Yale Forklift A976 (ERP045, 050, 060, 070VL) Service Manual – PDF DOWNLOAD

Yale Forklift A976 (ERP045, 050, 060, 070VL) Service Manual – PDF DOWNLOAD

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Yale Forklift A976 (ERP045, 050, 060, 070VL) Service Manual – PDF DOWNLOAD

Language : English
Pages : 5552
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift A976 (ERP045, 050, 060, 070VL) 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
524319491-1600YRM1360-(03-2023)-UK-EN 789
General 797
Steering Axle Assembly Repair 799
Remove ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 799
Disassemble ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 801
Clean 804
Inspect 804
Assemble ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 805
Install ERC22-35VG (ERC045-070VG) (A968) 806
Install ERC16-20VA (ERC030-040VA) (A969) 807
Install ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 808
Remove ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 809
Disassemble ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 814
Clean 815
Inspect 815
Assemble ERP40-50VM, ERP50-55MV6 (ERP080-120VM, ERP100VML) (A985) 815
Assemble ERP22-35VL (ERP045-070VL) (A976) 816
Wheel Bearing Adjustment ERP22-35VL (ERP045-070VL) (A976) 817
Install ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) 818
Remove ERP16-20VF (ERP30-40VF) (A955) 824
Disassemble ERP16-20VF (ERP30-40VF) (A955) 824
Clean 826
Inspect 826
Assemble ERP16-20VF (ERP30-40VF) (A955) 826
Install ERP16-20VF (ERP30-40VF) (A955) 827
Tie Rod Replacement 828
Remove ERC20-35VG (ERC045-070VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 828
Clean 829
Inspect 829
Install ERC20-35VG (ERC045-070VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 829
Remove ERC16-20VA (ERC030-040VA) (A969) 829
Clean 830
Inspect 830
Install ERC16-20VA (ERC030-040VA) (A969) 830
Remove ERP20-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 831
Clean 832
Inspect 832
Install ERP20-35VL (ERP045-070VL) (A976) andERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 832
Remove ERP16-20VF (ERP30-40VF) (A955) 832
Clean 833
Inspect 833
Install ERP16-20VF (ERP30-40VF) (A955) 833
Spindle Repair 834
Remove ERC22-35VG (ERC45-70VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 834
Disassemble ERC22-35VG (ERC45-70VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 835
Clean 835
Inspect 836
Assemble ERC22-35VG (ERC45-70VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 836
Install ERC22-35VG (ERC45-70VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 836
Remove ERC16-20VA (ERC030-040VA) (A969) 837
Disassemble ERC16-20VA (ERC030-040VA) (A969) 838
Clean 838
Inspect 838
Assemble ERC16-20VA (ERC030-040VA) (A969) 839
Install ERC16-20VA (ERC030-040VA) (A969) 839
Remove ERP22-35VL (ERP45-70VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 840
Disassemble ERP22-35VL (ERP45-70VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 841
Clean 841
Inspect 842
Assemble ERP22-35VL (ERP45-70VL) (A976) 842
Install ERP22-35VL (ERP45-70VL) (A976) 842
Assemble ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 843
Install ERP22-35VL (ERP45-70VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 843
Remove ERP16-20VF (ERP30-40VF) (A955) 844
Disassemble ERP16-20VF (ERP30-40VF) (A955) 844
Clean 845
Inspect 845
Assemble ERP16-20VF (ERP30-40VF) (A955) 846
Install ERP16-20VF (ERP30-40VF) (A955) 846
Steering Cylinder Repair 847
Remove ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 847
Disassemble ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 850
Clean 851
Inspect 851
Assemble ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 851
Install ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 851
Remove ERC16-20VA (ERC030-040VA) (A969) 852
Disassemble ERC16-20VA (ERC030-040VA) (A969) 853
Clean 854
Inspect 855
Assemble ERC16-20VA (ERC030-040VA) (A969) 855
Install ERC16-20VA (ERC030-040VA) (A969) 855
Remove ERP16-20VF (ERP30-40VF) (A955) 855
Disassemble ERP16-20VF (ERP30-40VF) (A955) 856
Clean 857
Inspect 857
Assemble ERP16-20VF (ERP30-40VF) (A955) 857
Install ERP16-20VF (ERP30-40VF) (A955) 858
Remove ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 858
Disassemble ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 859
Clean 860
Inspect 860
Assemble ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 861
Install ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 861
Remove ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 861
Disassemble ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 863
Clean 863
Inspect 864
Assemble ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 864
Install ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 864
524319491-1600YRM1360-(10-2018)-UK-EN 867
General 873
Steering Axle Assembly Repair 874
Remove ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 875
Disassemble ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 876
Clean 880
Inspect 880
Assemble ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 880
Install ERC22-35VG (ERC045-070VG) (A968) 882
Install ERC16-20VA (ERC030-040VA) (A969) 883
Install ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 884
Remove ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 886
Disassemble ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 890
Clean 892
Inspect 892
Assemble ERP40-50VM, ERP50-55MV6 (ERP080-120VM, ERP100VML) (A985) 892
Assemble ERP22-35VL (ERP045-070VL) (A976) 893
Wheel Bearing Adjustment ERP22-35VL (ERP045-070VL) (A976) 894
Install ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) 895
Remove ERP16-20VF (ERP30-40VF) (A955) 901
Disassemble ERP16-20VF (ERP30-40VF) (A955) 901
Clean 903
Inspect 903
Assemble ERP16-20VF (ERP30-40VF) (A955) 903
Install ERP16-20VF (ERP30-40VF) (A955) 904
Tie Rod Replacement 904
Remove ERC20-35VG (ERC045-070VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 905
Clean 906
Inspect 906
Install ERC20-35VG (ERC045-070VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 906
Remove ERC16-20VA (ERC030-040VA) (A969) 906
Clean 907
Inspect 907
Install ERC16-20VA (ERC030-040VA) (A969) 907
Remove ERP20-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 908
Clean 908
Inspect 909
Install ERP20-35VL (ERP045-070VL) (A976) andERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 909
Remove ERP16-20VF (ERP30-40VF) (A955) 909
Clean 910
Inspect 910
Install ERP16-20VF (ERP30-40VF) (A955) 910
Spindle Repair 910
Remove ERC22-35VG (ERC45-70VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 910
Disassemble ERC22-35VG (ERC45-70VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 912
Clean 912
Inspect 912
Assemble ERC22-35VG (ERC45-70VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 913
Install ERC22-35VG (ERC45-70VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 913
Remove ERC16-20VA (ERC030-040VA) (A969) 914
Disassemble ERC16-20VA (ERC030-040VA) (A969) 914
Clean 915
Inspect 915
Assemble ERC16-20VA (ERC030-040VA) (A969) 915
Install ERC16-20VA (ERC030-040VA) (A969) 916
Remove ERP22-35VL (ERP45-70VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 916
Disassemble ERP22-35VL (ERP45-70VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 918
Clean 918
Inspect 918
Assemble ERP22-35VL (ERP45-70VL) (A976) 919
Install ERP22-35VL (ERP45-70VL) (A976) 919
Assemble ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 919
Install ERP22-35VL (ERP45-70VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 919
Remove ERP16-20VF (ERP30-40VF) (A955) 920
Disassemble ERP16-20VF (ERP30-40VF) (A955) 921
Clean 922
Inspect 922
Assemble ERP16-20VF (ERP30-40VF) (A955) 922
Install ERP16-20VF (ERP30-40VF) (A955) 922
Steering Cylinder Repair 923
Remove ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 923
Disassemble ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 926
Clean 927
Inspect 927
Assemble ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 927
Install ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 927
Remove ERC16-20VA (ERC030-040VA) (A969) 928
Disassemble ERC16-20VA (ERC030-040VA) (A969) 929
Clean 930
Inspect 931
Assemble ERC16-20VA (ERC030-040VA) (A969) 931
Install ERC16-20VA (ERC030-040VA) (A969) 931
Remove ERP16-20VF (ERP30-40VF) (A955) 931
Disassemble ERP16-20VF (ERP30-40VF) (A955) 932
Clean 933
Inspect 933
Assemble ERP16-20VF (ERP30-40VF) (A955) 933
Install ERP16-20VF (ERP30-40VF) (A955) 934
Remove ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 934
Disassemble ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 935
Clean 936
Inspect 936
Assemble ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 937
Install ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 937
Remove ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 937
Disassemble ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 939
Clean 940
Inspect 940
Assemble ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 940
Install ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 940
524319492-1600YRM1363-(03-2023)-UK-EN 943
General 949
Discharging The Capacitors 949
Steering Control Unit (SCU) Repair 951
Remove 951
Disassemble 954
Clean 960
Inspect 960
Assemble 960
Install 961
Steering Wheel and Fixed Steering Column Assembly Repair 962
Remove 962
Disassemble 965
Clean 966
Inspect 967
Assemble 967
Install 967
Gear Replacement for Lift Trucks Built Prior to October, 2008 968
Steering Wheel and Telescopic Column Assembly Repair 970
Remove 970
Disassemble 973
Clean 976
Inspect 977
Assemble 977
Install 978
Torque Specifications 985
Steering Control Unit 985
Steering Column 985
524319492-1600YRM1363-(09-2014)-UK-EN 987
524319494-1900YRM1367-(04-2017)-UK-EN 1025
General 1031
Discharging the Capacitors 1031
Hydraulic Pump and Motor 1032
Remove 1032
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1033
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1036
Lift Truck Models ERP22-25VL (ERP045-070VL) (A976) 1039
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1044
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1049
Disassemble 1051
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969)ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1051
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1053
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1055
Inspect 1057
Clean 1057
Assemble 1057
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969)ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1057
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1057
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1058
Install 1058
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1058
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1059
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1060
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1061
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1062
Hydraulic Tank 1063
Remove 1063
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1063
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1066
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1067
Lift Truck Models ERP22-25VL (ERP045-070VL) (A976) 1071
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1073
Disassemble 1075
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1075
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1076
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1076
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1077
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1079
Clean 1081
Steam Method 1081
Chemical Method 1081
Inspect 1082
Small Leaks, Repair 1082
Large Leaks, Repair 1082
Additional Methods for Metal Tank Repair 1082
Assemble 1082
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1082
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1083
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1084
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1084
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1085
Install 1085
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1085
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1086
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1086
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1087
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1087
Hydraulic Filter Replacement 1088
Breather Clean and Inspect 1089
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 1089
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1092
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1092
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1092
Hydraulic Oil Cooler for Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1093
Add Hydraulic Oil 1093
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1093
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1095
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1095
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1095
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1096
Steer Accumulator Replacement 1097
Remove 1097
Install 1104
Specifications for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1104
Tank Capacity 1105
Specifications for Lift Truck ERC16-20VA (ERC030-040VA) (A969) 1105
Tank Capacity 1105
Specifications for Lift Truck ERP22-25VL (ERP045-070VL) (A976) 1105
Tank Capacity 1105
Specifications for Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1105
Tank Capacity 1105
Specifications for Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1105
Tank Capacity 1106
Torque Specifications for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1106
Hydraulic Pump and Motor 1106
Hydraulic Tank 1106
Torque Specifications for Lift Truck ERC16-20VA (ERC030-040VA) (A969) 1107
Hydraulic Pump and Motor 1107
Hydraulic Tank 1107
Torque Specifications for Lift Truck ERP22-35VL (ERP045-070VL) (A976) 1107
Hydraulic Pump and Motor 1107
Hydraulic Tank 1107
Torque Specifications for Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1107
Hydraulic Pump and Motor 1108
Hydraulic Tank 1108
Torque Specifications for Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1109
Hydraulic Pump and Motor 1109
Hydraulic Tank 1109
524319494-1900YRM1367-(08-2023)-UK-EN 1113
General 1119
Discharging the Capacitors 1119
Hydraulic Pump and Motor 1121
Remove 1121
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1121
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1127
Lift Truck Models ERP22-25VL (ERP045-070VL) (A976) 1131
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1136
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1141
Disassemble 1143
Lift Truck Models , ERC22-35VG (ERC045-070VG) (A968)ERC16-20VA (ERC030-040VA) (A969)ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1143
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1145
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1147
Inspect 1149
Clean 1149
Assemble 1149
Lift Truck Models , ERC22-35VG (ERC045-070VG) (A968)ERC16-20VA (ERC030-040VA) (A969)ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1149
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1150
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1150
Install 1150
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1150
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1151
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1152
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1153
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1154
Hydraulic Tank 1155
Remove 1155
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1155
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1158
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1161
Lift Truck Models ERP22-25VL (ERP045-070VL) (A976) 1164
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1166
Disassemble 1168
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1168
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1168
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1169
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1170
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1172
Clean 1174
Steam Method 1175
Chemical Method 1175
Inspect 1175
Small Leaks, Repair 1175
Large Leaks, Repair 1176
Additional Methods for Metal Tank Repair 1176
Assemble 1176
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1176
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1177
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1177
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1178
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1178
Install 1179
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1179
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1179
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1180
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1181
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1181
Hydraulic Filter Replacement 1182
Breather Clean and Inspect 1183
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 1183
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1185
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1185
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1186
Hydraulic Oil Cooler for Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1186
Add Hydraulic Oil 1186
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1186
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1188
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1188
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1188
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1189
Steer Accumulator Replacement 1191
Remove 1191
Install 1199
Specifications for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1200
Tank Capacity 1200
Specifications for Lift Truck ERC16-20VA (ERC030-040VA) (A969) 1200
Tank Capacity 1200
Specifications for Lift Truck ERP22-25VL (ERP045-070VL) (A976) 1200
Tank Capacity 1200
Specifications for Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1201
Tank Capacity 1201
Specifications for Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1201
Tank Capacity 1201
Torque Specifications for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1202
Hydraulic Pump and Motor 1202
Hydraulic Tank 1202
Torque Specifications for Lift Truck ERC16-20VA (ERC030-040VA) (A969) 1202
Hydraulic Pump and Motor 1202
Hydraulic Tank 1202
Torque Specifications for Lift Truck ERP22-35VL (ERP045-070VL) (A976) 1203
Hydraulic Pump and Motor 1203
Hydraulic Tank 1203
Torque Specifications for Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1203
Hydraulic Pump and Motor 1203
Hydraulic Tank 1203
Torque Specifications for Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1204
Hydraulic Pump and Motor 1204
Hydraulic Tank 1204
524319495-2000YRM1334-(03-2023)-UK-EN 1207
General 1215
Lift Trucks ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955) 1215
Lift Trucks ERC22-35VG (ERC045-070VG) (A968), ERP22-35VL (ERP045-070VL) (A976), and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1217
Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1221
Discharging the Capacitors 1223
Manual Hydraulic Control Valve Repair for 1 5-2 0T Trucks 1224
Remove 1224
Beginning Steps 1224
Disassemble Handles and Levers 1237
Disassemble Manual Control Valve 1240
Spool Seal Replacement 1250
Clean 1253
Inspect 1253
Assemble Manual Control Valve 1255
Assemble Handles and Levers 1266
Install 1269
Ending Steps 1281
Manual Hydraulic Control Valve Repair for 2 0-3 5T Trucks and 4 0-5 0T Pneumatic Trucks 1283
Remove 1283
Disassemble Handles and Levers 1299
Disassemble Manual Control Valve 1302
Disassemble Valve 1302
Disassemble Inlet Section 1305
Disassemble Lift, Tilt, and Auxiliary Sections 1305
Spool Seal Replacement 1307
Clean 1308
Inspect 1309
Assemble Manual Control Valve 1309
Assemble Lift, Tilt, and Auxiliary Sections 1309
Assemble Inlet Section 1310
Assemble Valve 1311
Assemble Handles and Levers 1319
Install 1323
Ending Steps 1335
Manual Hydraulic Control Valve Repair for 4 0-5 5T Cushion Trucks 1336
Remove 1336
Disassemble Handles and Levers 1350
Disassemble Manual Control Valve 1352
Disassemble Valve 1352
Disassemble Inlet Section 1355
Disassemble Lift, Tilt, and Auxiliary Sections 1356
Spool Seal Replacement 1358
Clean 1359
Inspect 1359
Assemble Manual Control Valve 1360
Assemble Lift, Tilt, and Auxiliary Sections 1360
Assemble Inlet Section 1361
Assemble Valve 1362
Assemble Handles and Levers 1369
Install 1372
Ending Steps 1384
E-Hydraulic Control Valve Repair for 1 5-2 0T Trucks 1385
Remove 1385
Disassemble 1391
Clean 1398
Inspect 1398
Assemble 1398
Install 1406
E-Hydraulic Controls 1411
Replace E-Hydraulic Control Components 1412
E-Hydraulic Control Valve Repair for 2 0-3 5T Trucks and 4 0-5 0T Pneumatic Trucks 1413
Remove 1413
Initial Steps 1413
Fitting Removal for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1413
Fitting Removal for Lift Truck ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1415
Electrical Disconnect and Control Valve Dismount 1417
Disassemble 1419
Clean 1424
Inspect 1424
Assemble 1424
Install 1432
Electrical Connect and Control Valve Mount 1432
Fitting Installation for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1434
Fitting Installation for Lift Truck ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1436
Ending Steps 1437
E-Hydraulic Controls 1438
Replace E-Hydraulic Control Components 1438
E-Hydraulic Control Valve Repair for 4 0-5 5T Cushion Trucks 1439
Remove 1439
Initial Steps 1439
Fitting Removal 1439
Electrical Disconnect and Control Valve Dismount 1441
Disassemble 1443
Clean 1448
Inspect 1448
Assemble 1448
Install 1456
Electrical Connect and Control Valve Mount 1456
Fitting Installation 1458
Ending Steps 1459
E-Hydraulic Controls 1460
Replace E-Hydraulic Control Components 1460
Checks and Adjustments
for 1 5-2 0T Lift Trucks 1461
Manual Control Valve 1461
Primary Relief Valve 1461
Optional Auxiliary Port Relief Valve 1461
E-Hydraulic Control Valve 1462
Primary Relief Valve 1462
Optional Secondary Port Relief Valve 1463
Hydraulic System Air Removal 1464
Checks and Adjustments
2 0-5 5T Lift Trucks 1465
Manual Control Valve 1465
External Leakage 1465
Primary Relief Cartridge 1465
Secondary Relief Valve 1466
E-Hydraulic Control Valve 1466
Primary Relief Valve 1466
Secondary Relief Valve 1467
PPRV Pilot Pressure Test 1468
Hydraulic System Air Removal 1469
Position Sensor and OPS Check and Adjustment 1470
Position Sensor 1470
(OPS) Operator Presence Solenoid 1470
Manual Control Valve Re-Calibration 1470
Calibration Procedure 1471
Control Valve 1471
Torque Specifications
for 1 5-2 0T Lift Trucks 1472
Manual Hydraulic Control Valve 1472
Manual Control Valve Handles and Levers 1472
E-Hydraulic Control Valve 1472
Torque Specifications
for 2 2-5 5T Lift Trucks 1473
Manual Hydraulic Control Valve 1473
Manual Control Valve Handles and Levers 1473
Manual Control Valve Covers 1473
E-Hydraulic Control Valve 1473
524319495-2000YRM1334-(09-2014)-UK-EN 1475
524319496-2100YRM1382-(02-2018)-UK-EN 1725
Safety Procedures When Working Near Mast 1733
General 1735
Description 1736
Tilt Cylinder Repair for 2 0-5 5T Trucks 1736
Remove 1736
Disassemble 1738
Inspect 1739
Clean 1739
Assemble 1739
Install 1741
Tilt Cylinders, Adjust 1741
Tilt Cylinder Leak Check 1744
Tilt Cylinder Repair
for 1 0-2 0T Trucks 1745
Remove 1745
Disassemble 1747
Inspect 1749
Clean 1749
Assemble 1749
Install 1749
Tilt Cylinders, Adjust 1750
Tilt Cylinders Leak Check 1751
Lift Cylinder Repair
for 2 0-3 5T Trucks 1752
Main Lift Cylinders 1752
Remove 1752
Two-Stage FFL 1752
Three-Stage FFL 1754
Four-Stage FFL 1754
Two-Stage LFL 1755
Disassemble 1755
Two-Stage FFL 1755
Three-Stage FFL 1757
Four-Stage FFL 1757
Two-Stage LFL 1759
Clean 1760
Inspect 1760
Assemble 1760
Two-Stage FFL 1760
Three-Stage FFL 1760
Four-Stage FFL 1761
Two-Stage LFL 1761
Install 1762
Two-Stage FFL 1762
System Air Bleed Procedures 1762
Three-Stage FFL 1762
Four-Stage FFL 1763
Two-Stage LFL 1763
Lift Cylinder Repair for Lift Truck Model ERP15VT (G807) 1764
Main Lift Cylinder 1764
Remove 1764
Main Lift Cylinders – Two-Stage FFL Mast 1764
Left-Hand Main Lift Cylinder – Three-Stage FFL Mast 1766
Right-Hand Main Lift Cylinder – Three-Stage FFL Mast 1770
Main Lift Cylinder – Two-Stage LFL Mast 1770
Disassemble 1773
Main Lift Cylinders – Two-Stage FFL Mast 1773
Main Lift Cylinder – Three-Stage FFL Mast 1775
Main Lift Cylinder – Two-Stage LFL Mast 1775
Clean 1776
Inspect 1776
Assemble 1777
Main Lift Cylinder – Two-Stage FFL Mast 1777
Main Lift Cylinder – Three-Stage FFL Mast 1777
Main Lift Cylinder – Two-Stage LFL Mast 1777
Install 1778
Main Lift Cylinder – Two-Stage FFL Mast 1778
Left-Hand Main Lift Cylinder – Three-Stage FFL Mast 1778
Right-Hand Main Lift Cylinder – Three-Stage FFL Mast 1779
Main Lift Cylinder – Two-Stage LFL Mast 1780
System Air Bleed Procedures 1781
All Main Lift Cylinders 1781
Lift Cylinder Repair for 1 5-2 0T Trucks 1781
Main Lift Cylinder 1781
Remove 1781
Two-Stage FFL 1782
Three-Stage FFL 1782
Two-Stage LFL 1783
Four-Stage FFL 1785
Disassemble 1786
Two-Stage FFL 1786
Three-Stage FFL 1788
Two-Stage LFL 1788
Four-Stage FFL 1789
Clean 1792
Inspect 1792
Assemble 1792
Two-Stage FFL 1792
Three-Stage FFL 1793
Two-Stage LFL 1793
Four-Stage FFL 1794
Install 1795
Two-Stage FFL 1795
System Air Bleed Procedures 1795
Three-Stage FFL Mast 1795
Two-Stage LFL 1796
Four-Stage FFL 1796
Mast and Carriage Install for Two-Stage FFL, Three-Stage FFL, and Two-Stage LFL 1797
Mast and Carriage Installation for Four-Stage FFL 1797
Lift Cylinder Repair
for 4 0-5 5T Trucks 1798
Main Lift Cylinders 1798
Remove 1798
Two-Stage FFL 1798
Three-Stage FFL 1800
Two-Stage LFL 1800
Disassemble 1801
Two-Stage FFL 1801
Three-Stage FFL 1803
Two-Stage LFL 1804
Clean 1805
Inspect 1805
Assemble 1805
Two-Stage FFL 1805
Three-Stage FFL 1806
Two-Stage LFL 1806
Install 1807
Two-Stage FFL 1807
System Air Bleed Procedures 1807
Three-Stage FFL 1807
Two-Stage LFL 1808
Free-Lift Cylinder Repair
for 2 0-3 5T Trucks 1809
Free-Lift Cylinder 1809
Remove 1809
Two and Three-Stage FFL Mast 1809
Four-Stage FFL For Lift Truck ERC22-356VG (ERC045-070VG) (A968) 1810
Disassemble 1812
Two and Three-Stage FFL Mast 1812
Four-Stage FFL Mast for Lift Truck ERC22-356VG (ERC045-070VG) (A968) 1813
Clean 1813
Inspect 1813
Assemble 1814
Two and Three-Stage FFL Mast 1814
Four-Stage FFL Mast for Lift Truck ERC22-356VG (ERC045-070VG) (A968) 1814
Install 1815
Two and Three-Stage FFL Mast 1815
Four-Stage FFL Mast for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1815
Free Lift Cylinder Repair for Lift Truck Model ERP15VT (G807) 1816
Free-Lift Cylinder 1816
Remove 1816
Three-Stage FFL Mast 1816
Disassemble 1818
Clean 1819
Inspect 1819
Assemble 1819
Install 1819
Free Lift Cylinder Repair
for 1 5-2 0T Trucks 1820
Free-Lift Cylinder 1820
Remove 1820
Two and Three-Stage FFL Mast 1820
Four-Stage FFL Mast 1822
Disassemble 1824
Two-Stage and Three-Stage FFL Masts 1824
Four Stage FFL Mast 1825
Clean 1826
Inspect 1826
Assemble 1826
Two-Stage and Three-Stage FFL Masts 1826
Four-Stage FFL Mast 1827
Install 1827
Two-Stage and Three-Stage FFL Masts 1827
Four-Stage FFL Mast 1827
All Masts 1829
Free-Lift Cylinder Repair
for 4 0-5 5T Trucks 1830
Free-Lift Cylinder 1830
Remove 1830
Two and Three-Stage FFL Mast 1830
Disassemble 1831
Two and Three-Stage FFL Mast 1831
Clean 1832
Inspect 1832
Assemble 1832
Two and Three-Stage FFL Mast 1832
Install 1833
Two and Three-Stage FFL Mast 1833
Sideshift Cylinder Repair
for 1 5-3 5T Trucks Prior to December 2016 1833
Remove 1833
Disassemble 1837
Clean and Inspect 1839
Assemble and Install 1839
Sideshift Cylinder Repair
for 1 5-3 5T Trucks After December 2016 1840
Remove 1840
Disassemble 1844
Clean and Inspect 1846
Assemble and Install 1846
Integral Side-Shift Cylinder Gland Leak Checks 1848
Sideshift Cylinder Repair
for 4 0-5 5T Trucks 1849
Remove 1849
Disassemble 1849
Clean and Inspect 1851
Assemble and Install 1851
Fork Positioner Cylinder Repair Prior to December 2016 1851
Remove 1851
Disassemble 1852
Clean 1854
Inspect 1854
Assemble 1855
Install 1855
Fork Positioner Cylinder Adjustment 1855
Fork Positioner Cylinder Repair After December 2016 1856
Remove 1856
Disassemble 1856
Clean 1859
Inspect 1859
Assemble 1860
Install 1860
Fork Positioner Cylinder Adjustment 1860
Lift Cylinder Leak Check 1861
Seal Kit Installation 1861
External Installation (Seal and Back-Up Ring) 1862
Internal Installation (Piston Rod Assembly) 1862
Torque Specifications for Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-25VL (ERP045-070VL) (A976) 1862
Tilt Cylinders 1862
Piston Rod Nut 1862
Gland 1863
Tilt Cylinder Mounting Capscrew 1863
Tilt Cylinder Rod End Capscrew 1863
Main and Free-Lift Cylinder 1863
Sideshift Cylinder 1863
Fork Positioner Cylinder 1863
Torque Specifications for Lift Truck Model ERP15VT (G807) 1863
Tilt Cylinders 1863
Main and Free-Lift Cylinders 1863
Sideshift Cylinder 1864
Torque Specifications for Lift Truck Models ERP16-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), ESC030-40AC (B883),ESC030-40AD (C883) 1864
Tilt Cylinders 1864
Main and Free-Lift Cylinders 1864
Sideshift Cylinder 1865
Fork Positioner Cylinder 1865
Torque Specifications for Lift Truck Model ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1865
Tilt Cylinders 1865
Main and Free-Lift Cylinder 1865
Sideshift Cylinder 1865
Torque Specifications for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1865
Tilt Cylinder 1866
Main and Free Lift Cylinder 1866
Sideshift Cylinder 1866
524319496-2100YRM1382-(07-2023)-UK-EN 1869
Safety Procedures When Working Near Mast 1879
General 1882
Description 1882
Tilt Cylinder Repair for 2 0-5 5T Trucks 1883
Remove 1883
Disassemble 1885
Inspect 1886
Clean 1886
Assemble 1886
Install 1888
Tilt Cylinders, Adjust 1888
Tilt Cylinder Leak Check 1891
Tilt Cylinder Repair
for 1 0-2 0T Trucks 1892
Remove 1892
Disassemble 1895
Inspect 1897
Clean 1897
Assemble 1897
Install 1897
Tilt Cylinders, Adjust 1898
Tilt Cylinders Leak Check 1899
Lift Cylinder Repair
for 2 0-3 5T Trucks 1901
Main Lift Cylinders 1901
Remove 1901
Two-Stage FFL 1901
Three-Stage FFL 1903
Four-Stage FFL 1903
Two-Stage LFL 1904
Disassemble 1904
Two-Stage FFL 1904
Three-Stage FFL 1906
Four-Stage FFL 1908
Two-Stage LFL 1909
Clean 1910
Inspect 1910
Assemble 1910
Two-Stage FFL 1910
Three-Stage FFL 1911
Four-Stage FFL 1911
Two-Stage LFL 1912
Install 1912
Two-Stage FFL 1912
System Air Bleed Procedures 1912
Three-Stage FFL 1913
Four-Stage FFL 1913
Two-Stage LFL 1914
Lift Cylinder Repair for Lift Truck Model ERP15VT (G807) 1915
Main Lift Cylinder 1915
Remove 1915
Main Lift Cylinders – Two-Stage FFL Mast 1915
Left-Hand Main Lift Cylinder – Three-Stage FFL Mast 1917
Right-Hand Main Lift Cylinder – Three-Stage FFL Mast 1921
Main Lift Cylinder – Two-Stage LFL Mast 1921
Disassemble 1924
Main Lift Cylinders – Two-Stage FFL Mast 1924
Main Lift Cylinder – Three-Stage FFL Mast 1926
Main Lift Cylinder – Two-Stage LFL Mast 1927
Clean 1928
Inspect 1928
Assemble 1928
Main Lift Cylinder – Two-Stage FFL Mast 1928
Main Lift Cylinder – Three-Stage FFL Mast 1929
Main Lift Cylinder – Two-Stage LFL Mast 1929
Install 1929
Main Lift Cylinder – Two-Stage FFL Mast 1929
Left-Hand Main Lift Cylinder – Three-Stage FFL Mast 1930
Right-Hand Main Lift Cylinder – Three-Stage FFL Mast 1931
Main Lift Cylinder – Two-Stage LFL Mast 1932
System Air Bleed Procedures 1932
All Main Lift Cylinders 1933
Lift Cylinder Repair for 1 5-2 0T Trucks 1934
Main Lift Cylinder 1934
Remove 1934
Two-Stage FFL 1934
Three-Stage FFL 1934
Two-Stage LFL 1935
Four-Stage FFL 1937
Disassemble 1939
Two-Stage FFL 1939
Three-Stage FFL 1940
Two-Stage LFL 1941
Four-Stage FFL 1942
Clean 1944
Inspect 1945
Assemble 1945
Two-Stage FFL 1945
Three-Stage FFL 1945
Two-Stage LFL 1946
Four-Stage FFL 1946
Install 1947
Two-Stage FFL 1947
System Air Bleed Procedures 1948
Three-Stage FFL Mast 1948
Two-Stage LFL 1948
Four-Stage FFL 1949
Mast and Carriage Install for Two-Stage FFL, Three-Stage FFL, and Two-Stage LFL 1949
Mast and Carriage Installation for Four-Stage FFL 1950
Lift Cylinder Repair for 4 0-5 5T Trucks 1951
Main Lift Cylinders 1951
Remove 1951
Two-Stage FFL 1951
Three-Stage FFL 1953
Two-Stage LFL 1953
Disassemble 1954
Two-Stage FFL 1954
Three-Stage FFL 1956
Two-Stage LFL 1957
Clean 1958
Inspect 1958
Assemble 1958
Two-Stage FFL 1958
Three-Stage FFL 1959
Two-Stage LFL 1959
Install 1960
Two-Stage FFL 1960
System Air Bleed Procedures 1960
Three-Stage FFL 1960
Two-Stage LFL 1961
Free-Lift Cylinder Repair for 2 0-3 5T Trucks 1962
Free-Lift Cylinder 1962
Remove 1962
Two and Three-Stage FFL Mast 1962
Four-Stage FFL For Lift Truck ERC22-356VG (ERC045-070VG) (A968) 1963
Disassemble 1965
Two and Three-Stage FFL Mast 1965
Four-Stage FFL Mast for Lift Truck ERC22-356VG (ERC045-070VG) (A968) 1966
Clean 1966
Inspect 1967
Assemble 1967
Two and Three-Stage FFL Mast 1967
Four-Stage FFL Mast for Lift Truck ERC22-356VG (ERC045-070VG) (A968) 1967
Install 1968
Two and Three-Stage FFL Mast 1968
Four-Stage FFL Mast for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1968
Free Lift Cylinder Repair for Lift Truck Model ERP15VT (G807) 1970
Free-Lift Cylinder 1970
Remove 1970
Three-Stage FFL Mast 1970
Disassemble 1972
Clean 1973
Inspect 1973
Assemble 1973
Install 1973
Free Lift Cylinder Repair for 1 5-2 0T Trucks 1975
Free-Lift Cylinder 1975
Remove 1975
Two and Three-Stage FFL Mast 1975
Four-Stage FFL Mast 1977
Disassemble 1980
Two-Stage and Three-Stage FFL Masts 1980
Four Stage FFL Mast 1980
Clean 1981
Inspect 1981
Assemble 1981
Two-Stage and Three-Stage FFL Masts 1981
Four-Stage FFL Mast 1982
Install 1982
Two-Stage and Three-Stage FFL Masts 1982
Four-Stage FFL Mast 1983
All Masts 1986
Free-Lift Cylinder Repair
for 4 0-5 5T Trucks 1987
Free-Lift Cylinder 1987
Remove 1987
Two and Three-Stage FFL Mast 1987
Disassemble 1988
Two and Three-Stage FFL Mast 1988
Clean 1989
Inspect 1989
Assemble 1989
Two and Three-Stage FFL Mast 1989
Install 1990
Two and Three-Stage FFL Mast 1990
Sideshift Cylinder Repair
for 1 5-3 5T Trucks Prior to December 2016 1991
Remove 1991
Disassemble 1994
Clean and Inspect 1996
Assemble and Install 1996
Sideshift Cylinder Repair
for 1 5-3 5T Trucks After December 2016 1998
Remove 1998
Disassemble 2001
Clean and Inspect 2002
Assemble and Install 2003
Integral Side-Shift Cylinder Gland Leak Checks 2005
Sideshift Cylinder Repair
for 4 0-5 5T Trucks 2006
Remove 2006
Disassemble 2007
Clean and Inspect 2008
Assemble and Install 2008
Fork Positioner Cylinder Repair Prior to December 2016 2009
Remove 2009
Disassemble 2009
Clean 2012
Inspect 2012
Assemble 2013
Install 2013
Fork Positioner Cylinder Adjustment 2013
Fork Positioner Cylinder Repair After December 2016 2015
Remove 2015
Disassemble 2015
Clean 2018
Inspect 2018
Assemble 2019
Install 2019
Fork Positioner Cylinder Adjustment 2019
Lift Cylinder Leak Check 2021
Seal Kit Installation 2022
External Installation (Seal and Back-Up Ring) 2022
Internal Installation (Piston Rod Assembly) 2022
Torque Specifications for Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-25VL (ERP045-070VL) (A976) 2023
Tilt Cylinders 2023
Piston Rod Nut 2023
Gland 2023
Tilt Cylinder Mounting Capscrew 2023
Tilt Cylinder Rod End Capscrew 2023
Main and Free-Lift Cylinder 2023
Sideshift Cylinder 2023
Fork Positioner Cylinder 2023
Torque Specifications for Lift Truck Model ERP15VT (G807) 2024
Tilt Cylinders 2024
Main and Free-Lift Cylinders 2024
Sideshift Cylinder 2024
Torque Specifications for Lift Truck Models ERP16-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), ESC030-40AC (B883),ESC030-40AD (C883) 2025
Tilt Cylinders 2025
Main and Free-Lift Cylinders 2025
Sideshift Cylinder 2025
Fork Positioner Cylinder 2025
Torque Specifications for Lift Truck Model ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2026
Tilt Cylinders 2026
Main and Free-Lift Cylinder 2026
Sideshift Cylinder 2026
Torque Specifications for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2026
Tilt Cylinder 2026
Main and Free Lift Cylinder 2026
Sideshift Cylinder 2026
524319497-2200YRM1335-(01-2023)-UK-EN 2029
General 2037
Description 2037
Display Panel Menu Access 2037
Menu Flowchart 2038
Supervisor Menu Flowchart 2038
Menu Navigation 2044
Icon Glossary 2048
Introduction 2048
Soft Key Icons 2048
Overlay Icons 2049
Icons on System Off Screen and Alert Screens 2049
Main Menu Title Screens 2053
Submenu Icons Grouped by Menu 2055
Operating Screen Icons 2055
Password Screen Icons 2056
Activity Log Submenu Icons 2056
Calibration Submenu Icons 2058
Display Submenu Icons 2060
Status Submenu Icons 2062
Truck Setup Submenu Icons 2065
Operating Screen 2072
Introduction 2072
Performance Mode Controls 2073
Status and Warning Icons 2073
Battery Discharge Indicator 2074
Direction and Parking Brake Indicators 2075
Hazard Flashers and Lighting Controls 2075
Steer Angle Indicator 2075
System Time 2075
Load Weight Indicator 2075
System Off/Alert Screens 2076
Introduction 2076
System Off Screen 2076
Alert Screens 2076
Password Screen 2078
Introduction 2078
Password Screen 2078
Service Technician Password Setup 2078
Adding/Removing/Changing Passwords 2079
Password Log 2082
Activity Log Menu 2083
Introduction 2083
Operator Checklist Log 2084
Password Log 2087
Impact Events Log 2089
Calibration Menu 2091
Introduction 2091
Load Weight Calibration 2091
Return to Set Tilt Stop Point Calibration 2092
E-Hydraulic and Manual Valve Threshold Calibration 2092
Steering Wheel Center Point Calibration 2093
Steer Axle Position Calibration 2093
Steer Axle Center Point Calibration 2094
Manual Hydraulics Calibration 2095
Display Menu 2096
Introduction 2096
Set Date and Time Format Menu 2096
Set Daylight Saving Time Menu 2097
Procedure for Setting Up Automatic Daylight Savings Time 2098
Set Time and Date Menu 2100
Procedure for Setting Time and Date 2100
Set Units Menu 2101
Status Menu 2102
Introduction 2102
VSM Versions 2102
Display Versions 2103
Truck Serial Number 2103
Hour Meters 2103
E-Hydraulic Controller Versions 2103
Pump Motor Controller Versions 2103
Traction Motor Controller 1 Versions 2103
Traction Motor Controller 2 Versions 2104
Light Controller Versions 2104
Impact Sensor Versions 2104
Truck Setup Menu 2105
Introduction 2105
Add/Remove Password 2105
Battery Settings 2105
Restore Default Settings 2106
Motion Alarm 2106
Impact Monitor Settings 2107
Impact Detection 2107
Setting Adjustments 2107
Initial Adjustment of Soft and Hard Impact Settings 2107
Readjustment of Soft and Hard Impact Settings 2107
Auto Power-Off Time Delay 2108
Return to Set Tilt 2108
Traction Speed Limit 2108
Scheduled Maintenance Reminder 2109
Minimum Pump Standby Flow Rate 2110
Operator Checklist 2110
Impact Monitor Shutdown 2111
Motor Braking 2112
Changing the Motor Braking Settings 2112
Steering Wheel Friction and Steering Turns Adjustment 2113
How to Adjust Settings 2113
Steering Friction Setting 2113
Steering Wheel Number of Turns 2114
524319497-2200YRM1335-(07-2020)-UK-EN 2117
General 2123
Description 2123
Display Panel Menu Access 2123
Menu Flowchart 2124
Supervisor Menu Flowchart 2124
Menu Navigation 2130
Icon Glossary 2134
Introduction 2134
Soft Key Icons 2134
Overlay Icons 2135
Icons on System Off Screen and Alert Screens 2135
Main Menu Title Screens 2139
Submenu Icons Grouped by Menu 2141
Operating Screen Icons 2141
Password Screen Icons 2142
Activity Log Submenu Icons 2142
Calibration Submenu Icons 2144
Display Submenu Icons 2146
Status Submenu Icons 2148
Truck Setup Submenu Icons 2151
Operating Screen 2158
Introduction 2158
Performance Mode Controls 2158
Status and Warning Icons 2159
Battery Discharge Indicator 2160
Direction and Parking Brake Indicators 2160
Hazard Flashers and Lighting Controls 2161
Steer Angle Indicator 2161
System Time 2161
Load Weight Indicator 2161
System Off/Alert Screens 2162
Introduction 2162
System Off Screen 2162
Alert Screens 2162
Password Screen 2164
Introduction 2164
Password Screen 2164
Service Technician Password Setup 2164
Adding/Removing/Changing Passwords 2165
Password Log 2168
Activity Log Menu 2169
Introduction 2169
Operator Checklist Log 2169
Password Log 2171
Impact Events Log 2173
Calibration Menu 2175
Introduction 2175
Load Weight Calibration 2175
Return to Set Tilt Stop Point Calibration 2176
E-Hydraulic and Manual Valve Threshold Calibration 2176
Steering Wheel Center Point Calibration 2177
Steer Axle Position Calibration 2177
Steer Axle Center Point Calibration 2178
Manual Hydraulics Calibration 2179
Display Menu 2180
Introduction 2180
Set Date and Time Format Menu 2180
Set Daylight Saving Time Menu 2181
Procedure for Setting Up Automatic Daylight Savings Time 2182
Set Time and Date Menu 2184
Procedure for Setting Time and Date 2184
Set Units Menu 2185
Status Menu 2186
Introduction 2186
VSM Versions 2186
Display Versions 2187
Truck Serial Number 2187
Hour Meters 2187
E-Hydraulic Controller Versions 2187
Pump Motor Controller Versions 2187
Traction Motor Controller 1 Versions 2187
Traction Motor Controller 2 Versions 2188
Light Controller Versions 2188
Impact Sensor Versions 2188
Truck Setup Menu 2189
Introduction 2189
Add/Remove Password 2189
Battery Settings 2189
Restore Default Settings 2190
Motion Alarm 2190
Impact Monitor Settings 2190
Impact Detection 2191
Setting Adjustments 2191
Initial Adjustment of Soft and Hard Impact Settings 2191
Readjustment of Soft and Hard Impact Settings 2191
Auto Power-Off Time Delay 2192
Return to Set Tilt 2192
Traction Speed Limit 2192
Scheduled Maintenance Reminder 2193
Minimum Pump Standby Flow Rate 2194
Operator Checklist 2194
Impact Monitor Shutdown 2195
Motor Braking 2196
Changing the Motor Braking Settings 2196
Steering Wheel Friction and Steering Turns Adjustment 2197
How to Adjust Settings 2197
Steering Friction Setting 2197
Steering Wheel Number of Turns 2198
524319498-2200YRM1336-(02-2023)-UK-EN 2201
General 2209
Description 2209
Display Panel Menu Access 2209
Menu Flowchart 2210
Technician Menu Flowchart 2210
Menu Navigation 2216
Icon Glossary 2220
Introduction 2220
Soft Key Icons 2220
Overlay Icons 2221
Heat Exchange Module Warning Indicator Screen 2221
System Off Screen and Alert Screens 2222
Main Menu Title Screens 2228
Submenu Icons Grouped by Menu 2229
Operating Screen Icons 2229
Password Screen Icons 2231
Activity Log Submenu Icons 2231
Calibration Submenu Icons 2232
Display Submenu Icons 2236
Status Submenu Icons 2238
Truck Setup Submenu Icons 2241
Diagnostics Submenu Icons 2253
Operating Screen 2263
Introduction 2263
Performance Mode Controls 2263
Status and Warning Icons 2264
Battery Discharge Indicator 2265
Direction and Parking Brake Indicators 2265
Hazard Flashers and Lighting Controls 2266
Steer Angle Indicator 2266
System Time 2266
Load Weight Indicator 2266
System Off/Alert Screens 2267
Introduction 2267
System Off Screen 2267
Alert Screens 2267
Password Screen 2269
Introduction 2269
Password Screen 2269
Service Technician Password Setup 2269
Adding/Removing/Changing Passwords 2270
Password Log 2273
Activity Log Menu 2274
Introduction 2274
Operator Checklist Log 2274
Password Log 2276
Impact Events Log 2278
Calibration Menu 2280
Introduction 2280
Load Weight Calibration 2280
Return to Set Tilt Stop Point Calibration 2281
E-Hydraulic and Manual Valve Threshold Calibration 2281
Steering Wheel Center Point Calibration 2282
Steer Axle Position Calibration 2283
Steer Axle Center Point Calibration 2284
Manual Hydraulics Calibration 2284
Display Menu 2285
Introduction 2285
Set Date and Time Format Menu 2285
Set Daylight Saving Time Menu 2286
Procedure for Setting Up Automatic Daylight Savings Time 2287
Set Time and Date Menu 2289
Procedure for Setting Time and Date 2289
Set Units Menu 2290
Status Menu 2291
Introduction 2291
VSM Versions 2291
Display Versions 2292
Truck Serial Number 2292
Hour Meters 2292
E-Hydraulic Controller Versions 2292
Pump Motor Controller Versions 2292
Traction Motor Controller 1 Versions 2292
Traction Motor Controller 2 Versions 2293
Light Controller Versions 2293
Impact Sensor Versions 2293
E-Steer Controller 1 Versions 2293
E-Steer Controller 2 Versions 2293
Truck Setup Menu 2294
Introduction 2294
Add/Remove Password 2295
Battery Settings 2295
Motor Braking 2295
Changing the Motor Braking Settings 2296
Battery Mode 2296
Battery Setup 2297
BDI Adjustment Setting 2298
Acceleration Rates 2299
Hour Meter Initialization 2300
Impact Monitor Shutdown 2300
Operator Checklist 2302
Minimum Pump Standby Flow Rate 2302
Scheduled Maintenance Reminder 2303
Traction Speed Limit 2304
Return to Set Tilt 2304
Auto Power-Off Time Delay 2305
Impact Monitor Settings 2305
Impact Detection 2306
Setting Adjustments 2306
Initial Adjustment of Soft and Hard Impact Settings 2306
Readjustment of Soft and Hard Impact Settings 2306
Motion Alarm 2306
Lift Hydraulic Function Maximum Speed and Ramp Times 2307
Lower Hydraulic Function Maximum Speed and Ramp Times 2307
Tilt Forward Hydraulic Function Maximum Speed and Ramp Times 2308
Tilt Backward Hydraulic Function Maximum Speed and Ramp Times 2308
Auxiliary 1A Hydraulic Function Maximum Speed and Ramp Times 2308
Auxiliary 1B Hydraulic Function Maximum Speed and Ramp Times 2308
Auxiliary 2A Hydraulic Function Maximum Speed and Ramp Times 2308
Auxiliary 2B Hydraulic Function Maximum Speed and Ramp Times 2308
Optional Hydraulic Functions 2308
Rear Lights Control 2309
Restore Default Settings 2309
Steering Wheel Friction and Steering Turns Adjustment 2310
Navigation 2311
How to Adjust Settings 2311
Steering Friction 2311
Steering Wheel Number of Turns 2312
Diagnostics Menu 2314
Introduction 2314
Fault Code Log 2314
Fault Log Details 2315
Speedometer 2316
Direction Switch 2316
Traction Motor 1 Status 2317
Traction Motor 2 Status 2317
Occupancy Sensor 2317
Brake System Sensors 2317
Pump Status 2318
Hydraulic Control Inputs 2319
E-Hydraulic Valves 2319
Hydraulic Sensors 2320
System Voltages 2320
Steering Position Sensors 2322
E-Steering Position Sensors 2322
Electric Brake 2323
Navigation 2324
ESS Diagnostics Menus A, B, and C 2325
Menu A 2325
Menu B 2326
Menu C 2328
524319498-2200YRM1336-(07-2020)-UK-EN 2331
General 2337
Description 2337
Display Panel Menu Access 2337
Menu Flowchart 2338
Technician Menu Flowchart 2338
Menu Navigation 2344
Icon Glossary 2348
Introduction 2348
Soft Key Icons 2348
Overlay Icons 2349
Heat Exchange Module Warning Indicator Screen 2349
System Off Screen and Alert Screens 2350
Main Menu Title Screens 2355
Submenu Icons Grouped by Menu 2357
Operating Screen Icons 2357
Password Screen Icons 2358
Activity Log Submenu Icons 2358
Calibration Submenu Icons 2360
Display Submenu Icons 2363
Status Submenu Icons 2365
Truck Setup Submenu Icons 2369
Diagnostics Submenu Icons 2380
Operating Screen 2390
Introduction 2390
Performance Mode Controls 2390
Status and Warning Icons 2391
Battery Discharge Indicator 2392
Direction and Parking Brake Indicators 2393
Hazard Flashers and Lighting Controls 2393
Steer Angle Indicator 2393
System Time 2393
Load Weight Indicator 2393
System Off/Alert Screens 2394
Introduction 2394
System Off Screen 2394
Alert Screens 2394
Password Screen 2396
Introduction 2396
Password Screen 2396
Service Technician Password Setup 2396
Adding/Removing/Changing Passwords 2397
Password Log 2399
Activity Log Menu 2400
Introduction 2400
Operator Checklist Log 2400
Password Log 2402
Impact Events Log 2404
Calibration Menu 2406
Introduction 2406
Load Weight Calibration 2406
Return to Set Tilt Stop Point Calibration 2407
E-Hydraulic and Manual Valve Threshold Calibration 2407
Steering Wheel Center Point Calibration 2408
Steer Axle Position Calibration 2409
Steer Axle Center Point Calibration 2409
Manual Hydraulics Calibration 2410
Display Menu 2411
Introduction 2411
Set Date and Time Format Menu 2411
Set Daylight Saving Time Menu 2412
Procedure for Setting Up Automatic Daylight Savings Time 2413
Set Time and Date Menu 2415
Procedure for Setting Time and Date 2415
Set Units Menu 2416
Status Menu 2417
Introduction 2417
VSM Versions 2417
Display Versions 2418
Truck Serial Number 2418
Hour Meters 2418
E-Hydraulic Controller Versions 2418
Pump Motor Controller Versions 2418
Traction Motor Controller 1 Versions 2418
Traction Motor Controller 2 Versions 2419
Light Controller Versions 2419
Impact Sensor Versions 2419
E-Steer Controller 1 Versions 2419
E-Steer Controller 2 Versions 2419
Truck Setup Menu 2420
Introduction 2420
Add/Remove Password 2421
Battery Settings 2421
Motor Braking 2421
Changing the Motor Braking Settings 2422
Battery Mode 2422
Battery Setup 2423
BDI Adjustment Setting 2424
Acceleration Rates 2425
Hour Meter Initialization 2426
Impact Monitor Shutdown 2426
Operator Checklist 2427
Minimum Pump Standby Flow Rate 2428
Scheduled Maintenance Reminder 2428
Traction Speed Limit 2430
Return to Set Tilt 2430
Auto Power-Off Time Delay 2430
Impact Monitor Settings 2431
Impact Detection 2431
Setting Adjustments 2431
Initial Adjustment of Soft and Hard Impact Settings 2431
Readjustment of Soft and Hard Impact Settings 2432
Motion Alarm 2432
Lift Hydraulic Function Maximum Speed and Ramp Times 2432
Lower Hydraulic Function Maximum Speed and Ramp Times 2433
Tilt Forward Hydraulic Function Maximum Speed and Ramp Times 2433
Tilt Backward Hydraulic Function Maximum Speed and Ramp Times 2433
Auxiliary 1A Hydraulic Function Maximum Speed and Ramp Times 2433
Auxiliary 1B Hydraulic Function Maximum Speed and Ramp Times 2434
Auxiliary 2A Hydraulic Function Maximum Speed and Ramp Times 2434
Auxiliary 2B Hydraulic Function Maximum Speed and Ramp Times 2434
Optional Hydraulic Functions 2434
Rear Lights Control 2434
Restore Default Settings 2435
Steering Wheel Friction and Steering Turns Adjustment 2435
Navigation 2436
How to Adjust Settings 2436
Steering Friction 2436
Steering Wheel Number of Turns 2437
Diagnostics Menu 2439
Introduction 2439
Fault Code Log 2439
Fault Log Details 2440
Speedometer 2441
Direction Switch 2441
Traction Motor 1 Status 2441
Traction Motor 2 Status 2442
Occupancy Sensor 2442
Brake System Sensors 2442
Pump Status 2443
Hydraulic Control Inputs 2443
E-Hydraulic Valves 2443
Hydraulic Sensors 2444
System Voltages 2444
Steering Position Sensors 2445
E-Steering Position Sensors 2445
Electric Brake 2446
Navigation 2447
524319499-2200YRM1369-(01-2020)-UK-EN 2449
General 2457
Discharging the Capacitors 2458
Display Panel and Key or Keyless Switch Replacement 2459
Display Panel, Replace 2459
Remove 2459
Install 2462
Electronic and Manual Hydraulic Controls 2463
General 2463
Manual Hydraulic Controls 2464
Upper Front Cover 2464
Direction Control Switch 2465
Remove 2465
Install 2470
Clamp Button 2470
Remove 2470
Install 2471
Return To Set Tilt (RTST) Button 2471
Remove 2471
Install 2471
Emergency Disconnect Switch 2472
Remove 2472
Install 2472
E-Hydraulic Controls – Test 2473
Mini-Levers 2473
Full Stroke Test 2473
Function Returns to Neutral Test 2473
Push (Override) Button 2474
E-Hydraulic Controls 2474
Mini-levers, Remove and Install 2474
Armrest Assembly 2475
Remove 2475
Install 2477
Horn Button 2477
Remove 2477
Install 2478
Direction Control Switch 2478
Remove 2478
Install 2479
Emergency Disconnect Switch 2479
Remove 2479
Install 2480
Push (Override) Buttons and Function Selection Button 2480
Remove 2480
Install 2482
Electronic-Hydraulic Controls, After January, 2020 2482
General 2482
E-Hydraulic Controls – TEST 2484
Mini-Levers 2484
Full Stroke Test 2484
Function Returns to Neutral Test 2484
Push Button (push (override) button) 2485
Mini-levers, Remove and Install 2485
Armrest Assembly 2485
Remove 2485
Install 2488
Horn Button 2488
Remove 2488
Install 2489
Direction Control Switch 2489
Remove 2489
Install 2489
Emergency Disconnect Switch 2489
Remove 2490
Install 2490
Push (Override) Buttons 2491
Remove 2491
Install 2492
Sensors and Switches 2493
General 2493
Synchronous Steering Valve 2493
Steering Axle Sensor 2493
Remove 2493
Install 2498
Hydraulic Motor Speed Sensor 2499
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 2499
Remove 2499
Install 2504
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2505
Remove 2505
Install 2509
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 2509
Remove 2509
Install 2510
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2510
Remove 2510
Install 2512
Hydraulic Motor Temperature Sensor 2512
Hydraulic Tank Level Sensor 2512
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2512
Remove 2512
Install 2514
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 2514
Remove 2514
Install 2515
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2515
Remove 2515
Install 2516
Hydraulic Filter Sensor 2516
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2516
Remove 2516
Install 2517
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968,) ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2518
Remove 2518
Install 2519
Hydraulic Oil Temperature Sensor 2520
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2520
Remove 2520
Install 2520
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 2520
Remove 2520
Install 2521
Traction Speed Sensor 2521
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2521
Remove 2521
Install 2523
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 2524
Remove 2524
Install 2526
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2526
Remove 2526
Install 2527
Traction Motor Temperature Sensor ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 2528
Traction Motor Temperature Sensor ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2528
Remove 2528
Install 2529
Tilt Position Sensor ERC22-35VG (ERC045-070VG) (A968), ERP22-35VL (ERP045-070VL) (A976), and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2529
Remove 2529
Install 2531
Tilt Position Sensor ERC16-20VA (ERC030-040VA) (A969) 2532
Remove 2532
Install 2532
Tilt Position Sensor ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2533
Remove 2533
Install 2534
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) 2535
Remove 2535
Install 2538
Low Level Brake Fluid Switch for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2539
Remove 2539
Install 2540
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) 2541
Remove 2541
Install 2541
Service Brake Pressure Sensor for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2542
Remove 2542
Install 2542
Accelerator Pedal Position Sensor 2542
Remove 2542
Install 2543
Seat Belt Sequence Module 2543
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2543
Remove 2543
Install 2543
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 2544
Remove 2544
Install 2544
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 2544
Remove 2544
Install 2545
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2545
Remove 2545
Install 2546
Seat Sensor (Operator Presence System) 2546
Non-Suspension Seat 2546
Remove 2546
Install 2548
Full Suspension and Swivel Seats 2548
Remove 2548
Install 2549
Steering Direction Sensor 2549
Remove 2549
Install 2550
Load Weight Sensor 2550
Remove 2550
Install 2552
Battery Gate Switch 2552
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2552
Remove 2552
Install 2554
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 2554
Remove 2554
Install 2556
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2557
Remove 2557
Install 2558
Horn Switch 2558
Fixed Steering Column 2558
Remove 2558
Install 2559
Telescopic Steering Column 2559
Remove 2559
Install 2560
Impact Sensor 2560
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2560
Remove 2560
Install 2562
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 2562
Remove 2562
Install 2563
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2564
Remove 2564
Install 2565
Rear and Hood Horn Button Switches 2565
Rear Horn Button Switch 2565
Remove 2565
Install 2566
Hood Horn Button Switch 2566
Remove 2566
Install 2567
Motor Controllers Replacement 2568
General 2568
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 2582
Traction Motor and Hydraulic Pump and Motor Controllers 2582
Remove 2582
Install 2589
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2590
Hydraulic Pump and Motor Controller 2590
Remove 2590
Install 2596
Traction Motor Controllers 2597
Remove 2597
Install 2604
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2605
Traction Motor and Hydraulic Pump and Motor Controllers 2605
Remove 2605
Install 2607
Line Contactor 2608
Remove 2608
Install 2616
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) 2617
Remove 2617
Install 2619
Fans for Lift Truck Model Manufactured Before November 2014ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2620
Remove 2620
Install 2620
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) 2620
Remove 2627
Install 2631
Vehicle System Manager 2631
General 2631
Remove 2632
Install 2636
Programming a New VSM and/or Display Panel 2637
PC Service Tool Software 2637
Fuses and Relays 2638
Backup Alarm 2652
Battery Connection 2655
Inspect 2655
Replacing Cables 2655
Cab Heater 2657
Lights 2657
General 2657
Work Lights (Front and Rear) 2661
Halogen Bulb Lights 2661
Remove 2661
Install 2661
LED Lights 2661
Remove 2661
Install 2662
Strobe Light 2662
Remove 2662
Install 2662
LED Tail, Backup, and Brake Lights 2663
Remove 2663
Install 2664
Front Marker/Turn Signal Lights 2664
Remove 2664
Install 2664
Dome Light 2664
Remove 2664
Install 2665
Converter 2665
Remove 2666
Install 2674
524319499-2200YRM1369-(04-2023)-UK-EN 2677
General 2687
Discharging the Capacitors 2688
Display Panel and Key or Keyless Switch Replacement 2689
Display Panel, Replace 2689
Remove 2689
Install 2692
Electronic and Manual Hydraulic Controls 2693
General 2693
Manual Hydraulic Controls 2694
Upper Front Cover 2694
Direction Control Switch 2695
Remove 2695
Install 2701
Clamp Button 2701
Remove 2701
Install 2702
Return To Set Tilt (RTST) Button 2702
Remove 2702
Install 2702
Emergency Disconnect Switch 2703
Remove 2703
Install 2703
E-Hydraulic Controls – Test 2704
Mini-Levers 2704
Full Stroke Test 2704
Function Returns to Neutral Test 2704
Push (Override) Button 2705
E-Hydraulic Controls 2705
Mini-levers, Remove and Install 2705
Armrest Assembly 2706
Remove 2706
Install 2708
Horn Button 2708
Remove 2708
Install 2709
Direction Control Switch 2709
Remove 2709
Install 2710
Emergency Disconnect Switch 2710
Remove 2710
Install 2711
Push (Override) Buttons and Function Selection Button 2711
Remove 2711
Install 2714
Electronic-Hydraulic Controls, After January, 2020 2715
General 2715
E-Hydraulic Controls – TEST 2716
Mini-Levers 2716
Full Stroke Test 2716
Function Returns to Neutral Test 2716
Push Button (push (override) button) 2717
Mini-levers, Remove and Install 2717
Armrest Assembly 2717
Remove 2717
Install 2720
Horn Button 2720
Remove 2720
Install 2720
Direction Control Switch 2720
Remove 2720
Install 2721
Emergency Disconnect Switch 2721
Remove 2721
Install 2722
Push (Override) Buttons 2722
Remove 2722
Install 2723
Sensors and Switches 2724
General 2724
Synchronous Steering Valve 2724
Steering Axle Sensor 2724
Remove 2724
Install 2729
Hydraulic Motor Speed Sensor 2730
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 2730
Remove 2730
Install 2735
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2736
Remove 2736
Install 2740
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 2740
Remove 2740
Install 2741
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2741
Remove 2741
Install 2743
Hydraulic Motor Temperature Sensor 2743
Hydraulic Tank Level Sensor 2743
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2743
Remove 2743
Install 2745
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 2745
Remove 2745
Install 2746
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2746
Remove 2746
Install 2747
Hydraulic Filter Sensor 2747
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2747
Remove 2747
Install 2748
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968,) ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2749
Remove 2749
Install 2750
Hydraulic Oil Temperature Sensor 2751
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2751
Remove 2751
Install 2751
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 2751
Remove 2751
Install 2752
Traction Speed Sensor 2752
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2752
Remove 2752
Install 2754
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 2755
Remove 2755
Install 2757
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2757
Remove 2757
Install 2758
Traction Motor Temperature Sensor ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 2759
Traction Motor Temperature Sensor ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2759
Remove 2759
Install 2760
Tilt Position Sensor ERC22-35VG (ERC045-070VG) (A968), ERP22-35VL (ERP045-070VL) (A976), and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2760
Remove 2760
Install 2762
Tilt Position Sensor ERC16-20VA (ERC030-040VA) (A969) 2762
Remove 2763
Install 2763
Tilt Position Sensor ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2763
Remove 2763
Install 2764
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) 2765
Remove 2765
Install 2768
Low Level Brake Fluid Switch for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2769
Remove 2769
Install 2770
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) 2771
Remove 2771
Install 2771
Service Brake Pressure Sensor for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2771
Remove 2771
Install 2772
Accelerator Pedal Position Sensor 2772
Remove 2772
Install 2772
Seat Belt Sequence Module 2773
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2773
Remove 2773
Install 2774
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 2774
Remove 2774
Install 2774
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 2774
Remove 2774
Install 2775
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2775
Remove 2775
Install 2775
Seat Sensor (Operator Presence System) 2776
Non-Suspension Seat 2776
Remove 2776
Install 2778
Full Suspension and Swivel Seats 2778
Remove 2778
Install 2779
Steering Direction Sensor 2779
Remove 2779
Install 2779
Load Weight Sensor 2780
Remove 2780
Install 2781
Battery Gate Switch 2782
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2782
Remove 2782
Install 2784
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 2784
Remove 2784
Install 2786
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2786
Remove 2786
Install 2787
Horn Switch 2788
Fixed Steering Column 2788
Remove 2788
Install 2789
Telescopic Steering Column 2789
Remove 2789
Install 2790
Impact Sensor 2790
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2790
Remove 2790
Install 2792
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 2792
Remove 2792
Install 2793
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2794
Remove 2794
Install 2795
Rear and Hood Horn Button Switches 2795
Rear Horn Button Switch 2795
Remove 2795
Install 2796
Hood Horn Button Switch 2796
Remove 2796
Install 2797
Motor Controllers Replacement 2798
General 2798
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 2812
Traction Motor and Hydraulic Pump and Motor Controllers 2812
Remove 2812
Install 2819
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2819
Hydraulic Pump and Motor Controller 2819
Remove 2819
Install 2826
Traction Motor Controllers 2827
Remove 2827
Install 2834
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2835
Traction Motor and Hydraulic Pump and Motor Controllers 2835
Remove 2835
Install 2837
Line Contactor 2838
Remove 2838
Install 2845
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) 2847
Remove 2847
Install 2849
Fans for Lift Truck Model Manufactured Before November 2014 ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2850
Remove 2850
Install 2850
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) 2850
Remove 2857
Install 2861
Vehicle System Manager 2862
General 2862
Remove 2862
Install 2867
Programming a New VSM and/or Display Panel 2868
PC Service Tool Software 2868
Fuses and Relays 2869
Backup Alarm 2883
Battery Connection 2887
Inspect 2887
Replacing Cables 2887
Cab Heater 2889
Lights 2889
General 2889
Work Lights (Front and Rear) 2893
Halogen Bulb Lights 2893
Remove 2893
Install 2893
LED Lights 2893
Remove 2893
Install 2894
Strobe Light 2894
Remove 2894
Install 2894
LED Tail, Backup, and Brake Lights 2895
Remove 2895
Install 2896
Front Marker/Turn Signal Lights 2896
Remove 2896
Install 2896
Dome Light 2896
Remove 2896
Install 2897
Converter 2897
Remove 2897
Install 2906
524319500-4000YRM1338-(04-2023)-UK-EN 2909
General 2915
Safety Procedures When Working Near Mast 2917
Fork Replacement 2920
Remove 2920
Install 2921
Checks 2921
Carriages Repair 2923
Standard Carriage 2923
Remove 2923
Clean and Inspect 2924
Install 2924
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 2925
Remove 2925
Clean and Inspect 2928
Repair 2929
Install 2929
Integral Sideshift Carriage, Lift Trucks Manufactured After December, 2016 2930
Remove 2930
Disassemble 2934
Clean and Inspect 2934
Assemble 2935
Install 2936
Fork Positioner, Lift Trucks Manufactured Prior To December, 2016 2936
Remove 2937
Clean and Inspect 2940
Disassemble and Assemble 2940
Install 2940
Fork Positioner Hydraulic Hose Adjustment 2942
Fork Positioner Carriage, Lift Trucks Manufactured After December, 2016 2943
Remove 2943
Clean and Inspect 2948
Disassemble and Assemble 2948
Install 2948
Fork Positioner Hydraulic Hose Adjustment 2949
Two-Stage Mast With Limited Free-Lift Repair 2951
Remove 2951
Disassemble 2955
Clean and Inspect 2958
Assemble 2961
Install 2961
Header Hose Installation and Adjustment 2964
Installation 2964
Adjustment 2971
Two-Stage Mast With Full Free-Lift Repair 2972
Remove 2972
Disassemble 2976
Clean and Inspect 2979
Assemble 2982
Install 2983
Header Hose Installation and Adjustment 2985
Installation 2985
Adjustment 2994
Three-Stage Mast With Full Free-Lift Repair 2995
Remove 2995
Disassemble 3000
Clean and Inspect 3003
Assemble 3005
Install 3006
Header Hose Installation and Adjustment 3009
Installation 3009
Adjustment 3019
Four-Stage Mast With Full Free-Lift Repair 3020
Remove 3020
Disassemble 3025
Clean and Inspect 3030
Assemble 3032
Install 3035
Header Hose Installation and Adjustment 3036
Installation 3036
Adjustment 3045
Quick Disconnect Attachments 3045
Disconnect 3045
Reconnect 3045
Lift Chains Adjustment 3047
Carriage Adjustments 3049
Mast Adjustments 3049
Load Roller, Adjust 3049
Mast Side Kicking, Adjust 3052
524319500-4000YRM1338-(10-2017)-UK-EN 3055
General 3059
Safety Procedures When Working Near Mast 3060
Fork Replacement 3063
Remove 3063
Install 3064
Checks 3065
Carriages Repair 3066
Standard Carriage 3066
Remove 3066
Clean and Inspect 3067
Install 3068
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 3068
Remove 3068
Clean and Inspect 3072
Repair 3072
Install 3073
Integral Sideshift Carriage, Lift Trucks Manufactured After December, 2016 3074
Remove 3074
Disassemble 3078
Clean and Inspect 3078
Assemble 3079
Install 3080
Fork Positioner, Lift Trucks Manufactured Prior To December, 2016 3080
Remove 3080
Clean and Inspect 3083
Disassemble and Assemble 3084
Install 3084
Fork Positioner Hydraulic Hose Adjustment 3085
Fork Positioner Carriage, Lift Trucks Manufactured After December, 2016 3087
Remove 3087
Clean and Inspect 3091
Disassemble and Assemble 3091
Install 3091
Fork Positioner Hydraulic Hose Adjustment 3092
Two-Stage Mast With Limited Free-Lift Repair 3093
Remove 3093
Disassemble 3097
Clean and Inspect 3099
Assemble 3101
Install 3102
Header Hose Installation and Adjustment 3104
Installation 3104
Adjustment 3111
Two-Stage Mast With Full Free-Lift Repair 3111
Remove 3111
Disassemble 3115
Clean and Inspect 3118
Assemble 3120
Install 3121
Header Hose Installation and Adjustment 3124
Installation 3124
Adjustment 3132
Three-Stage Mast With Full Free-Lift Repair 3132
Remove 3132
Disassemble 3136
Clean and Inspect 3139
Assemble 3141
Install 3142
Header Hose Installation and Adjustment 3144
Installation 3144
Adjustment 3153
Four-Stage Mast With Full Free-Lift Repair 3154
Remove 3154
Disassemble 3158
Clean and Inspect 3163
Assemble 3165
Install 3167
Header Hose Installation and Adjustment 3170
Installation 3170
Adjustment 3178
Quick Disconnect Attachments 3179
Disconnect 3179
Reconnect 3179
Lift Chains Adjustment 3180
Carriage Adjustments 3182
Mast Adjustments 3182
Load Roller, Adjust 3182
Mast Side Kicking, Adjust 3184
524319504-9000YRM1377-(09-2019)-UK-EN 3187
SECTION 9010 Operational Diagnostic Procedures 3203
Group 05 – Operational Checkout 3205
SECTION 9025 Traction Motor 3215
Group 10 – Principles of Operation 3217
Group 30 – Observed Symptoms 3223
SECTION 9030 Electrical System 3225
Group 03 – General Maintenance and Diagnostic Data 3235
Group 10 – Principles of Operation 3279
Group 20 – Diagnostic Trouble Codes 3311
Group 30 – Observed Symptoms 3923
Group 55 – Icons and Graphics 3967
SECTION 9035 Drive Axle/Unit 3975
Group 10 – Principles of Operation 3977
Group 30 – Observed Symptoms 3987
Group 20 – Diagnostic Trouble Codes 3999
SECTION 9050 Hydraulic Systems 4001
Group 10 – Principles of Operation 4005
Group 33 – Observed Symptoms-Gear Pump 4043
Group 43 – Tests and Adjustments-Gear Pump 4123
SECTION 9060 Operators Station 4153
Group 10 – Principles of Operation 4155
SECTION 9070 Front End (Mast) and Chassis 4195
Group 10 – Principles of Operation 4197
Group 30 – Observed Symptoms 4215
SECTION 9080 Supplementary Data 4259
Group 50 – Abbreviations and Acronyms 4261
524319751-1300YRM1370-(04-2023)-UK-EN 4269
General 4275
Discharging the Capacitors 4275
Description 4276
Transaxle Assembly 4277
Remove 4277
Install 4285
Maintenance and Repair 4288
Wheel Studs 4288
Removal of Defective Wheel Studs 4288
Removal of Sheared Off Wheel Stud 4288
Installation 4290
Transaxle Output Breathers 4290
Removal 4290
Installation 4291
Speed Sensor Repair 4292
Removal 4292
Installation 4293
Protective Cap 4293
Removal 4293
Installation 4294
Traction Motor 4294
Removal 4294
Installation 4295
Park Brake Actuator 4296
Removal 4296
Repair 4297
O-ring Replacement 4297
Rotary Shaft Seal Replacement 4297
Breather Valve Replacement 4298
Installation 4298
Service Brake Actuator 4300
Removal 4300
Repair 4300
Installation 4302
Brake Disc Set and Ball Ramp Actuator 4303
Removal 4303
Installation 4304
Output Assembly 4306
Removal 4306
Installation 4308
First Transmission Stage 4309
Removal 4309
Installation 4311
Alternate Pinion Installation 4316
Brake Pedal and Linkages 4318
General 4318
Master Cylinder Repair 4318
Remove 4318
Disassemble 4320
Clean 4321
Inspect 4322
Assemble 4322
Bench Bleed Master Cylinder 4322
Install and Adjust 4322
Brake Pedal Components 4323
Remove 4323
Disassemble 4323
Inspect 4324
Assemble 4324
Install 4324
Brake Pedal and Master Cylinder Adjustments 4324
Brake Pedal Adjustment 4324
Master Cylinder Adjustment 4325
Adjust Push Rod 4325
Parking Brake Valve Repair 4326
Remove 4326
Disassemble 4328
Assemble 4329
Install 4329
Tools 4330
524319751-1300YRM1370-(08-2014)-UK-EN 4333
524319753-8000YRM1372-(04-2019)-UK-EN 4393
General 4399
Serial Number Data 4399
Discharging the Capacitors 4400
How to Move Disabled Lift Truck 4400
How to Tow Lift Truck 4400
How to Put Lift Truck on Blocks 4401
How to Raise Drive Tires 4401
How to Raise Steering Tires 4401
How to Clean a Lift Truck 4402
Maintenance Schedule 4403
Maintenance Procedures Every 8 Hours or Daily 4408
How to Make Checks With Key or Keyless Switch OFF 4408
Tires and Wheels 4408
Forks 4409
General 4409
Inspect 4409
Remove 4410
Install 4412
Adjustment 4412
Inspection of Mast, Carriage, Header Hoses, Lift Chains, and Attachments 4413
Safety Labels 4413
Steering Column Adjustments 4414
Tilt Adjust Feature 4414
Tilt Memory Feature 4414
Telescopic Feature 4414
Operator Restraint System 4414
Emergency Locking Retractor (ELR) 4415
Seat Adjustments 4416
Seat Position Adjustment (Standard Seat) 4416
Seat Position Adjustment (Swivel Seat) 4416
Seat Adjustment for Operator Weight 4416
Battery Restraint System 4417
Hood Latch and Hood Release Handle 4422
Battery 4424
Hydraulic System 4425
How to Make Checks With Key or Keyless Switch ON 4426
Horn, Lights, and Backup Alarm 4426
Motion Alarm 4427
Emergency Disconnect Switch 4427
Steering System 4428
Service Brakes 4429
Automatic Parking Brake 4429
Hydraulic Control Levers and Pedals 4429
Direction and Speed Control Pedals 4429
Lift System Operation 4429
Oil Leaks 4430
Maintenance Procedures Every 500 Hours or Three Months 4430
Forks 4430
Inspect 4430
Header Hose Checks 4431
Mast Lubrication 4432
Brake Fluid Check 4436
Master Cylinder Oil Check 4436
Bleeding the Brake System 4439
Operator Presence System Check 4441
Drive Axle Unit Assembly, Gear Oil Level Check 4441
Drive Axle Unit Assembly, Wet Brake Oil Level Check 4442
Tilt Cylinder Rod End Pins 4444
Lift Chains 4444
Wear Check 4444
Lift Chain Lubrication 4445
Fork Pins and Guides 4446
Check Upper and Lower Bearings, Integral Sideshift Carriage 4446
Check Lower Mounting Hook, Integral Sideshift Carriage 4447
Hydraulic Tank Breather, Check 4448
Electrical Inspection 4449
Line Contactor 4449
Steering Axle 4452
King Pins and Tie Rods, Lubricate 4452
Other Lubrication 4453
Hydraulic Control Levers 4453
Cab Heater 4453
Maintenance Procedures Every 2000 Hours or Yearly 4453
Hydraulic System 4453
Hydraulic Filter Element, Replace 4453
Hydraulic Tank Breather, Change 4455
Service Brakes 4456
Master Cylinder Oil, Change 4456
Forks, Inspect 4458
Integral Sideshift Carriage, Replace Upper and Lower Bearings 4459
Lift Chains 4459
Steer Wheel Bearings, Lubricate 4460
Maintenance Procedures Every 4000 Hours or Two Years 4460
Hydraulic Oil Change 4460
Steering Direction Sensor Inspection 4463
Fixed Steering Column 4463
Telescopic Steering Column 4465
Telescopic Steering Column Lubrication 4466
Drive Axle Unit Assembly, Gear Oil Change 4467
Drive Axle Unit Assembly, Wet Brake Oil Change 4468
Battery Maintenance 4470
How to Charge Battery 4471
Rapid Charge 4472
How to Change Batteries 4473
General 4473
Remove the Battery 4474
Install the Battery 4481
How to Change Batteries, Forklift Removal System 4482
Lift and Tilt System Leak Check 4485
Lift Cylinder Leak Check 4485
Tilt Cylinder Leak Check 4486
Safety Procedures When Working Near Mast 4486
WHEN WORKING NEAR THE MAST ALWAYS: 4486
Lift Chain Adjustments 4489
Welding Repairs 4490
Overhead Guard Changes 4491
Wheels and Tires 4491
General 4491
Pneumatic Tires Repair 4491
Remove Wheels From Lift Truck 4491
Remove Tire From Wheel 4492
Install Wheel in Tire 4495
Add Air to Pneumatic Tires With Tube 4497
Wheels, Install 4498
Solid Rubber Tires on Pneumatic Wheels, Change 4498
Wheels, Install 4502
524319753-8000YRM1372-(07-2023)-UK-EN 4505
General 4513
Serial Number Data 4513
Discharging the Capacitors 4514
How to Move Disabled Lift Truck 4514
How to Tow Lift Truck 4514
How to Put Lift Truck on Blocks 4515
How to Raise Drive Tires 4515
How to Raise Steering Tires 4516
How to Clean a Lift Truck 4517
Maintenance Schedule 4518
Maintenance Procedures Every 8 Hours or Daily 4523
How to Make Checks With Key or Keyless Switch OFF 4523
Tires and Wheels 4523
Forks 4523
General 4523
Inspect 4523
Remove 4524
Install 4526
Adjustment 4527
Visual Inspection of Mast, Mast hardware, and Tilt Cylinder Hardware 4527
Inspection of Mast, Carriage, Header Hoses, Lift Chains, and Attachments 4527
Safety Labels 4528
Steering Column Adjustments 4528
Tilt Adjust Feature 4529
Tilt Memory Feature 4529
Telescopic Feature 4529
Operator Restraint System 4529
Emergency Locking Retractor (ELR) 4531
Seat Adjustments 4531
Seat Position Adjustment (Standard Seat) 4531
Seat Position Adjustment (Swivel Seat) 4531
Seat Adjustment for Operator Weight 4531
Battery Restraint System 4533
Hood Latch and Hood Release Handle 4537
Battery 4539
Hydraulic System 4540
How to Make Checks With Key or Keyless Switch ON 4541
Horn, Lights, and Backup Alarm 4541
Motion Alarm 4542
Emergency Disconnect Switch 4542
Steering System 4544
Service Brakes 4544
Automatic Parking Brake 4544
Hydraulic Control Levers and Pedals 4544
Direction and Speed Control Pedals 4544
Lift System Operation 4544
Oil Leaks 4545
Maintenance Procedures Every 500 Hours or Three Months 4546
Forks 4546
Inspect 4546
Header Hose Checks 4547
Mast Lubrication 4548
Brake Fluid Check 4553
Master Cylinder Oil Check 4553
Bleeding the Brake System 4555
Operator Presence System Check 4557
Drive Axle Unit Assembly, Gear Oil Level Check 4557
Drive Axle Unit Assembly, Wet Brake Oil Level Check 4558
Tilt Cylinder Adjustments 4560
Tilt Cylinder Rod End Pins 4561
Lift Chains 4561
Wear Check 4561
Lift Chain Lubrication 4562
Fork Pins and Guides 4563
Check Upper and Lower Bearings, Integral Sideshift Carriage 4563
Check Lower Mounting Hook, Integral Sideshift Carriage 4565
Hydraulic Tank Breather, Check 4565
Electrical Inspection 4566
Line Contactor 4566
Steering Axle 4569
King Pins and Tie Rods, Lubricate 4569
Other Lubrication 4570
Hydraulic Control Levers 4570
Cab Heater 4570
Maintenance Procedures Every 2000 Hours or Yearly 4571
Hydraulic System 4571
Hydraulic Filter Element, Replace 4571
Hydraulic Tank Breather, Change 4573
Service Brakes 4574
Master Cylinder Oil, Change 4574
Forks, Inspect 4576
Integral Sideshift Carriage, Replace Upper and Lower Bearings 4578
Lift Chains 4578
Steer Wheel Bearings, Lubricate 4578
Maintenance Procedures Every 4000 Hours or Two Years 4579
Hydraulic Oil Change 4579
Steering Direction Sensor Inspection 4582
Fixed Steering Column 4582
Telescopic Steering Column 4584
Telescopic Steering Column Lubrication 4585
Drive Axle Unit Assembly, Gear Oil Change 4586
Drive Axle Unit Assembly, Wet Brake Oil Change 4587
Battery Maintenance 4590
How to Charge Battery 4590
Rapid Charge 4591
How to Change Batteries 4592
General 4592
Remove the Battery 4593
Install the Battery 4600
How to Change Batteries, Forklift Removal System 4601
Lift and Tilt System Leak Check 4605
Lift Cylinder Leak Check 4605
Tilt Cylinder Leak Check 4605
Safety Procedures When Working Near Mast 4606
WHEN WORKING NEAR THE MAST ALWAYS: 4606
Lift Chain Adjustments 4609
Welding Repairs 4611
Overhead Guard Changes 4612
Wheels and Tires 4613
General 4613
Pneumatic Tires Repair 4613
Remove Wheels From Lift Truck 4613
Remove Tire From Wheel 4613
Install Wheel in Tire 4617
Add Air to Pneumatic Tires With Tube 4620
Wheels, Install 4620
Solid Rubber Tires on Pneumatic Wheels, Change 4620
Wheels, Install 4624
524319754-8000YRM1375-(04-2023)-UK-EN 4627
Counterweights 4633
Hydraulic System 4633
Steering System 4634
Specifications 4634
Turning Radius 4634
Wheels and Tires 4635
Battery Specifications 4636
Capacities 4637
Tilt Angles 4637
Maximum Carriage and Tilt Creep Rates 4638
Mast Speeds 4639
Torque Specifications 4641
Frame 4641
Drive Axle, Speed Reducer, And Differential 4641
Steering Axle 4641
Masts 4641
Hydraulic Pump and Motor 4641
Hydraulic System 4641
Adhesives And Sealants 4642
524319754-8000YRM1375-(11-2019)-UK-EN 4645
Counterweights 4649
Hydraulic System 4649
Steering System 4650
Specifications 4650
Turning Radius 4650
Wheels and Tires 4651
Battery Specifications 4651
Capacities 4652
Tilt Angles 4653
Maximum Carriage and Tilt Creep Rates 4653
Mast Speeds 4654
Torque Specifications 4655
Frame 4655
Drive Axle, Speed Reducer, And Differential 4655
Steering Axle 4655
Masts 4656
Hydraulic Pump and Motor 4656
Hydraulic System 4656
Adhesives And Sealants 4656
524327049-0620YRM1385-(02-2023)-UK-EN 4659
General 4667
Discharging the Capacitors for Lift Truck Models ESC030-040AC (B883), ESC030-040AD (C883) 4673
Discharging the Capacitors (All Other Models) 4675
Traction Motor Repair 4676
For Lift Truck Models , and ERP15-20VT (ERP030-040VT) (G807)ERP16-20VF (ERP30-40VF) (A955), ESC030-040AC (B883) 4676
Remove 4676
Disassemble 4677
Electrical Connector Repair or Replacement 4679
Clean 4679
Inspect 4679
Assemble 4680
Install 4682
For Lift Truck ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 4684
Remove 4684
Disassemble 4684
Electrical Connector Repair or Replacement 4687
Clean 4687
Inspect 4687
Assemble 4688
Install 4688
For Lift Truck ERP2 2-3 5VL (ERP045-070VL) (A976) 4688
Remove 4688
Disassemble 4688
Clean 4690
Inspect 4690
Assemble 4691
Install 4691
For Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080120VM, ERP100VML) (A985) 4691
Remove 4691
Clean 4693
Install 4693
For Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 4693
Remove 4693
Disassemble 4693
Electrical Connector Repair or Replacement 4695
Clean 4695
Inspect 4695
Assemble 4696
Install 4697
Traction Motor Repair for 4-5 5T Lift Trucks 4698
For Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080120VM, ERP100VML) (A985) 4698
Remove 4698
Clean 4700
Install 4700
Hydraulic Motor Repair 4701
For Lift Trucks and ERP15-20VT (ERP030-040VT) (G807)ERP16-20VF (ERP30-40VF) (A955)ESC030-040AC (B883), ESC030-040AD (C883) 4701
Remove 4701
Disassemble 4702
Electrical Connector Repair or Replacement 4704
Clean 4704
Inspect 4704
Assemble 4705
Install 4707
For Lift Truck ERC22-35VG (ERC045-070VG) (A968) 4708
Remove 4708
Disassemble 4710
Standard Motor 4710
Enhanced Motor 4712
Electrical Connector Repair or Replacement 4713
Clean 4714
Inspect 4714
Assemble 4715
Standard Motor 4715
Enhanced Motor 4715
Install 4716
For Lift Truck Models ERP2 2-3 5VL (ERP045-070VL) (A976) and ERC16-20VA (ERC030-040VA) (A969) 4716
Remove 4716
Disassemble 4716
Electrical Connector Repair or Replacement 4722
Clean 4723
Inspect 4723
Assemble 4724
Install 4725
For Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 4725
Remove 4725
Disassemble 4725
Electrical Connector Repair or Replacement 4728
Clean 4728
Inspect 4729
Assemble 4729
Install 4730
Hydraulic Motor Repair For 4 0-5 5T Lift Trucks 4730
Remove 4730
Disassemble 4730
Electrical Connector Repair or Replacement 4732
Clean 4732
Inspect 4733
Assemble 4733
Install 4734
Torque Specifications 4735
Traction Motor for Lift Trucks and ERP15-20VT (ERP030-040VT) (G807)ERP16-20VF (ERP30-40VF) (A955) 4735
Traction Motor for Lift Truck and ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969),ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 4735
Traction Motor for Lift Truck ESC030-040AC (B883), ESC030-040AD (C883) 4735
Hydraulic Motor for Lift Trucks and ERP15-20VT (ERP030-040VT) (G807)ERP16-20VF (ERP30-40VF) (A955) 4735
Hydraulic Motor for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 4735
Hydraulic Motor for Lift Truck ERP22-35VG (ERP045-070VG) (A976) 4735
Hydraulic Motor for Lift Truck ERC16-20VA (ERC030-040VA) (A969) 4735
Hydraulic Motor for Lift Truck ESC030-040AC (B883), ESC030-040AD (C883) 4735
Hydraulic Motor for Lift Truck and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 4736
524327049-0620YRM1385-(06-2015)-UK-EN 4739
General 4743
Discharging the Capacitors for Lift Truck Models ESC030-040AC (B883), ESC030-040AD (C883) 4750
Discharging the Capacitors (All Other Models) 4751
Traction Motor Repair 4751
For Lift Truck Models ERP15-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), and ESC030-040AC (B883) 4752
Remove 4752
Disassemble 4753
Electrical Connector Repair or Replacement 4756
Clean 4756
Inspect 4756
Assemble 4757
Install 4760
For Lift Truck ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 4762
Remove 4762
Disassemble 4762
Electrical Connector Repair or Replacement 4766
Clean 4766
Inspect 4766
Assemble 4767
Install 4767
For Lift Truck ERP2 2-3 5VL (ERP045-070VL) (A976) 4767
Remove 4767
Disassemble 4767
Clean 4769
Inspect 4769
Assemble 4770
Install 4770
For Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 4770
Remove 4770
Disassemble 4771
Electrical Connector Repair or Replacement 4772
Clean 4772
Inspect 4773
Assemble 4773
Install 4774
4774
Traction Motor Repair For Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 4774
Remove 4774
Clean 4776
Install 4776
Hydraulic Motor Repair 4776
For Lift Trucks ERP15-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), and ESC030-040AC (B883), ESC030-040AD (C883) 4776
Remove 4776
Disassemble 4778
Electrical Connector Repair or Replacement 4780
Clean 4780
Inspect 4780
Assemble 4781
Install 4783
For Lift Truck ERC22-35VG (ERC045-070VG) (A968) 4785
Remove 4785
Disassemble 4786
Standard Motor 4786
Enhanced Motor 4787
Electrical Connector Repair or Replacement 4789
Clean 4790
Inspect 4791
Assemble 4791
Standard Motor 4791
Enhanced Motor 4792
Install 4793
For Lift Truck Models ERP2 2-3 5VL (ERP045-070VL) (A976) and ERC16-20VA (ERC030-040VA) (A969) 4794
Remove 4794
Disassemble 4794
Electrical Connector Repair or Replacement 4800
Clean 4801
Inspect 4801
Assemble 4802
Install 4803
4803
Hydraulic Motor Repair For 4 0-5 5T Lift Trucks 4803
Remove 4803
Disassemble 4803
Electrical Connector Repair or Replacement 4806
Clean 4807
Inspect 4807
Assemble 4808
Install 4808
Torque Specifications 4809
Traction Motor for Lift Trucks ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955) 4809
Traction Motor for Lift Truck ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 4809
Traction Motor for Lift Truck ESC030-040AC (B883), ESC030-040AD (C883) 4809
Hydraulic Motor for Lift Trucks ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955) 4809
Hydraulic Motor for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 4809
Hydraulic Motor for Lift Truck ERP22-35VG (ERP045-070VG) (A976) 4809
Hydraulic Motor for Lift Truck ERC16-20VA (ERC030-040VA) (A969) 4809
Hydraulic Motor for Lift Truck ESC030-040AC (B883), ESC030-040AD (C883) 4809
Hydraulic Motor for Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 4810
524332383-8000YRM1384-(01-2020)-UK-EN 4813
524332383-8000YRM1384-(04-2023)-UK-EN 4855
550025937-0100YRM1446-(02-2023)-UK-EN 4899
General 4905
Discharging the Capacitors 4906
Window Replacement 4907
Front Panel 4907
Remove, Lift Truck Models ERP22-35VL (ERP045-070VL) (A976), ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985), ERP15-20VT (ERP030-040VT) (G807), and ERP16-20VF (ERP30-40VF) (A955) 4907
Remove, Lift Truck Models ERP13VC, ERP15VC (B888) 4908
Clean 4910
Inspect 4910
Install, Lift Truck Models ERP22-35VL (ERP045-070VL) (A976), ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985), ERP15-20VT (ERP030-040VT) (G807), and ERP16-20VF (ERP30-40VF) (A955) 4910
Install, Lift Truck Models ERP13VC, ERP15VC (B888) 4910
Rear Panel 4910
Remove 4910
Clean 4914
Inspect 4914
Install 4914
Door Window 4915
Disassemble Window 4915
Clean 4916
Inspect 4916
Assemble Window 4916
Window Wipers Replacement 4917
Front Wiper Assembly 4917
Remove, Lift Truck Models ERP22-35VL (ERP045-070VL) (A976), ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985), ERP15-20VT (ERP030-040VT) (G807), and ERP16-20VF (ERP30-40VF) (A955) 4917
Remove, Lift Truck Models ERP13VC, ERP15VC (B888) 4922
Clean 4923
Inspect 4924
Install, Lift Truck Models ERP22-35VL (ERP045-070VL) (A976), ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985), ERP15-20VT (ERP030-040VT) (G807), and ERP16-20VF (ERP30-40VF) (A955) 4924
Install, Lift Truck Models ERP13VC, ERP15VC (B888) 4925
Cab Component Repair 4926
Roof Liner 4926
Remove 4926
Clean 4927
Inspect 4927
Install 4927
Top Panel 4928
Remove, Lift Truck Models ERP22-35VL (ERP045-070VL) (A976), ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985), ERP15-20VT (ERP030-040VT) (G807), and ERP16-20VF (ERP30-40VF) (A955) 4928
Remove, Lift Truck Models ERP13VC, ERP15VC (B888) 4930
Clean 4931
Inspect 4931
Install, Lift Truck Models ERP22-35VL (ERP045-070VL) (A976), ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985), ERP15-20VT (ERP030-040VT) (G807), and ERP16-20VF (ERP30-40VF) (A955) 4931
Install, Lift Truck Models ERP13VC, ERP15VC (B888) 4931
Cab Door Assembly 4932
Door Assembly 4932
Remove 4932
Lift Truck Models and ERP22-35VL (ERP045-070VL) (A976)ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 4932
Lift Truck Models and ERP15-20VT (ERP030-040VT) (G807)ERP16-20VF (ERP30-40VF) (A955) 4934
Disassemble Left Door 4936
Disassemble Right Door 4938
Clean 4940
Inspect 4940
Assemble Right Door 4940
Assemble Left Door 4940
Install 4941
Lift Truck Models and ERP22-35VL (ERP045-070VL) (A976)ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 4941
Lift Truck Models and ERP15-20VT (ERP030-040VT) (G807)ERP16-20VF (ERP30-40VF) (A955) 4941
Cab Heater 4942
Cab Heater 4942
Remove 4942
Clean 4949
Inspect 4949
Install 4949
Troubleshooting 4951
Weather Panel Replacement 4954
Remove 4954
Roof Panels 4954
Front Screen Panel 4957
Install 4958
Front Screen Panel 4958
Roof Panels 4958
550025937-0100YRM1446-(09-2014)-UK-EN 4961
550073240-1900YRM1620-(01-2023)-UK-EN 5015
Proper Flushing after Major Hydraulic Repairs 5021
Introduction 5021
The Phases of Wear 5021
Causes of Hydraulic System Failure 5021
Progression of Contaminant Caused Hydraulic System Failure 5022
Hydraulic System Flushing Techniques 5022
Double Oil and Filter Change 5022
Mechanical Cleaning 5023
Cleaning of Components 5023
How to Clean Tubes and Hoses 5023
Filter Caddy 5023
Start-Up Procedure for Cleaned System 5024
Contaminated Oil Coolers 5024
Additional Filter Caddy Functions 5025
How to Handle Different Fluids 5025
Water Removal Filters 5025
Fluid Conditioning and System Flushing Procedures 5026
Operation of the Filter Caddy 5026
Filter Caddy operation 5026
Fluid Conditioning Procedure 5026
Filter Caddy Start-Up 5027
System Flushing Procedure 5027
Component Cleaning Procedure 5028
Reservoir Cleaning Procedure 5028
Cylinder Cleaning Procedure 5028
Hose and Tube Cleaning Procedure 5028
Valve Cleaning Procedure 5029
Front-End Attachment Cleaning Procedure 5030
System Flushing Procedure 5030
Filter Caddy Start-Up 5031
System Start-Up and Flushing 5031
Reservoir Fluid Cleaning Times 5032
Dealing With Different Fluid Types 5033
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 5033
Filter Caddy Maintenance 5033
Servicing the Strainer 5033
DC Motor 5033
Hydraulic Oil Sampling Method and Procedure 5034
Hydraulic Oil Sampling Method 5034
Objective 5034
General Guidelines 5034
Synopsis 5035
Hydraulic Oil Analysis Report Guidelines 5036
Sampling Conditions 5036
Equipment 5036
Sampling Procedure 5037
Hydraulic Oil Sampling 5037
Sample Labeling 5037
Results Documentation 5037
550073240-1900YRM1620-(03-2020)-UK-EN 5039
Proper Flushing after Major Hydraulic Repairs 5043
Introduction 5043
The Phases of Wear 5043
Causes of Hydraulic System Failure 5043
Progression of Contaminant Caused Hydraulic System Failure 5044
Hydraulic System Flushing Techniques 5044
Double Oil and Filter Change 5044
Mechanical Cleaning 5045
Cleaning of Components 5045
How to Clean Tubes and Hoses 5045
Filter Caddy 5045
Start-Up Procedure for Cleaned System 5046
Contaminated Oil Coolers 5046
Additional Filter Caddy Functions 5046
How to Handle Different Fluids 5046
Water Removal Filters 5047
Fluid Conditioning and System Flushing Procedures 5047
Operation of the Filter Caddy 5047
Filter Caddy operation 5047
Fluid Conditioning Procedure 5048
Filter Caddy Start-Up 5048
System Flushing Procedure 5049
Component Cleaning Procedure 5049
Reservoir Cleaning Procedure 5049
Cylinder Cleaning Procedure 5049
Hose and Tube Cleaning Procedure 5050
Valve Cleaning Procedure 5050
Front-End Attachment Cleaning Procedure 5051
System Flushing Procedure 5051
Filter Caddy Start-Up 5052
System Start-Up and Flushing 5052
Reservoir Fluid Cleaning Times 5053
Dealing With Different Fluid Types 5053
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 5053
Filter Caddy Maintenance 5054
Servicing the Strainer 5054
DC Motor 5054
Hydraulic Oil Sampling Method and Procedure 5054
Hydraulic Oil Sampling Method 5054
Objective 5054
General Guidelines 5054
Synopsis 5055
Hydraulic Oil Analysis Report Guidelines 5056
Sampling Conditions 5057
Equipment 5057
Sampling Procedure 5057
Hydraulic Oil Sampling 5057
Sample Labeling 5058
Results Documentation 5058
550093750-2100YRM1668-(02-2018)-UK-EN 5061
General 5065
Safety Procedures When Working Near Mast 5066
Main Lift Cylinder Repair 5068
Remove 5068
Disassemble 5070
Clean 5072
Inspect 5072
Assemble 5072
Install 5073
Main Lift Cylinder Leak Check 5073
Free-Lift Cylinder 5074
Remove 5074
Disassemble 5075
Clean 5077
Inspect 5077
Assemble 5077
Install 5077
Tilt Cylinder Repair 5078
Remove 5078
Disassemble 5080
Clean 5082
Inspect 5082
Assemble 5082
Install 5083
Tilt Cylinder Adjustment 5084
Tilt Cylinder Leak Check 5085
Integral Sideshift Cylinder Repair Prior to December 2016 5087
Remove 5087
Disassemble 5088
Clean 5089
Inspect 5089
Assemble 5089
Install 5089
Integral Sideshift Cylinder Repair After December 2016 5090
General 5090
Remove 5090
Disassemble 5092
Clean 5092
Inspect 5092
Assemble 5092
Install 5093
Integral Side-Shift Cylinder Gland Leak Checks 5094
Fork Positioner Cylinder Repair Prior to December 2016 5095
Remove 5095
Disassemble 5095
Clean 5097
Inspect 5098
Assemble 5098
Install 5098
Fork Positioner Cylinder Adjustment 5098
Fork Positioner Cylinder Repair After December 2016 5099
General 5099
Remove 5099
Disassemble 5099
Clean 5102
Inspect 5103
Assemble 5103
Install 5103
Fork Positioner Cylinder Adjustment 5103
Seal Kit Installation 5104
External Installation (Seal and Backup Ring) 5104
Internal Installation (Piston Rod Assembly) 5104
Torque Specifications 5105
Main Lift Cylinders 5105
Free-Lift Cylinder 5105
Tilt Cylinders 5105
Integral Sideshift Cylinder 5105
Fork Positioner Cylinder 5105
550093750-2100YRM1668-(04-2023)-UK-EN 5109
General 5115
Safety Procedures When Working Near Mast 5118
Main Lift Cylinder Repair 5120
Remove 5120
Disassemble 5122
Clean 5124
Inspect 5124
Assemble 5124
Install 5125
Main Lift Cylinder Leak Check 5125
Free-Lift Cylinder 5126
Remove 5126
Disassemble 5127
Clean 5129
Inspect 5129
Assemble 5129
Install 5129
Tilt Cylinder Repair 5131
Remove 5131
Disassemble 5133
Clean 5134
Inspect 5135
Assemble 5135
Install 5136
Tilt Cylinder Adjustment 5136
Tilt Cylinder Leak Check 5138
Integral Sideshift Cylinder Repair Prior to December 2016 5140
Remove 5140
Disassemble 5140
Clean 5141
Inspect 5141
Assemble 5141
Install 5142
Integral Sideshift Cylinder Repair After December 2016 5143
General 5143
Remove 5143
Disassemble 5144
Clean 5145
Inspect 5145
Assemble 5145
Install 5145
Integral Side-Shift Cylinder Gland Leak Checks 5146
Fork Positioner Cylinder Repair Prior to December 2016 5147
Remove 5147
Disassemble 5147
Clean 5150
Inspect 5150
Assemble 5151
Install 5151
Fork Positioner Cylinder Adjustment 5151
Fork Positioner Cylinder Repair After December 2016 5153
General 5153
Remove 5153
Disassemble 5153
Clean 5156
Inspect 5156
Assemble 5157
Install 5157
Fork Positioner Cylinder Adjustment 5157
Seal Kit Installation 5159
External Installation (Seal and Backup Ring) 5159
Internal Installation (Piston Rod Assembly) 5159
Torque Specifications 5160
Main Lift Cylinders 5160
Free-Lift Cylinder 5160
Tilt Cylinders 5160
Integral Sideshift Cylinder 5160
Fork Positioner Cylinder 5160
550093755-4000YRM1669-(04-2023)-UK-EN 5163
General 5171
Safety Procedures When Working Near Mast 5173
Fork Replacement 5175
Standard Carriage and Integral Sideshift Carriage 5175
Remove 5175
Install 5176
Checks 5176
Fork Positioner Carriage 5178
Remove 5179
Install 5179
Checks 5181
Carriages Repair, Two-Stage LFL Mast 5184
Standard Carriage 5184
Remove 5184
Clean and Inspect 5185
Install 5185
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 5185
Remove 5185
Disassemble 5187
Clean and Inspect 5188
Assemble 5189
Install 5189
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 through Late June, 2018 5190
Remove 5190
Disassemble 5193
Clean and Inspect 5193
Assemble 5194
Install 5195
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 5195
Remove 5195
Disassemble 5198
Clean and Inspect 5198
Assemble 5199
Install 5200
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 5200
Remove 5200
Install 5202
Fork Positioner Hydraulic Hose Adjustment 5204
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 5205
Remove 5205
Disassemble and Assemble 5209
Clean and Inspect 5209
Install 5209
Fork Positioner Hydraulic Hose Adjustment 5210
Fork Positioner Carriage, Lift Trucks Manufactured Late June, 2018 and After 5211
Remove 5211
Disassemble and Assemble 5215
Clean and Inspect 5215
Install 5215
Fork Positioner Hydraulic Hose Adjustment 5216
Two-Stage LFL Mast Repair 5218
Mast With Serial Number F507 5218
Remove 5218
Disassemble 5222
Clean and Inspect 5229
Assemble 5231
Install 5232
Header Hoses 5234
Remove 5234
Installation 5234
Adjustment 5238
Mast With Serial Number F562 5239
Remove 5239
Disassemble 5243
Clean and Inspect 5250
Assemble 5252
Install 5253
Header Hose Installation and Adjustment 5254
Remove 5254
Installation 5255
Adjustment 5259
Carriages Repair, Three-Stage FFL Mast 5261
Standard Carriage 5261
Remove 5261
Clean and Inspect 5262
Install 5263
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 5263
Remove 5263
Disassemble 5264
Clean and Inspect 5265
Assemble 5266
Install 5266
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 5267
Remove 5267
Disassemble 5269
Clean and Inspect 5270
Assemble 5271
Install 5271
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 5272
Remove 5272
Disassemble 5274
Clean and Inspect 5275
Assemble 5276
Install 5276
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 5277
Remove 5277
Install 5279
Fork Positioner Hydraulic Hose Adjustment 5281
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 5282
Remove 5282
Disassemble and Assemble 5284
Clean and Inspect 5284
Install 5284
Fork Positioner Hydraulic Hose Adjustment 5285
Fork Positioner Carriage, Lift Trucks Manufactured After Late June, 2018 5286
Remove 5286
Disassemble and Assemble 5289
Clean and Inspect 5289
Install 5289
Fork Positioner Hydraulic Hose Adjustment 5290
Three-Stage FFL Mast Repair 5292
Mast With Serial Number F508 5292
Remove 5292
Disassemble 5295
Clean and Inspect 5305
Assemble 5308
Install 5309
Header Hose Installation and Adjustment 5311
Remove 5311
Installation 5311
Adjustment 5320
Mast With Serial Number F563 5320
Remove 5320
Disassemble 5324
Clean and Inspect 5334
Assemble 5337
Install 5338
Header Hose Installation and Adjustment 5340
Remove 5340
Installation 5340
Adjustment 5348
Mast Adjustments 5350
Load Roller, Adjust 5350
Mast Side Kicking, Adjust 5352
Carriage Adjustments 5353
Lift Chains Adjustment 5355
Hydraulic Quick Disconnect Hoses 5357
Disconnecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models GLC020-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910, B910, C910) and GLP/GDP20-35VX (CP/CLP/CDP040-070VX) (B875, C875, D875) 5357
Lift Trucks Equipped With E-Hydraulic Controls 5357
Lift Trucks Equipped With Manual Hydraulic Controls 5357
Connecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models GLC020-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910, B910, C910) and GLP/GDP20-35VX (CP/CLP/CDP040-070VX) (B875, C875, D875) 5358
Lift Trucks Equipped With E-Hydraulic Controls 5358
Lift Trucks Equipped With Manual Hydraulic Controls 5358
Disconnecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 5358
Connecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 5358
550093755-4000YRM1669-(06-2019)-UK-EN 5361
General 5367
Safety Procedures When Working Near Mast 5368
Fork Replacement 5370
Standard Carriage and Integral Sideshift Carriage 5370
Remove 5370
Install 5372
Checks 5372
Fork Positioner Carriage 5374
Remove 5375
Install 5375
Checks 5377
Carriages Repair, Two-Stage LFL Mast 5379
Standard Carriage 5379
Remove 5379
Clean and Inspect 5380
Install 5381
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 5381
Remove 5381
Disassemble 5382
Clean and Inspect 5383
Assemble 5384
Install 5384
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 through Late June, 2018 5385
Remove 5385
Disassemble 5388
Clean and Inspect 5388
Assemble 5389
Install 5389
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 5390
Remove 5390
Disassemble 5393
Clean and Inspect 5393
Assemble 5394
Install 5394
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 5395
Remove 5395
Install 5397
Fork Positioner Hydraulic Hose Adjustment 5399
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 5400
Remove 5400
Disassemble and Assemble 5404
Clean and Inspect 5404
Install 5404
Fork Positioner Hydraulic Hose Adjustment 5405
Fork Positioner Carriage, Lift Trucks Manufactured Late June, 2018 and After 5406
Remove 5406
Disassemble and Assemble 5410
Clean and Inspect 5410
Install 5410
Fork Positioner Hydraulic Hose Adjustment 5411
Two-Stage LFL Mast Repair 5412
Mast With Serial Number F507 5412
Remove 5412
Disassemble 5416
Clean and Inspect 5423
Assemble 5425
Install 5426
Header Hoses 5428
Remove 5428
Installation 5428
Adjustment 5432
Mast With Serial Number F562 5433
Remove 5433
Disassemble 5437
Clean and Inspect 5444
Assemble 5446
Install 5447
Header Hose Installation and Adjustment 5448
Remove 5448
Installation 5449
Adjustment 5453
Carriages Repair, Three-Stage FFL Mast 5454
Standard Carriage 5454
Remove 5454
Clean and Inspect 5456
Install 5456
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 5456
Remove 5456
Disassemble 5458
Clean and Inspect 5459
Assemble 5460
Install 5460
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 5461
Remove 5461
Disassemble 5463
Clean and Inspect 5464
Assemble 5465
Install 5465
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 5466
Remove 5466
Disassemble 5468
Clean and Inspect 5469
Assemble 5470
Install 5470
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 5471
Remove 5471
Install 5473
Fork Positioner Hydraulic Hose Adjustment 5475
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 5476
Remove 5476
Disassemble and Assemble 5478
Clean and Inspect 5478
Install 5478
Fork Positioner Hydraulic Hose Adjustment 5479
Fork Positioner Carriage, Lift Trucks Manufactured After Late June, 2018 5480
Remove 5480
Disassemble and Assemble 5483
Clean and Inspect 5483
Install 5483
Fork Positioner Hydraulic Hose Adjustment 5484
Three-Stage FFL Mast Repair 5485
Mast With Serial Number F508 5485
Remove 5485
Disassemble 5489
Clean and Inspect 5499
Assemble 5502
Install 5503
Header Hose Installation and Adjustment 5505
Remove 5505
Installation 5505
Adjustment 5513
Mast With Serial Number F563 5514
Remove 5514
Disassemble 5517
Clean and Inspect 5527
Assemble 5530
Install 5531
Header Hose Installation and Adjustment 5533
Remove 5533
Installation 5533
Adjustment 5541
Mast Adjustments 5542
Load Roller, Adjust 5542
Mast Side Kicking, Adjust 5544
Carriage Adjustments 5544
Lift Chains Adjustment 5546
Hydraulic Quick Disconnect Hoses 5548
Disconnecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models GLC020-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910, B910, C910) and GLP/GDP20-35VX (CP/CLP/CDP040-070VX) (B875, C875, D875) 5548
Lift Trucks Equipped With E-Hydraulic Controls 5548
Lift Trucks Equipped With Manual Hydraulic Controls 5549
Connecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models GLC020-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910, B910, C910) and GLP/GDP20-35VX (CP/CLP/CDP040-070VX) (B875, C875, D875) 5549
Lift Trucks Equipped With E-Hydraulic Controls 5549
Lift Trucks Equipped With Manual Hydraulic Controls 5550
Disconnecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 5550
Connecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 5550
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