Yale Forklift A976 (ERP22VL, 25VL, 30VL, 35VL) Service Manual - PDF

Yale Forklift A976 (ERP22VL, 25VL, 30VL, 35VL) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift A976 (ERP22VL, 25VL, 30VL, 35VL) Service Manual – PDF DOWNLOAD

Language : English
Pages : 5546
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift A976 (ERP22VL, 25VL, 30VL, 35VL) Service Manual – PDF DOWNLOAD

General 5
Threaded Fasteners 5
Nomenclature, Threads 5
Strength Identification 6
Cotter (Split) Pins 7
Fastener Torque Tables 12
Conversion Table 14
General 27
Battery Type 27
Lead-Acid Batteries 27
Lithium-Ion Batteries 28
Specific Gravity 28
Chemical Reaction in a Cell 28
Electrical Terms 30
Battery Selection 31
Battery Voltage 32
Battery as a Counterweight 32
Battery Ratings 32
Kilowatt-Hours 32
Battery Maintenance 33
Safety Procedures 33
Maintenance Records 33
New Battery 33
Cleaning Battery 34
Adding Water to Battery 36
Hydrometer 36
Battery Temperature 37
Charging Battery 38
Types of Battery Charges 39
Methods of Charging 40
Troubleshooting Charger 41
Knowing When Battery Is Fully Charged 41
Where to Charge Batteries 41
Equipment Needed 41
Battery Connectors 42
Battery Care 42
Troubleshooting 44
General 53
Battery Type 53
Lead-Acid Batteries 53
Lithium-Ion Batteries 54
Specific Gravity 54
Chemical Reaction in a Cell 54
Electrical Terms 56
Battery Selection 56
Battery Voltage 57
Battery as a Counterweight 58
Battery Ratings 58
Kilowatt-Hours 58
Battery Maintenance 58
Safety Procedures 58
Maintenance Records 59
New Battery 59
Cleaning Battery 59
Adding Water to Battery 61
Hydrometer 62
Battery Temperature 63
Charging Battery 64
Types of Battery Charges 64
Methods of Charging 66
Troubleshooting Charger 66
Knowing When Battery Is Fully Charged 67
Where to Charge Batteries 67
Equipment Needed 67
Battery Connectors 68
Battery Care 68
Troubleshooting 70
Series Code / Model Designation Reference Table 83
General 85
Deutsch Crimping Tool 86
How to Strip a Wire for Use With Deutsch Crimping Tool 86
How to Crimp With the Deutsch Crimping Tool 87
Calibration Test for the Deutsch Crimping Tool 89
Deutsch Connectors 91
DT, DTM, and DTP Series Connectors 91
HD Series Connectors 134
Metri-Pack Connectors 156
Remove and Install 156
Micro-Pack Connectors 159
Weather-Pack Connectors 160
AMPSEAL Crimping Tools 162
AMP Hand Crimping Tool With Certi-Crimp 162
Description 162
Stripping Wire for Use with AMP Hand Crimping Tool 163
Insulation Crimp Adjustment 164
Maintenance and Inspection for AMP Hand Crimping Tool 164
AMP Hand Crimping Tool 164
Crimp Height Inspection 164
How to use AMP Hand Crimping Tool 165
AMP Pro-Crimper II Tool 165
Description 165
Remove and Install Die Set and Locator Assembly 166
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 166
Contact Support Adjustment 167
Crimp Height Adjustment 168
Maintenance and Inspection Procedures 168
PRO-CRIMPER II Tool 168
Crimp Height Inspection 168
How to Use AMP PRO-CRIMPER II Tool 169
AMPSEAL Connector Assemblies 170
Description for Plug Connector Assembly 170
Seal Plug 171
Contact Crimping 171
Description for Plug Connector and Header Assembly 176
Voltage Reading 179
Seal Plug 179
Contact Crimping 179
AMP Superseal 1 5 Crimping Tools 186
Mini Mic Receptacle and Tab Contacts 186
Description 186
Crimping Conditions and Measurements 186
Insertion of Rubber Seal on Cable 188
AMP Hand Application Tool 193
Description 193
Maintenance and Inspection 193
Crimp Height Inspection 193
Crimp Height Adjustment 194
How to Use AMP Hand Application Tool 194
AMP Pro-Crimper II Tool 195
Description 195
Remove and Install Die Set and Locator Assembly 195
Adjustments 196
Contact Support 196
Crimp Height 197
Inspections and Maintenance 198
Crimp Height Inspection 198
Visual Inspection 198
Maintenance 199
How to Use Pro-Crimper II Tool 199
AMP Superseal 1 5 Connector Assemblies 200
Description 200
Repair and Maintenance 207
Panel Mount Option 207
AMP Fastin-Faston Hand Tools 208
Description – AMP Double Action Hand Tool 208
Maintenance and Inspection Procedures 208
Daily Maintenance 208
Periodic Tool Inspection 209
Lubrication 209
Visual Inspection 209
Crimp Height Inspection 209
Certi-Crimp Ratchet Inspection 210
How to Use AMP Double Action Hand Tool 211
Description – AMP Extraction Tool 212
Maintenance and Inspection 213
How to Use AMP Extraction Tool 213
AMP Fastin-Faston Receptacles and Housings 215
Description 215
Wire Repair 223
Wire Splicing Requirements 223
Deutsch Jiffy Splice 224
Twisted/Shielded Cable and Leads Repair 230
Special Tools 232
Series Code / Model Designation Reference Table 247
General 250
Deutsch Crimping Tool 250
How to Strip a Wire for Use With Deutsch Crimping Tool 250
How to Crimp With the Deutsch Crimping Tool 251
Calibration Test for the Deutsch Crimping Tool 253
Deutsch Connectors 255
DT, DTM, and DTP Series Connectors 255
HD Series Connectors 297
Metri-Pack Connectors 320
Remove and Install 320
Micro-Pack Connectors 322
Weather-Pack Connectors 323
AMPSEAL Crimping Tools 325
AMP Hand Crimping Tool With Certi-Crimp 325
Description 325
Stripping Wire for Use with AMP Hand Crimping Tool 325
Insulation Crimp Adjustment 326
Maintenance and Inspection for AMP Hand Crimping Tool 326
AMP Hand Crimping Tool 326
Crimp Height Inspection 326
How to use AMP Hand Crimping Tool 327
AMP Pro-Crimper II Tool 327
Description 327
Remove and Install Die Set and Locator Assembly 328
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 329
Contact Support Adjustment 329
Crimp Height Adjustment 330
Maintenance and Inspection Procedures 330
PRO-CRIMPER II Tool 330
Crimp Height Inspection 330
How to Use AMP PRO-CRIMPER II Tool 331
AMPSEAL Connector Assemblies 332
Description for Plug Connector Assembly 332
Seal Plug 333
Contact Crimping 333
Description for Plug Connector and Header Assembly 338
Voltage Reading 340
Seal Plug 340
Contact Crimping 340
AMP Superseal 1 5 Crimping Tools 347
Mini Mic Receptacle and Tab Contacts 347
Description 347
Crimping Conditions and Measurements 347
Insertion of Rubber Seal on Cable 349
AMP Hand Application Tool 354
Description 354
Maintenance and Inspection 354
Crimp Height Inspection 354
Crimp Height Adjustment 355
How to Use AMP Hand Application Tool 355
AMP Pro-Crimper II Tool 356
Description 356
Remove and Install Die Set and Locator Assembly 357
Adjustments 357
Contact Support 357
Crimp Height 358
Inspections and Maintenance 359
Crimp Height Inspection 359
Visual Inspection 359
Maintenance 360
How to Use Pro-Crimper II Tool 360
AMP Superseal 1 5 Connector Assemblies 361
Description 361
Repair and Maintenance 368
Panel Mount Option 368
AMP Fastin-Faston Hand Tools 369
Description – AMP Double Action Hand Tool 369
Maintenance and Inspection Procedures 369
Daily Maintenance 369
Periodic Tool Inspection 370
Lubrication 370
Visual Inspection 370
Crimp Height Inspection 370
Certi-Crimp Ratchet Inspection 371
How to Use AMP Double Action Hand Tool 372
Description – AMP Extraction Tool 373
Maintenance and Inspection 373
How to Use AMP Extraction Tool 374
AMP Fastin-Faston Receptacles and Housings 375
Description 375
Wire Repair 382
Wire Splicing Requirements 382
Deutsch Jiffy Splice 383
Twisted/Shielded Cable and Leads Repair 388
Special Tools 391
General 407
Description 407
Frame 407
Discharging the Capacitors 414
Rapid Charge 414
Ground Test 416
Mud Guards 418
Covers and Floor Plates 419
For Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 419
For Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 421
For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 422
For Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 423
For Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 427
Overhead Guard Replacement 428
Remove 428
For Lift Trucks ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 428
For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 434
For Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 437
Install 439
For Lift Trucks ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 439
For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 439
For Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 441
Battery and Operator Restraint System Repair 442
General 442
Battery Restraint System 442
Auxiliary Counterweight Support Bracket for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH,ERC100VHS) (A938) 456
Operator Restraint System 457
Emergency Locking Retractor (ELR) 461
E-Hydraulic Armrest Assembly Repair 461
Hood and Seat Assembly Replacement 462
General For Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 462
Hood Assembly 462
Seat Assembly 468
General For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 471
Hood Assembly 471
Seat Assembly 475
Opening and Closing the Hood 479
Manual Hydraulic Control Levers 479
E-Hydraulic Mini-Levers 480
Remove 481
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 481
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 490
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 492
Install 497
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 497
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 498
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 499
Ground Test For Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 501
Ground Test For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 501
Hood and Seat Assembly Replacement for Lift Truck Model ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 502
General 502
Hood Assembly 502
Seat Assembly 505
Opening and Closing the Hood 507
Manual Hydraulic Control Levers 507
E-Hydraulic Mini-Levers 508
Remove 509
Install 513
Ground Test 514
Master Cylinder Repair and Adjustment for 1 5-3 5T Cushion and 2 2-5 5T Pneumatic Lift Trucks 515
Master Cylinder Repair and Adjustment for 4 0-5 5T Cushion Lift Trucks 515
Brake Pedal Components 521
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) 521
For Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 521
Remove 521
Disassemble 521
Inspect 522
Assemble 522
Install 522
Brake Pedal Adjustment For Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 523
Brake System Air Removal 524
For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 524
Using Pressure Bleed System 524
Using Brake Pedal Pressure For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 524
For Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 525
Counterweight Replacement for Lift Truck Models ERC22-35VG (ERC045-070) (A968) and ERC16-20VA (ERC030-040VA) (A969) 526
Remove 529
Install 530
Counterweight Replacement for Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 531
Remove 538
Clean and Inspect, Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 542
Install 544
Counterweight Replacement for Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 547
Remove 549
Install 549
Traction Motor Replacement for Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 551
Traction Motor Replacement for Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 558
Traction Motor Replacement for Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 559
Hydraulic Tank Inspection 562
Inspect 562
Clean 566
Painting Instructions 567
Safety Label Replacement 570
Battery Specifications 579
Torque Specifications for Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 586
Overhead Guard 586
Counterweight 586
Traction Motor 586
Torque Specifications for Lift Truck ERP22-35VL (ERP045-070VL) (A976) 586
Overhead Guard 586
Counterweight 586
Torque Specifications for Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 586
Overhead Guard 586
Counterweight 586
Torque Specifications for Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 586
Overhead Guard 586
Counterweight 586
General 595
Description 595
Frame 595
Discharging the Capacitors 602
Rapid Charge 602
Ground Test 604
Mud Guards 605
Covers and Floor Plates 606
For Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 606
For Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 607
For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 609
For Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 610
For Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 614
Overhead Guard Replacement 614
Remove 615
For Lift Trucks ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 615
For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 620
For Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 622
Install 624
For Lift Trucks ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 624
For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 624
For Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 626
Battery and Operator Restraint System Repair 626
General 626
Battery Restraint System 626
Auxiliary Counterweight Support Bracket for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938) 641
Operator Restraint System 642
Emergency Locking Retractor (ELR) 646
E-Hydraulic Armrest Assembly Repair 646
Hood and Seat Assembly Replacement 646
General For Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 647
Hood Assembly 647
Seat Assembly 653
General For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 656
Hood Assembly 656
Seat Assembly 660
Opening and Closing the Hood 664
Manual Hydraulic Control Levers 664
E-Hydraulic Mini-Levers 665
Remove 666
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 666
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 675
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 677
Install 682
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 682
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 683
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 684
Ground Test For Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 685
Ground Test For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 685
Hood and Seat Assembly Replacement for Lift Truck Model ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 686
General 686
Hood Assembly 686
Seat Assembly 689
Opening and Closing the Hood 691
Manual Hydraulic Control Levers 691
E-Hydraulic Mini-Levers 692
Remove 693
Install 697
Ground Test 698
Master Cylinder Repair and Adjustment for 1 5-3 5T Cushion and 2 2-5 5T Pneumatic Lift Trucks 698
Master Cylinder Repair and Adjustment for 4 0-5 5T Cushion Lift Trucks 698
Brake Pedal Components 703
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) 703
For Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 704
Remove 704
Disassemble 704
Inspect 705
Assemble 705
Install 705
Brake Pedal Adjustment For Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 706
Brake System Air Removal 706
For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 706
Using Pressure Bleed System 706
Using Brake Pedal Pressure For Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 707
For Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 707
Counterweight Replacement for Lift Truck Models ERC22-35VG (ERC045-070) (A968) and ERC16-20VA (ERC030-040VA) (A969) 707
Remove 710
Install 711
Counterweight Replacement for Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 712
Remove 719
Clean and Inspect, Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 723
Install 725
Counterweight Replacement for Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 727
Remove 730
Install 730
Traction Motor Replacement for Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 731
Traction Motor Replacement for Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 737
Traction Motor Replacement for Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 738
Hydraulic Tank Inspection 740
Inspect 740
Clean 746
Painting Instructions 746
Safety Label Replacement 748
Battery Specifications 756
Torque Specifications for Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 763
Overhead Guard 763
Counterweight 763
Traction Motor 763
Torque Specifications for Lift Truck ERP22-35VL (ERP045-070VL) (A976) 763
Overhead Guard 764
Counterweight 764
Torque Specifications for Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 764
Overhead Guard 764
Counterweight 764
Torque Specifications for Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 764
Overhead Guard 764
Counterweight 764
General 775
Steering Axle Assembly Repair 777
Remove ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 777
Disassemble ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 779
Clean 782
Inspect 782
Assemble ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 783
Install ERC22-35VG (ERC045-070VG) (A968) 784
Install ERC16-20VA (ERC030-040VA) (A969) 785
Install ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 786
Remove ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 787
Disassemble ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 792
Clean 793
Inspect 793
Assemble ERP40-50VM, ERP50-55MV6 (ERP080-120VM, ERP100VML) (A985) 793
Assemble ERP22-35VL (ERP045-070VL) (A976) 794
Wheel Bearing Adjustment ERP22-35VL (ERP045-070VL) (A976) 795
Install ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) 796
Remove ERP16-20VF (ERP30-40VF) (A955) 802
Disassemble ERP16-20VF (ERP30-40VF) (A955) 802
Clean 804
Inspect 804
Assemble ERP16-20VF (ERP30-40VF) (A955) 804
Install ERP16-20VF (ERP30-40VF) (A955) 805
Tie Rod Replacement 806
Remove ERC20-35VG (ERC045-070VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 806
Clean 807
Inspect 807
Install ERC20-35VG (ERC045-070VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 807
Remove ERC16-20VA (ERC030-040VA) (A969) 807
Clean 808
Inspect 808
Install ERC16-20VA (ERC030-040VA) (A969) 808
Remove ERP20-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 809
Clean 810
Inspect 810
Install ERP20-35VL (ERP045-070VL) (A976) andERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 810
Remove ERP16-20VF (ERP30-40VF) (A955) 810
Clean 811
Inspect 811
Install ERP16-20VF (ERP30-40VF) (A955) 811
Spindle Repair 812
Remove ERC22-35VG (ERC45-70VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 812
Disassemble ERC22-35VG (ERC45-70VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 813
Clean 813
Inspect 814
Assemble ERC22-35VG (ERC45-70VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 814
Install ERC22-35VG (ERC45-70VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 814
Remove ERC16-20VA (ERC030-040VA) (A969) 815
Disassemble ERC16-20VA (ERC030-040VA) (A969) 816
Clean 816
Inspect 816
Assemble ERC16-20VA (ERC030-040VA) (A969) 817
Install ERC16-20VA (ERC030-040VA) (A969) 817
Remove ERP22-35VL (ERP45-70VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 818
Disassemble ERP22-35VL (ERP45-70VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 819
Clean 819
Inspect 820
Assemble ERP22-35VL (ERP45-70VL) (A976) 820
Install ERP22-35VL (ERP45-70VL) (A976) 820
Assemble ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 821
Install ERP22-35VL (ERP45-70VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 821
Remove ERP16-20VF (ERP30-40VF) (A955) 822
Disassemble ERP16-20VF (ERP30-40VF) (A955) 822
Clean 823
Inspect 823
Assemble ERP16-20VF (ERP30-40VF) (A955) 824
Install ERP16-20VF (ERP30-40VF) (A955) 824
Steering Cylinder Repair 825
Remove ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 825
Disassemble ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 828
Clean 829
Inspect 829
Assemble ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 829
Install ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 829
Remove ERC16-20VA (ERC030-040VA) (A969) 830
Disassemble ERC16-20VA (ERC030-040VA) (A969) 831
Clean 832
Inspect 833
Assemble ERC16-20VA (ERC030-040VA) (A969) 833
Install ERC16-20VA (ERC030-040VA) (A969) 833
Remove ERP16-20VF (ERP30-40VF) (A955) 833
Disassemble ERP16-20VF (ERP30-40VF) (A955) 834
Clean 835
Inspect 835
Assemble ERP16-20VF (ERP30-40VF) (A955) 835
Install ERP16-20VF (ERP30-40VF) (A955) 836
Remove ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 836
Disassemble ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 837
Clean 838
Inspect 838
Assemble ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 839
Install ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 839
Remove ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 839
Disassemble ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 841
Clean 841
Inspect 842
Assemble ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 842
Install ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 842
General 851
Steering Axle Assembly Repair 852
Remove ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 853
Disassemble ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 854
Clean 858
Inspect 858
Assemble ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 858
Install ERC22-35VG (ERC045-070VG) (A968) 860
Install ERC16-20VA (ERC030-040VA) (A969) 861
Install ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 862
Remove ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 864
Disassemble ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 868
Clean 870
Inspect 870
Assemble ERP40-50VM, ERP50-55MV6 (ERP080-120VM, ERP100VML) (A985) 870
Assemble ERP22-35VL (ERP045-070VL) (A976) 871
Wheel Bearing Adjustment ERP22-35VL (ERP045-070VL) (A976) 872
Install ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) 873
Remove ERP16-20VF (ERP30-40VF) (A955) 879
Disassemble ERP16-20VF (ERP30-40VF) (A955) 879
Clean 881
Inspect 881
Assemble ERP16-20VF (ERP30-40VF) (A955) 881
Install ERP16-20VF (ERP30-40VF) (A955) 882
Tie Rod Replacement 882
Remove ERC20-35VG (ERC045-070VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 883
Clean 884
Inspect 884
Install ERC20-35VG (ERC045-070VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 884
Remove ERC16-20VA (ERC030-040VA) (A969) 884
Clean 885
Inspect 885
Install ERC16-20VA (ERC030-040VA) (A969) 885
Remove ERP20-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 886
Clean 886
Inspect 887
Install ERP20-35VL (ERP045-070VL) (A976) andERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 887
Remove ERP16-20VF (ERP30-40VF) (A955) 887
Clean 888
Inspect 888
Install ERP16-20VF (ERP30-40VF) (A955) 888
Spindle Repair 888
Remove ERC22-35VG (ERC45-70VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 888
Disassemble ERC22-35VG (ERC45-70VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 890
Clean 890
Inspect 890
Assemble ERC22-35VG (ERC45-70VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 891
Install ERC22-35VG (ERC45-70VG) (A968) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 891
Remove ERC16-20VA (ERC030-040VA) (A969) 892
Disassemble ERC16-20VA (ERC030-040VA) (A969) 892
Clean 893
Inspect 893
Assemble ERC16-20VA (ERC030-040VA) (A969) 893
Install ERC16-20VA (ERC030-040VA) (A969) 894
Remove ERP22-35VL (ERP45-70VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 894
Disassemble ERP22-35VL (ERP45-70VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 896
Clean 896
Inspect 896
Assemble ERP22-35VL (ERP45-70VL) (A976) 897
Install ERP22-35VL (ERP45-70VL) (A976) 897
Assemble ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 897
Install ERP22-35VL (ERP45-70VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 897
Remove ERP16-20VF (ERP30-40VF) (A955) 898
Disassemble ERP16-20VF (ERP30-40VF) (A955) 899
Clean 900
Inspect 900
Assemble ERP16-20VF (ERP30-40VF) (A955) 900
Install ERP16-20VF (ERP30-40VF) (A955) 900
Steering Cylinder Repair 901
Remove ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 901
Disassemble ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 904
Clean 905
Inspect 905
Assemble ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 905
Install ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 905
Remove ERC16-20VA (ERC030-040VA) (A969) 906
Disassemble ERC16-20VA (ERC030-040VA) (A969) 907
Clean 908
Inspect 909
Assemble ERC16-20VA (ERC030-040VA) (A969) 909
Install ERC16-20VA (ERC030-040VA) (A969) 909
Remove ERP16-20VF (ERP30-40VF) (A955) 909
Disassemble ERP16-20VF (ERP30-40VF) (A955) 910
Clean 911
Inspect 911
Assemble ERP16-20VF (ERP30-40VF) (A955) 911
Install ERP16-20VF (ERP30-40VF) (A955) 912
Remove ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 912
Disassemble ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 913
Clean 914
Inspect 914
Assemble ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 915
Install ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 915
Remove ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 915
Disassemble ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 917
Clean 918
Inspect 918
Assemble ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 918
Install ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 918
General 927
Discharging The Capacitors 927
Steering Control Unit (SCU) Repair 929
Remove 929
Disassemble 932
Clean 938
Inspect 938
Assemble 938
Install 939
Steering Wheel and Fixed Steering Column Assembly Repair 940
Remove 940
Disassemble 943
Clean 944
Inspect 945
Assemble 945
Install 945
Gear Replacement for Lift Trucks Built Prior to October, 2008 946
Steering Wheel and Telescopic Column Assembly Repair 948
Remove 948
Disassemble 951
Clean 954
Inspect 955
Assemble 955
Install 956
Torque Specifications 963
Steering Control Unit 963
Steering Column 963
General 1009
Discharging the Capacitors 1009
Hydraulic Pump and Motor 1010
Remove 1010
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1011
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1014
Lift Truck Models ERP22-25VL (ERP045-070VL) (A976) 1017
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1022
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1027
Disassemble 1029
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969)ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1029
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1031
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1033
Inspect 1035
Clean 1035
Assemble 1035
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969)ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1035
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1035
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1036
Install 1036
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1036
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1037
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1038
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1039
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1040
Hydraulic Tank 1041
Remove 1041
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1041
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1044
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1045
Lift Truck Models ERP22-25VL (ERP045-070VL) (A976) 1049
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1051
Disassemble 1053
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1053
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1054
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1054
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1055
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1057
Clean 1059
Steam Method 1059
Chemical Method 1059
Inspect 1060
Small Leaks, Repair 1060
Large Leaks, Repair 1060
Additional Methods for Metal Tank Repair 1060
Assemble 1060
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1060
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1061
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1062
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1062
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1063
Install 1063
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1063
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1064
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1064
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1065
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1065
Hydraulic Filter Replacement 1066
Breather Clean and Inspect 1067
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 1067
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1070
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1070
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1070
Hydraulic Oil Cooler for Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1071
Add Hydraulic Oil 1071
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1071
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1073
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1073
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1073
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1074
Steer Accumulator Replacement 1075
Remove 1075
Install 1082
Specifications for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1082
Tank Capacity 1083
Specifications for Lift Truck ERC16-20VA (ERC030-040VA) (A969) 1083
Tank Capacity 1083
Specifications for Lift Truck ERP22-25VL (ERP045-070VL) (A976) 1083
Tank Capacity 1083
Specifications for Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1083
Tank Capacity 1083
Specifications for Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1083
Tank Capacity 1084
Torque Specifications for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1084
Hydraulic Pump and Motor 1084
Hydraulic Tank 1084
Torque Specifications for Lift Truck ERC16-20VA (ERC030-040VA) (A969) 1085
Hydraulic Pump and Motor 1085
Hydraulic Tank 1085
Torque Specifications for Lift Truck ERP22-35VL (ERP045-070VL) (A976) 1085
Hydraulic Pump and Motor 1085
Hydraulic Tank 1085
Torque Specifications for Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1085
Hydraulic Pump and Motor 1086
Hydraulic Tank 1086
Torque Specifications for Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1087
Hydraulic Pump and Motor 1087
Hydraulic Tank 1087
General 1097
Discharging the Capacitors 1097
Hydraulic Pump and Motor 1099
Remove 1099
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1099
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1105
Lift Truck Models ERP22-25VL (ERP045-070VL) (A976) 1109
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1114
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1119
Disassemble 1121
Lift Truck Models , ERC22-35VG (ERC045-070VG) (A968)ERC16-20VA (ERC030-040VA) (A969)ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1121
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1123
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1125
Inspect 1127
Clean 1127
Assemble 1127
Lift Truck Models , ERC22-35VG (ERC045-070VG) (A968)ERC16-20VA (ERC030-040VA) (A969)ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1127
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1128
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1128
Install 1128
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1128
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1129
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1130
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1131
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1132
Hydraulic Tank 1133
Remove 1133
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1133
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1136
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1139
Lift Truck Models ERP22-25VL (ERP045-070VL) (A976) 1142
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1144
Disassemble 1146
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1146
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1146
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1147
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1148
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1150
Clean 1152
Steam Method 1153
Chemical Method 1153
Inspect 1153
Small Leaks, Repair 1153
Large Leaks, Repair 1154
Additional Methods for Metal Tank Repair 1154
Assemble 1154
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1154
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1155
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1155
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1156
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1156
Install 1157
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1157
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1157
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1158
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1159
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1159
Hydraulic Filter Replacement 1160
Breather Clean and Inspect 1161
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 1161
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1163
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1163
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1164
Hydraulic Oil Cooler for Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1164
Add Hydraulic Oil 1164
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 1164
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1166
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 1166
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 1166
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1167
Steer Accumulator Replacement 1169
Remove 1169
Install 1177
Specifications for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1178
Tank Capacity 1178
Specifications for Lift Truck ERC16-20VA (ERC030-040VA) (A969) 1178
Tank Capacity 1178
Specifications for Lift Truck ERP22-25VL (ERP045-070VL) (A976) 1178
Tank Capacity 1178
Specifications for Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1179
Tank Capacity 1179
Specifications for Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1179
Tank Capacity 1179
Torque Specifications for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1180
Hydraulic Pump and Motor 1180
Hydraulic Tank 1180
Torque Specifications for Lift Truck ERC16-20VA (ERC030-040VA) (A969) 1180
Hydraulic Pump and Motor 1180
Hydraulic Tank 1180
Torque Specifications for Lift Truck ERP22-35VL (ERP045-070VL) (A976) 1181
Hydraulic Pump and Motor 1181
Hydraulic Tank 1181
Torque Specifications for Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1181
Hydraulic Pump and Motor 1181
Hydraulic Tank 1181
Torque Specifications for Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1182
Hydraulic Pump and Motor 1182
Hydraulic Tank 1182
General 1193
Lift Trucks ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955) 1193
Lift Trucks ERC22-35VG (ERC045-070VG) (A968), ERP22-35VL (ERP045-070VL) (A976), and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1195
Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1199
Discharging the Capacitors 1201
Manual Hydraulic Control Valve Repair for 1 5-2 0T Trucks 1202
Remove 1202
Beginning Steps 1202
Disassemble Handles and Levers 1215
Disassemble Manual Control Valve 1218
Spool Seal Replacement 1228
Clean 1231
Inspect 1231
Assemble Manual Control Valve 1233
Assemble Handles and Levers 1244
Install 1247
Ending Steps 1259
Manual Hydraulic Control Valve Repair for 2 0-3 5T Trucks and 4 0-5 0T Pneumatic Trucks 1261
Remove 1261
Disassemble Handles and Levers 1277
Disassemble Manual Control Valve 1280
Disassemble Valve 1280
Disassemble Inlet Section 1283
Disassemble Lift, Tilt, and Auxiliary Sections 1283
Spool Seal Replacement 1285
Clean 1286
Inspect 1287
Assemble Manual Control Valve 1287
Assemble Lift, Tilt, and Auxiliary Sections 1287
Assemble Inlet Section 1288
Assemble Valve 1289
Assemble Handles and Levers 1297
Install 1301
Ending Steps 1313
Manual Hydraulic Control Valve Repair for 4 0-5 5T Cushion Trucks 1314
Remove 1314
Disassemble Handles and Levers 1328
Disassemble Manual Control Valve 1330
Disassemble Valve 1330
Disassemble Inlet Section 1333
Disassemble Lift, Tilt, and Auxiliary Sections 1334
Spool Seal Replacement 1336
Clean 1337
Inspect 1337
Assemble Manual Control Valve 1338
Assemble Lift, Tilt, and Auxiliary Sections 1338
Assemble Inlet Section 1339
Assemble Valve 1340
Assemble Handles and Levers 1347
Install 1350
Ending Steps 1362
E-Hydraulic Control Valve Repair for 1 5-2 0T Trucks 1363
Remove 1363
Disassemble 1369
Clean 1376
Inspect 1376
Assemble 1376
Install 1384
E-Hydraulic Controls 1389
Replace E-Hydraulic Control Components 1390
E-Hydraulic Control Valve Repair for 2 0-3 5T Trucks and 4 0-5 0T Pneumatic Trucks 1391
Remove 1391
Initial Steps 1391
Fitting Removal for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1391
Fitting Removal for Lift Truck ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1393
Electrical Disconnect and Control Valve Dismount 1395
Disassemble 1397
Clean 1402
Inspect 1402
Assemble 1402
Install 1410
Electrical Connect and Control Valve Mount 1410
Fitting Installation for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1412
Fitting Installation for Lift Truck ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1414
Ending Steps 1415
E-Hydraulic Controls 1416
Replace E-Hydraulic Control Components 1416
E-Hydraulic Control Valve Repair for 4 0-5 5T Cushion Trucks 1417
Remove 1417
Initial Steps 1417
Fitting Removal 1417
Electrical Disconnect and Control Valve Dismount 1419
Disassemble 1421
Clean 1426
Inspect 1426
Assemble 1426
Install 1434
Electrical Connect and Control Valve Mount 1434
Fitting Installation 1436
Ending Steps 1437
E-Hydraulic Controls 1438
Replace E-Hydraulic Control Components 1438
Checks and Adjustments
for 1 5-2 0T Lift Trucks 1439
Manual Control Valve 1439
Primary Relief Valve 1439
Optional Auxiliary Port Relief Valve 1439
E-Hydraulic Control Valve 1440
Primary Relief Valve 1440
Optional Secondary Port Relief Valve 1441
Hydraulic System Air Removal 1442
Checks and Adjustments
2 0-5 5T Lift Trucks 1443
Manual Control Valve 1443
External Leakage 1443
Primary Relief Cartridge 1443
Secondary Relief Valve 1444
E-Hydraulic Control Valve 1444
Primary Relief Valve 1444
Secondary Relief Valve 1445
PPRV Pilot Pressure Test 1446
Hydraulic System Air Removal 1447
Position Sensor and OPS Check and Adjustment 1448
Position Sensor 1448
(OPS) Operator Presence Solenoid 1448
Manual Control Valve Re-Calibration 1448
Calibration Procedure 1449
Control Valve 1449
Torque Specifications
for 1 5-2 0T Lift Trucks 1450
Manual Hydraulic Control Valve 1450
Manual Control Valve Handles and Levers 1450
E-Hydraulic Control Valve 1450
Torque Specifications
for 2 2-5 5T Lift Trucks 1451
Manual Hydraulic Control Valve 1451
Manual Control Valve Handles and Levers 1451
Manual Control Valve Covers 1451
E-Hydraulic Control Valve 1451
Safety Procedures When Working Near Mast 1711
General 1713
Description 1714
Tilt Cylinder Repair for 2 0-5 5T Trucks 1714
Remove 1714
Disassemble 1716
Inspect 1717
Clean 1717
Assemble 1717
Install 1719
Tilt Cylinders, Adjust 1719
Tilt Cylinder Leak Check 1722
Tilt Cylinder Repair
for 1 0-2 0T Trucks 1723
Remove 1723
Disassemble 1725
Inspect 1727
Clean 1727
Assemble 1727
Install 1727
Tilt Cylinders, Adjust 1728
Tilt Cylinders Leak Check 1729
Lift Cylinder Repair
for 2 0-3 5T Trucks 1730
Main Lift Cylinders 1730
Remove 1730
Two-Stage FFL 1730
Three-Stage FFL 1732
Four-Stage FFL 1732
Two-Stage LFL 1733
Disassemble 1733
Two-Stage FFL 1733
Three-Stage FFL 1735
Four-Stage FFL 1735
Two-Stage LFL 1737
Clean 1738
Inspect 1738
Assemble 1738
Two-Stage FFL 1738
Three-Stage FFL 1738
Four-Stage FFL 1739
Two-Stage LFL 1739
Install 1740
Two-Stage FFL 1740
System Air Bleed Procedures 1740
Three-Stage FFL 1740
Four-Stage FFL 1741
Two-Stage LFL 1741
Lift Cylinder Repair for Lift Truck Model ERP15VT (G807) 1742
Main Lift Cylinder 1742
Remove 1742
Main Lift Cylinders – Two-Stage FFL Mast 1742
Left-Hand Main Lift Cylinder – Three-Stage FFL Mast 1744
Right-Hand Main Lift Cylinder – Three-Stage FFL Mast 1748
Main Lift Cylinder – Two-Stage LFL Mast 1748
Disassemble 1751
Main Lift Cylinders – Two-Stage FFL Mast 1751
Main Lift Cylinder – Three-Stage FFL Mast 1753
Main Lift Cylinder – Two-Stage LFL Mast 1753
Clean 1754
Inspect 1754
Assemble 1755
Main Lift Cylinder – Two-Stage FFL Mast 1755
Main Lift Cylinder – Three-Stage FFL Mast 1755
Main Lift Cylinder – Two-Stage LFL Mast 1755
Install 1756
Main Lift Cylinder – Two-Stage FFL Mast 1756
Left-Hand Main Lift Cylinder – Three-Stage FFL Mast 1756
Right-Hand Main Lift Cylinder – Three-Stage FFL Mast 1757
Main Lift Cylinder – Two-Stage LFL Mast 1758
System Air Bleed Procedures 1759
All Main Lift Cylinders 1759
Lift Cylinder Repair for 1 5-2 0T Trucks 1759
Main Lift Cylinder 1759
Remove 1759
Two-Stage FFL 1760
Three-Stage FFL 1760
Two-Stage LFL 1761
Four-Stage FFL 1763
Disassemble 1764
Two-Stage FFL 1764
Three-Stage FFL 1766
Two-Stage LFL 1766
Four-Stage FFL 1767
Clean 1770
Inspect 1770
Assemble 1770
Two-Stage FFL 1770
Three-Stage FFL 1771
Two-Stage LFL 1771
Four-Stage FFL 1772
Install 1773
Two-Stage FFL 1773
System Air Bleed Procedures 1773
Three-Stage FFL Mast 1773
Two-Stage LFL 1774
Four-Stage FFL 1774
Mast and Carriage Install for Two-Stage FFL, Three-Stage FFL, and Two-Stage LFL 1775
Mast and Carriage Installation for Four-Stage FFL 1775
Lift Cylinder Repair
for 4 0-5 5T Trucks 1776
Main Lift Cylinders 1776
Remove 1776
Two-Stage FFL 1776
Three-Stage FFL 1778
Two-Stage LFL 1778
Disassemble 1779
Two-Stage FFL 1779
Three-Stage FFL 1781
Two-Stage LFL 1782
Clean 1783
Inspect 1783
Assemble 1783
Two-Stage FFL 1783
Three-Stage FFL 1784
Two-Stage LFL 1784
Install 1785
Two-Stage FFL 1785
System Air Bleed Procedures 1785
Three-Stage FFL 1785
Two-Stage LFL 1786
Free-Lift Cylinder Repair
for 2 0-3 5T Trucks 1787
Free-Lift Cylinder 1787
Remove 1787
Two and Three-Stage FFL Mast 1787
Four-Stage FFL For Lift Truck ERC22-356VG (ERC045-070VG) (A968) 1788
Disassemble 1790
Two and Three-Stage FFL Mast 1790
Four-Stage FFL Mast for Lift Truck ERC22-356VG (ERC045-070VG) (A968) 1791
Clean 1791
Inspect 1791
Assemble 1792
Two and Three-Stage FFL Mast 1792
Four-Stage FFL Mast for Lift Truck ERC22-356VG (ERC045-070VG) (A968) 1792
Install 1793
Two and Three-Stage FFL Mast 1793
Four-Stage FFL Mast for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1793
Free Lift Cylinder Repair for Lift Truck Model ERP15VT (G807) 1794
Free-Lift Cylinder 1794
Remove 1794
Three-Stage FFL Mast 1794
Disassemble 1796
Clean 1797
Inspect 1797
Assemble 1797
Install 1797
Free Lift Cylinder Repair
for 1 5-2 0T Trucks 1798
Free-Lift Cylinder 1798
Remove 1798
Two and Three-Stage FFL Mast 1798
Four-Stage FFL Mast 1800
Disassemble 1802
Two-Stage and Three-Stage FFL Masts 1802
Four Stage FFL Mast 1803
Clean 1804
Inspect 1804
Assemble 1804
Two-Stage and Three-Stage FFL Masts 1804
Four-Stage FFL Mast 1805
Install 1805
Two-Stage and Three-Stage FFL Masts 1805
Four-Stage FFL Mast 1805
All Masts 1807
Free-Lift Cylinder Repair
for 4 0-5 5T Trucks 1808
Free-Lift Cylinder 1808
Remove 1808
Two and Three-Stage FFL Mast 1808
Disassemble 1809
Two and Three-Stage FFL Mast 1809
Clean 1810
Inspect 1810
Assemble 1810
Two and Three-Stage FFL Mast 1810
Install 1811
Two and Three-Stage FFL Mast 1811
Sideshift Cylinder Repair
for 1 5-3 5T Trucks Prior to December 2016 1811
Remove 1811
Disassemble 1815
Clean and Inspect 1817
Assemble and Install 1817
Sideshift Cylinder Repair
for 1 5-3 5T Trucks After December 2016 1818
Remove 1818
Disassemble 1822
Clean and Inspect 1824
Assemble and Install 1824
Integral Side-Shift Cylinder Gland Leak Checks 1826
Sideshift Cylinder Repair
for 4 0-5 5T Trucks 1827
Remove 1827
Disassemble 1827
Clean and Inspect 1829
Assemble and Install 1829
Fork Positioner Cylinder Repair Prior to December 2016 1829
Remove 1829
Disassemble 1830
Clean 1832
Inspect 1832
Assemble 1833
Install 1833
Fork Positioner Cylinder Adjustment 1833
Fork Positioner Cylinder Repair After December 2016 1834
Remove 1834
Disassemble 1834
Clean 1837
Inspect 1837
Assemble 1838
Install 1838
Fork Positioner Cylinder Adjustment 1838
Lift Cylinder Leak Check 1839
Seal Kit Installation 1839
External Installation (Seal and Back-Up Ring) 1840
Internal Installation (Piston Rod Assembly) 1840
Torque Specifications for Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-25VL (ERP045-070VL) (A976) 1840
Tilt Cylinders 1840
Piston Rod Nut 1840
Gland 1841
Tilt Cylinder Mounting Capscrew 1841
Tilt Cylinder Rod End Capscrew 1841
Main and Free-Lift Cylinder 1841
Sideshift Cylinder 1841
Fork Positioner Cylinder 1841
Torque Specifications for Lift Truck Model ERP15VT (G807) 1841
Tilt Cylinders 1841
Main and Free-Lift Cylinders 1841
Sideshift Cylinder 1842
Torque Specifications for Lift Truck Models ERP16-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), ESC030-40AC (B883),ESC030-40AD (C883) 1842
Tilt Cylinders 1842
Main and Free-Lift Cylinders 1842
Sideshift Cylinder 1843
Fork Positioner Cylinder 1843
Torque Specifications for Lift Truck Model ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1843
Tilt Cylinders 1843
Main and Free-Lift Cylinder 1843
Sideshift Cylinder 1843
Torque Specifications for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1843
Tilt Cylinder 1844
Main and Free Lift Cylinder 1844
Sideshift Cylinder 1844
Safety Procedures When Working Near Mast 1857
General 1860
Description 1860
Tilt Cylinder Repair for 2 0-5 5T Trucks 1861
Remove 1861
Disassemble 1863
Inspect 1864
Clean 1864
Assemble 1864
Install 1866
Tilt Cylinders, Adjust 1866
Tilt Cylinder Leak Check 1869
Tilt Cylinder Repair
for 1 0-2 0T Trucks 1870
Remove 1870
Disassemble 1873
Inspect 1875
Clean 1875
Assemble 1875
Install 1875
Tilt Cylinders, Adjust 1876
Tilt Cylinders Leak Check 1877
Lift Cylinder Repair
for 2 0-3 5T Trucks 1879
Main Lift Cylinders 1879
Remove 1879
Two-Stage FFL 1879
Three-Stage FFL 1881
Four-Stage FFL 1881
Two-Stage LFL 1882
Disassemble 1882
Two-Stage FFL 1882
Three-Stage FFL 1884
Four-Stage FFL 1886
Two-Stage LFL 1887
Clean 1888
Inspect 1888
Assemble 1888
Two-Stage FFL 1888
Three-Stage FFL 1889
Four-Stage FFL 1889
Two-Stage LFL 1890
Install 1890
Two-Stage FFL 1890
System Air Bleed Procedures 1890
Three-Stage FFL 1891
Four-Stage FFL 1891
Two-Stage LFL 1892
Lift Cylinder Repair for Lift Truck Model ERP15VT (G807) 1893
Main Lift Cylinder 1893
Remove 1893
Main Lift Cylinders – Two-Stage FFL Mast 1893
Left-Hand Main Lift Cylinder – Three-Stage FFL Mast 1895
Right-Hand Main Lift Cylinder – Three-Stage FFL Mast 1899
Main Lift Cylinder – Two-Stage LFL Mast 1899
Disassemble 1902
Main Lift Cylinders – Two-Stage FFL Mast 1902
Main Lift Cylinder – Three-Stage FFL Mast 1904
Main Lift Cylinder – Two-Stage LFL Mast 1905
Clean 1906
Inspect 1906
Assemble 1906
Main Lift Cylinder – Two-Stage FFL Mast 1906
Main Lift Cylinder – Three-Stage FFL Mast 1907
Main Lift Cylinder – Two-Stage LFL Mast 1907
Install 1907
Main Lift Cylinder – Two-Stage FFL Mast 1907
Left-Hand Main Lift Cylinder – Three-Stage FFL Mast 1908
Right-Hand Main Lift Cylinder – Three-Stage FFL Mast 1909
Main Lift Cylinder – Two-Stage LFL Mast 1910
System Air Bleed Procedures 1910
All Main Lift Cylinders 1911
Lift Cylinder Repair for 1 5-2 0T Trucks 1912
Main Lift Cylinder 1912
Remove 1912
Two-Stage FFL 1912
Three-Stage FFL 1912
Two-Stage LFL 1913
Four-Stage FFL 1915
Disassemble 1917
Two-Stage FFL 1917
Three-Stage FFL 1918
Two-Stage LFL 1919
Four-Stage FFL 1920
Clean 1922
Inspect 1923
Assemble 1923
Two-Stage FFL 1923
Three-Stage FFL 1923
Two-Stage LFL 1924
Four-Stage FFL 1924
Install 1925
Two-Stage FFL 1925
System Air Bleed Procedures 1926
Three-Stage FFL Mast 1926
Two-Stage LFL 1926
Four-Stage FFL 1927
Mast and Carriage Install for Two-Stage FFL, Three-Stage FFL, and Two-Stage LFL 1927
Mast and Carriage Installation for Four-Stage FFL 1928
Lift Cylinder Repair for 4 0-5 5T Trucks 1929
Main Lift Cylinders 1929
Remove 1929
Two-Stage FFL 1929
Three-Stage FFL 1931
Two-Stage LFL 1931
Disassemble 1932
Two-Stage FFL 1932
Three-Stage FFL 1934
Two-Stage LFL 1935
Clean 1936
Inspect 1936
Assemble 1936
Two-Stage FFL 1936
Three-Stage FFL 1937
Two-Stage LFL 1937
Install 1938
Two-Stage FFL 1938
System Air Bleed Procedures 1938
Three-Stage FFL 1938
Two-Stage LFL 1939
Free-Lift Cylinder Repair for 2 0-3 5T Trucks 1940
Free-Lift Cylinder 1940
Remove 1940
Two and Three-Stage FFL Mast 1940
Four-Stage FFL For Lift Truck ERC22-356VG (ERC045-070VG) (A968) 1941
Disassemble 1943
Two and Three-Stage FFL Mast 1943
Four-Stage FFL Mast for Lift Truck ERC22-356VG (ERC045-070VG) (A968) 1944
Clean 1944
Inspect 1945
Assemble 1945
Two and Three-Stage FFL Mast 1945
Four-Stage FFL Mast for Lift Truck ERC22-356VG (ERC045-070VG) (A968) 1945
Install 1946
Two and Three-Stage FFL Mast 1946
Four-Stage FFL Mast for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1946
Free Lift Cylinder Repair for Lift Truck Model ERP15VT (G807) 1948
Free-Lift Cylinder 1948
Remove 1948
Three-Stage FFL Mast 1948
Disassemble 1950
Clean 1951
Inspect 1951
Assemble 1951
Install 1951
Free Lift Cylinder Repair for 1 5-2 0T Trucks 1953
Free-Lift Cylinder 1953
Remove 1953
Two and Three-Stage FFL Mast 1953
Four-Stage FFL Mast 1955
Disassemble 1958
Two-Stage and Three-Stage FFL Masts 1958
Four Stage FFL Mast 1958
Clean 1959
Inspect 1959
Assemble 1959
Two-Stage and Three-Stage FFL Masts 1959
Four-Stage FFL Mast 1960
Install 1960
Two-Stage and Three-Stage FFL Masts 1960
Four-Stage FFL Mast 1961
All Masts 1964
Free-Lift Cylinder Repair
for 4 0-5 5T Trucks 1965
Free-Lift Cylinder 1965
Remove 1965
Two and Three-Stage FFL Mast 1965
Disassemble 1966
Two and Three-Stage FFL Mast 1966
Clean 1967
Inspect 1967
Assemble 1967
Two and Three-Stage FFL Mast 1967
Install 1968
Two and Three-Stage FFL Mast 1968
Sideshift Cylinder Repair
for 1 5-3 5T Trucks Prior to December 2016 1969
Remove 1969
Disassemble 1972
Clean and Inspect 1974
Assemble and Install 1974
Sideshift Cylinder Repair
for 1 5-3 5T Trucks After December 2016 1976
Remove 1976
Disassemble 1979
Clean and Inspect 1980
Assemble and Install 1981
Integral Side-Shift Cylinder Gland Leak Checks 1983
Sideshift Cylinder Repair
for 4 0-5 5T Trucks 1984
Remove 1984
Disassemble 1985
Clean and Inspect 1986
Assemble and Install 1986
Fork Positioner Cylinder Repair Prior to December 2016 1987
Remove 1987
Disassemble 1987
Clean 1990
Inspect 1990
Assemble 1991
Install 1991
Fork Positioner Cylinder Adjustment 1991
Fork Positioner Cylinder Repair After December 2016 1993
Remove 1993
Disassemble 1993
Clean 1996
Inspect 1996
Assemble 1997
Install 1997
Fork Positioner Cylinder Adjustment 1997
Lift Cylinder Leak Check 1999
Seal Kit Installation 2000
External Installation (Seal and Back-Up Ring) 2000
Internal Installation (Piston Rod Assembly) 2000
Torque Specifications for Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-25VL (ERP045-070VL) (A976) 2001
Tilt Cylinders 2001
Piston Rod Nut 2001
Gland 2001
Tilt Cylinder Mounting Capscrew 2001
Tilt Cylinder Rod End Capscrew 2001
Main and Free-Lift Cylinder 2001
Sideshift Cylinder 2001
Fork Positioner Cylinder 2001
Torque Specifications for Lift Truck Model ERP15VT (G807) 2002
Tilt Cylinders 2002
Main and Free-Lift Cylinders 2002
Sideshift Cylinder 2002
Torque Specifications for Lift Truck Models ERP16-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), ESC030-40AC (B883),ESC030-40AD (C883) 2003
Tilt Cylinders 2003
Main and Free-Lift Cylinders 2003
Sideshift Cylinder 2003
Fork Positioner Cylinder 2003
Torque Specifications for Lift Truck Model ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2004
Tilt Cylinders 2004
Main and Free-Lift Cylinder 2004
Sideshift Cylinder 2004
Torque Specifications for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2004
Tilt Cylinder 2004
Main and Free Lift Cylinder 2004
Sideshift Cylinder 2004
General 2015
Description 2015
Display Panel Menu Access 2015
Menu Flowchart 2016
Supervisor Menu Flowchart 2016
Menu Navigation 2022
Icon Glossary 2026
Introduction 2026
Soft Key Icons 2026
Overlay Icons 2027
Icons on System Off Screen and Alert Screens 2027
Main Menu Title Screens 2031
Submenu Icons Grouped by Menu 2033
Operating Screen Icons 2033
Password Screen Icons 2034
Activity Log Submenu Icons 2034
Calibration Submenu Icons 2036
Display Submenu Icons 2038
Status Submenu Icons 2040
Truck Setup Submenu Icons 2043
Operating Screen 2050
Introduction 2050
Performance Mode Controls 2051
Status and Warning Icons 2051
Battery Discharge Indicator 2052
Direction and Parking Brake Indicators 2053
Hazard Flashers and Lighting Controls 2053
Steer Angle Indicator 2053
System Time 2053
Load Weight Indicator 2053
System Off/Alert Screens 2054
Introduction 2054
System Off Screen 2054
Alert Screens 2054
Password Screen 2056
Introduction 2056
Password Screen 2056
Service Technician Password Setup 2056
Adding/Removing/Changing Passwords 2057
Password Log 2060
Activity Log Menu 2061
Introduction 2061
Operator Checklist Log 2062
Password Log 2065
Impact Events Log 2067
Calibration Menu 2069
Introduction 2069
Load Weight Calibration 2069
Return to Set Tilt Stop Point Calibration 2070
E-Hydraulic and Manual Valve Threshold Calibration 2070
Steering Wheel Center Point Calibration 2071
Steer Axle Position Calibration 2071
Steer Axle Center Point Calibration 2072
Manual Hydraulics Calibration 2073
Display Menu 2074
Introduction 2074
Set Date and Time Format Menu 2074
Set Daylight Saving Time Menu 2075
Procedure for Setting Up Automatic Daylight Savings Time 2076
Set Time and Date Menu 2078
Procedure for Setting Time and Date 2078
Set Units Menu 2079
Status Menu 2080
Introduction 2080
VSM Versions 2080
Display Versions 2081
Truck Serial Number 2081
Hour Meters 2081
E-Hydraulic Controller Versions 2081
Pump Motor Controller Versions 2081
Traction Motor Controller 1 Versions 2081
Traction Motor Controller 2 Versions 2082
Light Controller Versions 2082
Impact Sensor Versions 2082
Truck Setup Menu 2083
Introduction 2083
Add/Remove Password 2083
Battery Settings 2083
Restore Default Settings 2084
Motion Alarm 2084
Impact Monitor Settings 2085
Impact Detection 2085
Setting Adjustments 2085
Initial Adjustment of Soft and Hard Impact Settings 2085
Readjustment of Soft and Hard Impact Settings 2085
Auto Power-Off Time Delay 2086
Return to Set Tilt 2086
Traction Speed Limit 2086
Scheduled Maintenance Reminder 2087
Minimum Pump Standby Flow Rate 2088
Operator Checklist 2088
Impact Monitor Shutdown 2089
Motor Braking 2090
Changing the Motor Braking Settings 2090
Steering Wheel Friction and Steering Turns Adjustment 2091
How to Adjust Settings 2091
Steering Friction Setting 2091
Steering Wheel Number of Turns 2092
General 2101
Description 2101
Display Panel Menu Access 2101
Menu Flowchart 2102
Supervisor Menu Flowchart 2102
Menu Navigation 2108
Icon Glossary 2112
Introduction 2112
Soft Key Icons 2112
Overlay Icons 2113
Icons on System Off Screen and Alert Screens 2113
Main Menu Title Screens 2117
Submenu Icons Grouped by Menu 2119
Operating Screen Icons 2119
Password Screen Icons 2120
Activity Log Submenu Icons 2120
Calibration Submenu Icons 2122
Display Submenu Icons 2124
Status Submenu Icons 2126
Truck Setup Submenu Icons 2129
Operating Screen 2136
Introduction 2136
Performance Mode Controls 2136
Status and Warning Icons 2137
Battery Discharge Indicator 2138
Direction and Parking Brake Indicators 2138
Hazard Flashers and Lighting Controls 2139
Steer Angle Indicator 2139
System Time 2139
Load Weight Indicator 2139
System Off/Alert Screens 2140
Introduction 2140
System Off Screen 2140
Alert Screens 2140
Password Screen 2142
Introduction 2142
Password Screen 2142
Service Technician Password Setup 2142
Adding/Removing/Changing Passwords 2143
Password Log 2146
Activity Log Menu 2147
Introduction 2147
Operator Checklist Log 2147
Password Log 2149
Impact Events Log 2151
Calibration Menu 2153
Introduction 2153
Load Weight Calibration 2153
Return to Set Tilt Stop Point Calibration 2154
E-Hydraulic and Manual Valve Threshold Calibration 2154
Steering Wheel Center Point Calibration 2155
Steer Axle Position Calibration 2155
Steer Axle Center Point Calibration 2156
Manual Hydraulics Calibration 2157
Display Menu 2158
Introduction 2158
Set Date and Time Format Menu 2158
Set Daylight Saving Time Menu 2159
Procedure for Setting Up Automatic Daylight Savings Time 2160
Set Time and Date Menu 2162
Procedure for Setting Time and Date 2162
Set Units Menu 2163
Status Menu 2164
Introduction 2164
VSM Versions 2164
Display Versions 2165
Truck Serial Number 2165
Hour Meters 2165
E-Hydraulic Controller Versions 2165
Pump Motor Controller Versions 2165
Traction Motor Controller 1 Versions 2165
Traction Motor Controller 2 Versions 2166
Light Controller Versions 2166
Impact Sensor Versions 2166
Truck Setup Menu 2167
Introduction 2167
Add/Remove Password 2167
Battery Settings 2167
Restore Default Settings 2168
Motion Alarm 2168
Impact Monitor Settings 2168
Impact Detection 2169
Setting Adjustments 2169
Initial Adjustment of Soft and Hard Impact Settings 2169
Readjustment of Soft and Hard Impact Settings 2169
Auto Power-Off Time Delay 2170
Return to Set Tilt 2170
Traction Speed Limit 2170
Scheduled Maintenance Reminder 2171
Minimum Pump Standby Flow Rate 2172
Operator Checklist 2172
Impact Monitor Shutdown 2173
Motor Braking 2174
Changing the Motor Braking Settings 2174
Steering Wheel Friction and Steering Turns Adjustment 2175
How to Adjust Settings 2175
Steering Friction Setting 2175
Steering Wheel Number of Turns 2176
General 2187
Description 2187
Display Panel Menu Access 2187
Menu Flowchart 2188
Technician Menu Flowchart 2188
Menu Navigation 2194
Icon Glossary 2198
Introduction 2198
Soft Key Icons 2198
Overlay Icons 2199
Heat Exchange Module Warning Indicator Screen 2199
System Off Screen and Alert Screens 2200
Main Menu Title Screens 2206
Submenu Icons Grouped by Menu 2207
Operating Screen Icons 2207
Password Screen Icons 2209
Activity Log Submenu Icons 2209
Calibration Submenu Icons 2210
Display Submenu Icons 2214
Status Submenu Icons 2216
Truck Setup Submenu Icons 2219
Diagnostics Submenu Icons 2231
Operating Screen 2241
Introduction 2241
Performance Mode Controls 2241
Status and Warning Icons 2242
Battery Discharge Indicator 2243
Direction and Parking Brake Indicators 2243
Hazard Flashers and Lighting Controls 2244
Steer Angle Indicator 2244
System Time 2244
Load Weight Indicator 2244
System Off/Alert Screens 2245
Introduction 2245
System Off Screen 2245
Alert Screens 2245
Password Screen 2247
Introduction 2247
Password Screen 2247
Service Technician Password Setup 2247
Adding/Removing/Changing Passwords 2248
Password Log 2251
Activity Log Menu 2252
Introduction 2252
Operator Checklist Log 2252
Password Log 2254
Impact Events Log 2256
Calibration Menu 2258
Introduction 2258
Load Weight Calibration 2258
Return to Set Tilt Stop Point Calibration 2259
E-Hydraulic and Manual Valve Threshold Calibration 2259
Steering Wheel Center Point Calibration 2260
Steer Axle Position Calibration 2261
Steer Axle Center Point Calibration 2262
Manual Hydraulics Calibration 2262
Display Menu 2263
Introduction 2263
Set Date and Time Format Menu 2263
Set Daylight Saving Time Menu 2264
Procedure for Setting Up Automatic Daylight Savings Time 2265
Set Time and Date Menu 2267
Procedure for Setting Time and Date 2267
Set Units Menu 2268
Status Menu 2269
Introduction 2269
VSM Versions 2269
Display Versions 2270
Truck Serial Number 2270
Hour Meters 2270
E-Hydraulic Controller Versions 2270
Pump Motor Controller Versions 2270
Traction Motor Controller 1 Versions 2270
Traction Motor Controller 2 Versions 2271
Light Controller Versions 2271
Impact Sensor Versions 2271
E-Steer Controller 1 Versions 2271
E-Steer Controller 2 Versions 2271
Truck Setup Menu 2272
Introduction 2272
Add/Remove Password 2273
Battery Settings 2273
Motor Braking 2273
Changing the Motor Braking Settings 2274
Battery Mode 2274
Battery Setup 2275
BDI Adjustment Setting 2276
Acceleration Rates 2277
Hour Meter Initialization 2278
Impact Monitor Shutdown 2278
Operator Checklist 2280
Minimum Pump Standby Flow Rate 2280
Scheduled Maintenance Reminder 2281
Traction Speed Limit 2282
Return to Set Tilt 2282
Auto Power-Off Time Delay 2283
Impact Monitor Settings 2283
Impact Detection 2284
Setting Adjustments 2284
Initial Adjustment of Soft and Hard Impact Settings 2284
Readjustment of Soft and Hard Impact Settings 2284
Motion Alarm 2284
Lift Hydraulic Function Maximum Speed and Ramp Times 2285
Lower Hydraulic Function Maximum Speed and Ramp Times 2285
Tilt Forward Hydraulic Function Maximum Speed and Ramp Times 2286
Tilt Backward Hydraulic Function Maximum Speed and Ramp Times 2286
Auxiliary 1A Hydraulic Function Maximum Speed and Ramp Times 2286
Auxiliary 1B Hydraulic Function Maximum Speed and Ramp Times 2286
Auxiliary 2A Hydraulic Function Maximum Speed and Ramp Times 2286
Auxiliary 2B Hydraulic Function Maximum Speed and Ramp Times 2286
Optional Hydraulic Functions 2286
Rear Lights Control 2287
Restore Default Settings 2287
Steering Wheel Friction and Steering Turns Adjustment 2288
Navigation 2289
How to Adjust Settings 2289
Steering Friction 2289
Steering Wheel Number of Turns 2290
Diagnostics Menu 2292
Introduction 2292
Fault Code Log 2292
Fault Log Details 2293
Speedometer 2294
Direction Switch 2294
Traction Motor 1 Status 2295
Traction Motor 2 Status 2295
Occupancy Sensor 2295
Brake System Sensors 2295
Pump Status 2296
Hydraulic Control Inputs 2297
E-Hydraulic Valves 2297
Hydraulic Sensors 2298
System Voltages 2298
Steering Position Sensors 2300
E-Steering Position Sensors 2300
Electric Brake 2301
Navigation 2302
ESS Diagnostics Menus A, B, and C 2303
Menu A 2303
Menu B 2304
Menu C 2306
General 2315
Description 2315
Display Panel Menu Access 2315
Menu Flowchart 2316
Technician Menu Flowchart 2316
Menu Navigation 2322
Icon Glossary 2326
Introduction 2326
Soft Key Icons 2326
Overlay Icons 2327
Heat Exchange Module Warning Indicator Screen 2327
System Off Screen and Alert Screens 2328
Main Menu Title Screens 2333
Submenu Icons Grouped by Menu 2335
Operating Screen Icons 2335
Password Screen Icons 2336
Activity Log Submenu Icons 2336
Calibration Submenu Icons 2338
Display Submenu Icons 2341
Status Submenu Icons 2343
Truck Setup Submenu Icons 2347
Diagnostics Submenu Icons 2358
Operating Screen 2368
Introduction 2368
Performance Mode Controls 2368
Status and Warning Icons 2369
Battery Discharge Indicator 2370
Direction and Parking Brake Indicators 2371
Hazard Flashers and Lighting Controls 2371
Steer Angle Indicator 2371
System Time 2371
Load Weight Indicator 2371
System Off/Alert Screens 2372
Introduction 2372
System Off Screen 2372
Alert Screens 2372
Password Screen 2374
Introduction 2374
Password Screen 2374
Service Technician Password Setup 2374
Adding/Removing/Changing Passwords 2375
Password Log 2377
Activity Log Menu 2378
Introduction 2378
Operator Checklist Log 2378
Password Log 2380
Impact Events Log 2382
Calibration Menu 2384
Introduction 2384
Load Weight Calibration 2384
Return to Set Tilt Stop Point Calibration 2385
E-Hydraulic and Manual Valve Threshold Calibration 2385
Steering Wheel Center Point Calibration 2386
Steer Axle Position Calibration 2387
Steer Axle Center Point Calibration 2387
Manual Hydraulics Calibration 2388
Display Menu 2389
Introduction 2389
Set Date and Time Format Menu 2389
Set Daylight Saving Time Menu 2390
Procedure for Setting Up Automatic Daylight Savings Time 2391
Set Time and Date Menu 2393
Procedure for Setting Time and Date 2393
Set Units Menu 2394
Status Menu 2395
Introduction 2395
VSM Versions 2395
Display Versions 2396
Truck Serial Number 2396
Hour Meters 2396
E-Hydraulic Controller Versions 2396
Pump Motor Controller Versions 2396
Traction Motor Controller 1 Versions 2396
Traction Motor Controller 2 Versions 2397
Light Controller Versions 2397
Impact Sensor Versions 2397
E-Steer Controller 1 Versions 2397
E-Steer Controller 2 Versions 2397
Truck Setup Menu 2398
Introduction 2398
Add/Remove Password 2399
Battery Settings 2399
Motor Braking 2399
Changing the Motor Braking Settings 2400
Battery Mode 2400
Battery Setup 2401
BDI Adjustment Setting 2402
Acceleration Rates 2403
Hour Meter Initialization 2404
Impact Monitor Shutdown 2404
Operator Checklist 2405
Minimum Pump Standby Flow Rate 2406
Scheduled Maintenance Reminder 2406
Traction Speed Limit 2408
Return to Set Tilt 2408
Auto Power-Off Time Delay 2408
Impact Monitor Settings 2409
Impact Detection 2409
Setting Adjustments 2409
Initial Adjustment of Soft and Hard Impact Settings 2409
Readjustment of Soft and Hard Impact Settings 2410
Motion Alarm 2410
Lift Hydraulic Function Maximum Speed and Ramp Times 2410
Lower Hydraulic Function Maximum Speed and Ramp Times 2411
Tilt Forward Hydraulic Function Maximum Speed and Ramp Times 2411
Tilt Backward Hydraulic Function Maximum Speed and Ramp Times 2411
Auxiliary 1A Hydraulic Function Maximum Speed and Ramp Times 2411
Auxiliary 1B Hydraulic Function Maximum Speed and Ramp Times 2412
Auxiliary 2A Hydraulic Function Maximum Speed and Ramp Times 2412
Auxiliary 2B Hydraulic Function Maximum Speed and Ramp Times 2412
Optional Hydraulic Functions 2412
Rear Lights Control 2412
Restore Default Settings 2413
Steering Wheel Friction and Steering Turns Adjustment 2413
Navigation 2414
How to Adjust Settings 2414
Steering Friction 2414
Steering Wheel Number of Turns 2415
Diagnostics Menu 2417
Introduction 2417
Fault Code Log 2417
Fault Log Details 2418
Speedometer 2419
Direction Switch 2419
Traction Motor 1 Status 2419
Traction Motor 2 Status 2420
Occupancy Sensor 2420
Brake System Sensors 2420
Pump Status 2421
Hydraulic Control Inputs 2421
E-Hydraulic Valves 2421
Hydraulic Sensors 2422
System Voltages 2422
Steering Position Sensors 2423
E-Steering Position Sensors 2423
Electric Brake 2424
Navigation 2425
General 2435
Discharging the Capacitors 2436
Display Panel and Key or Keyless Switch Replacement 2437
Display Panel, Replace 2437
Remove 2437
Install 2440
Electronic and Manual Hydraulic Controls 2441
General 2441
Manual Hydraulic Controls 2442
Upper Front Cover 2442
Direction Control Switch 2443
Remove 2443
Install 2448
Clamp Button 2448
Remove 2448
Install 2449
Return To Set Tilt (RTST) Button 2449
Remove 2449
Install 2449
Emergency Disconnect Switch 2450
Remove 2450
Install 2450
E-Hydraulic Controls – Test 2451
Mini-Levers 2451
Full Stroke Test 2451
Function Returns to Neutral Test 2451
Push (Override) Button 2452
E-Hydraulic Controls 2452
Mini-levers, Remove and Install 2452
Armrest Assembly 2453
Remove 2453
Install 2455
Horn Button 2455
Remove 2455
Install 2456
Direction Control Switch 2456
Remove 2456
Install 2457
Emergency Disconnect Switch 2457
Remove 2457
Install 2458
Push (Override) Buttons and Function Selection Button 2458
Remove 2458
Install 2460
Electronic-Hydraulic Controls, After January, 2020 2460
General 2460
E-Hydraulic Controls – TEST 2462
Mini-Levers 2462
Full Stroke Test 2462
Function Returns to Neutral Test 2462
Push Button (push (override) button) 2463
Mini-levers, Remove and Install 2463
Armrest Assembly 2463
Remove 2463
Install 2466
Horn Button 2466
Remove 2466
Install 2467
Direction Control Switch 2467
Remove 2467
Install 2467
Emergency Disconnect Switch 2467
Remove 2468
Install 2468
Push (Override) Buttons 2469
Remove 2469
Install 2470
Sensors and Switches 2471
General 2471
Synchronous Steering Valve 2471
Steering Axle Sensor 2471
Remove 2471
Install 2476
Hydraulic Motor Speed Sensor 2477
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 2477
Remove 2477
Install 2482
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2483
Remove 2483
Install 2487
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 2487
Remove 2487
Install 2488
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2488
Remove 2488
Install 2490
Hydraulic Motor Temperature Sensor 2490
Hydraulic Tank Level Sensor 2490
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2490
Remove 2490
Install 2492
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 2492
Remove 2492
Install 2493
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2493
Remove 2493
Install 2494
Hydraulic Filter Sensor 2494
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2494
Remove 2494
Install 2495
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968,) ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2496
Remove 2496
Install 2497
Hydraulic Oil Temperature Sensor 2498
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2498
Remove 2498
Install 2498
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 2498
Remove 2498
Install 2499
Traction Speed Sensor 2499
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2499
Remove 2499
Install 2501
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 2502
Remove 2502
Install 2504
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2504
Remove 2504
Install 2505
Traction Motor Temperature Sensor ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 2506
Traction Motor Temperature Sensor ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2506
Remove 2506
Install 2507
Tilt Position Sensor ERC22-35VG (ERC045-070VG) (A968), ERP22-35VL (ERP045-070VL) (A976), and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2507
Remove 2507
Install 2509
Tilt Position Sensor ERC16-20VA (ERC030-040VA) (A969) 2510
Remove 2510
Install 2510
Tilt Position Sensor ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2511
Remove 2511
Install 2512
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) 2513
Remove 2513
Install 2516
Low Level Brake Fluid Switch for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2517
Remove 2517
Install 2518
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) 2519
Remove 2519
Install 2519
Service Brake Pressure Sensor for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2520
Remove 2520
Install 2520
Accelerator Pedal Position Sensor 2520
Remove 2520
Install 2521
Seat Belt Sequence Module 2521
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2521
Remove 2521
Install 2521
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 2522
Remove 2522
Install 2522
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 2522
Remove 2522
Install 2523
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2523
Remove 2523
Install 2524
Seat Sensor (Operator Presence System) 2524
Non-Suspension Seat 2524
Remove 2524
Install 2526
Full Suspension and Swivel Seats 2526
Remove 2526
Install 2527
Steering Direction Sensor 2527
Remove 2527
Install 2528
Load Weight Sensor 2528
Remove 2528
Install 2530
Battery Gate Switch 2530
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2530
Remove 2530
Install 2532
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 2532
Remove 2532
Install 2534
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2535
Remove 2535
Install 2536
Horn Switch 2536
Fixed Steering Column 2536
Remove 2536
Install 2537
Telescopic Steering Column 2537
Remove 2537
Install 2538
Impact Sensor 2538
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2538
Remove 2538
Install 2540
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 2540
Remove 2540
Install 2541
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2542
Remove 2542
Install 2543
Rear and Hood Horn Button Switches 2543
Rear Horn Button Switch 2543
Remove 2543
Install 2544
Hood Horn Button Switch 2544
Remove 2544
Install 2545
Motor Controllers Replacement 2546
General 2546
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 2560
Traction Motor and Hydraulic Pump and Motor Controllers 2560
Remove 2560
Install 2567
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2568
Hydraulic Pump and Motor Controller 2568
Remove 2568
Install 2574
Traction Motor Controllers 2575
Remove 2575
Install 2582
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2583
Traction Motor and Hydraulic Pump and Motor Controllers 2583
Remove 2583
Install 2585
Line Contactor 2586
Remove 2586
Install 2594
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) 2595
Remove 2595
Install 2597
Fans for Lift Truck Model Manufactured Before November 2014ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2598
Remove 2598
Install 2598
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) 2598
Remove 2605
Install 2609
Vehicle System Manager 2609
General 2609
Remove 2610
Install 2614
Programming a New VSM and/or Display Panel 2615
PC Service Tool Software 2615
Fuses and Relays 2616
Backup Alarm 2630
Battery Connection 2633
Inspect 2633
Replacing Cables 2633
Cab Heater 2635
Lights 2635
General 2635
Work Lights (Front and Rear) 2639
Halogen Bulb Lights 2639
Remove 2639
Install 2639
LED Lights 2639
Remove 2639
Install 2640
Strobe Light 2640
Remove 2640
Install 2640
LED Tail, Backup, and Brake Lights 2641
Remove 2641
Install 2642
Front Marker/Turn Signal Lights 2642
Remove 2642
Install 2642
Dome Light 2642
Remove 2642
Install 2643
Converter 2643
Remove 2644
Install 2652
General 2665
Discharging the Capacitors 2666
Display Panel and Key or Keyless Switch Replacement 2667
Display Panel, Replace 2667
Remove 2667
Install 2670
Electronic and Manual Hydraulic Controls 2671
General 2671
Manual Hydraulic Controls 2672
Upper Front Cover 2672
Direction Control Switch 2673
Remove 2673
Install 2679
Clamp Button 2679
Remove 2679
Install 2680
Return To Set Tilt (RTST) Button 2680
Remove 2680
Install 2680
Emergency Disconnect Switch 2681
Remove 2681
Install 2681
E-Hydraulic Controls – Test 2682
Mini-Levers 2682
Full Stroke Test 2682
Function Returns to Neutral Test 2682
Push (Override) Button 2683
E-Hydraulic Controls 2683
Mini-levers, Remove and Install 2683
Armrest Assembly 2684
Remove 2684
Install 2686
Horn Button 2686
Remove 2686
Install 2687
Direction Control Switch 2687
Remove 2687
Install 2688
Emergency Disconnect Switch 2688
Remove 2688
Install 2689
Push (Override) Buttons and Function Selection Button 2689
Remove 2689
Install 2692
Electronic-Hydraulic Controls, After January, 2020 2693
General 2693
E-Hydraulic Controls – TEST 2694
Mini-Levers 2694
Full Stroke Test 2694
Function Returns to Neutral Test 2694
Push Button (push (override) button) 2695
Mini-levers, Remove and Install 2695
Armrest Assembly 2695
Remove 2695
Install 2698
Horn Button 2698
Remove 2698
Install 2698
Direction Control Switch 2698
Remove 2698
Install 2699
Emergency Disconnect Switch 2699
Remove 2699
Install 2700
Push (Override) Buttons 2700
Remove 2700
Install 2701
Sensors and Switches 2702
General 2702
Synchronous Steering Valve 2702
Steering Axle Sensor 2702
Remove 2702
Install 2707
Hydraulic Motor Speed Sensor 2708
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 2708
Remove 2708
Install 2713
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2714
Remove 2714
Install 2718
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) 2718
Remove 2718
Install 2719
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2719
Remove 2719
Install 2721
Hydraulic Motor Temperature Sensor 2721
Hydraulic Tank Level Sensor 2721
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2721
Remove 2721
Install 2723
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 2723
Remove 2723
Install 2724
Lift Truck Models ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2724
Remove 2724
Install 2725
Hydraulic Filter Sensor 2725
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2725
Remove 2725
Install 2726
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968,) ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2727
Remove 2727
Install 2728
Hydraulic Oil Temperature Sensor 2729
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2729
Remove 2729
Install 2729
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 2729
Remove 2729
Install 2730
Traction Speed Sensor 2730
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2730
Remove 2730
Install 2732
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 2733
Remove 2733
Install 2735
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2735
Remove 2735
Install 2736
Traction Motor Temperature Sensor ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 2737
Traction Motor Temperature Sensor ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2737
Remove 2737
Install 2738
Tilt Position Sensor ERC22-35VG (ERC045-070VG) (A968), ERP22-35VL (ERP045-070VL) (A976), and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2738
Remove 2738
Install 2740
Tilt Position Sensor ERC16-20VA (ERC030-040VA) (A969) 2740
Remove 2741
Install 2741
Tilt Position Sensor ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2741
Remove 2741
Install 2742
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) 2743
Remove 2743
Install 2746
Low Level Brake Fluid Switch for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2747
Remove 2747
Install 2748
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) 2749
Remove 2749
Install 2749
Service Brake Pressure Sensor for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2749
Remove 2749
Install 2750
Accelerator Pedal Position Sensor 2750
Remove 2750
Install 2750
Seat Belt Sequence Module 2751
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2751
Remove 2751
Install 2752
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 2752
Remove 2752
Install 2752
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) 2752
Remove 2752
Install 2753
Lift Truck Models ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2753
Remove 2753
Install 2753
Seat Sensor (Operator Presence System) 2754
Non-Suspension Seat 2754
Remove 2754
Install 2756
Full Suspension and Swivel Seats 2756
Remove 2756
Install 2757
Steering Direction Sensor 2757
Remove 2757
Install 2757
Load Weight Sensor 2758
Remove 2758
Install 2759
Battery Gate Switch 2760
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2760
Remove 2760
Install 2762
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) 2762
Remove 2762
Install 2764
Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2764
Remove 2764
Install 2765
Horn Switch 2766
Fixed Steering Column 2766
Remove 2766
Install 2767
Telescopic Steering Column 2767
Remove 2767
Install 2768
Impact Sensor 2768
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2768
Remove 2768
Install 2770
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 2770
Remove 2770
Install 2771
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2772
Remove 2772
Install 2773
Rear and Hood Horn Button Switches 2773
Rear Horn Button Switch 2773
Remove 2773
Install 2774
Hood Horn Button Switch 2774
Remove 2774
Install 2775
Motor Controllers Replacement 2776
General 2776
Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 2790
Traction Motor and Hydraulic Pump and Motor Controllers 2790
Remove 2790
Install 2797
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 2797
Hydraulic Pump and Motor Controller 2797
Remove 2797
Install 2804
Traction Motor Controllers 2805
Remove 2805
Install 2812
Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2813
Traction Motor and Hydraulic Pump and Motor Controllers 2813
Remove 2813
Install 2815
Line Contactor 2816
Remove 2816
Install 2823
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) 2825
Remove 2825
Install 2827
Fans for Lift Truck Model Manufactured Before November 2014 ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 2828
Remove 2828
Install 2828
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) 2828
Remove 2835
Install 2839
Vehicle System Manager 2840
General 2840
Remove 2840
Install 2845
Programming a New VSM and/or Display Panel 2846
PC Service Tool Software 2846
Fuses and Relays 2847
Backup Alarm 2861
Battery Connection 2865
Inspect 2865
Replacing Cables 2865
Cab Heater 2867
Lights 2867
General 2867
Work Lights (Front and Rear) 2871
Halogen Bulb Lights 2871
Remove 2871
Install 2871
LED Lights 2871
Remove 2871
Install 2872
Strobe Light 2872
Remove 2872
Install 2872
LED Tail, Backup, and Brake Lights 2873
Remove 2873
Install 2874
Front Marker/Turn Signal Lights 2874
Remove 2874
Install 2874
Dome Light 2874
Remove 2874
Install 2875
Converter 2875
Remove 2875
Install 2884
General 2893
Safety Procedures When Working Near Mast 2895
Fork Replacement 2898
Remove 2898
Install 2899
Checks 2899
Carriages Repair 2901
Standard Carriage 2901
Remove 2901
Clean and Inspect 2902
Install 2902
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 2903
Remove 2903
Clean and Inspect 2906
Repair 2907
Install 2907
Integral Sideshift Carriage, Lift Trucks Manufactured After December, 2016 2908
Remove 2908
Disassemble 2912
Clean and Inspect 2912
Assemble 2913
Install 2914
Fork Positioner, Lift Trucks Manufactured Prior To December, 2016 2914
Remove 2915
Clean and Inspect 2918
Disassemble and Assemble 2918
Install 2918
Fork Positioner Hydraulic Hose Adjustment 2920
Fork Positioner Carriage, Lift Trucks Manufactured After December, 2016 2921
Remove 2921
Clean and Inspect 2926
Disassemble and Assemble 2926
Install 2926
Fork Positioner Hydraulic Hose Adjustment 2927
Two-Stage Mast With Limited Free-Lift Repair 2929
Remove 2929
Disassemble 2933
Clean and Inspect 2936
Assemble 2939
Install 2939
Header Hose Installation and Adjustment 2942
Installation 2942
Adjustment 2949
Two-Stage Mast With Full Free-Lift Repair 2950
Remove 2950
Disassemble 2954
Clean and Inspect 2957
Assemble 2960
Install 2961
Header Hose Installation and Adjustment 2963
Installation 2963
Adjustment 2972
Three-Stage Mast With Full Free-Lift Repair 2973
Remove 2973
Disassemble 2978
Clean and Inspect 2981
Assemble 2983
Install 2984
Header Hose Installation and Adjustment 2987
Installation 2987
Adjustment 2997
Four-Stage Mast With Full Free-Lift Repair 2998
Remove 2998
Disassemble 3003
Clean and Inspect 3008
Assemble 3010
Install 3013
Header Hose Installation and Adjustment 3014
Installation 3014
Adjustment 3023
Quick Disconnect Attachments 3023
Disconnect 3023
Reconnect 3023
Lift Chains Adjustment 3025
Carriage Adjustments 3027
Mast Adjustments 3027
Load Roller, Adjust 3027
Mast Side Kicking, Adjust 3030
General 3037
Safety Procedures When Working Near Mast 3038
Fork Replacement 3041
Remove 3041
Install 3042
Checks 3043
Carriages Repair 3044
Standard Carriage 3044
Remove 3044
Clean and Inspect 3045
Install 3046
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 3046
Remove 3046
Clean and Inspect 3050
Repair 3050
Install 3051
Integral Sideshift Carriage, Lift Trucks Manufactured After December, 2016 3052
Remove 3052
Disassemble 3056
Clean and Inspect 3056
Assemble 3057
Install 3058
Fork Positioner, Lift Trucks Manufactured Prior To December, 2016 3058
Remove 3058
Clean and Inspect 3061
Disassemble and Assemble 3062
Install 3062
Fork Positioner Hydraulic Hose Adjustment 3063
Fork Positioner Carriage, Lift Trucks Manufactured After December, 2016 3065
Remove 3065
Clean and Inspect 3069
Disassemble and Assemble 3069
Install 3069
Fork Positioner Hydraulic Hose Adjustment 3070
Two-Stage Mast With Limited Free-Lift Repair 3071
Remove 3071
Disassemble 3075
Clean and Inspect 3077
Assemble 3079
Install 3080
Header Hose Installation and Adjustment 3082
Installation 3082
Adjustment 3089
Two-Stage Mast With Full Free-Lift Repair 3089
Remove 3089
Disassemble 3093
Clean and Inspect 3096
Assemble 3098
Install 3099
Header Hose Installation and Adjustment 3102
Installation 3102
Adjustment 3110
Three-Stage Mast With Full Free-Lift Repair 3110
Remove 3110
Disassemble 3114
Clean and Inspect 3117
Assemble 3119
Install 3120
Header Hose Installation and Adjustment 3122
Installation 3122
Adjustment 3131
Four-Stage Mast With Full Free-Lift Repair 3132
Remove 3132
Disassemble 3136
Clean and Inspect 3141
Assemble 3143
Install 3145
Header Hose Installation and Adjustment 3148
Installation 3148
Adjustment 3156
Quick Disconnect Attachments 3157
Disconnect 3157
Reconnect 3157
Lift Chains Adjustment 3158
Carriage Adjustments 3160
Mast Adjustments 3160
Load Roller, Adjust 3160
Mast Side Kicking, Adjust 3162
SECTION 9010 Operational Diagnostic Procedures 3181
Group 05 – Operational Checkout 3183
SECTION 9025 Traction Motor 3193
Group 10 – Principles of Operation 3195
Group 30 – Observed Symptoms 3201
SECTION 9030 Electrical System 3203
Group 03 – General Maintenance and Diagnostic Data 3213
Group 10 – Principles of Operation 3257
Group 20 – Diagnostic Trouble Codes 3289
Group 30 – Observed Symptoms 3901
Group 55 – Icons and Graphics 3945
SECTION 9035 Drive Axle/Unit 3953
Group 10 – Principles of Operation 3955
Group 30 – Observed Symptoms 3965
Group 20 – Diagnostic Trouble Codes 3977
SECTION 9050 Hydraulic Systems 3979
Group 10 – Principles of Operation 3983
Group 33 – Observed Symptoms-Gear Pump 4021
Group 43 – Tests and Adjustments-Gear Pump 4101
SECTION 9060 Operators Station 4131
Group 10 – Principles of Operation 4133
SECTION 9070 Front End (Mast) and Chassis 4173
Group 10 – Principles of Operation 4175
Group 30 – Observed Symptoms 4193
SECTION 9080 Supplementary Data 4237
Group 50 – Abbreviations and Acronyms 4239
General 4253
Discharging the Capacitors 4253
Description 4254
Transaxle Assembly 4255
Remove 4255
Install 4263
Maintenance and Repair 4266
Wheel Studs 4266
Removal of Defective Wheel Studs 4266
Removal of Sheared Off Wheel Stud 4266
Installation 4268
Transaxle Output Breathers 4268
Removal 4268
Installation 4269
Speed Sensor Repair 4270
Removal 4270
Installation 4271
Protective Cap 4271
Removal 4271
Installation 4272
Traction Motor 4272
Removal 4272
Installation 4273
Park Brake Actuator 4274
Removal 4274
Repair 4275
O-ring Replacement 4275
Rotary Shaft Seal Replacement 4275
Breather Valve Replacement 4276
Installation 4276
Service Brake Actuator 4278
Removal 4278
Repair 4278
Installation 4280
Brake Disc Set and Ball Ramp Actuator 4281
Removal 4281
Installation 4282
Output Assembly 4284
Removal 4284
Installation 4286
First Transmission Stage 4287
Removal 4287
Installation 4289
Alternate Pinion Installation 4294
Brake Pedal and Linkages 4296
General 4296
Master Cylinder Repair 4296
Remove 4296
Disassemble 4298
Clean 4299
Inspect 4300
Assemble 4300
Bench Bleed Master Cylinder 4300
Install and Adjust 4300
Brake Pedal Components 4301
Remove 4301
Disassemble 4301
Inspect 4302
Assemble 4302
Install 4302
Brake Pedal and Master Cylinder Adjustments 4302
Brake Pedal Adjustment 4302
Master Cylinder Adjustment 4303
Adjust Push Rod 4303
Parking Brake Valve Repair 4304
Remove 4304
Disassemble 4306
Assemble 4307
Install 4307
Tools 4308
General 4379
Serial Number Data 4379
Discharging the Capacitors 4380
How to Move Disabled Lift Truck 4380
How to Tow Lift Truck 4380
How to Put Lift Truck on Blocks 4381
How to Raise Drive Tires 4381
How to Raise Steering Tires 4382
How to Clean a Lift Truck 4383
Maintenance Schedule 4384
Maintenance Procedures Every 8 Hours or Daily 4389
How to Make Checks With Key or Keyless Switch OFF 4389
Tires and Wheels 4389
Forks 4389
General 4389
Inspect 4389
Remove 4390
Install 4392
Adjustment 4393
Visual Inspection of Mast, Mast hardware, and Tilt Cylinder Hardware 4393
Inspection of Mast, Carriage, Header Hoses, Lift Chains, and Attachments 4393
Safety Labels 4394
Steering Column Adjustments 4394
Tilt Adjust Feature 4395
Tilt Memory Feature 4395
Telescopic Feature 4395
Operator Restraint System 4395
Emergency Locking Retractor (ELR) 4397
Seat Adjustments 4397
Seat Position Adjustment (Standard Seat) 4397
Seat Position Adjustment (Swivel Seat) 4397
Seat Adjustment for Operator Weight 4397
Battery Restraint System 4399
Hood Latch and Hood Release Handle 4403
Battery 4405
Hydraulic System 4406
How to Make Checks With Key or Keyless Switch ON 4407
Horn, Lights, and Backup Alarm 4407
Motion Alarm 4408
Emergency Disconnect Switch 4408
Steering System 4410
Service Brakes 4410
Automatic Parking Brake 4410
Hydraulic Control Levers and Pedals 4410
Direction and Speed Control Pedals 4410
Lift System Operation 4410
Oil Leaks 4411
Maintenance Procedures Every 500 Hours or Three Months 4412
Forks 4412
Inspect 4412
Header Hose Checks 4413
Mast Lubrication 4414
Brake Fluid Check 4419
Master Cylinder Oil Check 4419
Bleeding the Brake System 4421
Operator Presence System Check 4423
Drive Axle Unit Assembly, Gear Oil Level Check 4423
Drive Axle Unit Assembly, Wet Brake Oil Level Check 4424
Tilt Cylinder Adjustments 4426
Tilt Cylinder Rod End Pins 4427
Lift Chains 4427
Wear Check 4427
Lift Chain Lubrication 4428
Fork Pins and Guides 4429
Check Upper and Lower Bearings, Integral Sideshift Carriage 4429
Check Lower Mounting Hook, Integral Sideshift Carriage 4431
Hydraulic Tank Breather, Check 4431
Electrical Inspection 4432
Line Contactor 4432
Steering Axle 4435
King Pins and Tie Rods, Lubricate 4435
Other Lubrication 4436
Hydraulic Control Levers 4436
Cab Heater 4436
Maintenance Procedures Every 2000 Hours or Yearly 4437
Hydraulic System 4437
Hydraulic Filter Element, Replace 4437
Hydraulic Tank Breather, Change 4439
Service Brakes 4440
Master Cylinder Oil, Change 4440
Forks, Inspect 4442
Integral Sideshift Carriage, Replace Upper and Lower Bearings 4444
Lift Chains 4444
Steer Wheel Bearings, Lubricate 4444
Maintenance Procedures Every 4000 Hours or Two Years 4445
Hydraulic Oil Change 4445
Steering Direction Sensor Inspection 4448
Fixed Steering Column 4448
Telescopic Steering Column 4450
Telescopic Steering Column Lubrication 4451
Drive Axle Unit Assembly, Gear Oil Change 4452
Drive Axle Unit Assembly, Wet Brake Oil Change 4453
Battery Maintenance 4456
How to Charge Battery 4456
Rapid Charge 4457
How to Change Batteries 4458
General 4458
Remove the Battery 4459
Install the Battery 4466
How to Change Batteries, Forklift Removal System 4467
Lift and Tilt System Leak Check 4471
Lift Cylinder Leak Check 4471
Tilt Cylinder Leak Check 4471
Safety Procedures When Working Near Mast 4472
WHEN WORKING NEAR THE MAST ALWAYS: 4472
Lift Chain Adjustments 4475
Welding Repairs 4477
Overhead Guard Changes 4478
Wheels and Tires 4479
General 4479
Pneumatic Tires Repair 4479
Remove Wheels From Lift Truck 4479
Remove Tire From Wheel 4479
Install Wheel in Tire 4483
Add Air to Pneumatic Tires With Tube 4486
Wheels, Install 4486
Solid Rubber Tires on Pneumatic Wheels, Change 4486
Wheels, Install 4490
Counterweights 4499
Hydraulic System 4499
Steering System 4500
Specifications 4500
Turning Radius 4500
Wheels and Tires 4501
Battery Specifications 4502
Capacities 4503
Tilt Angles 4503
Maximum Carriage and Tilt Creep Rates 4504
Mast Speeds 4505
Torque Specifications 4507
Frame 4507
Drive Axle, Speed Reducer, And Differential 4507
Steering Axle 4507
Masts 4507
Hydraulic Pump and Motor 4507
Hydraulic System 4507
Adhesives And Sealants 4508
Counterweights 4515
Hydraulic System 4515
Steering System 4516
Specifications 4516
Turning Radius 4516
Wheels and Tires 4517
Battery Specifications 4517
Capacities 4518
Tilt Angles 4519
Maximum Carriage and Tilt Creep Rates 4519
Mast Speeds 4520
Torque Specifications 4521
Frame 4521
Drive Axle, Speed Reducer, And Differential 4521
Steering Axle 4521
Masts 4522
Hydraulic Pump and Motor 4522
Hydraulic System 4522
Adhesives And Sealants 4522
General 4531
Serial Number Data 4531
Discharging the Capacitors 4532
How to Move Disabled Lift Truck 4532
How to Tow Lift Truck 4532
How to Put Lift Truck on Blocks 4533
How to Raise Drive Tires 4533
How to Raise Steering Tires 4533
How to Clean a Lift Truck 4534
Maintenance Schedule 4535
Maintenance Procedures Every Shift 4540
How to Make Checks With Key or Keyless Switch OFF 4540
Tires and Wheels 4540
Forks 4541
General 4541
Inspect 4541
Remove 4542
Install 4544
Adjustment 4544
Inspection of Mast, Carriage, Header Hoses, Lift Chains, and Attachments 4545
Safety Labels 4545
Steering Column Adjustments 4546
Tilt Adjust Feature 4546
Tilt Memory Feature 4546
Telescopic Feature 4546
Operator Restraint System 4546
Emergency Locking Retractor (ELR) 4547
Seat Adjustments 4548
Seat Position Adjustment (Swivel Seat) 4548
Seat Position Adjustment (Full Suspension, High Back Seat) 4548
Seat Adjustment for Operator Weight 4548
Battery Restraint System 4550
Hood Latch and Hood Release Handle 4555
Battery 4557
Hydraulic System 4558
How to Make Checks With Key or Keyless Switch ON 4559
Horn, Lights, and Backup Alarm 4559
Motion Alarm 4560
Emergency Disconnect Switch 4560
Steering System 4561
Service Brakes 4561
Automatic Parking Brake 4561
Hydraulic Control Levers and Pedals 4562
Direction and Speed Control Pedals 4562
Lift System Operation 4562
Oil Leaks 4562
Maintenance Procedures Every 1000 Hours or 6 months 4562
Forks, Inspect 4562
Header Hose Checks 4564
Mast Lubrication 4565
Brake Fluid Check 4569
Master Cylinder Oil Check 4569
Bleeding the Brake System 4572
Operator Presence System Check 4574
Drive Axle Unit Assembly Gear Oil Level Check 4574
Drive Axle Unit Assembly, Wet Brake Oil Level Check 4575
Tilt Cylinder Rod End Pins 4577
Lift Chains 4577
Wear Check 4577
Lift Chain Lubrication 4578
Fork Pins and Guides 4579
Check Upper and Lower Bearings, Integral Sideshift Carriage 4579
Check Lower Mounting Hook, Integral Sideshift Carriage 4580
Hydraulic Tank Breather 4581
Electrical Inspection 4582
Line Contactor 4582
Other Lubrication 4585
Steering Axle 4585
King Pins and Tie Rods, Lubricate 4585
Hydraulic Control Levers 4586
Cab Heater 4586
Maintenance Procedures Every 2000 Hours or Yearly 4586
Hydraulic System 4587
Hydraulic Filter Element, Replace 4587
Hydraulic Tank Breather, Change 4589
Service Brakes 4590
Master Cylinder Oil, Change 4590
Forks, Inspect 4592
Integral Sideshift Carriage, Replace Upper and Lower Bearings 4594
Lift Chains 4594
Steer Wheel Bearings, Lubricate 4594
Maintenance Procedures Every 4000 Hours or Two Years 4594
Hydraulic Oil Change 4594
Steering Direction Sensor Inspection 4598
Fixed Steering Column 4598
Telescopic Steering Column 4599
Telescopic Steering Column Lubrication 4600
Drive Axle Unit Assembly, Gear Oil Change 4601
Drive Axle Unit Assembly, Wet Brake Oil Change 4602
Battery Maintenance 4604
How to Charge Battery 4605
Rapid Charge 4606
How to Change Batteries 4607
General 4607
Remove the Battery 4608
Install the Battery 4615
How to Change Batteries, Forklift Removal System 4616
How to Change Batteries, Optional Battery Exchange Stacker 4619
Lift and Tilt System Leak Check 4619
Lift Cylinder Leak Check 4619
Tilt Cylinder Leak Check 4620
Safety Procedures When Working Near Mast 4620
WHEN WORKING NEAR THE MAST ALWAYS: 4620
Lift Chain Adjustments 4623
Welding Repairs 4624
Overhead Guard Changes 4625
Wheels and Tires 4625
Snap-On Solid Rubber Tires 4625
Install Snap-On Solid Tire and Wheel on Lift Truck 4627
General 4639
Discharging the Capacitors for Lift Truck Models ESC030-040AC (B883), ESC030-040AD (C883) 4645
Discharging the Capacitors (All Other Models) 4647
Traction Motor Repair 4648
For Lift Truck Models , and ERP15-20VT (ERP030-040VT) (G807)ERP16-20VF (ERP30-40VF) (A955), ESC030-040AC (B883) 4648
Remove 4648
Disassemble 4649
Electrical Connector Repair or Replacement 4651
Clean 4651
Inspect 4651
Assemble 4652
Install 4654
For Lift Truck ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 4656
Remove 4656
Disassemble 4656
Electrical Connector Repair or Replacement 4659
Clean 4659
Inspect 4659
Assemble 4660
Install 4660
For Lift Truck ERP2 2-3 5VL (ERP045-070VL) (A976) 4660
Remove 4660
Disassemble 4660
Clean 4662
Inspect 4662
Assemble 4663
Install 4663
For Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080120VM, ERP100VML) (A985) 4663
Remove 4663
Clean 4665
Install 4665
For Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 4665
Remove 4665
Disassemble 4665
Electrical Connector Repair or Replacement 4667
Clean 4667
Inspect 4667
Assemble 4668
Install 4669
Traction Motor Repair for 4-5 5T Lift Trucks 4670
For Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080120VM, ERP100VML) (A985) 4670
Remove 4670
Clean 4672
Install 4672
Hydraulic Motor Repair 4673
For Lift Trucks and ERP15-20VT (ERP030-040VT) (G807)ERP16-20VF (ERP30-40VF) (A955)ESC030-040AC (B883), ESC030-040AD (C883) 4673
Remove 4673
Disassemble 4674
Electrical Connector Repair or Replacement 4676
Clean 4676
Inspect 4676
Assemble 4677
Install 4679
For Lift Truck ERC22-35VG (ERC045-070VG) (A968) 4680
Remove 4680
Disassemble 4682
Standard Motor 4682
Enhanced Motor 4684
Electrical Connector Repair or Replacement 4685
Clean 4686
Inspect 4686
Assemble 4687
Standard Motor 4687
Enhanced Motor 4687
Install 4688
For Lift Truck Models ERP2 2-3 5VL (ERP045-070VL) (A976) and ERC16-20VA (ERC030-040VA) (A969) 4688
Remove 4688
Disassemble 4688
Electrical Connector Repair or Replacement 4694
Clean 4695
Inspect 4695
Assemble 4696
Install 4697
For Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 4697
Remove 4697
Disassemble 4697
Electrical Connector Repair or Replacement 4700
Clean 4700
Inspect 4701
Assemble 4701
Install 4702
Hydraulic Motor Repair For 4 0-5 5T Lift Trucks 4702
Remove 4702
Disassemble 4702
Electrical Connector Repair or Replacement 4704
Clean 4704
Inspect 4705
Assemble 4705
Install 4706
Torque Specifications 4707
Traction Motor for Lift Trucks and ERP15-20VT (ERP030-040VT) (G807)ERP16-20VF (ERP30-40VF) (A955) 4707
Traction Motor for Lift Truck and ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969),ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 4707
Traction Motor for Lift Truck ESC030-040AC (B883), ESC030-040AD (C883) 4707
Hydraulic Motor for Lift Trucks and ERP15-20VT (ERP030-040VT) (G807)ERP16-20VF (ERP30-40VF) (A955) 4707
Hydraulic Motor for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 4707
Hydraulic Motor for Lift Truck ERP22-35VG (ERP045-070VG) (A976) 4707
Hydraulic Motor for Lift Truck ERC16-20VA (ERC030-040VA) (A969) 4707
Hydraulic Motor for Lift Truck ESC030-040AC (B883), ESC030-040AD (C883) 4707
Hydraulic Motor for Lift Truck and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 4708
General 4715
Discharging the Capacitors for Lift Truck Models ESC030-040AC (B883), ESC030-040AD (C883) 4722
Discharging the Capacitors (All Other Models) 4723
Traction Motor Repair 4723
For Lift Truck Models ERP15-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), and ESC030-040AC (B883) 4724
Remove 4724
Disassemble 4725
Electrical Connector Repair or Replacement 4728
Clean 4728
Inspect 4728
Assemble 4729
Install 4732
For Lift Truck ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 4734
Remove 4734
Disassemble 4734
Electrical Connector Repair or Replacement 4738
Clean 4738
Inspect 4738
Assemble 4739
Install 4739
For Lift Truck ERP2 2-3 5VL (ERP045-070VL) (A976) 4739
Remove 4739
Disassemble 4739
Clean 4741
Inspect 4741
Assemble 4742
Install 4742
For Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 4742
Remove 4742
Disassemble 4743
Electrical Connector Repair or Replacement 4744
Clean 4744
Inspect 4745
Assemble 4745
Install 4746
4746
Traction Motor Repair For Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 4746
Remove 4746
Clean 4748
Install 4748
Hydraulic Motor Repair 4748
For Lift Trucks ERP15-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), and ESC030-040AC (B883), ESC030-040AD (C883) 4748
Remove 4748
Disassemble 4750
Electrical Connector Repair or Replacement 4752
Clean 4752
Inspect 4752
Assemble 4753
Install 4755
For Lift Truck ERC22-35VG (ERC045-070VG) (A968) 4757
Remove 4757
Disassemble 4758
Standard Motor 4758
Enhanced Motor 4759
Electrical Connector Repair or Replacement 4761
Clean 4762
Inspect 4763
Assemble 4763
Standard Motor 4763
Enhanced Motor 4764
Install 4765
For Lift Truck Models ERP2 2-3 5VL (ERP045-070VL) (A976) and ERC16-20VA (ERC030-040VA) (A969) 4766
Remove 4766
Disassemble 4766
Electrical Connector Repair or Replacement 4772
Clean 4773
Inspect 4773
Assemble 4774
Install 4775
4775
Hydraulic Motor Repair For 4 0-5 5T Lift Trucks 4775
Remove 4775
Disassemble 4775
Electrical Connector Repair or Replacement 4778
Clean 4779
Inspect 4779
Assemble 4780
Install 4780
Torque Specifications 4781
Traction Motor for Lift Trucks ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955) 4781
Traction Motor for Lift Truck ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 4781
Traction Motor for Lift Truck ESC030-040AC (B883), ESC030-040AD (C883) 4781
Hydraulic Motor for Lift Trucks ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955) 4781
Hydraulic Motor for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 4781
Hydraulic Motor for Lift Truck ERP22-35VG (ERP045-070VG) (A976) 4781
Hydraulic Motor for Lift Truck ERC16-20VA (ERC030-040VA) (A969) 4781
Hydraulic Motor for Lift Truck ESC030-040AC (B883), ESC030-040AD (C883) 4781
Hydraulic Motor for Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 4782
General 4877
Discharging the Capacitors 4878
Window Replacement 4879
Front Panel 4879
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) 4879
Remove, Lift Truck Models ERP13VC, ERP15VC (B888) 4880
Clean 4882
Inspect 4882
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) 4882
Install, Lift Truck Models ERP13VC, ERP15VC (B888) 4882
Rear Panel 4882
Remove 4882
Clean 4886
Inspect 4886
Install 4886
Door Window 4887
Disassemble Window 4887
Clean 4888
Inspect 4888
Assemble Window 4888
Window Wipers Replacement 4889
Front Wiper Assembly 4889
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) 4889
Remove, Lift Truck Models ERP13VC, ERP15VC (B888) 4894
Clean 4895
Inspect 4896
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) 4896
Install, Lift Truck Models ERP13VC, ERP15VC (B888) 4897
Cab Component Repair 4898
Roof Liner 4898
Remove 4898
Clean 4899
Inspect 4899
Install 4899
Top Panel 4900
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) 4900
Remove, Lift Truck Models ERP13VC, ERP15VC (B888) 4902
Clean 4903
Inspect 4903
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) 4903
Install, Lift Truck Models ERP13VC, ERP15VC (B888) 4903
Cab Door Assembly 4904
Door Assembly 4904
Remove 4904
Lift Truck Models and ERP22-35VL (ERP045-070VL) (A976)ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 4904
Lift Truck Models and ERP15-20VT (ERP030-040VT) (G807)ERP16-20VF (ERP30-40VF) (A955) 4906
Disassemble Left Door 4908
Disassemble Right Door 4910
Clean 4912
Inspect 4912
Assemble Right Door 4912
Assemble Left Door 4912
Install 4913
Lift Truck Models and ERP22-35VL (ERP045-070VL) (A976)ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 4913
Lift Truck Models and ERP15-20VT (ERP030-040VT) (G807)ERP16-20VF (ERP30-40VF) (A955) 4913
Cab Heater 4914
Cab Heater 4914
Remove 4914
Clean 4921
Inspect 4921
Install 4921
Troubleshooting 4923
Weather Panel Replacement 4926
Remove 4926
Roof Panels 4926
Front Screen Panel 4929
Install 4930
Front Screen Panel 4930
Roof Panels 4930
Proper Flushing after Major Hydraulic Repairs 4993
Introduction 4993
The Phases of Wear 4993
Causes of Hydraulic System Failure 4993
Progression of Contaminant Caused Hydraulic System Failure 4994
Hydraulic System Flushing Techniques 4994
Double Oil and Filter Change 4994
Mechanical Cleaning 4995
Cleaning of Components 4995
How to Clean Tubes and Hoses 4995
Filter Caddy 4995
Start-Up Procedure for Cleaned System 4996
Contaminated Oil Coolers 4996
Additional Filter Caddy Functions 4997
How to Handle Different Fluids 4997
Water Removal Filters 4997
Fluid Conditioning and System Flushing Procedures 4998
Operation of the Filter Caddy 4998
Filter Caddy operation 4998
Fluid Conditioning Procedure 4998
Filter Caddy Start-Up 4999
System Flushing Procedure 4999
Component Cleaning Procedure 5000
Reservoir Cleaning Procedure 5000
Cylinder Cleaning Procedure 5000
Hose and Tube Cleaning Procedure 5000
Valve Cleaning Procedure 5001
Front-End Attachment Cleaning Procedure 5002
System Flushing Procedure 5002
Filter Caddy Start-Up 5003
System Start-Up and Flushing 5003
Reservoir Fluid Cleaning Times 5004
Dealing With Different Fluid Types 5005
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 5005
Filter Caddy Maintenance 5005
Servicing the Strainer 5005
DC Motor 5005
Hydraulic Oil Sampling Method and Procedure 5006
Hydraulic Oil Sampling Method 5006
Objective 5006
General Guidelines 5006
Synopsis 5007
Hydraulic Oil Analysis Report Guidelines 5008
Sampling Conditions 5008
Equipment 5008
Sampling Procedure 5009
Hydraulic Oil Sampling 5009
Sample Labeling 5009
Results Documentation 5009
Proper Flushing after Major Hydraulic Repairs 5015
Introduction 5015
The Phases of Wear 5015
Causes of Hydraulic System Failure 5015
Progression of Contaminant Caused Hydraulic System Failure 5016
Hydraulic System Flushing Techniques 5016
Double Oil and Filter Change 5016
Mechanical Cleaning 5017
Cleaning of Components 5017
How to Clean Tubes and Hoses 5017
Filter Caddy 5017
Start-Up Procedure for Cleaned System 5018
Contaminated Oil Coolers 5018
Additional Filter Caddy Functions 5018
How to Handle Different Fluids 5018
Water Removal Filters 5019
Fluid Conditioning and System Flushing Procedures 5019
Operation of the Filter Caddy 5019
Filter Caddy operation 5019
Fluid Conditioning Procedure 5020
Filter Caddy Start-Up 5020
System Flushing Procedure 5021
Component Cleaning Procedure 5021
Reservoir Cleaning Procedure 5021
Cylinder Cleaning Procedure 5021
Hose and Tube Cleaning Procedure 5022
Valve Cleaning Procedure 5022
Front-End Attachment Cleaning Procedure 5023
System Flushing Procedure 5023
Filter Caddy Start-Up 5024
System Start-Up and Flushing 5024
Reservoir Fluid Cleaning Times 5025
Dealing With Different Fluid Types 5025
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 5025
Filter Caddy Maintenance 5026
Servicing the Strainer 5026
DC Motor 5026
Hydraulic Oil Sampling Method and Procedure 5026
Hydraulic Oil Sampling Method 5026
Objective 5026
General Guidelines 5026
Synopsis 5027
Hydraulic Oil Analysis Report Guidelines 5028
Sampling Conditions 5029
Equipment 5029
Sampling Procedure 5029
Hydraulic Oil Sampling 5029
Sample Labeling 5030
Results Documentation 5030
General 5037
Safety Procedures When Working Near Mast 5038
Main Lift Cylinder Repair 5040
Remove 5040
Disassemble 5042
Clean 5044
Inspect 5044
Assemble 5044
Install 5045
Main Lift Cylinder Leak Check 5045
Free-Lift Cylinder 5046
Remove 5046
Disassemble 5047
Clean 5049
Inspect 5049
Assemble 5049
Install 5049
Tilt Cylinder Repair 5050
Remove 5050
Disassemble 5052
Clean 5054
Inspect 5054
Assemble 5054
Install 5055
Tilt Cylinder Adjustment 5056
Tilt Cylinder Leak Check 5057
Integral Sideshift Cylinder Repair Prior to December 2016 5059
Remove 5059
Disassemble 5060
Clean 5061
Inspect 5061
Assemble 5061
Install 5061
Integral Sideshift Cylinder Repair After December 2016 5062
General 5062
Remove 5062
Disassemble 5064
Clean 5064
Inspect 5064
Assemble 5064
Install 5065
Integral Side-Shift Cylinder Gland Leak Checks 5066
Fork Positioner Cylinder Repair Prior to December 2016 5067
Remove 5067
Disassemble 5067
Clean 5069
Inspect 5070
Assemble 5070
Install 5070
Fork Positioner Cylinder Adjustment 5070
Fork Positioner Cylinder Repair After December 2016 5071
General 5071
Remove 5071
Disassemble 5071
Clean 5074
Inspect 5075
Assemble 5075
Install 5075
Fork Positioner Cylinder Adjustment 5075
Seal Kit Installation 5076
External Installation (Seal and Backup Ring) 5076
Internal Installation (Piston Rod Assembly) 5076
Torque Specifications 5077
Main Lift Cylinders 5077
Free-Lift Cylinder 5077
Tilt Cylinders 5077
Integral Sideshift Cylinder 5077
Fork Positioner Cylinder 5077
General 5087
Safety Procedures When Working Near Mast 5090
Main Lift Cylinder Repair 5092
Remove 5092
Disassemble 5094
Clean 5096
Inspect 5096
Assemble 5096
Install 5097
Main Lift Cylinder Leak Check 5097
Free-Lift Cylinder 5098
Remove 5098
Disassemble 5099
Clean 5101
Inspect 5101
Assemble 5101
Install 5101
Tilt Cylinder Repair 5103
Remove 5103
Disassemble 5105
Clean 5106
Inspect 5107
Assemble 5107
Install 5108
Tilt Cylinder Adjustment 5108
Tilt Cylinder Leak Check 5110
Integral Sideshift Cylinder Repair Prior to December 2016 5112
Remove 5112
Disassemble 5112
Clean 5113
Inspect 5113
Assemble 5113
Install 5114
Integral Sideshift Cylinder Repair After December 2016 5115
General 5115
Remove 5115
Disassemble 5116
Clean 5117
Inspect 5117
Assemble 5117
Install 5117
Integral Side-Shift Cylinder Gland Leak Checks 5118
Fork Positioner Cylinder Repair Prior to December 2016 5119
Remove 5119
Disassemble 5119
Clean 5122
Inspect 5122
Assemble 5123
Install 5123
Fork Positioner Cylinder Adjustment 5123
Fork Positioner Cylinder Repair After December 2016 5125
General 5125
Remove 5125
Disassemble 5125
Clean 5128
Inspect 5128
Assemble 5129
Install 5129
Fork Positioner Cylinder Adjustment 5129
Seal Kit Installation 5131
External Installation (Seal and Backup Ring) 5131
Internal Installation (Piston Rod Assembly) 5131
Torque Specifications 5132
Main Lift Cylinders 5132
Free-Lift Cylinder 5132
Tilt Cylinders 5132
Integral Sideshift Cylinder 5132
Fork Positioner Cylinder 5132
General 5143
Safety Procedures When Working Near Mast 5145
Fork Replacement 5147
Standard Carriage and Integral Sideshift Carriage 5147
Remove 5147
Install 5148
Checks 5148
Fork Positioner Carriage 5150
Remove 5151
Install 5151
Checks 5153
Carriages Repair, Two-Stage LFL Mast 5156
Standard Carriage 5156
Remove 5156
Clean and Inspect 5157
Install 5157
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 5157
Remove 5157
Disassemble 5159
Clean and Inspect 5160
Assemble 5161
Install 5161
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 through Late June, 2018 5162
Remove 5162
Disassemble 5165
Clean and Inspect 5165
Assemble 5166
Install 5167
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 5167
Remove 5167
Disassemble 5170
Clean and Inspect 5170
Assemble 5171
Install 5172
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 5172
Remove 5172
Install 5174
Fork Positioner Hydraulic Hose Adjustment 5176
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 5177
Remove 5177
Disassemble and Assemble 5181
Clean and Inspect 5181
Install 5181
Fork Positioner Hydraulic Hose Adjustment 5182
Fork Positioner Carriage, Lift Trucks Manufactured Late June, 2018 and After 5183
Remove 5183
Disassemble and Assemble 5187
Clean and Inspect 5187
Install 5187
Fork Positioner Hydraulic Hose Adjustment 5188
Two-Stage LFL Mast Repair 5190
Mast With Serial Number F507 5190
Remove 5190
Disassemble 5194
Clean and Inspect 5201
Assemble 5203
Install 5204
Header Hoses 5206
Remove 5206
Installation 5206
Adjustment 5210
Mast With Serial Number F562 5211
Remove 5211
Disassemble 5215
Clean and Inspect 5222
Assemble 5224
Install 5225
Header Hose Installation and Adjustment 5226
Remove 5226
Installation 5227
Adjustment 5231
Carriages Repair, Three-Stage FFL Mast 5233
Standard Carriage 5233
Remove 5233
Clean and Inspect 5234
Install 5235
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 5235
Remove 5235
Disassemble 5236
Clean and Inspect 5237
Assemble 5238
Install 5238
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 5239
Remove 5239
Disassemble 5241
Clean and Inspect 5242
Assemble 5243
Install 5243
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 5244
Remove 5244
Disassemble 5246
Clean and Inspect 5247
Assemble 5248
Install 5248
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 5249
Remove 5249
Install 5251
Fork Positioner Hydraulic Hose Adjustment 5253
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 5254
Remove 5254
Disassemble and Assemble 5256
Clean and Inspect 5256
Install 5256
Fork Positioner Hydraulic Hose Adjustment 5257
Fork Positioner Carriage, Lift Trucks Manufactured After Late June, 2018 5258
Remove 5258
Disassemble and Assemble 5261
Clean and Inspect 5261
Install 5261
Fork Positioner Hydraulic Hose Adjustment 5262
Three-Stage FFL Mast Repair 5264
Mast With Serial Number F508 5264
Remove 5264
Disassemble 5267
Clean and Inspect 5277
Assemble 5280
Install 5281
Header Hose Installation and Adjustment 5283
Remove 5283
Installation 5283
Adjustment 5292
Mast With Serial Number F563 5292
Remove 5292
Disassemble 5296
Clean and Inspect 5306
Assemble 5309
Install 5310
Header Hose Installation and Adjustment 5312
Remove 5312
Installation 5312
Adjustment 5320
Mast Adjustments 5322
Load Roller, Adjust 5322
Mast Side Kicking, Adjust 5324
Carriage Adjustments 5325
Lift Chains Adjustment 5327
Hydraulic Quick Disconnect Hoses 5329
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) 5329
Lift Trucks Equipped With E-Hydraulic Controls 5329
Lift Trucks Equipped With Manual Hydraulic Controls 5329
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) 5330
Lift Trucks Equipped With E-Hydraulic Controls 5330
Lift Trucks Equipped With Manual Hydraulic Controls 5330
Disconnecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 5330
Connecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 5330
General 5339
Safety Procedures When Working Near Mast 5340
Fork Replacement 5342
Standard Carriage and Integral Sideshift Carriage 5342
Remove 5342
Install 5344
Checks 5344
Fork Positioner Carriage 5346
Remove 5347
Install 5347
Checks 5349
Carriages Repair, Two-Stage LFL Mast 5351
Standard Carriage 5351
Remove 5351
Clean and Inspect 5352
Install 5353
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 5353
Remove 5353
Disassemble 5354
Clean and Inspect 5355
Assemble 5356
Install 5356
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 through Late June, 2018 5357
Remove 5357
Disassemble 5360
Clean and Inspect 5360
Assemble 5361
Install 5361
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 5362
Remove 5362
Disassemble 5365
Clean and Inspect 5365
Assemble 5366
Install 5366
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 5367
Remove 5367
Install 5369
Fork Positioner Hydraulic Hose Adjustment 5371
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 5372
Remove 5372
Disassemble and Assemble 5376
Clean and Inspect 5376
Install 5376
Fork Positioner Hydraulic Hose Adjustment 5377
Fork Positioner Carriage, Lift Trucks Manufactured Late June, 2018 and After 5378
Remove 5378
Disassemble and Assemble 5382
Clean and Inspect 5382
Install 5382
Fork Positioner Hydraulic Hose Adjustment 5383
Two-Stage LFL Mast Repair 5384
Mast With Serial Number F507 5384
Remove 5384
Disassemble 5388
Clean and Inspect 5395
Assemble 5397
Install 5398
Header Hoses 5400
Remove 5400
Installation 5400
Adjustment 5404
Mast With Serial Number F562 5405
Remove 5405
Disassemble 5409
Clean and Inspect 5416
Assemble 5418
Install 5419
Header Hose Installation and Adjustment 5420
Remove 5420
Installation 5421
Adjustment 5425
Carriages Repair, Three-Stage FFL Mast 5426
Standard Carriage 5426
Remove 5426
Clean and Inspect 5428
Install 5428
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 5428
Remove 5428
Disassemble 5430
Clean and Inspect 5431
Assemble 5432
Install 5432
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 5433
Remove 5433
Disassemble 5435
Clean and Inspect 5436
Assemble 5437
Install 5437
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 5438
Remove 5438
Disassemble 5440
Clean and Inspect 5441
Assemble 5442
Install 5442
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 5443
Remove 5443
Install 5445
Fork Positioner Hydraulic Hose Adjustment 5447
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 5448
Remove 5448
Disassemble and Assemble 5450
Clean and Inspect 5450
Install 5450
Fork Positioner Hydraulic Hose Adjustment 5451
Fork Positioner Carriage, Lift Trucks Manufactured After Late June, 2018 5452
Remove 5452
Disassemble and Assemble 5455
Clean and Inspect 5455
Install 5455
Fork Positioner Hydraulic Hose Adjustment 5456
Three-Stage FFL Mast Repair 5457
Mast With Serial Number F508 5457
Remove 5457
Disassemble 5461
Clean and Inspect 5471
Assemble 5474
Install 5475
Header Hose Installation and Adjustment 5477
Remove 5477
Installation 5477
Adjustment 5485
Mast With Serial Number F563 5486
Remove 5486
Disassemble 5489
Clean and Inspect 5499
Assemble 5502
Install 5503
Header Hose Installation and Adjustment 5505
Remove 5505
Installation 5505
Adjustment 5513
Mast Adjustments 5514
Load Roller, Adjust 5514
Mast Side Kicking, Adjust 5516
Carriage Adjustments 5516
Lift Chains Adjustment 5518
Hydraulic Quick Disconnect Hoses 5520
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) 5520
Lift Trucks Equipped With E-Hydraulic Controls 5520
Lift Trucks Equipped With Manual Hydraulic Controls 5521
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) 5521
Lift Trucks Equipped With E-Hydraulic Controls 5521
Lift Trucks Equipped With Manual Hydraulic Controls 5522
Disconnecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 5522
Connecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 5522
General 5531
Threaded Fasteners 5531
Nomenclature, Threads 5531
Strength Identification 5532
Cotter (Split) Pins 5533
Fastener Torque Tables 5538
Conversion Table 5540