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Yale Forklift A969 (ERC030-ERC040VA) Service Manual – PDF DOWNLOAD
Yale Forklift A969 (ERC030-ERC040VA) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Yale Forklift A969 (ERC030-ERC040VA) Service Manual – PDF DOWNLOAD
Language : English
Pages : 4320
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Yale Forklift A969 (ERC030-ERC040VA) 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
524319494-1900YRM1367-(04-2017)-UK-EN 1167
General 1173
Discharging the Capacitors 1173
Hydraulic Pump and Motor 1174
Remove 1174
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1175
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1178
Lift Truck Models ERP22-25VL (ERP045-070VL) (A976) 1181
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1186
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1191
Disassemble 1193
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969)ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1193
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1195
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1197
Inspect 1199
Clean 1199
Assemble 1199
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969)ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1199
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1199
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1200
Install 1200
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1200
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1201
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1202
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1203
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1204
Hydraulic Tank 1205
Remove 1205
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1205
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1208
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1209
Lift Truck Models ERP22-25VL (ERP045-070VL) (A976) 1213
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1215
Disassemble 1217
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1217
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1218
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1218
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1219
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1221
Clean 1223
Steam Method 1223
Chemical Method 1223
Inspect 1224
Small Leaks, Repair 1224
Large Leaks, Repair 1224
Additional Methods for Metal Tank Repair 1224
Assemble 1224
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1224
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1225
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1226
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1226
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1227
Install 1227
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1227
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1228
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1228
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1229
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1229
Hydraulic Filter Replacement 1230
Breather Clean and Inspect 1231
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 1231
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1234
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1234
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1234
Hydraulic Oil Cooler for Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1235
Add Hydraulic Oil 1235
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1235
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1237
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1237
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1237
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1238
Steer Accumulator Replacement 1239
Remove 1239
Install 1246
Specifications for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1246
Tank Capacity 1247
Specifications for Lift Truck ERC16-20VA (ERC030-040VA) (A969) 1247
Tank Capacity 1247
Specifications for Lift Truck ERP22-25VL (ERP045-070VL) (A976) 1247
Tank Capacity 1247
Specifications for Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1247
Tank Capacity 1247
Specifications for Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1247
Tank Capacity 1248
Torque Specifications for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1248
Hydraulic Pump and Motor 1248
Hydraulic Tank 1248
Torque Specifications for Lift Truck ERC16-20VA (ERC030-040VA) (A969) 1249
Hydraulic Pump and Motor 1249
Hydraulic Tank 1249
Torque Specifications for Lift Truck ERP22-35VL (ERP045-070VL) (A976) 1249
Hydraulic Pump and Motor 1249
Hydraulic Tank 1249
Torque Specifications for Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1249
Hydraulic Pump and Motor 1250
Hydraulic Tank 1250
Torque Specifications for Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1251
Hydraulic Pump and Motor 1251
Hydraulic Tank 1251
524319494-1900YRM1367-(08-2023)-UK-EN 1255
General 1261
Discharging the Capacitors 1261
Hydraulic Pump and Motor 1263
Remove 1263
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1263
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1269
Lift Truck Models ERP22-25VL (ERP045-070VL) (A976) 1273
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1278
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1283
Disassemble 1285
Lift Truck Models , ERC22-35VG (ERC045-070VG) (A968)ERC16-20VA (ERC030-040VA) (A969)ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1285
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1287
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1289
Inspect 1291
Clean 1291
Assemble 1291
Lift Truck Models , ERC22-35VG (ERC045-070VG) (A968)ERC16-20VA (ERC030-040VA) (A969)ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1291
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1292
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1292
Install 1292
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1292
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1293
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1294
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1295
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1296
Hydraulic Tank 1297
Remove 1297
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1297
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1300
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1303
Lift Truck Models ERP22-25VL (ERP045-070VL) (A976) 1306
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1308
Disassemble 1310
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1310
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1310
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1311
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1312
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1314
Clean 1316
Steam Method 1317
Chemical Method 1317
Inspect 1317
Small Leaks, Repair 1317
Large Leaks, Repair 1318
Additional Methods for Metal Tank Repair 1318
Assemble 1318
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1318
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1319
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1319
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1320
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1320
Install 1321
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1321
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1321
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1322
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1323
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1323
Hydraulic Filter Replacement 1324
Breather Clean and Inspect 1325
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 1325
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1327
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1327
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1328
Hydraulic Oil Cooler for Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1328
Add Hydraulic Oil 1328
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1328
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1330
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1330
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1330
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1331
Steer Accumulator Replacement 1333
Remove 1333
Install 1341
Specifications for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1342
Tank Capacity 1342
Specifications for Lift Truck ERC16-20VA (ERC030-040VA) (A969) 1342
Tank Capacity 1342
Specifications for Lift Truck ERP22-25VL (ERP045-070VL) (A976) 1342
Tank Capacity 1342
Specifications for Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1343
Tank Capacity 1343
Specifications for Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1343
Tank Capacity 1343
Torque Specifications for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1344
Hydraulic Pump and Motor 1344
Hydraulic Tank 1344
Torque Specifications for Lift Truck ERC16-20VA (ERC030-040VA) (A969) 1344
Hydraulic Pump and Motor 1344
Hydraulic Tank 1344
Torque Specifications for Lift Truck ERP22-35VL (ERP045-070VL) (A976) 1345
Hydraulic Pump and Motor 1345
Hydraulic Tank 1345
Torque Specifications for Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1345
Hydraulic Pump and Motor 1345
Hydraulic Tank 1345
Torque Specifications for Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1346
Hydraulic Pump and Motor 1346
Hydraulic Tank 1346
524319497-2200YRM1335-(01-2023)-UK-EN 1349
General 1357
Description 1357
Display Panel Menu Access 1357
Menu Flowchart 1358
Supervisor Menu Flowchart 1358
Menu Navigation 1364
Icon Glossary 1368
Introduction 1368
Soft Key Icons 1368
Overlay Icons 1369
Icons on System Off Screen and Alert Screens 1369
Main Menu Title Screens 1373
Submenu Icons Grouped by Menu 1375
Operating Screen Icons 1375
Password Screen Icons 1376
Activity Log Submenu Icons 1376
Calibration Submenu Icons 1378
Display Submenu Icons 1380
Status Submenu Icons 1382
Truck Setup Submenu Icons 1385
Operating Screen 1392
Introduction 1392
Performance Mode Controls 1393
Status and Warning Icons 1393
Battery Discharge Indicator 1394
Direction and Parking Brake Indicators 1395
Hazard Flashers and Lighting Controls 1395
Steer Angle Indicator 1395
System Time 1395
Load Weight Indicator 1395
System Off/Alert Screens 1396
Introduction 1396
System Off Screen 1396
Alert Screens 1396
Password Screen 1398
Introduction 1398
Password Screen 1398
Service Technician Password Setup 1398
Adding/Removing/Changing Passwords 1399
Password Log 1402
Activity Log Menu 1403
Introduction 1403
Operator Checklist Log 1404
Password Log 1407
Impact Events Log 1409
Calibration Menu 1411
Introduction 1411
Load Weight Calibration 1411
Return to Set Tilt Stop Point Calibration 1412
E-Hydraulic and Manual Valve Threshold Calibration 1412
Steering Wheel Center Point Calibration 1413
Steer Axle Position Calibration 1413
Steer Axle Center Point Calibration 1414
Manual Hydraulics Calibration 1415
Display Menu 1416
Introduction 1416
Set Date and Time Format Menu 1416
Set Daylight Saving Time Menu 1417
Procedure for Setting Up Automatic Daylight Savings Time 1418
Set Time and Date Menu 1420
Procedure for Setting Time and Date 1420
Set Units Menu 1421
Status Menu 1422
Introduction 1422
VSM Versions 1422
Display Versions 1423
Truck Serial Number 1423
Hour Meters 1423
E-Hydraulic Controller Versions 1423
Pump Motor Controller Versions 1423
Traction Motor Controller 1 Versions 1423
Traction Motor Controller 2 Versions 1424
Light Controller Versions 1424
Impact Sensor Versions 1424
Truck Setup Menu 1425
Introduction 1425
Add/Remove Password 1425
Battery Settings 1425
Restore Default Settings 1426
Motion Alarm 1426
Impact Monitor Settings 1427
Impact Detection 1427
Setting Adjustments 1427
Initial Adjustment of Soft and Hard Impact Settings 1427
Readjustment of Soft and Hard Impact Settings 1427
Auto Power-Off Time Delay 1428
Return to Set Tilt 1428
Traction Speed Limit 1428
Scheduled Maintenance Reminder 1429
Minimum Pump Standby Flow Rate 1430
Operator Checklist 1430
Impact Monitor Shutdown 1431
Motor Braking 1432
Changing the Motor Braking Settings 1432
Steering Wheel Friction and Steering Turns Adjustment 1433
How to Adjust Settings 1433
Steering Friction Setting 1433
Steering Wheel Number of Turns 1434
524319497-2200YRM1335-(07-2020)-UK-EN 1437
General 1443
Description 1443
Display Panel Menu Access 1443
Menu Flowchart 1444
Supervisor Menu Flowchart 1444
Menu Navigation 1450
Icon Glossary 1454
Introduction 1454
Soft Key Icons 1454
Overlay Icons 1455
Icons on System Off Screen and Alert Screens 1455
Main Menu Title Screens 1459
Submenu Icons Grouped by Menu 1461
Operating Screen Icons 1461
Password Screen Icons 1462
Activity Log Submenu Icons 1462
Calibration Submenu Icons 1464
Display Submenu Icons 1466
Status Submenu Icons 1468
Truck Setup Submenu Icons 1471
Operating Screen 1478
Introduction 1478
Performance Mode Controls 1478
Status and Warning Icons 1479
Battery Discharge Indicator 1480
Direction and Parking Brake Indicators 1480
Hazard Flashers and Lighting Controls 1481
Steer Angle Indicator 1481
System Time 1481
Load Weight Indicator 1481
System Off/Alert Screens 1482
Introduction 1482
System Off Screen 1482
Alert Screens 1482
Password Screen 1484
Introduction 1484
Password Screen 1484
Service Technician Password Setup 1484
Adding/Removing/Changing Passwords 1485
Password Log 1488
Activity Log Menu 1489
Introduction 1489
Operator Checklist Log 1489
Password Log 1491
Impact Events Log 1493
Calibration Menu 1495
Introduction 1495
Load Weight Calibration 1495
Return to Set Tilt Stop Point Calibration 1496
E-Hydraulic and Manual Valve Threshold Calibration 1496
Steering Wheel Center Point Calibration 1497
Steer Axle Position Calibration 1497
Steer Axle Center Point Calibration 1498
Manual Hydraulics Calibration 1499
Display Menu 1500
Introduction 1500
Set Date and Time Format Menu 1500
Set Daylight Saving Time Menu 1501
Procedure for Setting Up Automatic Daylight Savings Time 1502
Set Time and Date Menu 1504
Procedure for Setting Time and Date 1504
Set Units Menu 1505
Status Menu 1506
Introduction 1506
VSM Versions 1506
Display Versions 1507
Truck Serial Number 1507
Hour Meters 1507
E-Hydraulic Controller Versions 1507
Pump Motor Controller Versions 1507
Traction Motor Controller 1 Versions 1507
Traction Motor Controller 2 Versions 1508
Light Controller Versions 1508
Impact Sensor Versions 1508
Truck Setup Menu 1509
Introduction 1509
Add/Remove Password 1509
Battery Settings 1509
Restore Default Settings 1510
Motion Alarm 1510
Impact Monitor Settings 1510
Impact Detection 1511
Setting Adjustments 1511
Initial Adjustment of Soft and Hard Impact Settings 1511
Readjustment of Soft and Hard Impact Settings 1511
Auto Power-Off Time Delay 1512
Return to Set Tilt 1512
Traction Speed Limit 1512
Scheduled Maintenance Reminder 1513
Minimum Pump Standby Flow Rate 1514
Operator Checklist 1514
Impact Monitor Shutdown 1515
Motor Braking 1516
Changing the Motor Braking Settings 1516
Steering Wheel Friction and Steering Turns Adjustment 1517
How to Adjust Settings 1517
Steering Friction Setting 1517
Steering Wheel Number of Turns 1518
524319498-2200YRM1336-(02-2023)-UK-EN 1521
General 1529
Description 1529
Display Panel Menu Access 1529
Menu Flowchart 1530
Technician Menu Flowchart 1530
Menu Navigation 1536
Icon Glossary 1540
Introduction 1540
Soft Key Icons 1540
Overlay Icons 1541
Heat Exchange Module Warning Indicator Screen 1541
System Off Screen and Alert Screens 1542
Main Menu Title Screens 1548
Submenu Icons Grouped by Menu 1549
Operating Screen Icons 1549
Password Screen Icons 1551
Activity Log Submenu Icons 1551
Calibration Submenu Icons 1552
Display Submenu Icons 1556
Status Submenu Icons 1558
Truck Setup Submenu Icons 1561
Diagnostics Submenu Icons 1573
Operating Screen 1583
Introduction 1583
Performance Mode Controls 1583
Status and Warning Icons 1584
Battery Discharge Indicator 1585
Direction and Parking Brake Indicators 1585
Hazard Flashers and Lighting Controls 1586
Steer Angle Indicator 1586
System Time 1586
Load Weight Indicator 1586
System Off/Alert Screens 1587
Introduction 1587
System Off Screen 1587
Alert Screens 1587
Password Screen 1589
Introduction 1589
Password Screen 1589
Service Technician Password Setup 1589
Adding/Removing/Changing Passwords 1590
Password Log 1593
Activity Log Menu 1594
Introduction 1594
Operator Checklist Log 1594
Password Log 1596
Impact Events Log 1598
Calibration Menu 1600
Introduction 1600
Load Weight Calibration 1600
Return to Set Tilt Stop Point Calibration 1601
E-Hydraulic and Manual Valve Threshold Calibration 1601
Steering Wheel Center Point Calibration 1602
Steer Axle Position Calibration 1603
Steer Axle Center Point Calibration 1604
Manual Hydraulics Calibration 1604
Display Menu 1605
Introduction 1605
Set Date and Time Format Menu 1605
Set Daylight Saving Time Menu 1606
Procedure for Setting Up Automatic Daylight Savings Time 1607
Set Time and Date Menu 1609
Procedure for Setting Time and Date 1609
Set Units Menu 1610
Status Menu 1611
Introduction 1611
VSM Versions 1611
Display Versions 1612
Truck Serial Number 1612
Hour Meters 1612
E-Hydraulic Controller Versions 1612
Pump Motor Controller Versions 1612
Traction Motor Controller 1 Versions 1612
Traction Motor Controller 2 Versions 1613
Light Controller Versions 1613
Impact Sensor Versions 1613
E-Steer Controller 1 Versions 1613
E-Steer Controller 2 Versions 1613
Truck Setup Menu 1614
Introduction 1614
Add/Remove Password 1615
Battery Settings 1615
Motor Braking 1615
Changing the Motor Braking Settings 1616
Battery Mode 1616
Battery Setup 1617
BDI Adjustment Setting 1618
Acceleration Rates 1619
Hour Meter Initialization 1620
Impact Monitor Shutdown 1620
Operator Checklist 1622
Minimum Pump Standby Flow Rate 1622
Scheduled Maintenance Reminder 1623
Traction Speed Limit 1624
Return to Set Tilt 1624
Auto Power-Off Time Delay 1625
Impact Monitor Settings 1625
Impact Detection 1626
Setting Adjustments 1626
Initial Adjustment of Soft and Hard Impact Settings 1626
Readjustment of Soft and Hard Impact Settings 1626
Motion Alarm 1626
Lift Hydraulic Function Maximum Speed and Ramp Times 1627
Lower Hydraulic Function Maximum Speed and Ramp Times 1627
Tilt Forward Hydraulic Function Maximum Speed and Ramp Times 1628
Tilt Backward Hydraulic Function Maximum Speed and Ramp Times 1628
Auxiliary 1A Hydraulic Function Maximum Speed and Ramp Times 1628
Auxiliary 1B Hydraulic Function Maximum Speed and Ramp Times 1628
Auxiliary 2A Hydraulic Function Maximum Speed and Ramp Times 1628
Auxiliary 2B Hydraulic Function Maximum Speed and Ramp Times 1628
Optional Hydraulic Functions 1628
Rear Lights Control 1629
Restore Default Settings 1629
Steering Wheel Friction and Steering Turns Adjustment 1630
Navigation 1631
How to Adjust Settings 1631
Steering Friction 1631
Steering Wheel Number of Turns 1632
Diagnostics Menu 1634
Introduction 1634
Fault Code Log 1634
Fault Log Details 1635
Speedometer 1636
Direction Switch 1636
Traction Motor 1 Status 1637
Traction Motor 2 Status 1637
Occupancy Sensor 1637
Brake System Sensors 1637
Pump Status 1638
Hydraulic Control Inputs 1639
E-Hydraulic Valves 1639
Hydraulic Sensors 1640
System Voltages 1640
Steering Position Sensors 1642
E-Steering Position Sensors 1642
Electric Brake 1643
Navigation 1644
ESS Diagnostics Menus A, B, and C 1645
Menu A 1645
Menu B 1646
Menu C 1648
524319498-2200YRM1336-(07-2020)-UK-EN 1651
General 1657
Description 1657
Display Panel Menu Access 1657
Menu Flowchart 1658
Technician Menu Flowchart 1658
Menu Navigation 1664
Icon Glossary 1668
Introduction 1668
Soft Key Icons 1668
Overlay Icons 1669
Heat Exchange Module Warning Indicator Screen 1669
System Off Screen and Alert Screens 1670
Main Menu Title Screens 1675
Submenu Icons Grouped by Menu 1677
Operating Screen Icons 1677
Password Screen Icons 1678
Activity Log Submenu Icons 1678
Calibration Submenu Icons 1680
Display Submenu Icons 1683
Status Submenu Icons 1685
Truck Setup Submenu Icons 1689
Diagnostics Submenu Icons 1700
Operating Screen 1710
Introduction 1710
Performance Mode Controls 1710
Status and Warning Icons 1711
Battery Discharge Indicator 1712
Direction and Parking Brake Indicators 1713
Hazard Flashers and Lighting Controls 1713
Steer Angle Indicator 1713
System Time 1713
Load Weight Indicator 1713
System Off/Alert Screens 1714
Introduction 1714
System Off Screen 1714
Alert Screens 1714
Password Screen 1716
Introduction 1716
Password Screen 1716
Service Technician Password Setup 1716
Adding/Removing/Changing Passwords 1717
Password Log 1719
Activity Log Menu 1720
Introduction 1720
Operator Checklist Log 1720
Password Log 1722
Impact Events Log 1724
Calibration Menu 1726
Introduction 1726
Load Weight Calibration 1726
Return to Set Tilt Stop Point Calibration 1727
E-Hydraulic and Manual Valve Threshold Calibration 1727
Steering Wheel Center Point Calibration 1728
Steer Axle Position Calibration 1729
Steer Axle Center Point Calibration 1729
Manual Hydraulics Calibration 1730
Display Menu 1731
Introduction 1731
Set Date and Time Format Menu 1731
Set Daylight Saving Time Menu 1732
Procedure for Setting Up Automatic Daylight Savings Time 1733
Set Time and Date Menu 1735
Procedure for Setting Time and Date 1735
Set Units Menu 1736
Status Menu 1737
Introduction 1737
VSM Versions 1737
Display Versions 1738
Truck Serial Number 1738
Hour Meters 1738
E-Hydraulic Controller Versions 1738
Pump Motor Controller Versions 1738
Traction Motor Controller 1 Versions 1738
Traction Motor Controller 2 Versions 1739
Light Controller Versions 1739
Impact Sensor Versions 1739
E-Steer Controller 1 Versions 1739
E-Steer Controller 2 Versions 1739
Truck Setup Menu 1740
Introduction 1740
Add/Remove Password 1741
Battery Settings 1741
Motor Braking 1741
Changing the Motor Braking Settings 1742
Battery Mode 1742
Battery Setup 1743
BDI Adjustment Setting 1744
Acceleration Rates 1745
Hour Meter Initialization 1746
Impact Monitor Shutdown 1746
Operator Checklist 1747
Minimum Pump Standby Flow Rate 1748
Scheduled Maintenance Reminder 1748
Traction Speed Limit 1750
Return to Set Tilt 1750
Auto Power-Off Time Delay 1750
Impact Monitor Settings 1751
Impact Detection 1751
Setting Adjustments 1751
Initial Adjustment of Soft and Hard Impact Settings 1751
Readjustment of Soft and Hard Impact Settings 1752
Motion Alarm 1752
Lift Hydraulic Function Maximum Speed and Ramp Times 1752
Lower Hydraulic Function Maximum Speed and Ramp Times 1753
Tilt Forward Hydraulic Function Maximum Speed and Ramp Times 1753
Tilt Backward Hydraulic Function Maximum Speed and Ramp Times 1753
Auxiliary 1A Hydraulic Function Maximum Speed and Ramp Times 1753
Auxiliary 1B Hydraulic Function Maximum Speed and Ramp Times 1754
Auxiliary 2A Hydraulic Function Maximum Speed and Ramp Times 1754
Auxiliary 2B Hydraulic Function Maximum Speed and Ramp Times 1754
Optional Hydraulic Functions 1754
Rear Lights Control 1754
Restore Default Settings 1755
Steering Wheel Friction and Steering Turns Adjustment 1755
Navigation 1756
How to Adjust Settings 1756
Steering Friction 1756
Steering Wheel Number of Turns 1757
Diagnostics Menu 1759
Introduction 1759
Fault Code Log 1759
Fault Log Details 1760
Speedometer 1761
Direction Switch 1761
Traction Motor 1 Status 1761
Traction Motor 2 Status 1762
Occupancy Sensor 1762
Brake System Sensors 1762
Pump Status 1763
Hydraulic Control Inputs 1763
E-Hydraulic Valves 1763
Hydraulic Sensors 1764
System Voltages 1764
Steering Position Sensors 1765
E-Steering Position Sensors 1765
Electric Brake 1766
Navigation 1767
524319499-2200YRM1369-(01-2020)-UK-EN 1769
General 1777
Discharging the Capacitors 1778
Display Panel and Key or Keyless Switch Replacement 1779
Display Panel, Replace 1779
Remove 1779
Install 1782
Electronic and Manual Hydraulic Controls 1783
General 1783
Manual Hydraulic Controls 1784
Upper Front Cover 1784
Direction Control Switch 1785
Remove 1785
Install 1790
Clamp Button 1790
Remove 1790
Install 1791
Return To Set Tilt (RTST) Button 1791
Remove 1791
Install 1791
Emergency Disconnect Switch 1792
Remove 1792
Install 1792
E-Hydraulic Controls – Test 1793
Mini-Levers 1793
Full Stroke Test 1793
Function Returns to Neutral Test 1793
Push (Override) Button 1794
E-Hydraulic Controls 1794
Mini-levers, Remove and Install 1794
Armrest Assembly 1795
Remove 1795
Install 1797
Horn Button 1797
Remove 1797
Install 1798
Direction Control Switch 1798
Remove 1798
Install 1799
Emergency Disconnect Switch 1799
Remove 1799
Install 1800
Push (Override) Buttons and Function Selection Button 1800
Remove 1800
Install 1802
Electronic-Hydraulic Controls, After January, 2020 1802
General 1802
E-Hydraulic Controls – TEST 1804
Mini-Levers 1804
Full Stroke Test 1804
Function Returns to Neutral Test 1804
Push Button (push (override) button) 1805
Mini-levers, Remove and Install 1805
Armrest Assembly 1805
Remove 1805
Install 1808
Horn Button 1808
Remove 1808
Install 1809
Direction Control Switch 1809
Remove 1809
Install 1809
Emergency Disconnect Switch 1809
Remove 1810
Install 1810
Push (Override) Buttons 1811
Remove 1811
Install 1812
Sensors and Switches 1813
General 1813
Synchronous Steering Valve 1813
Steering Axle Sensor 1813
Remove 1813
Install 1818
Hydraulic Motor Speed Sensor 1819
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1819
Remove 1819
Install 1824
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1825
Remove 1825
Install 1829
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1829
Remove 1829
Install 1830
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1830
Remove 1830
Install 1832
Hydraulic Motor Temperature Sensor 1832
Hydraulic Tank Level Sensor 1832
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1832
Remove 1832
Install 1834
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 1834
Remove 1834
Install 1835
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1835
Remove 1835
Install 1836
Hydraulic Filter Sensor 1836
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1836
Remove 1836
Install 1837
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968,) ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1838
Remove 1838
Install 1839
Hydraulic Oil Temperature Sensor 1840
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1840
Remove 1840
Install 1840
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1840
Remove 1840
Install 1841
Traction Speed Sensor 1841
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1841
Remove 1841
Install 1843
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 1844
Remove 1844
Install 1846
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1846
Remove 1846
Install 1847
Traction Motor Temperature Sensor ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 1848
Traction Motor Temperature Sensor ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1848
Remove 1848
Install 1849
Tilt Position Sensor ERC22-35VG (ERC045-070VG) (A968), ERP22-35VL (ERP045-070VL) (A976), and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1849
Remove 1849
Install 1851
Tilt Position Sensor ERC16-20VA (ERC030-040VA) (A969) 1852
Remove 1852
Install 1852
Tilt Position Sensor ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1853
Remove 1853
Install 1854
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) 1855
Remove 1855
Install 1858
Low Level Brake Fluid Switch for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1859
Remove 1859
Install 1860
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) 1861
Remove 1861
Install 1861
Service Brake Pressure Sensor for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1862
Remove 1862
Install 1862
Accelerator Pedal Position Sensor 1862
Remove 1862
Install 1863
Seat Belt Sequence Module 1863
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1863
Remove 1863
Install 1863
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1864
Remove 1864
Install 1864
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1864
Remove 1864
Install 1865
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1865
Remove 1865
Install 1866
Seat Sensor (Operator Presence System) 1866
Non-Suspension Seat 1866
Remove 1866
Install 1868
Full Suspension and Swivel Seats 1868
Remove 1868
Install 1869
Steering Direction Sensor 1869
Remove 1869
Install 1870
Load Weight Sensor 1870
Remove 1870
Install 1872
Battery Gate Switch 1872
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1872
Remove 1872
Install 1874
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1874
Remove 1874
Install 1876
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1877
Remove 1877
Install 1878
Horn Switch 1878
Fixed Steering Column 1878
Remove 1878
Install 1879
Telescopic Steering Column 1879
Remove 1879
Install 1880
Impact Sensor 1880
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1880
Remove 1880
Install 1882
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 1882
Remove 1882
Install 1883
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1884
Remove 1884
Install 1885
Rear and Hood Horn Button Switches 1885
Rear Horn Button Switch 1885
Remove 1885
Install 1886
Hood Horn Button Switch 1886
Remove 1886
Install 1887
Motor Controllers Replacement 1888
General 1888
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 1902
Traction Motor and Hydraulic Pump and Motor Controllers 1902
Remove 1902
Install 1909
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1910
Hydraulic Pump and Motor Controller 1910
Remove 1910
Install 1916
Traction Motor Controllers 1917
Remove 1917
Install 1924
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1925
Traction Motor and Hydraulic Pump and Motor Controllers 1925
Remove 1925
Install 1927
Line Contactor 1928
Remove 1928
Install 1936
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) 1937
Remove 1937
Install 1939
Fans for Lift Truck Model Manufactured Before November 2014ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1940
Remove 1940
Install 1940
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) 1940
Remove 1947
Install 1951
Vehicle System Manager 1951
General 1951
Remove 1952
Install 1956
Programming a New VSM and/or Display Panel 1957
PC Service Tool Software 1957
Fuses and Relays 1958
Backup Alarm 1972
Battery Connection 1975
Inspect 1975
Replacing Cables 1975
Cab Heater 1977
Lights 1977
General 1977
Work Lights (Front and Rear) 1981
Halogen Bulb Lights 1981
Remove 1981
Install 1981
LED Lights 1981
Remove 1981
Install 1982
Strobe Light 1982
Remove 1982
Install 1982
LED Tail, Backup, and Brake Lights 1983
Remove 1983
Install 1984
Front Marker/Turn Signal Lights 1984
Remove 1984
Install 1984
Dome Light 1984
Remove 1984
Install 1985
Converter 1985
Remove 1986
Install 1994
524319499-2200YRM1369-(04-2023)-UK-EN 1997
General 2007
Discharging the Capacitors 2008
Display Panel and Key or Keyless Switch Replacement 2009
Display Panel, Replace 2009
Remove 2009
Install 2012
Electronic and Manual Hydraulic Controls 2013
General 2013
Manual Hydraulic Controls 2014
Upper Front Cover 2014
Direction Control Switch 2015
Remove 2015
Install 2021
Clamp Button 2021
Remove 2021
Install 2022
Return To Set Tilt (RTST) Button 2022
Remove 2022
Install 2022
Emergency Disconnect Switch 2023
Remove 2023
Install 2023
E-Hydraulic Controls – Test 2024
Mini-Levers 2024
Full Stroke Test 2024
Function Returns to Neutral Test 2024
Push (Override) Button 2025
E-Hydraulic Controls 2025
Mini-levers, Remove and Install 2025
Armrest Assembly 2026
Remove 2026
Install 2028
Horn Button 2028
Remove 2028
Install 2029
Direction Control Switch 2029
Remove 2029
Install 2030
Emergency Disconnect Switch 2030
Remove 2030
Install 2031
Push (Override) Buttons and Function Selection Button 2031
Remove 2031
Install 2034
Electronic-Hydraulic Controls, After January, 2020 2035
General 2035
E-Hydraulic Controls – TEST 2036
Mini-Levers 2036
Full Stroke Test 2036
Function Returns to Neutral Test 2036
Push Button (push (override) button) 2037
Mini-levers, Remove and Install 2037
Armrest Assembly 2037
Remove 2037
Install 2040
Horn Button 2040
Remove 2040
Install 2040
Direction Control Switch 2040
Remove 2040
Install 2041
Emergency Disconnect Switch 2041
Remove 2041
Install 2042
Push (Override) Buttons 2042
Remove 2042
Install 2043
Sensors and Switches 2044
General 2044
Synchronous Steering Valve 2044
Steering Axle Sensor 2044
Remove 2044
Install 2049
Hydraulic Motor Speed Sensor 2050
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 2050
Remove 2050
Install 2055
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2056
Remove 2056
Install 2060
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 2060
Remove 2060
Install 2061
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2061
Remove 2061
Install 2063
Hydraulic Motor Temperature Sensor 2063
Hydraulic Tank Level Sensor 2063
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2063
Remove 2063
Install 2065
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 2065
Remove 2065
Install 2066
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2066
Remove 2066
Install 2067
Hydraulic Filter Sensor 2067
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2067
Remove 2067
Install 2068
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968,) ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2069
Remove 2069
Install 2070
Hydraulic Oil Temperature Sensor 2071
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2071
Remove 2071
Install 2071
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 2071
Remove 2071
Install 2072
Traction Speed Sensor 2072
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2072
Remove 2072
Install 2074
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 2075
Remove 2075
Install 2077
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2077
Remove 2077
Install 2078
Traction Motor Temperature Sensor ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 2079
Traction Motor Temperature Sensor ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2079
Remove 2079
Install 2080
Tilt Position Sensor ERC22-35VG (ERC045-070VG) (A968), ERP22-35VL (ERP045-070VL) (A976), and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2080
Remove 2080
Install 2082
Tilt Position Sensor ERC16-20VA (ERC030-040VA) (A969) 2082
Remove 2083
Install 2083
Tilt Position Sensor ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2083
Remove 2083
Install 2084
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) 2085
Remove 2085
Install 2088
Low Level Brake Fluid Switch for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2089
Remove 2089
Install 2090
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) 2091
Remove 2091
Install 2091
Service Brake Pressure Sensor for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2091
Remove 2091
Install 2092
Accelerator Pedal Position Sensor 2092
Remove 2092
Install 2092
Seat Belt Sequence Module 2093
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2093
Remove 2093
Install 2094
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 2094
Remove 2094
Install 2094
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 2094
Remove 2094
Install 2095
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2095
Remove 2095
Install 2095
Seat Sensor (Operator Presence System) 2096
Non-Suspension Seat 2096
Remove 2096
Install 2098
Full Suspension and Swivel Seats 2098
Remove 2098
Install 2099
Steering Direction Sensor 2099
Remove 2099
Install 2099
Load Weight Sensor 2100
Remove 2100
Install 2101
Battery Gate Switch 2102
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2102
Remove 2102
Install 2104
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 2104
Remove 2104
Install 2106
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2106
Remove 2106
Install 2107
Horn Switch 2108
Fixed Steering Column 2108
Remove 2108
Install 2109
Telescopic Steering Column 2109
Remove 2109
Install 2110
Impact Sensor 2110
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2110
Remove 2110
Install 2112
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 2112
Remove 2112
Install 2113
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2114
Remove 2114
Install 2115
Rear and Hood Horn Button Switches 2115
Rear Horn Button Switch 2115
Remove 2115
Install 2116
Hood Horn Button Switch 2116
Remove 2116
Install 2117
Motor Controllers Replacement 2118
General 2118
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 2132
Traction Motor and Hydraulic Pump and Motor Controllers 2132
Remove 2132
Install 2139
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2139
Hydraulic Pump and Motor Controller 2139
Remove 2139
Install 2146
Traction Motor Controllers 2147
Remove 2147
Install 2154
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2155
Traction Motor and Hydraulic Pump and Motor Controllers 2155
Remove 2155
Install 2157
Line Contactor 2158
Remove 2158
Install 2165
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) 2167
Remove 2167
Install 2169
Fans for Lift Truck Model Manufactured Before November 2014 ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2170
Remove 2170
Install 2170
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) 2170
Remove 2177
Install 2181
Vehicle System Manager 2182
General 2182
Remove 2182
Install 2187
Programming a New VSM and/or Display Panel 2188
PC Service Tool Software 2188
Fuses and Relays 2189
Backup Alarm 2203
Battery Connection 2207
Inspect 2207
Replacing Cables 2207
Cab Heater 2209
Lights 2209
General 2209
Work Lights (Front and Rear) 2213
Halogen Bulb Lights 2213
Remove 2213
Install 2213
LED Lights 2213
Remove 2213
Install 2214
Strobe Light 2214
Remove 2214
Install 2214
LED Tail, Backup, and Brake Lights 2215
Remove 2215
Install 2216
Front Marker/Turn Signal Lights 2216
Remove 2216
Install 2216
Dome Light 2216
Remove 2216
Install 2217
Converter 2217
Remove 2217
Install 2226
524319504-9000YRM1377-(09-2019)-UK-EN 2229
SECTION 9010 Operational Diagnostic Procedures 2245
Group 05 – Operational Checkout 2247
SECTION 9025 Traction Motor 2257
Group 10 – Principles of Operation 2259
Group 30 – Observed Symptoms 2265
SECTION 9030 Electrical System 2267
Group 03 – General Maintenance and Diagnostic Data 2277
Group 10 – Principles of Operation 2321
Group 20 – Diagnostic Trouble Codes 2353
Group 30 – Observed Symptoms 2965
Group 55 – Icons and Graphics 3009
SECTION 9035 Drive Axle/Unit 3017
Group 10 – Principles of Operation 3019
Group 30 – Observed Symptoms 3029
Group 20 – Diagnostic Trouble Codes 3041
SECTION 9050 Hydraulic Systems 3043
Group 10 – Principles of Operation 3047
Group 33 – Observed Symptoms-Gear Pump 3085
Group 43 – Tests and Adjustments-Gear Pump 3165
SECTION 9060 Operators Station 3195
Group 10 – Principles of Operation 3197
SECTION 9070 Front End (Mast) and Chassis 3237
Group 10 – Principles of Operation 3239
Group 30 – Observed Symptoms 3257
SECTION 9080 Supplementary Data 3301
Group 50 – Abbreviations and Acronyms 3303
524327049-0620YRM1385-(02-2023)-UK-EN 3311
General 3319
Discharging the Capacitors for Lift Truck Models ESC030-040AC (B883), ESC030-040AD (C883) 3325
Discharging the Capacitors (All Other Models) 3327
Traction Motor Repair 3328
For Lift Truck Models , and ERP15-20VT (ERP030-040VT) (G807)ERP16-20VF (ERP30-40VF) (A955), ESC030-040AC (B883) 3328
Remove 3328
Disassemble 3329
Electrical Connector Repair or Replacement 3331
Clean 3331
Inspect 3331
Assemble 3332
Install 3334
For Lift Truck ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 3336
Remove 3336
Disassemble 3336
Electrical Connector Repair or Replacement 3339
Clean 3339
Inspect 3339
Assemble 3340
Install 3340
For Lift Truck ERP2 2-3 5VL (ERP045-070VL) (A976) 3340
Remove 3340
Disassemble 3340
Clean 3342
Inspect 3342
Assemble 3343
Install 3343
For Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080120VM, ERP100VML) (A985) 3343
Remove 3343
Clean 3345
Install 3345
For Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 3345
Remove 3345
Disassemble 3345
Electrical Connector Repair or Replacement 3347
Clean 3347
Inspect 3347
Assemble 3348
Install 3349
Traction Motor Repair for 4-5 5T Lift Trucks 3350
For Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080120VM, ERP100VML) (A985) 3350
Remove 3350
Clean 3352
Install 3352
Hydraulic Motor Repair 3353
For Lift Trucks and ERP15-20VT (ERP030-040VT) (G807)ERP16-20VF (ERP30-40VF) (A955)ESC030-040AC (B883), ESC030-040AD (C883) 3353
Remove 3353
Disassemble 3354
Electrical Connector Repair or Replacement 3356
Clean 3356
Inspect 3356
Assemble 3357
Install 3359
For Lift Truck ERC22-35VG (ERC045-070VG) (A968) 3360
Remove 3360
Disassemble 3362
Standard Motor 3362
Enhanced Motor 3364
Electrical Connector Repair or Replacement 3365
Clean 3366
Inspect 3366
Assemble 3367
Standard Motor 3367
Enhanced Motor 3367
Install 3368
For Lift Truck Models ERP2 2-3 5VL (ERP045-070VL) (A976) and ERC16-20VA (ERC030-040VA) (A969) 3368
Remove 3368
Disassemble 3368
Electrical Connector Repair or Replacement 3374
Clean 3375
Inspect 3375
Assemble 3376
Install 3377
For Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 3377
Remove 3377
Disassemble 3377
Electrical Connector Repair or Replacement 3380
Clean 3380
Inspect 3381
Assemble 3381
Install 3382
Hydraulic Motor Repair For 4 0-5 5T Lift Trucks 3382
Remove 3382
Disassemble 3382
Electrical Connector Repair or Replacement 3384
Clean 3384
Inspect 3385
Assemble 3385
Install 3386
Torque Specifications 3387
Traction Motor for Lift Trucks and ERP15-20VT (ERP030-040VT) (G807)ERP16-20VF (ERP30-40VF) (A955) 3387
Traction Motor for Lift Truck and ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969),ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 3387
Traction Motor for Lift Truck ESC030-040AC (B883), ESC030-040AD (C883) 3387
Hydraulic Motor for Lift Trucks and ERP15-20VT (ERP030-040VT) (G807)ERP16-20VF (ERP30-40VF) (A955) 3387
Hydraulic Motor for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 3387
Hydraulic Motor for Lift Truck ERP22-35VG (ERP045-070VG) (A976) 3387
Hydraulic Motor for Lift Truck ERC16-20VA (ERC030-040VA) (A969) 3387
Hydraulic Motor for Lift Truck ESC030-040AC (B883), ESC030-040AD (C883) 3387
Hydraulic Motor for Lift Truck and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 3388
524327049-0620YRM1385-(06-2015)-UK-EN 3391
General 3395
Discharging the Capacitors for Lift Truck Models ESC030-040AC (B883), ESC030-040AD (C883) 3402
Discharging the Capacitors (All Other Models) 3403
Traction Motor Repair 3403
For Lift Truck Models ERP15-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), and ESC030-040AC (B883) 3404
Remove 3404
Disassemble 3405
Electrical Connector Repair or Replacement 3408
Clean 3408
Inspect 3408
Assemble 3409
Install 3412
For Lift Truck ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 3414
Remove 3414
Disassemble 3414
Electrical Connector Repair or Replacement 3418
Clean 3418
Inspect 3418
Assemble 3419
Install 3419
For Lift Truck ERP2 2-3 5VL (ERP045-070VL) (A976) 3419
Remove 3419
Disassemble 3419
Clean 3421
Inspect 3421
Assemble 3422
Install 3422
For Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 3422
Remove 3422
Disassemble 3423
Electrical Connector Repair or Replacement 3424
Clean 3424
Inspect 3425
Assemble 3425
Install 3426
3426
Traction Motor Repair For Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 3426
Remove 3426
Clean 3428
Install 3428
Hydraulic Motor Repair 3428
For Lift Trucks ERP15-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), and ESC030-040AC (B883), ESC030-040AD (C883) 3428
Remove 3428
Disassemble 3430
Electrical Connector Repair or Replacement 3432
Clean 3432
Inspect 3432
Assemble 3433
Install 3435
For Lift Truck ERC22-35VG (ERC045-070VG) (A968) 3437
Remove 3437
Disassemble 3438
Standard Motor 3438
Enhanced Motor 3439
Electrical Connector Repair or Replacement 3441
Clean 3442
Inspect 3443
Assemble 3443
Standard Motor 3443
Enhanced Motor 3444
Install 3445
For Lift Truck Models ERP2 2-3 5VL (ERP045-070VL) (A976) and ERC16-20VA (ERC030-040VA) (A969) 3446
Remove 3446
Disassemble 3446
Electrical Connector Repair or Replacement 3452
Clean 3453
Inspect 3453
Assemble 3454
Install 3455
3455
Hydraulic Motor Repair For 4 0-5 5T Lift Trucks 3455
Remove 3455
Disassemble 3455
Electrical Connector Repair or Replacement 3458
Clean 3459
Inspect 3459
Assemble 3460
Install 3460
Torque Specifications 3461
Traction Motor for Lift Trucks ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955) 3461
Traction Motor for Lift Truck ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 3461
Traction Motor for Lift Truck ESC030-040AC (B883), ESC030-040AD (C883) 3461
Hydraulic Motor for Lift Trucks ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955) 3461
Hydraulic Motor for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 3461
Hydraulic Motor for Lift Truck ERP22-35VG (ERP045-070VG) (A976) 3461
Hydraulic Motor for Lift Truck ERC16-20VA (ERC030-040VA) (A969) 3461
Hydraulic Motor for Lift Truck ESC030-040AC (B883), ESC030-040AD (C883) 3461
Hydraulic Motor for Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 3462
524332383-8000YRM1384-(01-2020)-UK-EN 3465
524332383-8000YRM1384-(04-2023)-UK-EN 3507
550025844-1800YRM1438-(01-2011)-UK-EN 3551
toc 3551
Brake System 3551
Safety Precautions Maintenance and Repair 3552
General 3555
Brake System 3555
Service Brakes Repair 3556
Remove and Disassemble 3556
Clean 3559
Inspect 3560
Assemble and Install 3560
Adjust 3564
Parking Brake Repair 3564
Remove and Disassemble 3564
Inspect 3567
Assemble and Install 3567
Adjust 3569
Master Cylinder Repair 3570
Remove 3570
Disassemble 3570
Clean 3571
Inspect 3571
Assemble 3572
Bench Bleed Master Cylinder 3572
Install and Adjust 3572
Brake Pedal Components 3573
Remove 3573
Disassemble 3575
Inspect 3575
Assemble 3575
Install 3575
Automatic Park Brake 3576
General 3576
Remove 3576
Manual Release Handle 3576
Automatic Park Brake Assembly 3578
Automatic Park Brake Module 3578
Disassemble 3578
Clean and Inspect 3578
Assemble 3578
Install 3578
Automatic Park Brake Module 3578
Automatic Park Brake Assembly 3579
Manual Release Handle 3579
Finishing Steps 3579
Adjustments 3579
Service Brakes Adjustment 3579
Brake Adjust 3579
Parking Brake Adjustment 3580
Brake System Air Removal 3581
Using Pressure Bleed System 3581
Using Brake Pedal Pressure 3581
Brake Pedal Adjustment 3582
Master Cylinder Adjustment 3582
Adjust Push Rod 3582
Parking Brake Not Applied Switch Test 3583
Torque Specifications 3583
550025844-1800YRM1438-(04-2023)-UK-EN 3587
General 3593
Brake System 3593
Service Brakes Repair 3594
Remove and Disassemble 3594
Clean 3598
Inspect 3599
Assemble and Install 3599
Adjust 3604
Parking Brake Repair 3605
Remove and Disassemble 3605
Inspect 3608
Assemble and Install 3608
Adjust 3610
Master Cylinder Repair 3611
Remove 3611
Disassemble 3611
Clean 3612
Inspect 3613
Assemble 3613
Bench Bleed Master Cylinder 3613
Install and Adjust 3613
Brake Pedal Components 3615
Remove 3615
Disassemble 3617
Inspect 3618
Assemble 3618
Install 3618
Automatic Park Brake 3619
General 3619
Remove 3619
Manual Release Handle 3619
Automatic Park Brake Assembly 3621
Automatic Park Brake Module 3621
Disassemble 3621
Clean and Inspect 3622
Assemble 3622
Install 3622
Automatic Park Brake Module 3622
Automatic Park Brake Assembly 3622
Manual Release Handle 3622
Finishing Steps 3622
Adjustments 3622
Service Brakes Adjustment 3623
Brake Adjust 3623
Parking Brake Adjustment 3623
Brake System Air Removal 3626
Using Pressure Bleed System 3626
Using Brake Pedal Pressure 3626
Brake Pedal Adjustment 3627
Master Cylinder Adjustment 3627
Adjust Push Rod 3627
Parking Brake Not Applied Switch Test 3627
Torque Specifications 3628
550025849-2000YRM1439-(04-2023)-UK-EN 3631
General 3637
Discharging the Capacitors 3639
Manual Hydraulic Control Valve Repair 3640
Remove 3640
Beginning Steps 3640
Disassemble Handles and Levers 3651
Disassemble Manual Control Valve 3653
Spool Seal Replacement 3661
Clean 3664
Inspect 3664
Assemble Manual Control Valve 3665
Assemble Handles and Levers 3675
Install 3678
Ending Steps 3688
E-Hydraulic Control Valve Repair 3690
Remove 3690
Beginning Steps 3690
Fitting Removal 3690
Electrical Disconnect and Control Valve Dismount 3692
Disassemble 3694
Clean 3699
Inspect 3699
Assemble 3699
Install 3701
Electrical Connect and Control Valve Mount 3701
Fitting Installation 3702
Ending Steps 3704
E-Hydraulic Controls 3704
Replace E-Hydraulic Control Components 3705
Checks and Adjustments 3706
Manual Control Valve 3706
Primary Relief Valve 3706
Optional Work Port Relief Valve 3707
E-Hydraulic Control Valve 3707
Primary Relief Valve 3707
Secondary Port Relief Valve 3708
Hydraulic System Air Removal 3708
Position Sensor and OPS Check and Adjustment 3709
Position Sensor 3709
(OPS) Operator Presence Solenoid 3709
Manual Control Valve Re-Calibration 3709
Calibration Procedure 3710
Control Valve 3710
Torque Specifications 3711
Manual Hydraulic Control Valve 3711
Manual Control Valve Handles and Levers 3711
E-Hydraulic Control Valve 3711
550025849-2000YRM1439-(10-2011)-UK-EN 3713
toc 3713
Main Control Valves 3713
Safety Precautions Maintenance and Repair 3714
General 3717
Discharging the Capacitors 3719
Manual Hydraulic Control Valve Repair 3720
Remove 3720
Beginning Steps 3720
Remove Control Valve 3721
Disassemble Handles and Levers 3730
Disassemble Manual Control Valve 3732
Spool Seal Replacement 3738
Clean 3743
Inspect 3743
Assemble Manual Control Valve 3743
Assemble Handles and Levers 3754
Install 3757
Install Control Valve 3757
Ending Steps 3767
E-Hydraulic Control Valve Repair 3768
Remove 3768
Beginning Steps 3768
Fitting Removal 3768
Electrical Disconnect and Control Valve Dismount 3769
Disassemble 3771
Clean 3773
Inspect 3774
Assemble 3774
Install 3776
Electrical Connect and Control Valve Mount 3776
Fitting Installation 3778
Ending Steps 3779
E-Hydraulic Controls 3779
Replace E-Hydraulic Control Components 3780
Checks and Adjustments 3780
Manual Control Valve 3780
Primary Relief Valve 3780
Optional Work Port Relief Valve 3781
E-Hydraulic Control Valve 3781
Primary Relief Valve 3781
Secondary Port Relief Valve 3782
Hydraulic System Air Removal 3782
Position Sensor and OPS Check and Adjustment 3783
Position Sensor 3783
(OPS) Operator Presence Solenoid 3783
Manual Control Valve Re-Calibration 3783
Calibration Procedure 3784
Control Valve 3784
Torque Specifications 3785
Manual Hydraulic Control Valve 3785
Manual Control Valve Handles and Levers 3785
E-Hydraulic Control Valve 3785
tables 3713
Table 1 Handle Options 3754
Table 2 Position Sensor Connector Pin Layout 3767
Table 3 Lower Solenoid Connector Pin Layout 3777
Table 4 Upper Solenoid Connector Pin Layout 3777
Table 5 Position Sensor Wiring 3783
Table 6 Sensor Power Check 3783
550025854-2100YRM1440-(02-2018)-UK-EN 3789
Safety Procedures When Working Near Mast 3793
General 3795
Tilt Cylinder Repair 3797
Remove 3797
Disassemble 3798
Clean 3800
Inspect 3800
Assemble 3800
Install 3801
Adjust Tilt Cylinders 3802
Lift Cylinder Repair 3802
Main Lift Cylinders 3803
Remove 3803
Disassemble 3805
Two-Stage FFL 3805
Three-Stage FFL 3806
Two-Stage LFL 3807
Clean 3808
Inspect 3808
Assemble 3808
Two-Stage FFL 3808
Three-Stage FFL 3809
Two-Stage LFL 3809
Install 3809
System Air Bleed Procedures 3810
Free-Lift Cylinder Repair 3810
Remove 3810
Two-Stage FFL 3810
Three-Stage FFL 3812
Disassemble 3812
Clean 3813
Inspect 3813
Assemble 3814
Install 3814
Two-Stage FFL 3814
Three-Stage FFL 3814
All Free-Lift Cylinders 3815
Sideshift Cylinder Repair Prior to December 2016 3815
Remove 3815
Disassemble 3815
Clean and Inspect 3817
Assemble 3817
Install 3817
Sideshift Cylinder Repair After December 2016 3817
Remove 3818
Disassemble 3820
Clean and Inspect 3820
Assemble 3820
Install 3821
Integral Side-Shift Cylinder Gland Leak
Checks 3822
Fork Positioner Cylinder Repair Prior to December 2016 3822
Remove 3822
Disassemble 3822
Clean 3826
Inspect 3826
Assemble 3826
Install 3826
Fork Positioner Cylinder Adjustment 3826
Fork Positioner Cylinder Repair After December 2016 3827
Remove 3827
Disassemble 3827
Clean 3830
Inspect 3830
Assemble 3831
Install 3831
Fork Positioner Cylinder Adjustment 3831
Seal Kit Installation 3832
External Installation (Seal and Back-Up Ring) 3832
Internal Installation (Piston Rod Assembly) 3833
Torque Specifications 3833
Tilt Cylinders 3833
Main Lift Cylinder 3833
Free-Lift Cylinder 3833
Sideshift Cylinder 3833
Fork Positioner Cylinder 3833
550025854-2100YRM1440-(04-2023)-UK-EN 3837
Safety Procedures When Working Near Mast 3843
General 3846
Tilt Cylinder Repair 3849
Remove 3849
Disassemble 3850
Clean 3852
Inspect 3852
Assemble 3852
Install 3853
Adjust Tilt Cylinders 3854
Lift Cylinder Repair 3855
Main Lift Cylinders 3855
Remove 3855
Disassemble 3857
Two-Stage FFL 3857
Three-Stage FFL 3858
Two-Stage LFL 3859
Clean 3860
Inspect 3860
Assemble 3860
Two-Stage FFL 3860
Three-Stage FFL 3861
Two-Stage LFL 3861
Install 3861
System Air Bleed Procedures 3862
Free-Lift Cylinder Repair 3863
Remove 3863
Two-Stage FFL 3863
Three-Stage FFL 3865
Disassemble 3865
Clean 3867
Inspect 3867
Assemble 3867
Install 3867
Two-Stage FFL 3867
Three-Stage FFL 3868
All Free-Lift Cylinders 3868
Sideshift Cylinder Repair Prior to December 2016 3869
Remove 3869
Disassemble 3869
Clean and Inspect 3870
Assemble 3870
Install 3870
Sideshift Cylinder Repair After December 2016 3871
Remove 3871
Disassemble 3873
Clean and Inspect 3873
Assemble 3873
Install 3874
Integral Side-Shift Cylinder Gland Leak
Checks 3875
Fork Positioner Cylinder Repair Prior to December 2016 3876
Remove 3876
Disassemble 3876
Clean 3878
Inspect 3878
Assemble 3879
Install 3879
Fork Positioner Cylinder Adjustment 3879
Fork Positioner Cylinder Repair After December 2016 3881
Remove 3881
Disassemble 3881
Clean 3883
Inspect 3883
Assemble 3884
Install 3884
Fork Positioner Cylinder Adjustment 3884
Seal Kit Installation 3886
External Installation (Seal and Back-Up Ring) 3886
Internal Installation (Piston Rod Assembly) 3886
Torque Specifications 3887
Tilt Cylinders 3887
Main Lift Cylinder 3887
Free-Lift Cylinder 3887
Sideshift Cylinder 3887
Fork Positioner Cylinder 3887
550025859-4000YRM1441-(04-2023)-UK-EN 3889
General 3895
Safety Procedures When Working Near Mast 3895
Fork Replacement 3898
Standard Carriage and Integral Sideshift Carriage 3898
Remove 3898
Install 3900
Checks 3900
Fork Positioner Carriage 3901
Carriages Repair 3902
Standard Carriage 3902
Remove 3902
Repair 3903
Install 3903
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 3904
Remove 3904
Clean and Inspect 3906
Repair 3907
Install 3908
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 3908
Remove 3908
Disassemble 3911
Clean and Inspect 3911
Assemble 3912
Install 3913
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 3913
Remove 3913
Disassemble 3916
Clean and Inspect 3916
Assemble 3917
Install 3918
Fork Positioner, Lift Trucks Manufactured Before December, 2016 3918
Remove 3918
Clean and Inspect 3922
Disassemble and Assemble 3922
Install 3922
Fork Positioner Hydraulic Hose Adjustment 3924
Fork Positioner, Lift Trucks Manufactured December, 2016 and After 3925
Remove 3925
Disassemble and Assemble 3928
Clean and Inspect 3928
Install 3928
Fork Positioner Hydraulic Hose Adjustment 3929
Mast Repair 3931
Remove 3931
Two-Stage LFL and Two-Stage FFL Masts, Disassemble 3934
Three-Stage FFL Mast, Disassemble 3938
Clean and Inspect 3940
Two-Stage LFL and Two-Stage FFL Mast, Assemble 3941
Three-Stage FFL Mast, Assemble 3942
Mast, Install 3943
Header Hose Arrangement 3946
Two-Stage LFL 3946
Two-Stage FFL 3952
Three-Stage FFL 3959
Adjustment 3967
Lift Chains Adjustment 3968
Carriage Adjustments 3970
Mast Adjustments 3972
Load Roller Adjustment 3972
Mast Side Kicking Adjustment 3973
550025859-4000YRM1441-(06-2019)-UK-EN 3975
General 3979
Safety Procedures When Working Near Mast 3979
Fork Replacement 3981
Standard Carriage and Integral Sideshift Carriage 3981
Remove 3981
Install 3983
Checks 3983
Fork Positioner Carriage 3984
Carriages Repair 3984
Standard Carriage 3984
Remove 3984
Repair 3986
Install 3986
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 3986
Remove 3986
Clean and Inspect 3989
Repair 3990
Install 3991
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 3991
Remove 3991
Disassemble 3994
Clean and Inspect 3994
Assemble 3995
Install 3995
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 3996
Remove 3996
Disassemble 3999
Clean and Inspect 3999
Assemble 4000
Install 4000
Fork Positioner, Lift Trucks Manufactured Before December, 2016 4001
Remove 4001
Clean and Inspect 4005
Disassemble and Assemble 4005
Install 4005
Fork Positioner Hydraulic Hose Adjustment 4006
Fork Positioner, Lift Trucks Manufactured December, 2016 and After 4008
Remove 4008
Disassemble and Assemble 4011
Clean and Inspect 4011
Install 4011
Fork Positioner Hydraulic Hose Adjustment 4012
Mast Repair 4013
Remove 4013
Two-Stage LFL and Two-Stage FFL Masts, Disassemble 4016
Three-Stage FFL Mast, Disassemble 4021
Clean and Inspect 4023
Two-Stage LFL and Two-Stage FFL Mast, Assemble 4024
Three-Stage FFL Mast, Assemble 4025
Mast, Install 4026
Header Hose Arrangement 4028
Two-Stage LFL 4029
Two-Stage FFL 4035
Three-Stage FFL 4042
Adjustment 4050
Lift Chains Adjustment 4050
Carriage Adjustments 4051
Mast Adjustments 4053
Load Roller Adjustment 4054
Mast Side Kicking Adjustment 4055
550025864-8000YRM1442-(04-2019)-UK-EN 4057
General 4063
Serial Number Data 4063
Discharging the Capacitors 4064
Rapid Charge 4064
How to Move Disabled Lift Truck 4065
How to Tow Lift Truck 4065
How to Put Lift Truck on Blocks 4066
How to Raise Drive Tires 4066
How to Raise Steering Tires 4066
How to Clean a Lift Truck 4067
Safety Procedures When Working Near Mast 4067
WHEN WORKING NEAR THE MAST ALWAYS: 4068
Maintenance Schedule 4070
Maintenance Procedures Every 8 Hours or Daily 4075
How to Make Checks With Key or Keyless Switch OFF 4075
Tires and Wheels 4075
Forks 4076
General 4076
Inspect 4076
Remove 4077
Install 4080
Adjustment 4080
Inspection of Mast, Carriage, Header Hoses, Lift Chains, and Attachments 4081
Safety Labels 4081
Steering Column Adjustments 4082
Tilt Adjust Feature 4082
Tilt Memory Feature 4082
Telescopic Feature 4082
Operator Restraint System 4082
Emergency Locking Retractor (ELR) 4083
Seat Adjustments 4084
Seat Position Adjustment 4084
Seat Adjustment for Operator Weight 4084
Battery Restraint System 4085
Battery 4089
Hydraulic System 4090
How to Make Checks With Key or Keyless Switch ON 4092
Horn, Lights, and Backup Alarm 4092
Emergency Disconnect Switch 4092
Steering System 4093
Service Brakes 4094
Parking Brake 4094
Automatic Parking Brake 4094
Hydraulic Control Levers and Pedals 4094
Direction and Speed Control Pedals 4094
Lift System Operation 4094
Oil Leaks 4095
Maintenance Procedures Every 500 Hours or Three Months 4095
Forks, Inspect 4095
Header Hose Checks 4096
Mast Lubrication 4097
Parking Brake Adjustment 4101
Brake Fluid Check 4103
Master Cylinder Fluid Check 4103
Operator Presence System Check 4104
Differential and Speed Reducer 4104
Tilt Cylinder Rod End Pins 4105
Lift Chains 4106
Wear Check 4106
Lift Chain Lubrication 4107
Fork Pins and Guides 4108
Check Upper and Lower Bearings, Integral Sideshift Carriage 4108
Check Lower Mounting Hook, Integral Sideshift Carriage 4110
Steering Axle 4111
Lubricate King Pins and Tie Rods 4111
Hydraulic Tank Breather, Check 4112
Other Lubrication 4114
Line Contactor 4114
Maintenance Procedures Every 2000 Hours or Yearly 4116
Hydraulic System 4116
Hydraulic Filter Element, Replace 4116
Hydraulic Tank Breather, Change 4117
Differential and Speed Reducer Oil Change 4120
Brake Fluid Replacement 4122
Service Brakes 4123
Forks, Inspect 4125
Integral Sideshift Carriage, Replace Upper and Lower Bearings 4126
Lift Chains 4126
Wheel Bearings 4126
Steer Wheels, Lubrication 4126
Drive Wheels, Lubrication 4126
Maintenance Procedures Every 4000 Hours Or Two Years 4126
Hydraulic Oil, Change 4126
Steering Direction Sensor Inspection 4127
Fixed Steering Column 4127
Telescopic Steering Column 4129
Telescopic Steering Column Lubrication 4130
Battery Maintenance 4131
How to Charge Battery 4131
How to Change Batteries 4132
General 4132
Remove the Battery 4133
Install the Battery 4137
Lift and Tilt System Leak Check 4138
Lift Cylinders Leak Check 4139
Tilt Cylinder Leak Check 4139
Lift Chain Adjustments 4140
Welding Repairs 4141
Overhead Guard Changes 4141
Wheels and Tires 4142
Adhesives and Sealants 4143
550025864-8000YRM1442-(07-2023)-UK-EN 4147
General 4153
Serial Number Data 4153
Discharging the Capacitors 4154
Rapid Charge 4154
How to Move Disabled Lift Truck 4155
How to Tow Lift Truck 4155
How to Put Lift Truck on Blocks 4156
How to Raise Drive Tires 4156
How to Raise Steering Tires 4156
How to Clean a Lift Truck 4157
Safety Procedures When Working Near Mast 4158
WHEN WORKING NEAR THE MAST ALWAYS: 4158
Maintenance Schedule 4161
Maintenance Procedures Every 8 Hours or Daily 4167
How to Make Checks With Key or Keyless Switch OFF 4167
Tires and Wheels 4167
Forks 4167
General 4167
Inspect 4167
Remove 4169
Install 4172
Adjustment 4173
Inspection of Mast, Carriage, Header Hoses, Lift Chains, and Attachments 4173
Safety Labels 4174
Steering Column Adjustments 4174
Tilt Adjust Feature 4174
Tilt Memory Feature 4174
Telescopic Feature 4175
Operator Restraint System 4175
Emergency Locking Retractor (ELR) 4176
Seat Adjustments 4177
Seat Position Adjustment 4177
Seat Adjustment for Operator Weight 4177
Battery Restraint System 4178
Battery 4181
Hydraulic System 4182
How to Make Checks With Key or Keyless Switch ON 4184
Horn, Lights, and Backup Alarm 4184
Emergency Disconnect Switch 4184
Steering System 4185
Service Brakes 4186
Parking Brake 4186
Automatic Parking Brake 4186
Hydraulic Control Levers and Pedals 4186
Direction and Speed Control Pedals 4186
Lift System Operation 4187
Oil Leaks 4187
Maintenance Procedures Every 500 Hours or Three Months 4188
Forks, Inspect 4188
Header Hose Checks 4189
Mast Lubrication 4190
Parking Brake Adjustment 4194
Brake Fluid Check 4196
Master Cylinder Fluid Check 4196
Operator Presence System Check 4197
Differential and Speed Reducer 4197
Tilt Cylinder Rod End Pins 4198
Lift Chains 4199
Wear Check 4199
Lift Chain Lubrication 4200
Fork Pins and Guides 4201
Check Upper and Lower Bearings, Integral Sideshift Carriage 4201
Check Lower Mounting Hook, Integral Sideshift Carriage 4204
Steering Axle 4204
Lubricate King Pins and Tie Rods 4204
Hydraulic Tank Breather, Check 4205
Other Lubrication 4207
Line Contactor 4207
Maintenance Procedures Every 2000 Hours or Yearly 4209
Hydraulic System 4209
Hydraulic Filter Element, Replace 4209
Hydraulic Tank Breather, Change 4210
Differential and Speed Reducer Oil Change 4213
Brake Fluid Replacement 4215
Service Brakes 4216
Forks, Inspect 4218
Integral Sideshift Carriage, Replace Upper and Lower Bearings 4219
Lift Chains 4219
Wheel Bearings 4219
Steer Wheels, Lubrication 4219
Drive Wheels, Lubrication 4219
Maintenance Procedures Every 4000 Hours Or Two Years 4220
Hydraulic Oil, Change 4220
Steering Direction Sensor Inspection 4220
Fixed Steering Column 4220
Telescopic Steering Column 4222
Telescopic Steering Column Lubrication 4224
Battery Maintenance 4225
How to Charge Battery 4225
How to Change Batteries 4226
General 4226
Remove the Battery 4226
Install the Battery 4230
Lift and Tilt System Leak Check 4232
Lift Cylinders Leak Check 4232
Tilt Cylinder Leak Check 4232
Lift Chain Adjustments 4233
Welding Repairs 4235
Overhead Guard Changes 4236
Wheels and Tires 4237
Adhesives and Sealants 4239
550025872-8000YRM1443-(04-2023)-UK-EN 4241
Counterweights 4247
Hydraulic System 4247
Steering System 4248
Specifications 4248
Turning Radius 4248
Wheels and Tires 4248
Battery Specifications 4249
Capacities 4250
Tilt Angles 4250
Maximum Carriage and Tilt Creep Rates 4251
Mast Speeds 4251
Torque Specifications 4253
Frame 4253
Drive Axle 4253
Differential and Speed Reducer 4253
Brake System 4253
Steering Axle 4254
Masts 4254
Tilt Cylinders 4254
Hydraulic Pump and Motor 4254
Hydraulic Tank 4255
Hydraulic Control Valves 4255
Manual Valve 4255
Manual Handles and Levers 4255
Manual Valve Covers 4255
E-Hydraulic Valve 4255
Electrical System 4256
Adhesives and Sealants 4257
550025872-8000YRM1443-(09-2018)-UK-EN 4259
Counterweights 4263
Hydraulic System 4263
Steering System 4263
Specifications 4263
Turning Radius 4264
Wheels and Tires 4264
Battery Specifications 4265
Capacities 4265
Tilt Angles 4266
Maximum Carriage and Tilt Creep Rates 4266
Mast Speeds 4267
Torque Specifications 4268
Frame 4268
Drive Axle 4268
Differential and Speed Reducer 4268
Brake System 4269
Steering Axle 4269
Masts 4269
Tilt Cylinders 4270
Hydraulic Pump and Motor 4270
Hydraulic Tank 4270
Hydraulic Control Valves 4270
Manual Valve 4270
Manual Handles and Levers 4271
Manual Valve Covers 4271
E-Hydraulic Valve 4271
Electrical System 4271
Adhesives and Sealants 4271
550073240-1900YRM1620-(01-2023)-UK-EN 4275
Proper Flushing after Major Hydraulic Repairs 4281
Introduction 4281
The Phases of Wear 4281
Causes of Hydraulic System Failure 4281
Progression of Contaminant Caused Hydraulic System Failure 4282
Hydraulic System Flushing Techniques 4282
Double Oil and Filter Change 4282
Mechanical Cleaning 4283
Cleaning of Components 4283
How to Clean Tubes and Hoses 4283
Filter Caddy 4283
Start-Up Procedure for Cleaned System 4284
Contaminated Oil Coolers 4284
Additional Filter Caddy Functions 4285
How to Handle Different Fluids 4285
Water Removal Filters 4285
Fluid Conditioning and System Flushing Procedures 4286
Operation of the Filter Caddy 4286
Filter Caddy operation 4286
Fluid Conditioning Procedure 4286
Filter Caddy Start-Up 4287
System Flushing Procedure 4287
Component Cleaning Procedure 4288
Reservoir Cleaning Procedure 4288
Cylinder Cleaning Procedure 4288
Hose and Tube Cleaning Procedure 4288
Valve Cleaning Procedure 4289
Front-End Attachment Cleaning Procedure 4290
System Flushing Procedure 4290
Filter Caddy Start-Up 4291
System Start-Up and Flushing 4291
Reservoir Fluid Cleaning Times 4292
Dealing With Different Fluid Types 4293
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 4293
Filter Caddy Maintenance 4293
Servicing the Strainer 4293
DC Motor 4293
Hydraulic Oil Sampling Method and Procedure 4294
Hydraulic Oil Sampling Method 4294
Objective 4294
General Guidelines 4294
Synopsis 4295
Hydraulic Oil Analysis Report Guidelines 4296
Sampling Conditions 4296
Equipment 4296
Sampling Procedure 4297
Hydraulic Oil Sampling 4297
Sample Labeling 4297
Results Documentation 4297
550073240-1900YRM1620-(03-2020)-UK-EN 4299
Proper Flushing after Major Hydraulic Repairs 4303
Introduction 4303
The Phases of Wear 4303
Causes of Hydraulic System Failure 4303
Progression of Contaminant Caused Hydraulic System Failure 4304
Hydraulic System Flushing Techniques 4304
Double Oil and Filter Change 4304
Mechanical Cleaning 4305
Cleaning of Components 4305
How to Clean Tubes and Hoses 4305
Filter Caddy 4305
Start-Up Procedure for Cleaned System 4306
Contaminated Oil Coolers 4306
Additional Filter Caddy Functions 4306
How to Handle Different Fluids 4306
Water Removal Filters 4307
Fluid Conditioning and System Flushing Procedures 4307
Operation of the Filter Caddy 4307
Filter Caddy operation 4307
Fluid Conditioning Procedure 4308
Filter Caddy Start-Up 4308
System Flushing Procedure 4309
Component Cleaning Procedure 4309
Reservoir Cleaning Procedure 4309
Cylinder Cleaning Procedure 4309
Hose and Tube Cleaning Procedure 4310
Valve Cleaning Procedure 4310
Front-End Attachment Cleaning Procedure 4311
System Flushing Procedure 4311
Filter Caddy Start-Up 4312
System Start-Up and Flushing 4312
Reservoir Fluid Cleaning Times 4313
Dealing With Different Fluid Types 4313
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 4313
Filter Caddy Maintenance 4314
Servicing the Strainer 4314
DC Motor 4314
Hydraulic Oil Sampling Method and Procedure 4314
Hydraulic Oil Sampling Method 4314
Objective 4314
General Guidelines 4314
Synopsis 4315
Hydraulic Oil Analysis Report Guidelines 4316
Sampling Conditions 4317
Equipment 4317
Sampling Procedure 4317
Hydraulic Oil Sampling 4317
Sample Labeling 4318
Results Documentation 4318
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