Yale Forklift B888 (ERP13VC, ERP15VC) Service Manual – PDF DOWNLOAD

Yale Forklift B888 (ERP13VC, ERP15VC) Service Manual – PDF DOWNLOAD

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Yale Forklift B888 (ERP13VC, ERP15VC) Service Manual – PDF DOWNLOAD

Language : English
Pages : 2818
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift B888 (ERP13VC, ERP15VC) Service Manual – PDF DOWNLOAD

524150797-8000YRM0231-(02-2023)-UK-EN 1
General 7
Threaded Fasteners 7
Nomenclature, Threads 7
Strength Identification 8
Cotter (Split) Pins 9
Fastener Torque Tables 14
Conversion Table 16
524150797-8000YRM0231-(03-2020)-UK-EN 23
General 27
Threaded Fasteners 27
Nomenclature, Threads 27
Strength Identification 28
Cotter (Split) Pins 29
Fastener Torque Tables 34
Conversion Table 36
524158040-2240YRM0001-(01-2023)-UK-EN 43
General 49
Battery Type 49
Lead-Acid Batteries 49
Lithium-Ion Batteries 50
Specific Gravity 50
Chemical Reaction in a Cell 50
Electrical Terms 52
Battery Selection 53
Battery Voltage 54
Battery as a Counterweight 54
Battery Ratings 54
Kilowatt-Hours 54
Battery Maintenance 55
Safety Procedures 55
Maintenance Records 55
New Battery 55
Cleaning Battery 56
Adding Water to Battery 58
Hydrometer 58
Battery Temperature 59
Charging Battery 60
Types of Battery Charges 61
Methods of Charging 62
Troubleshooting Charger 63
Knowing When Battery Is Fully Charged 63
Where to Charge Batteries 63
Equipment Needed 63
Battery Connectors 64
Battery Care 64
Troubleshooting 66
524158040-2240YRM0001-(03-2020)-UK-EN 71
General 75
Battery Type 75
Lead-Acid Batteries 75
Lithium-Ion Batteries 76
Specific Gravity 76
Chemical Reaction in a Cell 76
Electrical Terms 78
Battery Selection 78
Battery Voltage 79
Battery as a Counterweight 80
Battery Ratings 80
Kilowatt-Hours 80
Battery Maintenance 80
Safety Procedures 80
Maintenance Records 81
New Battery 81
Cleaning Battery 81
Adding Water to Battery 83
Hydrometer 84
Battery Temperature 85
Charging Battery 86
Types of Battery Charges 86
Methods of Charging 88
Troubleshooting Charger 88
Knowing When Battery Is Fully Charged 89
Where to Charge Batteries 89
Equipment Needed 89
Battery Connectors 90
Battery Care 90
Troubleshooting 92
524223769-2200YRM1128-(01-2023)-UK-EN 97
Series Code / Model Designation Reference Table 105
General 107
Deutsch Crimping Tool 108
How to Strip a Wire for Use With Deutsch Crimping Tool 108
How to Crimp With the Deutsch Crimping Tool 109
Calibration Test for the Deutsch Crimping Tool 111
Deutsch Connectors 113
DT, DTM, and DTP Series Connectors 113
HD Series Connectors 156
Metri-Pack Connectors 178
Remove and Install 178
Micro-Pack Connectors 181
Weather-Pack Connectors 182
AMPSEAL Crimping Tools 184
AMP Hand Crimping Tool With Certi-Crimp 184
Description 184
Stripping Wire for Use with AMP Hand Crimping Tool 185
Insulation Crimp Adjustment 186
Maintenance and Inspection for AMP Hand Crimping Tool 186
AMP Hand Crimping Tool 186
Crimp Height Inspection 186
How to use AMP Hand Crimping Tool 187
AMP Pro-Crimper II Tool 187
Description 187
Remove and Install Die Set and Locator Assembly 188
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 188
Contact Support Adjustment 189
Crimp Height Adjustment 190
Maintenance and Inspection Procedures 190
PRO-CRIMPER II Tool 190
Crimp Height Inspection 190
How to Use AMP PRO-CRIMPER II Tool 191
AMPSEAL Connector Assemblies 192
Description for Plug Connector Assembly 192
Seal Plug 193
Contact Crimping 193
Description for Plug Connector and Header Assembly 198
Voltage Reading 201
Seal Plug 201
Contact Crimping 201
AMP Superseal 1 5 Crimping Tools 208
Mini Mic Receptacle and Tab Contacts 208
Description 208
Crimping Conditions and Measurements 208
Insertion of Rubber Seal on Cable 210
AMP Hand Application Tool 215
Description 215
Maintenance and Inspection 215
Crimp Height Inspection 215
Crimp Height Adjustment 216
How to Use AMP Hand Application Tool 216
AMP Pro-Crimper II Tool 217
Description 217
Remove and Install Die Set and Locator Assembly 217
Adjustments 218
Contact Support 218
Crimp Height 219
Inspections and Maintenance 220
Crimp Height Inspection 220
Visual Inspection 220
Maintenance 221
How to Use Pro-Crimper II Tool 221
AMP Superseal 1 5 Connector Assemblies 222
Description 222
Repair and Maintenance 229
Panel Mount Option 229
AMP Fastin-Faston Hand Tools 230
Description – AMP Double Action Hand Tool 230
Maintenance and Inspection Procedures 230
Daily Maintenance 230
Periodic Tool Inspection 231
Lubrication 231
Visual Inspection 231
Crimp Height Inspection 231
Certi-Crimp Ratchet Inspection 232
How to Use AMP Double Action Hand Tool 233
Description – AMP Extraction Tool 234
Maintenance and Inspection 235
How to Use AMP Extraction Tool 235
AMP Fastin-Faston Receptacles and Housings 237
Description 237
Wire Repair 245
Wire Splicing Requirements 245
Deutsch Jiffy Splice 246
Twisted/Shielded Cable and Leads Repair 252
Special Tools 254
524223769-2200YRM1128-(07-2020)-UK-EN 263
Series Code / Model Designation Reference Table 269
General 272
Deutsch Crimping Tool 272
How to Strip a Wire for Use With Deutsch Crimping Tool 272
How to Crimp With the Deutsch Crimping Tool 273
Calibration Test for the Deutsch Crimping Tool 275
Deutsch Connectors 277
DT, DTM, and DTP Series Connectors 277
HD Series Connectors 319
Metri-Pack Connectors 342
Remove and Install 342
Micro-Pack Connectors 344
Weather-Pack Connectors 345
AMPSEAL Crimping Tools 347
AMP Hand Crimping Tool With Certi-Crimp 347
Description 347
Stripping Wire for Use with AMP Hand Crimping Tool 347
Insulation Crimp Adjustment 348
Maintenance and Inspection for AMP Hand Crimping Tool 348
AMP Hand Crimping Tool 348
Crimp Height Inspection 348
How to use AMP Hand Crimping Tool 349
AMP Pro-Crimper II Tool 349
Description 349
Remove and Install Die Set and Locator Assembly 350
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 351
Contact Support Adjustment 351
Crimp Height Adjustment 352
Maintenance and Inspection Procedures 352
PRO-CRIMPER II Tool 352
Crimp Height Inspection 352
How to Use AMP PRO-CRIMPER II Tool 353
AMPSEAL Connector Assemblies 354
Description for Plug Connector Assembly 354
Seal Plug 355
Contact Crimping 355
Description for Plug Connector and Header Assembly 360
Voltage Reading 362
Seal Plug 362
Contact Crimping 362
AMP Superseal 1 5 Crimping Tools 369
Mini Mic Receptacle and Tab Contacts 369
Description 369
Crimping Conditions and Measurements 369
Insertion of Rubber Seal on Cable 371
AMP Hand Application Tool 376
Description 376
Maintenance and Inspection 376
Crimp Height Inspection 376
Crimp Height Adjustment 377
How to Use AMP Hand Application Tool 377
AMP Pro-Crimper II Tool 378
Description 378
Remove and Install Die Set and Locator Assembly 379
Adjustments 379
Contact Support 379
Crimp Height 380
Inspections and Maintenance 381
Crimp Height Inspection 381
Visual Inspection 381
Maintenance 382
How to Use Pro-Crimper II Tool 382
AMP Superseal 1 5 Connector Assemblies 383
Description 383
Repair and Maintenance 390
Panel Mount Option 390
AMP Fastin-Faston Hand Tools 391
Description – AMP Double Action Hand Tool 391
Maintenance and Inspection Procedures 391
Daily Maintenance 391
Periodic Tool Inspection 392
Lubrication 392
Visual Inspection 392
Crimp Height Inspection 392
Certi-Crimp Ratchet Inspection 393
How to Use AMP Double Action Hand Tool 394
Description – AMP Extraction Tool 395
Maintenance and Inspection 395
How to Use AMP Extraction Tool 396
AMP Fastin-Faston Receptacles and Housings 397
Description 397
Wire Repair 404
Wire Splicing Requirements 404
Deutsch Jiffy Splice 405
Twisted/Shielded Cable and Leads Repair 410
Special Tools 413
524319497-2200YRM1335-(01-2023)-UK-EN 421
General 429
Description 429
Display Panel Menu Access 429
Menu Flowchart 430
Supervisor Menu Flowchart 430
Menu Navigation 436
Icon Glossary 440
Introduction 440
Soft Key Icons 440
Overlay Icons 441
Icons on System Off Screen and Alert Screens 441
Main Menu Title Screens 445
Submenu Icons Grouped by Menu 447
Operating Screen Icons 447
Password Screen Icons 448
Activity Log Submenu Icons 448
Calibration Submenu Icons 450
Display Submenu Icons 452
Status Submenu Icons 454
Truck Setup Submenu Icons 457
Operating Screen 464
Introduction 464
Performance Mode Controls 465
Status and Warning Icons 465
Battery Discharge Indicator 466
Direction and Parking Brake Indicators 467
Hazard Flashers and Lighting Controls 467
Steer Angle Indicator 467
System Time 467
Load Weight Indicator 467
System Off/Alert Screens 468
Introduction 468
System Off Screen 468
Alert Screens 468
Password Screen 470
Introduction 470
Password Screen 470
Service Technician Password Setup 470
Adding/Removing/Changing Passwords 471
Password Log 474
Activity Log Menu 475
Introduction 475
Operator Checklist Log 476
Password Log 479
Impact Events Log 481
Calibration Menu 483
Introduction 483
Load Weight Calibration 483
Return to Set Tilt Stop Point Calibration 484
E-Hydraulic and Manual Valve Threshold Calibration 484
Steering Wheel Center Point Calibration 485
Steer Axle Position Calibration 485
Steer Axle Center Point Calibration 486
Manual Hydraulics Calibration 487
Display Menu 488
Introduction 488
Set Date and Time Format Menu 488
Set Daylight Saving Time Menu 489
Procedure for Setting Up Automatic Daylight Savings Time 490
Set Time and Date Menu 492
Procedure for Setting Time and Date 492
Set Units Menu 493
Status Menu 494
Introduction 494
VSM Versions 494
Display Versions 495
Truck Serial Number 495
Hour Meters 495
E-Hydraulic Controller Versions 495
Pump Motor Controller Versions 495
Traction Motor Controller 1 Versions 495
Traction Motor Controller 2 Versions 496
Light Controller Versions 496
Impact Sensor Versions 496
Truck Setup Menu 497
Introduction 497
Add/Remove Password 497
Battery Settings 497
Restore Default Settings 498
Motion Alarm 498
Impact Monitor Settings 499
Impact Detection 499
Setting Adjustments 499
Initial Adjustment of Soft and Hard Impact Settings 499
Readjustment of Soft and Hard Impact Settings 499
Auto Power-Off Time Delay 500
Return to Set Tilt 500
Traction Speed Limit 500
Scheduled Maintenance Reminder 501
Minimum Pump Standby Flow Rate 502
Operator Checklist 502
Impact Monitor Shutdown 503
Motor Braking 504
Changing the Motor Braking Settings 504
Steering Wheel Friction and Steering Turns Adjustment 505
How to Adjust Settings 505
Steering Friction Setting 505
Steering Wheel Number of Turns 506
524319497-2200YRM1335-(07-2020)-UK-EN 509
General 515
Description 515
Display Panel Menu Access 515
Menu Flowchart 516
Supervisor Menu Flowchart 516
Menu Navigation 522
Icon Glossary 526
Introduction 526
Soft Key Icons 526
Overlay Icons 527
Icons on System Off Screen and Alert Screens 527
Main Menu Title Screens 531
Submenu Icons Grouped by Menu 533
Operating Screen Icons 533
Password Screen Icons 534
Activity Log Submenu Icons 534
Calibration Submenu Icons 536
Display Submenu Icons 538
Status Submenu Icons 540
Truck Setup Submenu Icons 543
Operating Screen 550
Introduction 550
Performance Mode Controls 550
Status and Warning Icons 551
Battery Discharge Indicator 552
Direction and Parking Brake Indicators 552
Hazard Flashers and Lighting Controls 553
Steer Angle Indicator 553
System Time 553
Load Weight Indicator 553
System Off/Alert Screens 554
Introduction 554
System Off Screen 554
Alert Screens 554
Password Screen 556
Introduction 556
Password Screen 556
Service Technician Password Setup 556
Adding/Removing/Changing Passwords 557
Password Log 560
Activity Log Menu 561
Introduction 561
Operator Checklist Log 561
Password Log 563
Impact Events Log 565
Calibration Menu 567
Introduction 567
Load Weight Calibration 567
Return to Set Tilt Stop Point Calibration 568
E-Hydraulic and Manual Valve Threshold Calibration 568
Steering Wheel Center Point Calibration 569
Steer Axle Position Calibration 569
Steer Axle Center Point Calibration 570
Manual Hydraulics Calibration 571
Display Menu 572
Introduction 572
Set Date and Time Format Menu 572
Set Daylight Saving Time Menu 573
Procedure for Setting Up Automatic Daylight Savings Time 574
Set Time and Date Menu 576
Procedure for Setting Time and Date 576
Set Units Menu 577
Status Menu 578
Introduction 578
VSM Versions 578
Display Versions 579
Truck Serial Number 579
Hour Meters 579
E-Hydraulic Controller Versions 579
Pump Motor Controller Versions 579
Traction Motor Controller 1 Versions 579
Traction Motor Controller 2 Versions 580
Light Controller Versions 580
Impact Sensor Versions 580
Truck Setup Menu 581
Introduction 581
Add/Remove Password 581
Battery Settings 581
Restore Default Settings 582
Motion Alarm 582
Impact Monitor Settings 582
Impact Detection 583
Setting Adjustments 583
Initial Adjustment of Soft and Hard Impact Settings 583
Readjustment of Soft and Hard Impact Settings 583
Auto Power-Off Time Delay 584
Return to Set Tilt 584
Traction Speed Limit 584
Scheduled Maintenance Reminder 585
Minimum Pump Standby Flow Rate 586
Operator Checklist 586
Impact Monitor Shutdown 587
Motor Braking 588
Changing the Motor Braking Settings 588
Steering Wheel Friction and Steering Turns Adjustment 589
How to Adjust Settings 589
Steering Friction Setting 589
Steering Wheel Number of Turns 590
524319498-2200YRM1336-(02-2023)-UK-EN 593
General 601
Description 601
Display Panel Menu Access 601
Menu Flowchart 602
Technician Menu Flowchart 602
Menu Navigation 608
Icon Glossary 612
Introduction 612
Soft Key Icons 612
Overlay Icons 613
Heat Exchange Module Warning Indicator Screen 613
System Off Screen and Alert Screens 614
Main Menu Title Screens 620
Submenu Icons Grouped by Menu 621
Operating Screen Icons 621
Password Screen Icons 623
Activity Log Submenu Icons 623
Calibration Submenu Icons 624
Display Submenu Icons 628
Status Submenu Icons 630
Truck Setup Submenu Icons 633
Diagnostics Submenu Icons 645
Operating Screen 655
Introduction 655
Performance Mode Controls 655
Status and Warning Icons 656
Battery Discharge Indicator 657
Direction and Parking Brake Indicators 657
Hazard Flashers and Lighting Controls 658
Steer Angle Indicator 658
System Time 658
Load Weight Indicator 658
System Off/Alert Screens 659
Introduction 659
System Off Screen 659
Alert Screens 659
Password Screen 661
Introduction 661
Password Screen 661
Service Technician Password Setup 661
Adding/Removing/Changing Passwords 662
Password Log 665
Activity Log Menu 666
Introduction 666
Operator Checklist Log 666
Password Log 668
Impact Events Log 670
Calibration Menu 672
Introduction 672
Load Weight Calibration 672
Return to Set Tilt Stop Point Calibration 673
E-Hydraulic and Manual Valve Threshold Calibration 673
Steering Wheel Center Point Calibration 674
Steer Axle Position Calibration 675
Steer Axle Center Point Calibration 676
Manual Hydraulics Calibration 676
Display Menu 677
Introduction 677
Set Date and Time Format Menu 677
Set Daylight Saving Time Menu 678
Procedure for Setting Up Automatic Daylight Savings Time 679
Set Time and Date Menu 681
Procedure for Setting Time and Date 681
Set Units Menu 682
Status Menu 683
Introduction 683
VSM Versions 683
Display Versions 684
Truck Serial Number 684
Hour Meters 684
E-Hydraulic Controller Versions 684
Pump Motor Controller Versions 684
Traction Motor Controller 1 Versions 684
Traction Motor Controller 2 Versions 685
Light Controller Versions 685
Impact Sensor Versions 685
E-Steer Controller 1 Versions 685
E-Steer Controller 2 Versions 685
Truck Setup Menu 686
Introduction 686
Add/Remove Password 687
Battery Settings 687
Motor Braking 687
Changing the Motor Braking Settings 688
Battery Mode 688
Battery Setup 689
BDI Adjustment Setting 690
Acceleration Rates 691
Hour Meter Initialization 692
Impact Monitor Shutdown 692
Operator Checklist 694
Minimum Pump Standby Flow Rate 694
Scheduled Maintenance Reminder 695
Traction Speed Limit 696
Return to Set Tilt 696
Auto Power-Off Time Delay 697
Impact Monitor Settings 697
Impact Detection 698
Setting Adjustments 698
Initial Adjustment of Soft and Hard Impact Settings 698
Readjustment of Soft and Hard Impact Settings 698
Motion Alarm 698
Lift Hydraulic Function Maximum Speed and Ramp Times 699
Lower Hydraulic Function Maximum Speed and Ramp Times 699
Tilt Forward Hydraulic Function Maximum Speed and Ramp Times 700
Tilt Backward Hydraulic Function Maximum Speed and Ramp Times 700
Auxiliary 1A Hydraulic Function Maximum Speed and Ramp Times 700
Auxiliary 1B Hydraulic Function Maximum Speed and Ramp Times 700
Auxiliary 2A Hydraulic Function Maximum Speed and Ramp Times 700
Auxiliary 2B Hydraulic Function Maximum Speed and Ramp Times 700
Optional Hydraulic Functions 700
Rear Lights Control 701
Restore Default Settings 701
Steering Wheel Friction and Steering Turns Adjustment 702
Navigation 703
How to Adjust Settings 703
Steering Friction 703
Steering Wheel Number of Turns 704
Diagnostics Menu 706
Introduction 706
Fault Code Log 706
Fault Log Details 707
Speedometer 708
Direction Switch 708
Traction Motor 1 Status 709
Traction Motor 2 Status 709
Occupancy Sensor 709
Brake System Sensors 709
Pump Status 710
Hydraulic Control Inputs 711
E-Hydraulic Valves 711
Hydraulic Sensors 712
System Voltages 712
Steering Position Sensors 714
E-Steering Position Sensors 714
Electric Brake 715
Navigation 716
ESS Diagnostics Menus A, B, and C 717
Menu A 717
Menu B 718
Menu C 720
524319498-2200YRM1336-(07-2020)-UK-EN 723
General 729
Description 729
Display Panel Menu Access 729
Menu Flowchart 730
Technician Menu Flowchart 730
Menu Navigation 736
Icon Glossary 740
Introduction 740
Soft Key Icons 740
Overlay Icons 741
Heat Exchange Module Warning Indicator Screen 741
System Off Screen and Alert Screens 742
Main Menu Title Screens 747
Submenu Icons Grouped by Menu 749
Operating Screen Icons 749
Password Screen Icons 750
Activity Log Submenu Icons 750
Calibration Submenu Icons 752
Display Submenu Icons 755
Status Submenu Icons 757
Truck Setup Submenu Icons 761
Diagnostics Submenu Icons 772
Operating Screen 782
Introduction 782
Performance Mode Controls 782
Status and Warning Icons 783
Battery Discharge Indicator 784
Direction and Parking Brake Indicators 785
Hazard Flashers and Lighting Controls 785
Steer Angle Indicator 785
System Time 785
Load Weight Indicator 785
System Off/Alert Screens 786
Introduction 786
System Off Screen 786
Alert Screens 786
Password Screen 788
Introduction 788
Password Screen 788
Service Technician Password Setup 788
Adding/Removing/Changing Passwords 789
Password Log 791
Activity Log Menu 792
Introduction 792
Operator Checklist Log 792
Password Log 794
Impact Events Log 796
Calibration Menu 798
Introduction 798
Load Weight Calibration 798
Return to Set Tilt Stop Point Calibration 799
E-Hydraulic and Manual Valve Threshold Calibration 799
Steering Wheel Center Point Calibration 800
Steer Axle Position Calibration 801
Steer Axle Center Point Calibration 801
Manual Hydraulics Calibration 802
Display Menu 803
Introduction 803
Set Date and Time Format Menu 803
Set Daylight Saving Time Menu 804
Procedure for Setting Up Automatic Daylight Savings Time 805
Set Time and Date Menu 807
Procedure for Setting Time and Date 807
Set Units Menu 808
Status Menu 809
Introduction 809
VSM Versions 809
Display Versions 810
Truck Serial Number 810
Hour Meters 810
E-Hydraulic Controller Versions 810
Pump Motor Controller Versions 810
Traction Motor Controller 1 Versions 810
Traction Motor Controller 2 Versions 811
Light Controller Versions 811
Impact Sensor Versions 811
E-Steer Controller 1 Versions 811
E-Steer Controller 2 Versions 811
Truck Setup Menu 812
Introduction 812
Add/Remove Password 813
Battery Settings 813
Motor Braking 813
Changing the Motor Braking Settings 814
Battery Mode 814
Battery Setup 815
BDI Adjustment Setting 816
Acceleration Rates 817
Hour Meter Initialization 818
Impact Monitor Shutdown 818
Operator Checklist 819
Minimum Pump Standby Flow Rate 820
Scheduled Maintenance Reminder 820
Traction Speed Limit 822
Return to Set Tilt 822
Auto Power-Off Time Delay 822
Impact Monitor Settings 823
Impact Detection 823
Setting Adjustments 823
Initial Adjustment of Soft and Hard Impact Settings 823
Readjustment of Soft and Hard Impact Settings 824
Motion Alarm 824
Lift Hydraulic Function Maximum Speed and Ramp Times 824
Lower Hydraulic Function Maximum Speed and Ramp Times 825
Tilt Forward Hydraulic Function Maximum Speed and Ramp Times 825
Tilt Backward Hydraulic Function Maximum Speed and Ramp Times 825
Auxiliary 1A Hydraulic Function Maximum Speed and Ramp Times 825
Auxiliary 1B Hydraulic Function Maximum Speed and Ramp Times 826
Auxiliary 2A Hydraulic Function Maximum Speed and Ramp Times 826
Auxiliary 2B Hydraulic Function Maximum Speed and Ramp Times 826
Optional Hydraulic Functions 826
Rear Lights Control 826
Restore Default Settings 827
Steering Wheel Friction and Steering Turns Adjustment 827
Navigation 828
How to Adjust Settings 828
Steering Friction 828
Steering Wheel Number of Turns 829
Diagnostics Menu 831
Introduction 831
Fault Code Log 831
Fault Log Details 832
Speedometer 833
Direction Switch 833
Traction Motor 1 Status 833
Traction Motor 2 Status 834
Occupancy Sensor 834
Brake System Sensors 834
Pump Status 835
Hydraulic Control Inputs 835
E-Hydraulic Valves 835
Hydraulic Sensors 836
System Voltages 836
Steering Position Sensors 837
E-Steering Position Sensors 837
Electric Brake 838
Navigation 839
524319504-9000YRM1377-(09-2019)-UK-EN 841
SECTION 9010 Operational Diagnostic Procedures 857
Group 05 – Operational Checkout 859
SECTION 9025 Traction Motor 869
Group 10 – Principles of Operation 871
Group 30 – Observed Symptoms 877
SECTION 9030 Electrical System 879
Group 03 – General Maintenance and Diagnostic Data 889
Group 10 – Principles of Operation 933
Group 20 – Diagnostic Trouble Codes 965
Group 30 – Observed Symptoms 1577
Group 55 – Icons and Graphics 1621
SECTION 9035 Drive Axle/Unit 1629
Group 10 – Principles of Operation 1631
Group 30 – Observed Symptoms 1641
Group 20 – Diagnostic Trouble Codes 1653
SECTION 9050 Hydraulic Systems 1655
Group 10 – Principles of Operation 1659
Group 33 – Observed Symptoms-Gear Pump 1697
Group 43 – Tests and Adjustments-Gear Pump 1777
SECTION 9060 Operators Station 1807
Group 10 – Principles of Operation 1809
SECTION 9070 Front End (Mast) and Chassis 1849
Group 10 – Principles of Operation 1851
Group 30 – Observed Symptoms 1869
SECTION 9080 Supplementary Data 1913
Group 50 – Abbreviations and Acronyms 1915
550025937-0100YRM1446-(02-2023)-UK-EN 1923
General 1929
Discharging the Capacitors 1930
Window Replacement 1931
Front Panel 1931
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) 1931
Remove, Lift Truck Models ERP13VC, ERP15VC (B888) 1932
Clean 1934
Inspect 1934
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) 1934
Install, Lift Truck Models ERP13VC, ERP15VC (B888) 1934
Rear Panel 1934
Remove 1934
Clean 1938
Inspect 1938
Install 1938
Door Window 1939
Disassemble Window 1939
Clean 1940
Inspect 1940
Assemble Window 1940
Window Wipers Replacement 1941
Front Wiper Assembly 1941
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) 1941
Remove, Lift Truck Models ERP13VC, ERP15VC (B888) 1946
Clean 1947
Inspect 1948
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) 1948
Install, Lift Truck Models ERP13VC, ERP15VC (B888) 1949
Cab Component Repair 1950
Roof Liner 1950
Remove 1950
Clean 1951
Inspect 1951
Install 1951
Top Panel 1952
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) 1952
Remove, Lift Truck Models ERP13VC, ERP15VC (B888) 1954
Clean 1955
Inspect 1955
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) 1955
Install, Lift Truck Models ERP13VC, ERP15VC (B888) 1955
Cab Door Assembly 1956
Door Assembly 1956
Remove 1956
Lift Truck Models and ERP22-35VL (ERP045-070VL) (A976)ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1956
Lift Truck Models and ERP15-20VT (ERP030-040VT) (G807)ERP16-20VF (ERP30-40VF) (A955) 1958
Disassemble Left Door 1960
Disassemble Right Door 1962
Clean 1964
Inspect 1964
Assemble Right Door 1964
Assemble Left Door 1964
Install 1965
Lift Truck Models and ERP22-35VL (ERP045-070VL) (A976)ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1965
Lift Truck Models and ERP15-20VT (ERP030-040VT) (G807)ERP16-20VF (ERP30-40VF) (A955) 1965
Cab Heater 1966
Cab Heater 1966
Remove 1966
Clean 1973
Inspect 1973
Install 1973
Troubleshooting 1975
Weather Panel Replacement 1978
Remove 1978
Roof Panels 1978
Front Screen Panel 1981
Install 1982
Front Screen Panel 1982
Roof Panels 1982
550025937-0100YRM1446-(09-2014)-UK-EN 1985
550038795-0100YRM1514-(12-2015)-UK-EN 2039
Introduction 2043
General 2043
Description 2043
Discharging the Capacitors 2046
Covers and Floor Plate 2046
Overhead Guard Replacement 2048
Remove 2048
Install 2051
Hood and Seat Assembly 2052
General 2052
Remove 2054
Install 2056
Ground Test 2057
Counterweight Replacement 2057
Remove 2058
Install 2060
Master Drive Unit Replacement 2062
General 2062
Remove 2062
Install 2064
Safety Labels 2065
Painting Instructions 2068
Battery Specifications 2068
550038796-0620YRM1515-(12-2015)-UK-EN 2073
General 2077
Discharging the Capacitors 2078
Traction Motor Repair 2079
Remove 2079
Disassemble 2081
Electric Connector Repair or Replacement 2083
Clean 2083
Inspect 2083
Ground Fault Check 2084
Assemble 2084
Install 2084
Hydraulic Motor Repair 2084
Remove 2085
Disassemble 2086
Electrical Connector Repair or Replacement 2087
Clean 2088
Inspect 2088
Assemble 2089
Install 2091
Torque Specifications 2092
Traction Motor 2092
Hydraulic Motor and Pump 2092
550038797-1300YRM1516-(12-2015)-UK-EN 2095
General 2099
Discharging the Capacitors 2099
Load Axles 2100
Remove 2100
Install 2103
550038798-1600YRM1517-(12-2015)-UK-EN 2107
General 2111
Introduction 2111
Discharging the Capacitors 2112
Steering Pressure Check 2113
Operation Check 2115
Steering Control Unit (SCU) Repair 2115
Remove 2115
Disassemble 2120
Clean 2122
Inspect 2122
Assemble 2122
Install 2123
Steering Wheel and Fixed Steering Column Assembly Repair 2124
Remove 2124
Disassemble 2127
Clean 2129
Inspect 2129
Assemble 2129
Install 2130
Steering Wheel and Telescopic Column Assembly Repair 2131
Remove 2131
Disassemble 2134
Clean 2137
Inspect 2137
Assemble 2137
Install 2139
Master Drive Unit Repair 2139
Remove 2139
Disassemble 2139
Clean 2144
Inspect 2144
Assemble 2144
Install 2145
Steering Motor 2145
Remove 2145
Install 2145
Torque Specifications 2147
Fixed Steering Column 2147
Telescopic Steering Column 2147
Steering Control Unit 2147
Master Drive Unit 2147
Steer Motor 2147
550038799-1800YRM1518-(12-2015)-UK-EN 2151
General 2155
Brake System 2155
Discharging the Capacitors 2156
Service Brakes Repair 2156
Remove 2156
Disassemble 2158
Clean 2160
Inspect 2160
Assemble 2160
Install 2162
Parking Brake Repair 2163
Remove 2163
Install 2164
Master Cylinder Repair 2167
Remove 2167
Disassemble 2168
Clean 2170
Inspect 2170
Assemble 2170
Bench Bleed Master Cylinder 2171
Install and Adjust 2171
Brake Pedal Component Replacement 2172
Remove 2172
Disassemble 2173
Inspect 2173
Assemble 2173
Install 2173
Brake Pedal Adjustment 2173
Master Cylinder Adjustment 2175
Brake System Air Removal 2176
Using Pressure Bleed System 2176
Using Brake Pedal Pressure 2176
550038800-1900YRM1519-(12-2015)-UK-EN 2179
General 2183
Discharging the Capacitors 2183
Hydraulic Pump Repair 2183
Remove 2184
Disassemble 2189
Inspect 2190
Clean 2190
Assemble 2190
Install 2191
Hydraulic Tank Assembly 2195
Remove 2195
Disassemble 2197
Clean 2200
Steam Method 2200
Chemical Method 2201
Inspect 2201
Assemble 2201
Install 2205
Hydraulic Filter Replacement 2207
Lift Trucks Built Prior to November, 2013 2207
Lift Trucks Built After November, 2013 2208
Breather Clean and Inspect 2210
Add Hydraulic Oil 2210
Specifications 2210
Torque Specifications 2211
550038801-2000YRM1520-(12-2015)-UK-EN 2215
General 2219
2219
Manual Main Control Valve 2219
E-Hydraulic Main Control Valve 2220
Discharging the Capacitors 2221
Manual Hydraulic Control Valve Repair 2222
Remove 2222
Beginning Steps 2222
Disassemble Handles and Levers 2231
Disassemble Manual Control Valve 2233
Spool Seal Replacement 2240
Clean 2244
Inspect 2244
Assemble Manual Control Valve 2244
Assemble Handles and Levers 2253
Install 2256
Ending Steps 2264
Fourth Function Solenoid Valve 2265
Remove 2265
Disassemble 2266
Clean 2268
Inspect 2268
Assemble 2268
Install 2269
E-Hydraulic Control Valve Repair 2269
Remove 2269
Beginning Steps 2269
Disassemble 2272
Hydraulic Fittings 2272
Electro-Proportional Valves 2273
Clean 2278
Inspect 2278
Assemble 2279
Hydraulic Fittings 2279
Electro-Proportional Valves 2281
Install 2282
E-Hydraulic Controls 2284
Replace E-Hydraulic Control Components 2284
Checks and Adjustments 2284
Manual Control Valve 2285
Primary Relief Valve 2285
Optional Work Port Relief Valve 2285
E-Hydraulic Control Valve 2286
Primary Relief Valve 2286
Hydraulic System Air Removal 2287
Position Sensor and OPS Check and Adjustment 2288
Position Sensor 2288
(OPS) Operator Presence Solenoid 2288
Manual Control Valve Re-Calibration 2288
Calibration Procedure 2288
Control Valve 2289
Torque Specifications 2289
Manual Hydraulic Control Valve 2290
Manual Control Valve Handles and Levers 2290
Fourth Function Solenoid Valve (Manual Control Valve) 2290
E-Hydraulic Control Valve 2290
550038802-2100YRM1521-(12-2015)-UK-EN 2293
Safety Procedures When Working Near Mast 2297
General 2299
Description 2299
Tilt Cylinder Repair 2300
Remove 2300
Disassemble 2301
Inspect 2302
Clean 2302
Assemble 2303
Install 2303
Tilt Cylinders, Adjust 2303
Tilt Speed Restrictor; Lift Trucks Built After May, 2012 2305
Tilt Speed Restrictor; Lift Trucks Built After August, 2013 2306
Tilt Cylinders Leak Check 2307
Lift Cylinder Repair 2307
Main Lift Cylinder (Mast a270, a271 and a272) 2307
Remove 2307
Main Lift Cylinders – Two-Stage FFL Mast 2307
Left-Hand Main Lift Cylinder – Three-Stage FFL Mast 2309
Right-Hand Main Lift Cylinder – Three-Stage FFL Mast 2314
Main Lift Cylinder – Two-Stage LFL Mast 2315
Disassemble 2317
Main Lift Cylinders – Two-Stage FFL Mast 2317
Main Lift Cylinder – Three-Stage FFL Mast 2319
Main Lift Cylinder – Two-Stage LFL Mast 2319
Clean 2320
Inspect 2320
Assemble 2321
Main Lift Cylinder – Two-Stage FFL Mast 2321
Main Lift Cylinder – Three-Stage FFL Mast 2321
Main Lift Cylinder – Two-Stage LFL Mast 2321
Install 2322
Main Lift Cylinder – Two-Stage FFL Mast 2322
Left-Hand Main Lift Cylinder – Three-Stage FFL Mast 2322
Right-Hand Main Lift Cylinder – Three-Stage FFL Mast 2323
Main Lift Cylinder – Two-Stage LFL Mast 2324
System Air Bleed Procedures 2325
All Main Lift Cylinders 2326
Main Lift Cylinder (Mast c662) 2326
Remove 2326
Disassemble 2328
Clean 2329
Inspect 2329
Assemble 2329
Install 2330
Mast and Carriage Install 2330
Free Lift Cylinder Repair 2330
Free-Lift Cylinder (Mast a271 and a272) 2330
Remove 2330
Three-Stage FFL Mast 2330
Disassemble 2332
Clean 2333
Inspect 2333
Assemble 2333
Install 2333
Free-Lift Cylinder (Mast c662) 2334
Remove 2334
Disassemble 2336
Clean 2336
Inspect 2337
Assemble 2337
Install 2338
Carriage Install 2338
Sideshift Cylinder Repair 2338
Remove 2338
Disassemble 2340
Clean and Inspect 2340
Assemble and Install 2341
Seal Kit Installation 2341
External Installation (Seal and Back-Up Ring) 2341
Internal Installation (Piston Rod Assembly) 2342
Torque Specifications 2342
Tilt Cylinders 2342
Main and Free-Lift Cylinders 2342
Sideshift Cylinder 2343
550038805-2200YRM1524-(01-2020)-UK-EN 2347
General 2353
Discharging the Capacitors 2354
Display Panel and Key or Keyless Switch Replacement 2354
Display Panel, Replace 2354
Remove 2354
Install 2357
Electronic and Manual Hydraulic Controls 2358
General 2358
Manual Hydraulic Controls 2360
Upper Front Cover 2360
Remove and Install 2360
Direction Control Switch 2360
Remove 2360
Install 2362
Emergency Disconnect Switch 2362
Remove 2362
Install 2363
Attachment Button (Fourth Function) 2364
Remove 2364
Install 2364
E-Hydraulic Controls – Test 2364
Mini-Levers 2364
Full Stroke Test 2364
Function Returns to Neutral Test 2365
Push (Override) Button 2365
E-Hydraulic Controls 2365
Mini-levers, Remove and Install 2366
Armrest Assembly 2367
Remove 2367
Install 2368
Horn Button 2369
Remove 2369
Install 2370
Direction Control Switch 2370
Remove 2370
Install 2370
Emergency Disconnect Switch 2370
Remove 2371
Install 2371
push (override) buttons and Function Selection Button 2371
Remove 2372
Install 2373
Electronic-Hydraulic Controls, After January, 2020 2374
General 2374
E-Hydraulic Controls – TEST 2375
Mini-Levers 2375
Full Stroke Test 2375
Function Returns to Neutral Test 2375
Push (Override) Button 2376
Mini-levers, Remove and Install 2376
Armrest Assembly 2377
Remove 2377
Install 2379
Horn Button 2379
Remove 2379
Install 2379
Direction Control Switch 2379
Remove 2379
Install 2380
Emergency Disconnect Switch 2380
Remove 2381
Install 2381
push (override) button 2382
Remove 2382
Install 2383
Sensors and Switches 2384
General 2384
Hydraulic Motor Speed Sensor 2384
Remove 2384
Install 2385
Hydraulic Motor Temperature Sensor 2385
Remove 2385
Install 2386
Traction Motor Temperature Sensor 2386
Remove 2386
Install 2387
Traction Motor Speed Sensor 2387
Remove 2387
Install 2388
Low Level Brake Fluid Switch 2388
Remove 2388
Install 2388
Service Brake Pressure Sensor 2388
Remove 2388
Install 2389
Accelerator Pedal Position Sensor 2389
Remove 2389
Install 2390
Seat Sensor (Operator Presence System) 2390
Full Suspension and Swivel Seats 2390
Remove 2390
Install 2391
Seat Belt Sequence Module 2391
Remove 2391
Install 2391
Steering Wheel Position Sensor 2391
Remove 2391
Install 2393
Horn Switch 2393
Remove 2393
Install 2395
Rear Horn Button Switches 2395
Remove 2395
Install 2396
Tilt Position Sensor 2396
Remove 2396
Install 2397
Parking Brake Position Sensor 2397
Remove 2397
Install 2399
Hydraulic Tank Level Sensor 2399
Remove 2399
Install 2400
Hydraulic Filter Sensor; Lift Trucks Prior to November, 2013 2400
Remove 2400
Install 2400
Hydraulic Pressure Switch; Lift Trucks After November, 2013 2400
Remove 2400
Install 2400
Hydraulic Oil Temperature Sensor 2401
Remove 2401
Install 2401
Impact Sensor 2401
Remove 2401
Install 2403
Load Weight Sensor 2403
Remove 2403
Install 2404
Motor Controllers Replacement 2404
General 2404
Hydraulic Motor Controller 2405
Remove 2405
Install 2409
Traction Motor Controllers 2409
Remove 2409
Install 2410
Motor Controller Fans 2411
Hydraulic Motor Controller Fan 2411
Remove 2411
Install 2413
Traction Motor Controller Fan 2413
Remove 2413
Install 2414
Line Contactor 2414
Remove 2414
Install 2414
Vehicle Systems Manager 2415
General 2415
Remove 2415
Install 2417
Programming a New VSM and/or Display Panel 2418
General 2418
PC Service Tool Software 2418
Fuses 2419
Audible Alarm 2421
Battery Connection 2422
Inspect 2422
Replacing Cables 2422
Lights 2423
General 2423
Front Work Lights (LED Lights) 2424
Remove 2424
Install 2425
Strobe Light 2425
Remove 2425
Install 2425
LED Tail, Backup, and Brake Lights 2426
Remove 2426
Install 2426
Front Marker/Turn Signal Lights 2426
Remove 2426
Install 2428
Converter 2428
Remove 2428
Install 2428
12 Volt Outlet 2430
Remove 2430
Install 2431
550038806-4000YRM1525-(09-2017)-UK-EN 2433
General 2437
Safety Procedures When Working Near Mast 2438
Fork Replacement 2441
Standard Carriage and Integral Sideshift Carriage 2441
Remove 2441
Install 2442
Checks 2443
Fork Positioner Carriage 2444
Remove 2445
Install 2446
Checks 2446
Carriages Repair, Two-Stage LFL Mast 2447
Standard Carriage 2447
Remove 2447
Clean and Inspect 2450
Install 2450
Integral Sideshift Carriage 2450
Remove 2450
Disassemble 2452
Clean and Inspect 2453
Assemble 2454
Install 2454
Two-Stage Mast With Limited Free-Lift Repair 2455
Remove 2455
Disassemble 2458
Clean and Inspect 2461
Assemble 2463
Install 2463
Header Hose Installation and Adjustment 2465
Installation 2465
Adjustment 2471
Carriages Repair, Two-Stage FFL Mast 2472
Standard Carriage 2472
Remove 2472
Clean and Inspect 2473
Install 2474
Integral Sideshift Carriage 2474
Remove 2474
Disassemble 2477
Clean and Inspect 2477
Assemble 2478
Install 2479
Fork Positioner Carriage 2479
Remove 2479
Clean and Inspect 2481
Install 2481
Fork Positioner Hydraulic Hose Adjustment 2483
Two Stage Mast with Full Free Lift 2485
Remove 2485
Disassemble 2488
Clean and Inspect 2495
Assemble 2498
Install 2499
Header Hose Installation and Adjustment 2500
Install 2500
Adjust 2507
Carriages Repair, Three-Stage FFL Mast 2508
Standard Carriage 2508
Remove 2508
Clean and Inspect 2510
Install 2510
Integral Sideshift Carriage 2510
Remove 2510
Disassemble 2514
Clean and Inspect 2514
Assemble 2515
Install 2516
Fork Positioner Carriage 2516
Remove 2516
Clean and Inspect 2519
Install 2519
Fork Positioner Hydraulic Hose Adjustment 2520
Three-Stage Mast With Full Free-Lift Repair 2522
C662 Three-Stage FFL Mast 2522
Remove 2522
Disassemble 2525
Clean and Inspect 2532
Assemble 2534
Install 2535
Header Hose Installation and Adjustment 2536
Install 2536
Adjust 2543
A271 Three-Stage FFL Mast 2544
Remove 2544
Disassemble 2547
Clean and Inspect 2552
Assemble 2554
Install 2555
Header Hose Installation and Adjustment 2556
Installation 2556
Adjustment 2563
Lift Chains Adjustment 2563
Carriage Adjustments 2565
Tilt Cylinders Adjustment 2565
Mast Adjustments 2565
Load Roller, Adjust 2565
Mast Side Kicking, Adjust 2568
550038807-8000YRM1526-(11-2017)-UK-EN 2571
Introduction 2577
General 2577
Serial Number 2578
Discharging the Capacitors 2578
How to Tow a Disabled Lift Truck 2579
How to Put Lift Truck on Blocks 2581
How to Raise Drive Tires 2581
How to Raise Steer Tires 2582
How to Clean a Lift Truck 2582
Safety Procedures When Working Near Mast 2583
WHEN WORKING NEAR THE MAST ALWAYS: 2583
Maintenance Schedule 2586
Maintenance Procedures Every Shift 2592
How to Make Checks With the Key or Keyless Switch OFF 2592
Wheels and Tires 2592
Safety Labels 2592
Frame and Covers 2593
Forks, General 2594
Forks, Remove 2594
Forks, Inspect 2597
Fork Install 2597
Forks, Adjust 2598
Inspection of Mast, Carriage, Header Hoses, Lift Chains, and Attachments 2598
Hydraulic Oil Level and Leaks 2599
Operator Restraint System 2600
Emergency Locking Retractor (ELR) 2601
Seat Adjustments 2602
Seat Position Adjustment (Swivel Seat) 2602
Seat Position Adjustment (Full Suspension, High Back Seat) 2602
Seat Adjustment for Operator Weight 2602
Battery Restraint System 2604
Steering Column Adjustments 2608
Tilt Adjust Feature 2608
Tilt Memory Feature 2608
Telescopic Feature 2608
Battery Check 2608
How to Make Checks With the Key or Keyless Switch ON 2609
Control Levers and Pedals 2609
Direction and Speed Controls 2609
Electrical Components 2609
Steering System 2611
Hydraulic System 2611
Service Brakes 2612
Parking Brake 2612
Operator Presence System 2612
Oil Leaks 2612
Maintenance Procedures Every 1000 Hours or 6 Months 2612
Frames, Covers and Floor Plates 2613
Static Strap 2613
Pedals, Seat Assembly, Hood Hinges and Hood Latch 2613
Hydraulic Hoses, Fittings, and Clamps 2613
Hydraulic Breather Cap 2613
Parking Brake 2614
Brake Oil Change 2614
Mast 2614
Mast Sliding Surfaces 2614
Mast Pivot Pins, Bushings, and Mounting Hardware 2615
Header Hoses 2615
Fourth Function Mini Rollers Lubrication 2615
High Visibility Mast 2616
High Visibility and Heavy Duty Masts 2616
Lift Chain Wear Check 2618
Tilt Cylinder Rod End Pins 2619
Forks, Inspect 2620
Fork Guides and Pins 2621
Integral Sideshift Carriage 2622
Check Upper and Lower Bearings 2622
Check Lower Mounting Hooks 2624
Fork Positioner 2624
Electrical Inspection 2625
Contactors 2625
Direction and Speed Control Pedals 2626
Steering Column Adjustments 2626
Steering Column Tilt Memory Lever 2626
Operator Presence System 2626
Seat Belt Sequence Module 2627
Manual Hydraulic Levers 2627
Maintenance Procedures Every 2000 Hours or Yearly 2627
Load Tire and Wheel Assembly 2627
Frames, Covers and Floor Plates 2627
Static Strap 2627
Hydraulic System 2627
Hydraulic Oil Change, Cooler/ Freezer Construction 2627
Hydraulic Oil Filter, Change 2628
Hydraulic Breather, Change 2629
Steer Tire and Wheel Assembly 2630
Steering Axle 2630
Steering Motor and Steering Plate Torque Check 2630
Axle Stop Torque Check 2631
Lift Chains 2632
Forks, Inspect 2632
Integral Sideshift Carriage 2633
Master Drive Unit (MDU) 2634
Fluid Change 2634
MDU Mounting Bolts 2635
Trunnion Bearing 2635
Transition Plate 2635
Steer Hydraulic Motor 2635
Maintenance Procedures Every 4000 Hours or Two Years 2635
Frames, Covers and Floor Plates 2636
Static Strap 2636
Hydraulic Oil Change, Standard Construction 2636
Steering Position Sensor Inspection 2637
Fixed Steering Column 2637
Telescopic Steering Column 2638
Telescopic Steering Column Lubrication 2639
MDU Motor Spline Lubrication 2640
Welding Repairs 2640
Lift and Tilt System Leak Check 2640
Lift Cylinders Leak Check 2641
Tilt Cylinder Leak Check 2641
Battery Maintenance 2641
How to Charge Battery 2641
How to Change Battery 2643
Remove the Battery 2643
Install the Battery 2645
Battery Size Specifications 2646
Wheels and Tires 2646
Snap-On Solid Rubber Tires 2646
Lift Chain Adjustments 2649
550038808-8000YRM1527-(12-2015)-UK-EN 2655
General 2659
Lubrication Specifications 2659
Hydraulic System 2660
Steering System 2660
Tire Sizes 2661
Torque Specifications 2662
Electrical 2662
Steering System 2662
Hydraulic System 2662
Traction Motor 2663
Mast Speeds 2663
Maximum Carriage and Tilt Creep Rates 2666
Tilt Angles 2667
Master Drive Unit 2667
Travel Speeds 2667
Battery 2668
550038809-8000YRM1528-(12-2015)-UK-EN 2673
Diagrams 2677
550073240-1900YRM1620-(01-2023)-UK-EN 2695
Proper Flushing after Major Hydraulic Repairs 2701
Introduction 2701
The Phases of Wear 2701
Causes of Hydraulic System Failure 2701
Progression of Contaminant Caused Hydraulic System Failure 2702
Hydraulic System Flushing Techniques 2702
Double Oil and Filter Change 2702
Mechanical Cleaning 2703
Cleaning of Components 2703
How to Clean Tubes and Hoses 2703
Filter Caddy 2703
Start-Up Procedure for Cleaned System 2704
Contaminated Oil Coolers 2704
Additional Filter Caddy Functions 2705
How to Handle Different Fluids 2705
Water Removal Filters 2705
Fluid Conditioning and System Flushing Procedures 2706
Operation of the Filter Caddy 2706
Filter Caddy operation 2706
Fluid Conditioning Procedure 2706
Filter Caddy Start-Up 2707
System Flushing Procedure 2707
Component Cleaning Procedure 2708
Reservoir Cleaning Procedure 2708
Cylinder Cleaning Procedure 2708
Hose and Tube Cleaning Procedure 2708
Valve Cleaning Procedure 2709
Front-End Attachment Cleaning Procedure 2710
System Flushing Procedure 2710
Filter Caddy Start-Up 2711
System Start-Up and Flushing 2711
Reservoir Fluid Cleaning Times 2712
Dealing With Different Fluid Types 2713
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 2713
Filter Caddy Maintenance 2713
Servicing the Strainer 2713
DC Motor 2713
Hydraulic Oil Sampling Method and Procedure 2714
Hydraulic Oil Sampling Method 2714
Objective 2714
General Guidelines 2714
Synopsis 2715
Hydraulic Oil Analysis Report Guidelines 2716
Sampling Conditions 2716
Equipment 2716
Sampling Procedure 2717
Hydraulic Oil Sampling 2717
Sample Labeling 2717
Results Documentation 2717
550073240-1900YRM1620-(03-2020)-UK-EN 2719
Proper Flushing after Major Hydraulic Repairs 2723
Introduction 2723
The Phases of Wear 2723
Causes of Hydraulic System Failure 2723
Progression of Contaminant Caused Hydraulic System Failure 2724
Hydraulic System Flushing Techniques 2724
Double Oil and Filter Change 2724
Mechanical Cleaning 2725
Cleaning of Components 2725
How to Clean Tubes and Hoses 2725
Filter Caddy 2725
Start-Up Procedure for Cleaned System 2726
Contaminated Oil Coolers 2726
Additional Filter Caddy Functions 2726
How to Handle Different Fluids 2726
Water Removal Filters 2727
Fluid Conditioning and System Flushing Procedures 2727
Operation of the Filter Caddy 2727
Filter Caddy operation 2727
Fluid Conditioning Procedure 2728
Filter Caddy Start-Up 2728
System Flushing Procedure 2729
Component Cleaning Procedure 2729
Reservoir Cleaning Procedure 2729
Cylinder Cleaning Procedure 2729
Hose and Tube Cleaning Procedure 2730
Valve Cleaning Procedure 2730
Front-End Attachment Cleaning Procedure 2731
System Flushing Procedure 2731
Filter Caddy Start-Up 2732
System Start-Up and Flushing 2732
Reservoir Fluid Cleaning Times 2733
Dealing With Different Fluid Types 2733
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 2733
Filter Caddy Maintenance 2734
Servicing the Strainer 2734
DC Motor 2734
Hydraulic Oil Sampling Method and Procedure 2734
Hydraulic Oil Sampling Method 2734
Objective 2734
General Guidelines 2734
Synopsis 2735
Hydraulic Oil Analysis Report Guidelines 2736
Sampling Conditions 2737
Equipment 2737
Sampling Procedure 2737
Hydraulic Oil Sampling 2737
Sample Labeling 2738
Results Documentation 2738
550087451-8000YRM1526-(11-2017)-UK-EN 2741
Introduction 2747
General 2747
Serial Number 2748
Discharging the Capacitors 2748
How to Tow a Disabled Lift Truck 2749
How to Put Lift Truck on Blocks 2750
How to Raise Drive Tires 2750
How to Raise Steer Tires 2751
How to Clean a Lift Truck 2752
Safety Procedures When Working Near Mast 2752
WHEN WORKING NEAR THE MAST ALWAYS: 2753
Maintenance Schedule 2755
Maintenance Procedures Every 8 Hours or Daily 2760
How to Make Checks With the Key or Keyless Switch OFF 2761
Wheels and Tires 2761
Safety Labels 2761
Frame and Covers 2762
Forks, General 2762
Forks, Remove 2763
Forks, Inspect 2764
Fork Install 2765
Forks, Adjust 2765
Inspection of Mast, Carriage, Header Hoses, Lift Chains, and Attachments 2766
Hydraulic Oil Level and Leaks 2767
Operator Restraint System 2767
Emergency Locking Retractor (ELR) 2768
Seat Adjustments 2769
Seat Position Adjustment (Standard Seat) 2769
Seat Adjustment for Operator Weight 2769
Battery Restraint System 2771
Steering Column Adjustments 2774
Tilt Adjust Feature 2774
Tilt Memory Feature 2774
Telescopic Feature 2774
Battery Check 2774
How to Make Checks With the Key or Keyless Switch ON 2775
Control Levers and Pedals 2775
Direction and Speed Controls 2775
Electrical Components 2775
Steering System 2777
Hydraulic System 2777
Service Brakes 2777
Parking Brake 2778
Operator Presence System 2778
Maintenance Procedures Every 500 Hours or Three Months 2778
Frames, Covers and Floor Plates 2778
Static Strap 2778
Pedals, Seat Assembly, Hood Hinges and Hood Latch 2778
Hydraulic Hoses, Fittings, and Clamps 2778
Hydraulic Breather Cap 2778
Parking Brake 2779
Brake Oil Change 2779
Mast 2780
Mast Sliding Surfaces 2780
Mast Pivot Pins, Bushings, and Mounting Hardware 2780
Header Hoses 2781
Fourth Function Mini Rollers Lubrication 2781
Left Main Lift Cylinder 2781
Free-Lift Cylinder 2781
Lift Chain Wear Check 2783
Tilt Cylinder Rod End Pins 2784
Forks 2785
General 2785
Inspect 2785
Fork Guides and Pins 2786
Integral Sideshift Carriage 2786
Check Upper and Lower Bearings 2786
Check Lower Mounting Hooks 2788
Electrical Inspection 2788
Contactors 2788
Direction and Speed Control Pedals 2788
Steering Column Adjustments 2789
Steering Column Tilt Memory Lever 2789
Operator Presence System 2789
Seat Belt Sequence Module 2789
Manual Hydraulic Levers 2789
Maintenance Procedures Every 2000 Hours or Yearly 2790
Load Tire and Wheel Assembly 2790
Frames, Covers and Floor Plates 2790
Static Strap 2790
Hydraulic System 2790
Hydraulic Oil Change, Cooler/ Freezer Construction 2790
Hydraulic Oil Filter, Change 2791
Hydraulic Breather, Change 2792
Steer Tire and Wheel Assembly 2793
Steering Axle 2793
Steering Motor and Steering Plate Torque Check 2793
Axle Stop Torque Check 2794
Lift Chains 2795
Forks, Inspect 2795
Integral Sideshift Carriage 2796
Master Drive Unit (MDU) 2797
Fluid Change 2797
MDU Mounting Bolts 2797
Trunnion Bearing 2798
Transition Plate 2798
Steer Hydraulic Motor 2798
Maintenance Procedures Every 4000 Hours or Two Years 2798
Frames, Covers and Floor Plates 2798
Static Strap 2798
Hydraulic Oil Change, Standard Construction 2798
Steering Position Sensor Inspection 2799
Fixed Steering Column 2799
Telescopic Steering Column 2800
Telescopic Steering Column Lubrication 2801
MDU Motor Spline Lubrication 2802
Welding Repairs 2802
Lift and Tilt System Leak Check 2803
Lift Cylinders Leak Check 2803
Tilt Cylinder Leak Check 2803
Battery Maintenance 2803
How to Charge Battery 2804
How to Change Battery 2805
Remove the Battery 2805
Install the Battery 2807
Battery Size Specifications 2808
Wheels and Tires 2808
Solid Rubber Tires on Pneumatic Wheels, Change 2808
Wheels, Install 2813
Lift Chain Adjustments 2813