clamp Button 2927
Remove 2927
Install 2928
Return To Set Tilt (RTST) Button 2928
Remove 2928
Install 2928
Emergency Disconnect Switch 2929
Remove 2929
Install 2929
E-Hydraulic Controls – Test 2930
Mini-Levers 2930
Full Stroke Test 2930
Function Returns to Neutral Test 2930
Push (Override) Button 2931
E-Hydraulic Controls 2931
Mini-levers, Remove and Install 2931
Armrest Assembly 2932
Remove 2932
Install 2934
Horn Button 2934
Remove 2934
Install 2935
Direction Control Switch 2935
Remove 2935
Install 2936
Emergency Disconnect Switch 2936
Remove 2936
Install 2937
Push (Override) Buttons and Function Selection Button 2937
Remove 2937
Install 2940
Electronic-Hydraulic Controls, After January, 2020 2941
General 2941
E-Hydraulic Controls – TEST 2942
Mini-Levers 2942
Full Stroke Test 2942
Function Returns to Neutral Test 2942
Push Button (push (override) button) 2943
Mini-levers, Remove and Install 2943
Armrest Assembly 2943
Remove 2943
Install 2946
Horn Button 2946
Remove 2946
Install 2946
Direction Control Switch 2946
Remove 2946
Install 2947
Emergency Disconnect Switch 2947
Remove 2947
Install 2948
Push (Override) Buttons 2948
Remove 2948
Install 2949
Sensors and Switches 2950
General 2950
Synchronous Steering Valve 2950
Steering Axle Sensor 2950
Remove 2950
Install 2955
Hydraulic Motor Speed Sensor 2956
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 2956
Remove 2956
Install 2961
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2962
Remove 2962
Install 2966
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 2966
Remove 2966
Install 2967
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2967
Remove 2967
Install 2969
Hydraulic Motor Temperature Sensor 2969
Hydraulic Tank Level Sensor 2969
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2969
Remove 2969
Install 2971
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 2971
Remove 2971
Install 2972
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2972
Remove 2972
Install 2973
Hydraulic Filter Sensor 2973
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2973
Remove 2973
Install 2974
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968,) ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2975
Remove 2975
Install 2976
Hydraulic Oil Temperature Sensor 2977
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2977
Remove 2977
Install 2977
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 2977
Remove 2977
Install 2978
Traction Speed Sensor 2978
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2978
Remove 2978
Install 2980
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 2981
Remove 2981
Install 2983
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2983
Remove 2983
Install 2984
Traction Motor Temperature Sensor ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 2985
Traction Motor Temperature Sensor ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2985
Remove 2985
Install 2986
Tilt Position Sensor ERC22-35VG (ERC045-070VG) (A968), ERP22-35VL (ERP045-070VL) (A976), and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2986
Remove 2986
Install 2988
Tilt Position Sensor ERC16-20VA (ERC030-040VA) (A969) 2988
Remove 2989
Install 2989
Tilt Position Sensor ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2989
Remove 2989
Install 2990
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) 2991
Remove 2991
Install 2994
Low Level Brake Fluid Switch for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2995
Remove 2995
Install 2996
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) 2997
Remove 2997
Install 2997
Service Brake Pressure Sensor for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2997
Remove 2997
Install 2998
Accelerator Pedal Position Sensor 2998
Remove 2998
Install 2998
Seat Belt Sequence Module 2999
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2999
Remove 2999
Install 3000
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 3000
Remove 3000
Install 3000
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 3000
Remove 3000
Install 3001
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 3001
Remove 3001
Install 3001
Seat Sensor (Operator Presence System) 3002
Non-Suspension Seat 3002
Remove 3002
Install 3004
Full Suspension and Swivel Seats 3004
Remove 3004
Install 3005
Steering Direction Sensor 3005
Remove 3005
Install 3005
Load Weight Sensor 3006
Remove 3006
Install 3007
Battery Gate Switch 3008
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 3008
Remove 3008
Install 3010
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 3010
Remove 3010
Install 3012
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 3012
Remove 3012
Install 3013
Horn Switch 3014
Fixed Steering Column 3014
Remove 3014
Install 3015
Telescopic Steering Column 3015
Remove 3015
Install 3016
Impact Sensor 3016
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 3016
Remove 3016
Install 3018
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 3018
Remove 3018
Install 3019
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 3020
Remove 3020
Install 3021
Rear and Hood Horn Button Switches 3021
Rear Horn Button Switch 3021
Remove 3021
Install 3022
Hood Horn Button Switch 3022
Remove 3022
Install 3023
Motor Controllers Replacement 3024
General 3024
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 3038
Traction Motor and Hydraulic Pump and Motor Controllers 3038
Remove 3038
Install 3045
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 3045
Hydraulic Pump and Motor Controller 3045
Remove 3045
Install 3052
Traction Motor Controllers 3053
Remove 3053
Install 3060
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 3061
Traction Motor and Hydraulic Pump and Motor Controllers 3061
Remove 3061
Install 3063
Line Contactor 3064
Remove 3064
Install 3071
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) 3073
Remove 3073
Install 3075
Fans for Lift Truck Model Manufactured Before November 2014 ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 3076
Remove 3076
Install 3076
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) 3076
Remove 3083
Install 3087
Vehicle System Manager 3088
General 3088
Remove 3088
Install 3093
Programming a New VSM and/or Display Panel 3094
PC Service Tool Software 3094
Fuses and Relays 3095
Backup Alarm 3109
Battery Connection 3113
Inspect 3113
Replacing Cables 3113
Cab Heater 3115
Lights 3115
General 3115
Work Lights (Front and Rear) 3119
Halogen Bulb Lights 3119
Remove 3119
Install 3119
LED Lights 3119
Remove 3119
Install 3120
Strobe Light 3120
Remove 3120
Install 3120
LED Tail, Backup, and Brake Lights 3121
Remove 3121
Install 3122
Front Marker/Turn Signal Lights 3122
Remove 3122
Install 3122
Dome Light 3122
Remove 3122
Install 3123
Converter 3123
Remove 3123
Install 3132
524319500-4000YRM1338-(04-2023)-UK-EN 3135
General 3141
Safety Procedures When Working Near Mast 3143
Fork Replacement 3146
Remove 3146
Install 3147
Checks 3147
Carriages Repair 3149
Standard Carriage 3149
Remove 3149
Clean and Inspect 3150
Install 3150
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 3151
Remove 3151
Clean and Inspect 3154
Repair 3155
Install 3155
Integral Sideshift Carriage, Lift Trucks Manufactured After December, 2016 3156
Remove 3156
Disassemble 3160
Clean and Inspect 3160
Assemble 3161
Install 3162
Fork Positioner, Lift Trucks Manufactured Prior To December, 2016 3162
Remove 3163
Clean and Inspect 3166
Disassemble and Assemble 3166
Install 3166
Fork Positioner Hydraulic Hose Adjustment 3168
Fork Positioner Carriage, Lift Trucks Manufactured After December, 2016 3169
Remove 3169
Clean and Inspect 3174
Disassemble and Assemble 3174
Install 3174
Fork Positioner Hydraulic Hose Adjustment 3175
Two-Stage Mast With Limited Free-Lift Repair 3177
Remove 3177
Disassemble 3181
Clean and Inspect 3184
Assemble 3187
Install 3187
Header Hose Installation and Adjustment 3190
Installation 3190
Adjustment 3197
Two-Stage Mast With Full Free-Lift Repair 3198
Remove 3198
Disassemble 3202
Clean and Inspect 3205
Assemble 3208
Install 3209
Header Hose Installation and Adjustment 3211
Installation 3211
Adjustment 3220
Three-Stage Mast With Full Free-Lift Repair 3221
Remove 3221
Disassemble 3226
Clean and Inspect 3229
Assemble 3231
Install 3232
Header Hose Installation and Adjustment 3235
Installation 3235
Adjustment 3245
Four-Stage Mast With Full Free-Lift Repair 3246
Remove 3246
Disassemble 3251
Clean and Inspect 3256
Assemble 3258
Install 3261
Header Hose Installation and Adjustment 3262
Installation 3262
Adjustment 3271
Quick Disconnect Attachments 3271
Disconnect 3271
Reconnect 3271
Lift Chains Adjustment 3273
Carriage Adjustments 3275
Mast Adjustments 3275
Load Roller, Adjust 3275
Mast Side Kicking, Adjust 3278
524319500-4000YRM1338-(10-2017)-UK-EN 3281
General 3285
Safety Procedures When Working Near Mast 3286
Fork Replacement 3289
Remove 3289
Install 3290
Checks 3291
Carriages Repair 3292
Standard Carriage 3292
Remove 3292
Clean and Inspect 3293
Install 3294
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 3294
Remove 3294
Clean and Inspect 3298
Repair 3298
Install 3299
Integral Sideshift Carriage, Lift Trucks Manufactured After December, 2016 3300
Remove 3300
Disassemble 3304
Clean and Inspect 3304
Assemble 3305
Install 3306
Fork Positioner, Lift Trucks Manufactured Prior To December, 2016 3306
Remove 3306
Clean and Inspect 3309
Disassemble and Assemble 3310
Install 3310
Fork Positioner Hydraulic Hose Adjustment 3311
Fork Positioner Carriage, Lift Trucks Manufactured After December, 2016 3313
Remove 3313
Clean and Inspect 3317
Disassemble and Assemble 3317
Install 3317
Fork Positioner Hydraulic Hose Adjustment 3318
Two-Stage Mast With Limited Free-Lift Repair 3319
Remove 3319
Disassemble 3323
Clean and Inspect 3325
Assemble 3327
Install 3328
Header Hose Installation and Adjustment 3330
Installation 3330
Adjustment 3337
Two-Stage Mast With Full Free-Lift Repair 3337
Remove 3337
Disassemble 3341
Clean and Inspect 3344
Assemble 3346
Install 3347
Header Hose Installation and Adjustment 3350
Installation 3350
Adjustment 3358
Three-Stage Mast With Full Free-Lift Repair 3358
Remove 3358
Disassemble 3362
Clean and Inspect 3365
Assemble 3367
Install 3368
Header Hose Installation and Adjustment 3370
Installation 3370
Adjustment 3379
Four-Stage Mast With Full Free-Lift Repair 3380
Remove 3380
Disassemble 3384
Clean and Inspect 3389
Assemble 3391
Install 3393
Header Hose Installation and Adjustment 3396
Installation 3396
Adjustment 3404
Quick Disconnect Attachments 3405
Disconnect 3405
Reconnect 3405
Lift Chains Adjustment 3406
Carriage Adjustments 3408
Mast Adjustments 3408
Load Roller, Adjust 3408
Mast Side Kicking, Adjust 3410
524319501-8000YRM1364-(04-2019)-UK-EN 3413
General 3419
Serial Number Data 3419
Discharging the Capacitors 3420
How to Move Disabled Lift Truck 3420
How to Tow Lift Truck 3420
How to Put Lift Truck on Blocks 3421
How to Raise Drive Tires 3421
How to Raise Steering Tires 3421
How to Clean a Lift Truck 3422
Safety Procedures When Working Near Mast 3423
WHEN WORKING NEAR THE MAST ALWAYS: 3423
Maintenance Schedule 3426
Maintenance Procedures Every 8 Hours or Daily 3432
How to Make Checks With Key or Keyless Switch OFF 3432
Tires and Wheels 3432
Forks 3432
General 3432
Inspect 3433
Remove 3434
Install 3437
Adjustment 3437
Inspection of Mast, Carriage, Header Hoses, Lift Chains, and Attachments 3438
Safety Labels 3438
Steering Column Adjustments 3439
Tilt Adjust Feature 3439
Tilt Memory Feature 3439
Telescopic Feature 3439
Operator Restraint System 3439
Emergency Locking Retractor (ELR) 3440
Seat Adjustments 3441
Seat Position Adjustment (Standard Seat) 3441
Seat Position Adjustment (Swivel Seat) 3441
Seat Adjustment for Operator Weight 3441
Battery Restraint System 3442
Battery 3447
Hydraulic System 3448
How to Make Checks With Key or Keyless Switch ON 3450
Horn, Lights, and Backup Alarm 3450
Motion Alarm 3450
Emergency Disconnect Switch 3450
Steering System 3451
Service Brakes 3452
Parking Brake 3452
Hydraulic Control Levers and Pedals 3452
Direction and Speed Control Pedals 3452
Lift System Operation 3452
Oil Leaks 3453
Maintenance Procedures Every 500 Hours or Three Months 3453
Forks 3453
Inspect 3453
Header Hose Checks 3454
Mast Lubrication 3455
Parking Brake Adjustment 3459
Brake Fluid Check 3460
Master Cylinder Fluid Check 3460
Operator Presence System Check 3462
Differential and Speed Reducer 3462
Tilt Cylinder Rod End Pins 3463
Lift Chains 3464
Wear Check 3464
Lift Chain Lubrication 3465
Fork Pins and Guides 3466
Check Upper and Lower Bearings, Integral Sideshift Carriage 3466
Check Lower Mounting Hook, Integral Sideshift Carriage 3467
Steering King Pins 3468
Hydraulic Tank Breather, Check 3469
Other Lubrication 3471
Hydraulic Control Levers 3471
Contactor 3471
Maintenance Procedures Every 2000 Hours or Yearly 3473
Hydraulic System 3473
Hydraulic Filter Element, Replace 3473
Hydraulic Tank Breather, Change 3476
Service Brakes 3478
Differential and Speed Reducer Oil Change 3478
Brake Fluid Replacement 3481
Forks, Inspect 3481
Integral Sideshift Carriage, Replace Upper and Lower Bearings 3482
Lift Chains 3482
Wheel Bearings 3483
Steer Wheels, Lubrication 3483
Drive Wheels, Lubrication 3483
Maintenance Procedures Every 4000 Hours Or Two Years 3483
Hydraulic Oil, Change 3483
Steering Direction Sensor Inspection 3486
Fixed Steering Column 3486
Telescopic Steering Column 3487
Telescopic Steering Column Lubrication 3488
Battery Maintenance 3489
How to Charge Battery 3490
Rapid Charge 3491
How to Change Batteries 3491
General 3491
Remove the Battery 3492
Install the Battery 3497
How to Change Batteries, Forklift Removal System 3498
Lift and Tilt System Leak Check 3502
Lift Cylinders Leak Check 3502
Tilt Cylinder Leak Check 3503
Lift Chain Adjustments 3503
Welding Repairs 3504
Overhead Guard Changes 3505
Wheels and Tires 3505
Adhesives and Sealants 3507
524319501-8000YRM1364-(07-2023)-UK-EN 3511
General 3519
Serial Number Data 3519
Discharging the Capacitors 3520
How to Move Disabled Lift Truck 3520
How to Tow Lift Truck 3520
How to Put Lift Truck on Blocks 3521
How to Raise Drive Tires 3521
How to Raise Steering Tires 3521
How to Clean a Lift Truck 3522
Safety Procedures When Working Near Mast 3524
WHEN WORKING NEAR THE MAST ALWAYS: 3524
Maintenance Schedule 3527
Maintenance Procedures Every 8 Hours or Daily 3534
How to Make Checks With Key or Keyless Switch OFF 3534
Tires and Wheels 3534
Forks 3534
General 3534
Inspect 3534
Remove 3536
Install 3539
Adjustment 3539
Visual Inspection of Mast, Mast hardware, and Tilt Cylinder Hardware 3540
Inspection of Mast, Carriage, Header Hoses, Lift Chains, and Attachments 3540
Safety Labels 3541
Steering Column Adjustments 3541
Tilt Adjust Feature 3541
Tilt Memory Feature 3541
Telescopic Feature 3542
Operator Restraint System 3542
Emergency Locking Retractor (ELR) 3543
Seat Adjustments 3544
Seat Position Adjustment (Standard Seat) 3544
Seat Position Adjustment (Swivel Seat) 3544
Seat Adjustment for Operator Weight 3544
Battery Restraint System 3545
Battery 3550
Hydraulic System 3551
How to Make Checks With Key or Keyless Switch ON 3553
Horn, Lights, and Backup Alarm 3553
Motion Alarm 3553
Emergency Disconnect Switch 3553
Steering System 3554
Service Brakes 3555
Parking Brake 3555
Hydraulic Control Levers and Pedals 3555
Direction and Speed Control Pedals 3555
Lift System Operation 3555
Oil Leaks 3556
Maintenance Procedures Every 500 Hours or Three Months 3557
Forks 3557
Inspect 3557
Header Hose Checks 3558
Mast Lubrication 3559
Parking Brake Adjustment 3563
Brake Fluid Check 3564
Master Cylinder Fluid Check 3564
Operator Presence System Check 3566
Differential and Speed Reducer 3566
Tilt Cylinder Adjustments 3567
Tilt Cylinder Rod End Pins 3568
Lift Chains 3569
Wear Check 3569
Lift Chain Lubrication 3570
Fork Pins and Guides 3571
Check Upper and Lower Bearings, Integral Sideshift Carriage 3571
Check Lower Mounting Hook, Integral Sideshift Carriage 3572
Steering King Pins 3573
Hydraulic Tank Breather, Check 3574
Other Lubrication 3576
Hydraulic Control Levers 3576
Contactor 3576
Maintenance Procedures Every 2000 Hours or Yearly 3579
Hydraulic System 3579
Hydraulic Filter Element, Replace 3579
Hydraulic Tank Breather, Change 3581
Service Brakes 3583
Differential and Speed Reducer Oil Change 3583
Brake Fluid Replacement 3586
Forks, Inspect 3586
Integral Sideshift Carriage, Replace Upper and Lower Bearings 3587
Lift Chains 3587
Wheel Bearings 3588
Steer Wheels, Lubrication 3588
Drive Wheels, Lubrication 3588
Maintenance Procedures Every 4000 Hours Or Two Years 3589
Hydraulic Oil, Change 3589
Steering Direction Sensor Inspection 3591
Fixed Steering Column 3591
Telescopic Steering Column 3592
Telescopic Steering Column Lubrication 3594
Battery Maintenance 3595
How to Charge Battery 3595
Rapid Charge 3596
How to Change Batteries 3596
General 3596
Remove the Battery 3597
Install the Battery 3602
How to Change Batteries, Forklift Removal System 3603
Lift and Tilt System Leak Check 3608
Lift Cylinders Leak Check 3608
Tilt Cylinder Leak Check 3608
Lift Chain Adjustments 3609
Welding Repairs 3611
Overhead Guard Changes 3612
Wheels and Tires 3613
Adhesives and Sealants 3615
524319502-8000YRM1374-(04-2023)-UK-EN 3617
Counterweights 3623
Hydraulic System 3623
Steering System 3624
Specifications 3624
Turning Radius 3624
Wheels and Tires 3625
Battery Specifications 3626
Capacities 3627
Tilt Angles 3627
Maximum Carriage and Tilt Creep Rates 3628
Mast Speeds 3628
Torque Specifications 3636
Frame 3636
Drive Axle 3636
Differential and Speed Reducer 3636
Brake System 3636
Steering Axle 3637
Masts 3637
Tilt Cylinders 3637
Hydraulic Pump and Motor 3637
Hydraulic Tank 3637
Hydraulic Control Valves 3638
Manual Valve 3638
Manual Handles and Levers 3638
Manual Valve Covers 3638
E-Hydraulic Valve 3638
Electrical System 3639
Adhesives and Sealants 3640
524319502-8000YRM1374-(08-2018)-UK-EN 3643
Counterweights 3647
Hydraulic System 3647
Steering System 3648
Specifications 3648
Turning Radius 3648
Wheels and Tires 3649
Battery Specifications 3650
Capacities 3651
Tilt Angles 3651
Maximum Carriage and Tilt Creep Rates 3652
Mast Speeds 3652
Torque Specifications 3658
Frame 3658
Drive Axle 3658
Differential and Speed Reducer 3659
Brake System 3659
Steering Axle 3659
Masts 3660
Tilt Cylinders 3660
Hydraulic Pump and Motor 3660
Hydraulic Tank 3660
Hydraulic Control Valves 3660
Manual Valve 3660
Manual Handles and Levers 3661
Manual Valve Covers 3661
E-Hydraulic Valve 3661
Electrical System 3661
Adhesives and Sealants 3661
524319504-9000YRM1377-(09-2019)-UK-EN 3665
SECTION 9010 Operational Diagnostic Procedures 3681
Group 05 – Operational Checkout 3683
SECTION 9025 Traction Motor 3693
Group 10 – Principles of Operation 3695
Group 30 – Observed Symptoms 3701
SECTION 9030 Electrical System 3703
Group 03 – General Maintenance and Diagnostic Data 3713
Group 10 – Principles of Operation 3757
Group 20 – Diagnostic Trouble Codes 3789
Group 30 – Observed Symptoms 4401
Group 55 – Icons and Graphics 4445
SECTION 9035 Drive Axle/Unit 4453
Group 10 – Principles of Operation 4455
Group 30 – Observed Symptoms 4465
Group 20 – Diagnostic Trouble Codes 4477
SECTION 9050 Hydraulic Systems 4479
Group 10 – Principles of Operation 4483
Group 33 – Observed Symptoms-Gear Pump 4521
Group 43 – Tests and Adjustments-Gear Pump 4601
SECTION 9060 Operators Station 4631
Group 10 – Principles of Operation 4633
SECTION 9070 Front End (Mast) and Chassis 4673
Group 10 – Principles of Operation 4675
Group 30 – Observed Symptoms 4693
SECTION 9080 Supplementary Data 4737
Group 50 – Abbreviations and Acronyms 4739
524327049-0620YRM1385-(02-2023)-UK-EN 4747
General 4755
Discharging the Capacitors for Lift Truck Models ESC030-040AC (B883), ESC030-040AD (C883) 4761
Discharging the Capacitors (All Other Models) 4763
Traction Motor Repair 4764
For Lift Truck Models , and ERP15-20VT (ERP030-040VT) (G807)ERP16-20VF (ERP30-40VF) (A955), ESC030-040AC (B883) 4764
Remove 4764
Disassemble 4765
Electrical Connector Repair or Replacement 4767
Clean 4767
Inspect 4767
Assemble 4768
Install 4770
For Lift Truck ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 4772
Remove 4772
Disassemble 4772
Electrical Connector Repair or Replacement 4775
Clean 4775
Inspect 4775
Assemble 4776
Install 4776
For Lift Truck ERP2 2-3 5VL (ERP045-070VL) (A976) 4776
Remove 4776
Disassemble 4776
Clean 4778
Inspect 4778
Assemble 4779
Install 4779
For Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080120VM, ERP100VML) (A985) 4779
Remove 4779
Clean 4781
Install 4781
For Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 4781
Remove 4781
Disassemble 4781
Electrical Connector Repair or Replacement 4783
Clean 4783
Inspect 4783
Assemble 4784
Install 4785
Traction Motor Repair for 4-5 5T Lift Trucks 4786
For Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080120VM, ERP100VML) (A985) 4786
Remove 4786
Clean 4788
Install 4788
Hydraulic Motor Repair 4789
For Lift Trucks and ERP15-20VT (ERP030-040VT) (G807)ERP16-20VF (ERP30-40VF) (A955)ESC030-040AC (B883), ESC030-040AD (C883) 4789
Remove 4789
Disassemble 4790
Electrical Connector Repair or Replacement 4792
Clean 4792
Inspect 4792
Assemble 4793
Install 4795
For Lift Truck ERC22-35VG (ERC045-070VG) (A968) 4796
Remove 4796
Disassemble 4798
Standard Motor 4798
Enhanced Motor 4800
Electrical Connector Repair or Replacement 4801
Clean 4802
Inspect 4802
Assemble 4803
Standard Motor 4803
Enhanced Motor 4803
Install 4804
For Lift Truck Models ERP2 2-3 5VL (ERP045-070VL) (A976) and ERC16-20VA (ERC030-040VA) (A969) 4804
Remove 4804
Disassemble 4804
Electrical Connector Repair or Replacement 4810
Clean 4811
Inspect 4811
Assemble 4812
Install 4813
For Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 4813
Remove 4813
Disassemble 4813
Electrical Connector Repair or Replacement 4816
Clean 4816
Inspect 4817
Assemble 4817
Install 4818
Hydraulic Motor Repair For 4 0-5 5T Lift Trucks 4818
Remove 4818
Disassemble 4818
Electrical Connector Repair or Replacement 4820
Clean 4820
Inspect 4821
Assemble 4821
Install 4822
Torque Specifications 4823
Traction Motor for Lift Trucks and ERP15-20VT (ERP030-040VT) (G807)ERP16-20VF (ERP30-40VF) (A955) 4823
Traction Motor for Lift Truck and ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969),ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 4823
Traction Motor for Lift Truck ESC030-040AC (B883), ESC030-040AD (C883) 4823
Hydraulic Motor for Lift Trucks and ERP15-20VT (ERP030-040VT) (G807)ERP16-20VF (ERP30-40VF) (A955) 4823
Hydraulic Motor for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 4823
Hydraulic Motor for Lift Truck ERP22-35VG (ERP045-070VG) (A976) 4823
Hydraulic Motor for Lift Truck ERC16-20VA (ERC030-040VA) (A969) 4823
Hydraulic Motor for Lift Truck ESC030-040AC (B883), ESC030-040AD (C883) 4823
Hydraulic Motor for Lift Truck and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 4824
524327049-0620YRM1385-(06-2015)-UK-EN 4827
General 4831
Discharging the Capacitors for Lift Truck Models ESC030-040AC (B883), ESC030-040AD (C883) 4838
Discharging the Capacitors (All Other Models) 4839
Traction Motor Repair 4839
For Lift Truck Models ERP15-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), and ESC030-040AC (B883) 4840
Remove 4840
Disassemble 4841
Electrical Connector Repair or Replacement 4844
Clean 4844
Inspect 4844
Assemble 4845
Install 4848
For Lift Truck ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 4850
Remove 4850
Disassemble 4850
Electrical Connector Repair or Replacement 4854
Clean 4854
Inspect 4854
Assemble 4855
Install 4855
For Lift Truck ERP2 2-3 5VL (ERP045-070VL) (A976) 4855
Remove 4855
Disassemble 4855
Clean 4857
Inspect 4857
Assemble 4858
Install 4858
For Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 4858
Remove 4858
Disassemble 4859
Electrical Connector Repair or Replacement 4860
Clean 4860
Inspect 4861
Assemble 4861
Install 4862
4862
Traction Motor Repair For Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 4862
Remove 4862
Clean 4864
Install 4864
Hydraulic Motor Repair 4864
For Lift Trucks ERP15-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), and ESC030-040AC (B883), ESC030-040AD (C883) 4864
Remove 4864
Disassemble 4866
Electrical Connector Repair or Replacement 4868
Clean 4868
Inspect 4868
Assemble 4869
Install 4871
For Lift Truck ERC22-35VG (ERC045-070VG) (A968) 4873
Remove 4873
Disassemble 4874
Standard Motor 4874
Enhanced Motor 4875
Electrical Connector Repair or Replacement 4877
Clean 4878
Inspect 4879
Assemble 4879
Standard Motor 4879
Enhanced Motor 4880
Install 4881
For Lift Truck Models ERP2 2-3 5VL (ERP045-070VL) (A976) and ERC16-20VA (ERC030-040VA) (A969) 4882
Remove 4882
Disassemble 4882
Electrical Connector Repair or Replacement 4888
Clean 4889
Inspect 4889
Assemble 4890
Install 4891
4891
Hydraulic Motor Repair For 4 0-5 5T Lift Trucks 4891
Remove 4891
Disassemble 4891
Electrical Connector Repair or Replacement 4894
Clean 4895
Inspect 4895
Assemble 4896
Install 4896
Torque Specifications 4897
Traction Motor for Lift Trucks ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955) 4897
Traction Motor for Lift Truck ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 4897
Traction Motor for Lift Truck ESC030-040AC (B883), ESC030-040AD (C883) 4897
Hydraulic Motor for Lift Trucks ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955) 4897
Hydraulic Motor for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 4897
Hydraulic Motor for Lift Truck ERP22-35VG (ERP045-070VG) (A976) 4897
Hydraulic Motor for Lift Truck ERC16-20VA (ERC030-040VA) (A969) 4897
Hydraulic Motor for Lift Truck ESC030-040AC (B883), ESC030-040AD (C883) 4897
Hydraulic Motor for Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 4898
524332383-8000YRM1384-(01-2020)-UK-EN 4901
524332383-8000YRM1384-(04-2023)-UK-EN 4943
550025937-0100YRM1446-(02-2023)-UK-EN 4987
General 4993
Discharging the Capacitors 4994
Window Replacement 4995
Front Panel 4995
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) 4995
Remove, Lift Truck Models ERP13VC, ERP15VC (B888) 4996
Clean 4998
Inspect 4998
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) 4998
Install, Lift Truck Models ERP13VC, ERP15VC (B888) 4998
Rear Panel 4998
Remove 4998
Clean 5002
Inspect 5002
Install 5002
Door Window 5003
Disassemble Window 5003
Clean 5004
Inspect 5004
Assemble Window 5004
Window Wipers Replacement 5005
Front Wiper Assembly 5005
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) 5005
Remove, Lift Truck Models ERP13VC, ERP15VC (B888) 5010
Clean 5011
Inspect 5012
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) 5012
Install, Lift Truck Models ERP13VC, ERP15VC (B888) 5013
Cab Component Repair 5014
Roof Liner 5014
Remove 5014
Clean 5015
Inspect 5015
Install 5015
Top Panel 5016
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) 5016
Remove, Lift Truck Models ERP13VC, ERP15VC (B888) 5018
Clean 5019
Inspect 5019
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) 5019
Install, Lift Truck Models ERP13VC, ERP15VC (B888) 5019
Cab Door Assembly 5020
Door Assembly 5020
Remove 5020
Lift Truck Models and ERP22-35VL (ERP045-070VL) (A976)ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 5020
Lift Truck Models and ERP15-20VT (ERP030-040VT) (G807)ERP16-20VF (ERP30-40VF) (A955) 5022
Disassemble Left Door 5024
Disassemble Right Door 5026
Clean 5028
Inspect 5028
Assemble Right Door 5028
Assemble Left Door 5028
Install 5029
Lift Truck Models and ERP22-35VL (ERP045-070VL) (A976)ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 5029
Lift Truck Models and ERP15-20VT (ERP030-040VT) (G807)ERP16-20VF (ERP30-40VF) (A955) 5029
Cab Heater 5030
Cab Heater 5030
Remove 5030
Clean 5037
Inspect 5037
Install 5037
Troubleshooting 5039
Weather Panel Replacement 5042
Remove 5042
Roof Panels 5042
Front Screen Panel 5045
Install 5046
Front Screen Panel 5046
Roof Panels 5046
550025937-0100YRM1446-(09-2014)-UK-EN 5049
550073240-1900YRM1620-(01-2023)-UK-EN 5103
Proper Flushing after Major Hydraulic Repairs 5109
Introduction 5109
The Phases of Wear 5109
Causes of Hydraulic System Failure 5109
Progression of Contaminant Caused Hydraulic System Failure 5110
Hydraulic System Flushing Techniques 5110
Double Oil and Filter Change 5110
Mechanical Cleaning 5111
Cleaning of Components 5111
How to Clean Tubes and Hoses 5111
Filter Caddy 5111
Start-Up Procedure for Cleaned System 5112
Contaminated Oil Coolers 5112
Additional Filter Caddy Functions 5113
How to Handle Different Fluids 5113
Water Removal Filters 5113
Fluid Conditioning and System Flushing Procedures 5114
Operation of the Filter Caddy 5114
Filter Caddy operation 5114
Fluid Conditioning Procedure 5114
Filter Caddy Start-Up 5115
System Flushing Procedure 5115
Component Cleaning Procedure 5116
Reservoir Cleaning Procedure 5116
Cylinder Cleaning Procedure 5116
Hose and Tube Cleaning Procedure 5116
Valve Cleaning Procedure 5117
Front-End Attachment Cleaning Procedure 5118
System Flushing Procedure 5118
Filter Caddy Start-Up 5119
System Start-Up and Flushing 5119
Reservoir Fluid Cleaning Times 5120
Dealing With Different Fluid Types 5121
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 5121
Filter Caddy Maintenance 5121
Servicing the Strainer 5121
DC Motor 5121
Hydraulic Oil Sampling Method and Procedure 5122
Hydraulic Oil Sampling Method 5122
Objective 5122
General Guidelines 5122
Synopsis 5123
Hydraulic Oil Analysis Report Guidelines 5124
Sampling Conditions 5124
Equipment 5124
Sampling Procedure 5125
Hydraulic Oil Sampling 5125
Sample Labeling 5125
Results Documentation 5125
550073240-1900YRM1620-(03-2020)-UK-EN 5127
Proper Flushing after Major Hydraulic Repairs 5131
Introduction 5131
The Phases of Wear 5131
Causes of Hydraulic System Failure 5131
Progression of Contaminant Caused Hydraulic System Failure 5132
Hydraulic System Flushing Techniques 5132
Double Oil and Filter Change 5132
Mechanical Cleaning 5133
Cleaning of Components 5133
How to Clean Tubes and Hoses 5133
Filter Caddy 5133
Start-Up Procedure for Cleaned System 5134
Contaminated Oil Coolers 5134
Additional Filter Caddy Functions 5134
How to Handle Different Fluids 5134
Water Removal Filters 5135
Fluid Conditioning and System Flushing Procedures 5135
Operation of the Filter Caddy 5135
Filter Caddy operation 5135
Fluid Conditioning Procedure 5136
Filter Caddy Start-Up 5136
System Flushing Procedure 5137
Component Cleaning Procedure 5137
Reservoir Cleaning Procedure 5137
Cylinder Cleaning Procedure 5137
Hose and Tube Cleaning Procedure 5138
Valve Cleaning Procedure 5138
Front-End Attachment Cleaning Procedure 5139
System Flushing Procedure 5139
Filter Caddy Start-Up 5140
System Start-Up and Flushing 5140
Reservoir Fluid Cleaning Times 5141
Dealing With Different Fluid Types 5141
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 5141
Filter Caddy Maintenance 5142
Servicing the Strainer 5142
DC Motor 5142
Hydraulic Oil Sampling Method and Procedure 5142
Hydraulic Oil Sampling Method 5142
Objective 5142
General Guidelines 5142
Synopsis 5143
Hydraulic Oil Analysis Report Guidelines 5144
Sampling Conditions 5145
Equipment 5145
Sampling Procedure 5145
Hydraulic Oil Sampling 5145
Sample Labeling 5146
Results Documentation 5146
550093750-2100YRM1668-(02-2018)-UK-EN 5149
General 5153
Safety Procedures When Working Near Mast 5154
Main Lift Cylinder Repair 5156
Remove 5156
Disassemble 5158
Clean 5160
Inspect 5160
Assemble 5160
Install 5161
Main Lift Cylinder Leak Check 5161
Free-Lift Cylinder 5162
Remove 5162
Disassemble 5163
Clean 5165
Inspect 5165
Assemble 5165
Install 5165
Tilt Cylinder Repair 5166
Remove 5166
Disassemble 5168
Clean 5170
Inspect 5170
Assemble 5170
Install 5171
Tilt Cylinder Adjustment 5172
Tilt Cylinder Leak Check 5173
Integral Sideshift Cylinder Repair Prior to December 2016 5175
Remove 5175
Disassemble 5176
Clean 5177
Inspect 5177
Assemble 5177
Install 5177
Integral Sideshift Cylinder Repair After December 2016 5178
General 5178
Remove 5178
Disassemble 5180
Clean 5180
Inspect 5180
Assemble 5180
Install 5181
Integral Side-Shift Cylinder Gland Leak Checks 5182
Fork Positioner Cylinder Repair Prior to December 2016 5183
Remove 5183
Disassemble 5183
Clean 5185
Inspect 5186
Assemble 5186
Install 5186
Fork Positioner Cylinder Adjustment 5186
Fork Positioner Cylinder Repair After December 2016 5187
General 5187
Remove 5187
Disassemble 5187
Clean 5190
Inspect 5191
Assemble 5191
Install 5191
Fork Positioner Cylinder Adjustment 5191
Seal Kit Installation 5192
External Installation (Seal and Backup Ring) 5192
Internal Installation (Piston Rod Assembly) 5192
Torque Specifications 5193
Main Lift Cylinders 5193
Free-Lift Cylinder 5193
Tilt Cylinders 5193
Integral Sideshift Cylinder 5193
Fork Positioner Cylinder 5193
550093750-2100YRM1668-(04-2023)-UK-EN 5197
General 5203
Safety Procedures When Working Near Mast 5206
Main Lift Cylinder Repair 5208
Remove 5208
Disassemble 5210
Clean 5212
Inspect 5212
Assemble 5212
Install 5213
Main Lift Cylinder Leak Check 5213
Free-Lift Cylinder 5214
Remove 5214
Disassemble 5215
Clean 5217
Inspect 5217
Assemble 5217
Install 5217
Tilt Cylinder Repair 5219
Remove 5219
Disassemble 5221
Clean 5222
Inspect 5223
Assemble 5223
Install 5224
Tilt Cylinder Adjustment 5224
Tilt Cylinder Leak Check 5226
Integral Sideshift Cylinder Repair Prior to December 2016 5228
Remove 5228
Disassemble 5228
Clean 5229
Inspect 5229
Assemble 5229
Install 5230
Integral Sideshift Cylinder Repair After December 2016 5231
General 5231
Remove 5231
Disassemble 5232
Clean 5233
Inspect 5233
Assemble 5233
Install 5233
Integral Side-Shift Cylinder Gland Leak Checks 5234
Fork Positioner Cylinder Repair Prior to December 2016 5235
Remove 5235
Disassemble 5235
Clean 5238
Inspect 5238
Assemble 5239
Install 5239
Fork Positioner Cylinder Adjustment 5239
Fork Positioner Cylinder Repair After December 2016 5241
General 5241
Remove 5241
Disassemble 5241
Clean 5244
Inspect 5244
Assemble 5245
Install 5245
Fork Positioner Cylinder Adjustment 5245
Seal Kit Installation 5247
External Installation (Seal and Backup Ring) 5247
Internal Installation (Piston Rod Assembly) 5247
Torque Specifications 5248
Main Lift Cylinders 5248
Free-Lift Cylinder 5248
Tilt Cylinders 5248
Integral Sideshift Cylinder 5248
Fork Positioner Cylinder 5248
550093755-4000YRM1669-(04-2023)-UK-EN 5251
General 5259
Safety Procedures When Working Near Mast 5261
Fork Replacement 5263
Standard Carriage and Integral Sideshift Carriage 5263
Remove 5263
Install 5264
Checks 5264
Fork Positioner Carriage 5266
Remove 5267
Install 5267
Checks 5269
Carriages Repair, Two-Stage LFL Mast 5272
Standard Carriage 5272
Remove 5272
Clean and Inspect 5273
Install 5273
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 5273
Remove 5273
Disassemble 5275
Clean and Inspect 5276
Assemble 5277
Install 5277
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 through Late June, 2018 5278
Remove 5278
Disassemble 5281
Clean and Inspect 5281
Assemble 5282
Install 5283
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 5283
Remove 5283
Disassemble 5286
Clean and Inspect 5286
Assemble 5287
Install 5288
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 5288
Remove 5288
Install 5290
Fork Positioner Hydraulic Hose Adjustment 5292
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 5293
Remove 5293
Disassemble and Assemble 5297
Clean and Inspect 5297
Install 5297
Fork Positioner Hydraulic Hose Adjustment 5298
Fork Positioner Carriage, Lift Trucks Manufactured Late June, 2018 and After 5299
Remove 5299
Disassemble and Assemble 5303
Clean and Inspect 5303
Install 5303
Fork Positioner Hydraulic Hose Adjustment 5304
Two-Stage LFL Mast Repair 5306
Mast With Serial Number F507 5306
Remove 5306
Disassemble 5310
Clean and Inspect 5317
Assemble 5319
Install 5320
Header Hoses 5322
Remove 5322
Installation 5322
Adjustment 5326
Mast With Serial Number F562 5327
Remove 5327
Disassemble 5331
Clean and Inspect 5338
Assemble 5340
Install 5341
Header Hose Installation and Adjustment 5342
Remove 5342
Installation 5343
Adjustment 5347
Carriages Repair, Three-Stage FFL Mast 5349
Standard Carriage 5349
Remove 5349
Clean and Inspect 5350
Install 5351
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 5351
Remove 5351
Disassemble 5352
Clean and Inspect 5353
Assemble 5354
Install 5354
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 5355
Remove 5355
Disassemble 5357
Clean and Inspect 5358
Assemble 5359
Install 5359
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 5360
Remove 5360
Disassemble 5362
Clean and Inspect 5363
Assemble 5364
Install 5364
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 5365
Remove 5365
Install 5367
Fork Positioner Hydraulic Hose Adjustment 5369
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 5370
Remove 5370
Disassemble and Assemble 5372
Clean and Inspect 5372
Install 5372
Fork Positioner Hydraulic Hose Adjustment 5373
Fork Positioner Carriage, Lift Trucks Manufactured After Late June, 2018 5374
Remove 5374
Disassemble and Assemble 5377
Clean and Inspect 5377
Install 5377
Fork Positioner Hydraulic Hose Adjustment 5378
Three-Stage FFL Mast Repair 5380
Mast With Serial Number F508 5380
Remove 5380
Disassemble 5383
Clean and Inspect 5393
Assemble 5396
Install 5397
Header Hose Installation and Adjustment 5399
Remove 5399
Installation 5399
Adjustment 5408
Mast With Serial Number F563 5408
Remove 5408
Disassemble 5412
Clean and Inspect 5422
Assemble 5425
Install 5426
Header Hose Installation and Adjustment 5428
Remove 5428
Installation 5428
Adjustment 5436
Mast Adjustments 5438
Load Roller, Adjust 5438
Mast Side Kicking, Adjust 5440
Carriage Adjustments 5441
Lift Chains Adjustment 5443
Hydraulic Quick Disconnect Hoses 5445
Disconnecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models GLC020-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910, B910, C910) and GLP/GDP20-35VX (CP/CLP/CDP040-070VX) (B875, C875, D875) 5445
Lift Trucks Equipped With E-Hydraulic Controls 5445
Lift Trucks Equipped With Manual Hydraulic Controls 5445
Connecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models GLC020-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910, B910, C910) and GLP/GDP20-35VX (CP/CLP/CDP040-070VX) (B875, C875, D875) 5446
Lift Trucks Equipped With E-Hydraulic Controls 5446
Lift Trucks Equipped With Manual Hydraulic Controls 5446
Disconnecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 5446
Connecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 5446
550093755-4000YRM1669-(06-2019)-UK-EN 5449
General 5455
Safety Procedures When Working Near Mast 5456
Fork Replacement 5458
Standard Carriage and Integral Sideshift Carriage 5458
Remove 5458
Install 5460
Checks 5460
Fork Positioner Carriage 5462
Remove 5463
Install 5463
Checks 5465
Carriages Repair, Two-Stage LFL Mast 5467
Standard Carriage 5467
Remove 5467
Clean and Inspect 5468
Install 5469
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 5469
Remove 5469
Disassemble 5470
Clean and Inspect 5471
Assemble 5472
Install 5472
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 through Late June, 2018 5473
Remove 5473
Disassemble 5476
Clean and Inspect 5476
Assemble 5477
Install 5477
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 5478
Remove 5478
Disassemble 5481
Clean and Inspect 5481
Assemble 5482
Install 5482
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 5483
Remove 5483
Install 5485
Fork Positioner Hydraulic Hose Adjustment 5487
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 5488
Remove 5488
Disassemble and Assemble 5492
Clean and Inspect 5492
Install 5492
Fork Positioner Hydraulic Hose Adjustment 5493
Fork Positioner Carriage, Lift Trucks Manufactured Late June, 2018 and After 5494
Remove 5494
Disassemble and Assemble 5498
Clean and Inspect 5498
Install 5498
Fork Positioner Hydraulic Hose Adjustment 5499
Two-Stage LFL Mast Repair 5500
Mast With Serial Number F507 5500
Remove 5500
Disassemble 5504
Clean and Inspect 5511
Assemble 5513
Install 5514
Header Hoses 5516
Remove 5516
Installation 5516
Adjustment 5520
Mast With Serial Number F562 5521
Remove 5521
Disassemble 5525
Clean and Inspect 5532
Assemble 5534
Install 5535
Header Hose Installation and Adjustment 5536
Remove 5536
Installation 5537
Adjustment 5541
Carriages Repair, Three-Stage FFL Mast 5542
Standard Carriage 5542
Remove 5542
Clean and Inspect 5544
Install 5544
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 5544
Remove 5544
Disassemble 5546
Clean and Inspect 5547
Assemble 5548
Install 5548
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 5549
Remove 5549
Disassemble 5551
Clean and Inspect 5552
Assemble 5553
Install 5553
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 5554
Remove 5554
Disassemble 5556
Clean and Inspect 5557
Assemble 5558
Install 5558
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 5559
Remove 5559
Install 5561
Fork Positioner Hydraulic Hose Adjustment 5563
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 5564
Remove 5564
Disassemble and Assemble 5566
Clean and Inspect 5566
Install 5566
Fork Positioner Hydraulic Hose Adjustment 5567
Fork Positioner Carriage, Lift Trucks Manufactured After Late June, 2018 5568
Remove 5568
Disassemble and Assemble 5571
Clean and Inspect 5571
Install 5571
Fork Positioner Hydraulic Hose Adjustment 5572
Three-Stage FFL Mast Repair 5573
Mast With Serial Number F508 5573
Remove 5573
Disassemble 5577
Clean and Inspect 5587
Assemble 5590
Install 5591
Header Hose Installation and Adjustment 5593
Remove 5593
Installation 5593
Adjustment 5601
Mast With Serial Number F563 5602
Remove 5602
Disassemble 5605
Clean and Inspect 5615
Assemble 5618
Install 5619
Header Hose Installation and Adjustment 5621
Remove 5621
Installation 5621
Adjustment 5629
Mast Adjustments 5630
Load Roller, Adjust 5630
Mast Side Kicking, Adjust 5632
Carriage Adjustments 5632
Lift Chains Adjustment 5634
Hydraulic Quick Disconnect Hoses 5636
Disconnecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models GLC020-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910, B910, C910) and GLP/GDP20-35VX (CP/CLP/CDP040-070VX) (B875, C875, D875) 5636
Lift Trucks Equipped With E-Hydraulic Controls 5636
Lift Trucks Equipped With Manual Hydraulic Controls 5637
Connecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models GLC020-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910, B910, C910) and GLP/GDP20-35VX (CP/CLP/CDP040-070VX) (B875, C875, D875) 5637
Lift Trucks Equipped With E-Hydraulic Controls 5637
Lift Trucks Equipped With Manual Hydraulic Controls 5638
Disconnecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 5638
Connecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 5638