Yale Forklift G807 (ERP030VT, ERP035VT, ERP040VT) Service Manual – PDF DOWNLOAD

Yale Forklift G807 (ERP030VT, ERP035VT, ERP040VT) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift G807 (ERP030VT, ERP035VT, ERP040VT) Service Manual – PDF DOWNLOAD

Language : English
Pages : 4024
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift G807 (ERP030VT, ERP035VT, ERP040VT) 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
524183085-2200YRM1058-(04-2011)-UK-EN 97
toc 97
Troubleshooting and Adjustments Using the AC Controls Program (E 97
Safety Precautions Maintenance and Repair 98
General 101
Computer Requirements 101
Software, Install 101
Language Selection 101
Demo Mode 102
Connect PC to Lift Truck 106
Starting AC Controls Program 108
Lift Truck Control Setup 113
Change Lift Truck Serial Number or Hourmeter 113
Setting Factory Default Values or Changing Lift Truck Parameters 114
Create New Custom Lift Truck Configuration 120
Lift Truck Configuration Properties 123
Import New Lift Truck Configuration From Disk 126
Delete Custom Lift Truck Configuration or Password File 128
Dash Display 131
Custom Display Languages 131
Download Display Language 133
Clear Operator Log 133
Password Functions 136
Enable/Disable Password and Lift Truck Inspection Functions 136
Truck Inspection Checklist 136
Password 136
Password Properties 136
Create New Password File 141
Download Passwords 142
Upload Passwords 144
Reports Menu 146
Devices Report 146
Custom Report 146
Password Report 146
Operator Report 153
Current Settings Report 156
Status Code Report 160
Status Codes Log 163
Troubleshooting 165
Diagnostics 165
Help Menu 168
General 168
Contents 168
Technical Support 168
About Electric Truck AC Controls Program 168
524223769-2200YRM1128-(01-2023)-UK-EN 175
Series Code / Model Designation Reference Table 183
General 185
Deutsch Crimping Tool 186
How to Strip a Wire for Use With Deutsch Crimping Tool 186
How to Crimp With the Deutsch Crimping Tool 187
Calibration Test for the Deutsch Crimping Tool 189
Deutsch Connectors 191
DT, DTM, and DTP Series Connectors 191
HD Series Connectors 234
Metri-Pack Connectors 256
Remove and Install 256
Micro-Pack Connectors 259
Weather-Pack Connectors 260
AMPSEAL Crimping Tools 262
AMP Hand Crimping Tool With Certi-Crimp 262
Description 262
Stripping Wire for Use with AMP Hand Crimping Tool 263
Insulation Crimp Adjustment 264
Maintenance and Inspection for AMP Hand Crimping Tool 264
AMP Hand Crimping Tool 264
Crimp Height Inspection 264
How to use AMP Hand Crimping Tool 265
AMP Pro-Crimper II Tool 265
Description 265
Remove and Install Die Set and Locator Assembly 266
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 266
Contact Support Adjustment 267
Crimp Height Adjustment 268
Maintenance and Inspection Procedures 268
PRO-CRIMPER II Tool 268
Crimp Height Inspection 268
How to Use AMP PRO-CRIMPER II Tool 269
AMPSEAL Connector Assemblies 270
Description for Plug Connector Assembly 270
Seal Plug 271
Contact Crimping 271
Description for Plug Connector and Header Assembly 276
Voltage Reading 279
Seal Plug 279
Contact Crimping 279
AMP Superseal 1 5 Crimping Tools 286
Mini Mic Receptacle and Tab Contacts 286
Description 286
Crimping Conditions and Measurements 286
Insertion of Rubber Seal on Cable 288
AMP Hand Application Tool 293
Description 293
Maintenance and Inspection 293
Crimp Height Inspection 293
Crimp Height Adjustment 294
How to Use AMP Hand Application Tool 294
AMP Pro-Crimper II Tool 295
Description 295
Remove and Install Die Set and Locator Assembly 295
Adjustments 296
Contact Support 296
Crimp Height 297
Inspections and Maintenance 298
Crimp Height Inspection 298
Visual Inspection 298
Maintenance 299
How to Use Pro-Crimper II Tool 299
AMP Superseal 1 5 Connector Assemblies 300
Description 300
Repair and Maintenance 307
Panel Mount Option 307
AMP Fastin-Faston Hand Tools 308
Description – AMP Double Action Hand Tool 308
Maintenance and Inspection Procedures 308
Daily Maintenance 308
Periodic Tool Inspection 309
Lubrication 309
Visual Inspection 309
Crimp Height Inspection 309
Certi-Crimp Ratchet Inspection 310
How to Use AMP Double Action Hand Tool 311
Description – AMP Extraction Tool 312
Maintenance and Inspection 313
How to Use AMP Extraction Tool 313
AMP Fastin-Faston Receptacles and Housings 315
Description 315
Wire Repair 323
Wire Splicing Requirements 323
Deutsch Jiffy Splice 324
Twisted/Shielded Cable and Leads Repair 330
Special Tools 332
524223769-2200YRM1128-(07-2020)-UK-EN 341
Series Code / Model Designation Reference Table 347
General 350
Deutsch Crimping Tool 350
How to Strip a Wire for Use With Deutsch Crimping Tool 350
How to Crimp With the Deutsch Crimping Tool 351
Calibration Test for the Deutsch Crimping Tool 353
Deutsch Connectors 355
DT, DTM, and DTP Series Connectors 355
HD Series Connectors 397
Metri-Pack Connectors 420
Remove and Install 420
Micro-Pack Connectors 422
Weather-Pack Connectors 423
AMPSEAL Crimping Tools 425
AMP Hand Crimping Tool With Certi-Crimp 425
Description 425
Stripping Wire for Use with AMP Hand Crimping Tool 425
Insulation Crimp Adjustment 426
Maintenance and Inspection for AMP Hand Crimping Tool 426
AMP Hand Crimping Tool 426
Crimp Height Inspection 426
How to use AMP Hand Crimping Tool 427
AMP Pro-Crimper II Tool 427
Description 427
Remove and Install Die Set and Locator Assembly 428
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 429
Contact Support Adjustment 429
Crimp Height Adjustment 430
Maintenance and Inspection Procedures 430
PRO-CRIMPER II Tool 430
Crimp Height Inspection 430
How to Use AMP PRO-CRIMPER II Tool 431
AMPSEAL Connector Assemblies 432
Description for Plug Connector Assembly 432
Seal Plug 433
Contact Crimping 433
Description for Plug Connector and Header Assembly 438
Voltage Reading 440
Seal Plug 440
Contact Crimping 440
AMP Superseal 1 5 Crimping Tools 447
Mini Mic Receptacle and Tab Contacts 447
Description 447
Crimping Conditions and Measurements 447
Insertion of Rubber Seal on Cable 449
AMP Hand Application Tool 454
Description 454
Maintenance and Inspection 454
Crimp Height Inspection 454
Crimp Height Adjustment 455
How to Use AMP Hand Application Tool 455
AMP Pro-Crimper II Tool 456
Description 456
Remove and Install Die Set and Locator Assembly 457
Adjustments 457
Contact Support 457
Crimp Height 458
Inspections and Maintenance 459
Crimp Height Inspection 459
Visual Inspection 459
Maintenance 460
How to Use Pro-Crimper II Tool 460
AMP Superseal 1 5 Connector Assemblies 461
Description 461
Repair and Maintenance 468
Panel Mount Option 468
AMP Fastin-Faston Hand Tools 469
Description – AMP Double Action Hand Tool 469
Maintenance and Inspection Procedures 469
Daily Maintenance 469
Periodic Tool Inspection 470
Lubrication 470
Visual Inspection 470
Crimp Height Inspection 470
Certi-Crimp Ratchet Inspection 471
How to Use AMP Double Action Hand Tool 472
Description – AMP Extraction Tool 473
Maintenance and Inspection 473
How to Use AMP Extraction Tool 474
AMP Fastin-Faston Receptacles and Housings 475
Description 475
Wire Repair 482
Wire Splicing Requirements 482
Deutsch Jiffy Splice 483
Twisted/Shielded Cable and Leads Repair 488
Special Tools 491
524295629-0100YRM1329-(04-2023)-UK-EN 499
Introduction 505
General 505
Description of Operation 506
Discharging the Capacitors 507
Rapid Charge 507
Covers and Floor Plates 508
Overhead Guard Replacement 511
Remove 511
Install 516
Hood and Seat Assembly 517
Remove 520
Install 522
Ground Test 522
Counterweight Replacement 523
Remove 524
Install 529
Safety Labels 531
Painting Instructions 536
Battery Specifications 537
European Model Trucks ERP15-20VT (G807) 537
US Model Trucks ERP030-040VT (G807) 538
European Model Trucks ERP16-20VF (A955) 539
US Model Trucks ERP30-40VF (A955) 540
524295629-0100YRM1329-(09-2014)-UK-EN 543
524295630-1300YRM1330-(04-2023)-UK-EN 585
General 591
Discharging the Capacitors 592
Special Tools 592
Transaxle Assembly 593
Remove Transaxle From Frame 593
Remove the Parking Brake and Traction Motor 594
Install Parking Brake and Traction Motor 595
Install Transaxle to Frame 596
Maintenance and Repair 597
Speed Sensor Repair 597
Trunnion Cap Repair 598
Fluid Level Check 598
Fluid Change 599
Breather Repair 600
Stud Repair 601
Brake Cylinder Repair 602
Input Seal Repair 604
Cover to Housing Seal 604
During the Transaxle Warranty Period 604
After the Transaxle Warranty Period 605
Removing the Cover 605
Installing the Cover 606
Wet Brakes 607
Electronic Brake (E-Brake) 609
524295630-1300YRM1330-(10-2015)-UK-EN 611
General 615
Discharging the Capacitors 616
Special Tools 616
Transaxle Assembly 616
Remove Transaxle From Frame 617
Remove the Parking Brake and Traction Motor 618
Install Parking Brake and Traction Motor 619
Install Transaxle to Frame 620
Maintenance and Repair 620
Speed Sensor Repair 620
Trunnion Cap Repair 621
Fluid Level Check 622
Fluid Change 623
Breather Repair 624
Stud Repair 625
Brake Cylinder Repair 626
Input Seal Repair 627
Cover to Housing Seal 628
During the Transaxle Warranty Period 629
After the Transaxle Warranty Period 630
Removing the Cover 630
Installing the Cover 630
Wet Brakes 631
Electronic Brake (E-Brake) 633
524295631-1600YRM1331-(04-2023)-UK-EN 637
General 643
Introduction 643
Discharging The Capacitors 643
Steering Pressure Check, Lift Trucks Equipped With Hydraulic Steering 645
Operation Check 647
Steering Control Unit (SCU) Repair, Lift Trucks Equipped With Hydraulic Steering 648
Remove 648
Disassemble 651
Clean 656
Inspect 656
Assemble 656
Install 657
Steering Wheel and Fixed Steering Column Assembly Repair 659
Remove 659
Disassemble 662
Clean 664
Inspect 664
Assemble 664
Install 665
Gear Replacement for Lift Trucks Built Prior to 10/2008 666
Steering Wheel and Telescopic Column Assembly Repair 667
Remove 667
Disassemble 670
Clean 673
Inspect 674
Assemble 674
Install 675
Hydraulic Pump and Motor 682
Steering Actuator Components 682
Steer Tire and Wheel Assembly 682
Remove 682
Install 683
Wheel Hub Assembly, Lift Trucks Equipped With Hydraulic Steering 683
Remove 683
Clean 685
Inspect 686
Install 686
Wheel Hub Assembly, Lift Trucks Equipped With E-Steering 686
Remove 686
Clean 687
Inspect 688
Install 688
Steering Axle Assembly, Lift Trucks Equipped With Hydraulic Steering 688
Remove 688
Disassemble 689
Clean 690
Inspect 690
Assemble 690
Install 691
Steering Axle Assembly, Lift Trucks Equipped With E-Steering 691
Remove 691
Disassemble 694
Clean 696
Inspect 696
Assemble 696
Install 697
Torque Specifications 698
Fixed Steering Column 698
Telescopic Steering Column 698
Steering Control Unit 698
Steer Axle, Lift Trucks Equipped With Hydraulic Steering 698
Steer Axle, Lift Trucks Equipped With E-Steering 698
524295631-1600YRM1331-(07-2019)-UK-EN 701
General 705
Introduction 705
Discharging The Capacitors 705
Steering Pressure Check, Lift Trucks Equipped With Hydraulic Steering 706
Operation Check 708
Steering Control Unit (SCU) Repair, Lift Trucks Equipped With Hydraulic Steering 708
Remove 708
Disassemble 711
Clean 716
Inspect 716
Assemble 716
Install 717
Steering Wheel and Fixed Steering Column Assembly Repair 718
Remove 718
Disassemble 722
Clean 723
Inspect 724
Assemble 724
Install 724
Gear Replacement for Lift Trucks Built Prior to 10/2008 725
Steering Wheel and Telescopic Column Assembly Repair 726
Remove 726
Disassemble 729
Clean 733
Inspect 733
Assemble 733
Install 734
Hydraulic Pump and Motor 741
Steering Actuator Components 741
Steer Tire and Wheel Assembly 741
Remove 741
Install 742
Wheel Hub Assembly, Lift Trucks Equipped With Hydraulic Steering 742
Remove 742
Clean 744
Inspect 745
Install 745
Wheel Hub Assembly, Lift Trucks Equipped With E-Steering 745
Remove 745
Clean 746
Inspect 747
Install 747
Steering Axle Assembly, Lift Trucks Equipped With Hydraulic Steering 747
Remove 747
Disassemble 748
Clean 749
Inspect 749
Assemble 749
Install 750
Steering Axle Assembly, Lift Trucks Equipped With E-Steering 750
Remove 750
Disassemble 753
Clean 755
Inspect 755
Assemble 755
Install 756
Torque Specifications 756
Fixed Steering Column 756
Telescopic Steering Column 756
Steering Control Unit 756
Steer Axle, Lift Trucks Equipped With Hydraulic Steering 756
Steer Axle, Lift Trucks Equipped With E-Steering 756
524295632-1800YRM1332-(04-2023)-UK-EN 759
Introduction 765
General 765
Discharging the Capacitors 766
Brake Pedal Assembly Repair 767
Hydraulic Brake System 767
Remove 767
Disassemble 768
Assemble 768
Install 768
Electronic Brake (E-Brake) System 769
Remove 769
Disassemble 770
Assemble 771
Install 772
Adjustments 772
Brake Pedal Adjustment 772
Clevis Adjustment 772
Master Cylinder Repair 774
Remove 774
Disassemble 775
Clean and Inspect 777
Assemble 777
Install 777
Adjustments 778
Bleed the Brake System 778
Adjust Linkage 778
Brake Lines 780
Brake Line Replacement 780
Parking Brake 781
Manual Release Lever 781
Adjust Cable 781
Replace Cable 781
Remove 782
Install 783
524295632-1800YRM1332-(11-2015)-UK-EN 785
Introduction 789
General 789
Discharging the Capacitors 789
Brake Pedal Assembly Repair 790
Hydraulic Brake System 790
Remove 790
Disassemble 791
Assemble 792
Install 792
Electronic Brake (E-Brake) System 793
Remove 793
Disassemble 794
Assemble 795
Install 796
Adjustments 796
Brake Pedal Adjustment 796
Clevis Adjustment 796
Master Cylinder Repair 798
Remove 798
Disassemble 798
Clean and Inspect 802
Assemble 802
Install 802
Adjustments 802
Bleed the Brake System 802
Adjust Linkage 803
Brake Lines 803
Brake Line Replacement 804
Parking Brake 805
Manual Release Lever 805
Adjust Cable 805
Replace Cable 805
Remove 806
Install 807
524295633-1900YRM1333-(07-2023)-UK-EN 811
General 817
Hydraulic Pump Repair 818
Remove 818
Disassemble 822
Inspect 824
Clean 824
Assemble 824
Install 824
Hydraulic Tank Assembly 826
Remove 826
Disassemble 828
Clean 829
Steam Method 829
Chemical Method 829
Inspect 830
Assemble 830
Install 830
Hydraulic Filter Replacement 831
Breather Clean and Inspect 832
Add Hydraulic Oil 833
Steer Accumulator Replacement for Lift Truck Models ERP030-40VF (A955) 834
Remove 834
Install 836
Specifications 837
524295633-1900YRM1333-(10-2015)-UK-EN 839
General 843
Hydraulic Pump Repair 844
Remove 844
Disassemble 847
Inspect 849
Clean 849
Assemble 849
Install 849
Hydraulic Tank Assembly 850
Remove 850
Disassemble 853
Clean 853
Steam Method 854
Chemical Method 854
Inspect 854
Assemble 854
Install 855
Hydraulic Filter Replacement 856
Breather Clean and Inspect 857
Add Hydraulic Oil 857
Steer Accumulator Replacement for Lift Truck Models ERP030-40VF (A955) 858
Remove 858
Install 858
Specifications 861
524306565-8000YRM1340-(03-2017)-UK-EN 865
General 869
Lubrication Specifications 869
Hydraulic System 871
Steering System 872
Tire Sizes 874
Torque Specifications 875
Electrical 875
Steering SystemLift Truck Models ERP15-20VT (G807) Manufactured Before November, 2014 and ERP030-040VT (G807) 875
Steering SystemLift Truck Models ERP15-20VT (G807) Manufactured After November, 2014 876
Hydraulic System 876
E-Hydraulic Control Valve 876
Transaxle 876
Mast Speeds 876
Maximum Carriage and Tilt Creep Rates 881
Tilt Angles 882
Transaxle Assembly 882
Travel Speeds 882
Battery 884

ERP15-20VT (G807) European Model Trucks 884

ERP030-040VT (G807) US Model Trucks 885
Battery Discharge Rate 886
524319495-2000YRM1334-(03-2023)-UK-EN 889
General 897
Lift Trucks ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955) 897
Lift Trucks ERC22-35VG (ERC045-070VG) (A968), ERP22-35VL (ERP045-070VL) (A976), and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 899
Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 903
Discharging the Capacitors 905
Manual Hydraulic Control Valve Repair for 1 5-2 0T Trucks 906
Remove 906
Beginning Steps 906
Disassemble Handles and Levers 919
Disassemble Manual Control Valve 922
Spool Seal Replacement 932
Clean 935
Inspect 935
Assemble Manual Control Valve 937
Assemble Handles and Levers 948
Install 951
Ending Steps 963
Manual Hydraulic Control Valve Repair for 2 0-3 5T Trucks and 4 0-5 0T Pneumatic Trucks 965
Remove 965
Disassemble Handles and Levers 981
Disassemble Manual Control Valve 984
Disassemble Valve 984
Disassemble Inlet Section 987
Disassemble Lift, Tilt, and Auxiliary Sections 987
Spool Seal Replacement 989
Clean 990
Inspect 991
Assemble Manual Control Valve 991
Assemble Lift, Tilt, and Auxiliary Sections 991
Assemble Inlet Section 992
Assemble Valve 993
Assemble Handles and Levers 1001
Install 1005
Ending Steps 1017
Manual Hydraulic Control Valve Repair for 4 0-5 5T Cushion Trucks 1018
Remove 1018
Disassemble Handles and Levers 1032
Disassemble Manual Control Valve 1034
Disassemble Valve 1034
Disassemble Inlet Section 1037
Disassemble Lift, Tilt, and Auxiliary Sections 1038
Spool Seal Replacement 1040
Clean 1041
Inspect 1041
Assemble Manual Control Valve 1042
Assemble Lift, Tilt, and Auxiliary Sections 1042
Assemble Inlet Section 1043
Assemble Valve 1044
Assemble Handles and Levers 1051
Install 1054
Ending Steps 1066
E-Hydraulic Control Valve Repair for 1 5-2 0T Trucks 1067
Remove 1067
Disassemble 1073
Clean 1080
Inspect 1080
Assemble 1080
Install 1088
E-Hydraulic Controls 1093
Replace E-Hydraulic Control Components 1094
E-Hydraulic Control Valve Repair for 2 0-3 5T Trucks and 4 0-5 0T Pneumatic Trucks 1095
Remove 1095
Initial Steps 1095
Fitting Removal for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1095
Fitting Removal for Lift Truck ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1097
Electrical Disconnect and Control Valve Dismount 1099
Disassemble 1101
Clean 1106
Inspect 1106
Assemble 1106
Install 1114
Electrical Connect and Control Valve Mount 1114
Fitting Installation for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1116
Fitting Installation for Lift Truck ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1118
Ending Steps 1119
E-Hydraulic Controls 1120
Replace E-Hydraulic Control Components 1120
E-Hydraulic Control Valve Repair for 4 0-5 5T Cushion Trucks 1121
Remove 1121
Initial Steps 1121
Fitting Removal 1121
Electrical Disconnect and Control Valve Dismount 1123
Disassemble 1125
Clean 1130
Inspect 1130
Assemble 1130
Install 1138
Electrical Connect and Control Valve Mount 1138
Fitting Installation 1140
Ending Steps 1141
E-Hydraulic Controls 1142
Replace E-Hydraulic Control Components 1142
Checks and Adjustments
for 1 5-2 0T Lift Trucks 1143
Manual Control Valve 1143
Primary Relief Valve 1143
Optional Auxiliary Port Relief Valve 1143
E-Hydraulic Control Valve 1144
Primary Relief Valve 1144
Optional Secondary Port Relief Valve 1145
Hydraulic System Air Removal 1146
Checks and Adjustments
2 0-5 5T Lift Trucks 1147
Manual Control Valve 1147
External Leakage 1147
Primary Relief Cartridge 1147
Secondary Relief Valve 1148
E-Hydraulic Control Valve 1148
Primary Relief Valve 1148
Secondary Relief Valve 1149
PPRV Pilot Pressure Test 1150
Hydraulic System Air Removal 1151
Position Sensor and OPS Check and Adjustment 1152
Position Sensor 1152
(OPS) Operator Presence Solenoid 1152
Manual Control Valve Re-Calibration 1152
Calibration Procedure 1153
Control Valve 1153
Torque Specifications
for 1 5-2 0T Lift Trucks 1154
Manual Hydraulic Control Valve 1154
Manual Control Valve Handles and Levers 1154
E-Hydraulic Control Valve 1154
Torque Specifications
for 2 2-5 5T Lift Trucks 1155
Manual Hydraulic Control Valve 1155
Manual Control Valve Handles and Levers 1155
Manual Control Valve Covers 1155
E-Hydraulic Control Valve 1155
524319495-2000YRM1334-(09-2014)-UK-EN 1157
524319496-2100YRM1382-(02-2018)-UK-EN 1407
Safety Procedures When Working Near Mast 1415
General 1417
Description 1418
Tilt Cylinder Repair for 2 0-5 5T Trucks 1418
Remove 1418
Disassemble 1420
Inspect 1421
Clean 1421
Assemble 1421
Install 1423
Tilt Cylinders, Adjust 1423
Tilt Cylinder Leak Check 1426
Tilt Cylinder Repair
for 1 0-2 0T Trucks 1427
Remove 1427
Disassemble 1429
Inspect 1431
Clean 1431
Assemble 1431
Install 1431
Tilt Cylinders, Adjust 1432
Tilt Cylinders Leak Check 1433
Lift Cylinder Repair
for 2 0-3 5T Trucks 1434
Main Lift Cylinders 1434
Remove 1434
Two-Stage FFL 1434
Three-Stage FFL 1436
Four-Stage FFL 1436
Two-Stage LFL 1437
Disassemble 1437
Two-Stage FFL 1437
Three-Stage FFL 1439
Four-Stage FFL 1439
Two-Stage LFL 1441
Clean 1442
Inspect 1442
Assemble 1442
Two-Stage FFL 1442
Three-Stage FFL 1442
Four-Stage FFL 1443
Two-Stage LFL 1443
Install 1444
Two-Stage FFL 1444
System Air Bleed Procedures 1444
Three-Stage FFL 1444
Four-Stage FFL 1445
Two-Stage LFL 1445
Lift Cylinder Repair for Lift Truck Model ERP15VT (G807) 1446
Main Lift Cylinder 1446
Remove 1446
Main Lift Cylinders – Two-Stage FFL Mast 1446
Left-Hand Main Lift Cylinder – Three-Stage FFL Mast 1448
Right-Hand Main Lift Cylinder – Three-Stage FFL Mast 1452
Main Lift Cylinder – Two-Stage LFL Mast 1452
Disassemble 1455
Main Lift Cylinders – Two-Stage FFL Mast 1455
Main Lift Cylinder – Three-Stage FFL Mast 1457
Main Lift Cylinder – Two-Stage LFL Mast 1457
Clean 1458
Inspect 1458
Assemble 1459
Main Lift Cylinder – Two-Stage FFL Mast 1459
Main Lift Cylinder – Three-Stage FFL Mast 1459
Main Lift Cylinder – Two-Stage LFL Mast 1459
Install 1460
Main Lift Cylinder – Two-Stage FFL Mast 1460
Left-Hand Main Lift Cylinder – Three-Stage FFL Mast 1460
Right-Hand Main Lift Cylinder – Three-Stage FFL Mast 1461
Main Lift Cylinder – Two-Stage LFL Mast 1462
System Air Bleed Procedures 1463
All Main Lift Cylinders 1463
Lift Cylinder Repair for 1 5-2 0T Trucks 1463
Main Lift Cylinder 1463
Remove 1463
Two-Stage FFL 1464
Three-Stage FFL 1464
Two-Stage LFL 1465
Four-Stage FFL 1467
Disassemble 1468
Two-Stage FFL 1468
Three-Stage FFL 1470
Two-Stage LFL 1470
Four-Stage FFL 1471
Clean 1474
Inspect 1474
Assemble 1474
Two-Stage FFL 1474
Three-Stage FFL 1475
Two-Stage LFL 1475
Four-Stage FFL 1476
Install 1477
Two-Stage FFL 1477
System Air Bleed Procedures 1477
Three-Stage FFL Mast 1477
Two-Stage LFL 1478
Four-Stage FFL 1478
Mast and Carriage Install for Two-Stage FFL, Three-Stage FFL, and Two-Stage LFL 1479
Mast and Carriage Installation for Four-Stage FFL 1479
Lift Cylinder Repair
for 4 0-5 5T Trucks 1480
Main Lift Cylinders 1480
Remove 1480
Two-Stage FFL 1480
Three-Stage FFL 1482
Two-Stage LFL 1482
Disassemble 1483
Two-Stage FFL 1483
Three-Stage FFL 1485
Two-Stage LFL 1486
Clean 1487
Inspect 1487
Assemble 1487
Two-Stage FFL 1487
Three-Stage FFL 1488
Two-Stage LFL 1488
Install 1489
Two-Stage FFL 1489
System Air Bleed Procedures 1489
Three-Stage FFL 1489
Two-Stage LFL 1490
Free-Lift Cylinder Repair
for 2 0-3 5T Trucks 1491
Free-Lift Cylinder 1491
Remove 1491
Two and Three-Stage FFL Mast 1491
Four-Stage FFL For Lift Truck ERC22-356VG (ERC045-070VG) (A968) 1492
Disassemble 1494
Two and Three-Stage FFL Mast 1494
Four-Stage FFL Mast for Lift Truck ERC22-356VG (ERC045-070VG) (A968) 1495
Clean 1495
Inspect 1495
Assemble 1496
Two and Three-Stage FFL Mast 1496
Four-Stage FFL Mast for Lift Truck ERC22-356VG (ERC045-070VG) (A968) 1496
Install 1497
Two and Three-Stage FFL Mast 1497
Four-Stage FFL Mast for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1497
Free Lift Cylinder Repair for Lift Truck Model ERP15VT (G807) 1498
Free-Lift Cylinder 1498
Remove 1498
Three-Stage FFL Mast 1498
Disassemble 1500
Clean 1501
Inspect 1501
Assemble 1501
Install 1501
Free Lift Cylinder Repair
for 1 5-2 0T Trucks 1502
Free-Lift Cylinder 1502
Remove 1502
Two and Three-Stage FFL Mast 1502
Four-Stage FFL Mast 1504
Disassemble 1506
Two-Stage and Three-Stage FFL Masts 1506
Four Stage FFL Mast 1507
Clean 1508
Inspect 1508
Assemble 1508
Two-Stage and Three-Stage FFL Masts 1508
Four-Stage FFL Mast 1509
Install 1509
Two-Stage and Three-Stage FFL Masts 1509
Four-Stage FFL Mast 1509
All Masts 1511
Free-Lift Cylinder Repair
for 4 0-5 5T Trucks 1512
Free-Lift Cylinder 1512
Remove 1512
Two and Three-Stage FFL Mast 1512
Disassemble 1513
Two and Three-Stage FFL Mast 1513
Clean 1514
Inspect 1514
Assemble 1514
Two and Three-Stage FFL Mast 1514
Install 1515
Two and Three-Stage FFL Mast 1515
Sideshift Cylinder Repair
for 1 5-3 5T Trucks Prior to December 2016 1515
Remove 1515
Disassemble 1519
Clean and Inspect 1521
Assemble and Install 1521
Sideshift Cylinder Repair
for 1 5-3 5T Trucks After December 2016 1522
Remove 1522
Disassemble 1526
Clean and Inspect 1528
Assemble and Install 1528
Integral Side-Shift Cylinder Gland Leak Checks 1530
Sideshift Cylinder Repair
for 4 0-5 5T Trucks 1531
Remove 1531
Disassemble 1531
Clean and Inspect 1533
Assemble and Install 1533
Fork Positioner Cylinder Repair Prior to December 2016 1533
Remove 1533
Disassemble 1534
Clean 1536
Inspect 1536
Assemble 1537
Install 1537
Fork Positioner Cylinder Adjustment 1537
Fork Positioner Cylinder Repair After December 2016 1538
Remove 1538
Disassemble 1538
Clean 1541
Inspect 1541
Assemble 1542
Install 1542
Fork Positioner Cylinder Adjustment 1542
Lift Cylinder Leak Check 1543
Seal Kit Installation 1543
External Installation (Seal and Back-Up Ring) 1544
Internal Installation (Piston Rod Assembly) 1544
Torque Specifications for Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-25VL (ERP045-070VL) (A976) 1544
Tilt Cylinders 1544
Piston Rod Nut 1544
Gland 1545
Tilt Cylinder Mounting Capscrew 1545
Tilt Cylinder Rod End Capscrew 1545
Main and Free-Lift Cylinder 1545
Sideshift Cylinder 1545
Fork Positioner Cylinder 1545
Torque Specifications for Lift Truck Model ERP15VT (G807) 1545
Tilt Cylinders 1545
Main and Free-Lift Cylinders 1545
Sideshift Cylinder 1546
Torque Specifications for Lift Truck Models ERP16-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), ESC030-40AC (B883),ESC030-40AD (C883) 1546
Tilt Cylinders 1546
Main and Free-Lift Cylinders 1546
Sideshift Cylinder 1547
Fork Positioner Cylinder 1547
Torque Specifications for Lift Truck Model ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1547
Tilt Cylinders 1547
Main and Free-Lift Cylinder 1547
Sideshift Cylinder 1547
Torque Specifications for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1547
Tilt Cylinder 1548
Main and Free Lift Cylinder 1548
Sideshift Cylinder 1548
524319496-2100YRM1382-(07-2023)-UK-EN 1551
Safety Procedures When Working Near Mast 1561
General 1564
Description 1564
Tilt Cylinder Repair for 2 0-5 5T Trucks 1565
Remove 1565
Disassemble 1567
Inspect 1568
Clean 1568
Assemble 1568
Install 1570
Tilt Cylinders, Adjust 1570
Tilt Cylinder Leak Check 1573
Tilt Cylinder Repair
for 1 0-2 0T Trucks 1574
Remove 1574
Disassemble 1577
Inspect 1579
Clean 1579
Assemble 1579
Install 1579
Tilt Cylinders, Adjust 1580
Tilt Cylinders Leak Check 1581
Lift Cylinder Repair
for 2 0-3 5T Trucks 1583
Main Lift Cylinders 1583
Remove 1583
Two-Stage FFL 1583
Three-Stage FFL 1585
Four-Stage FFL 1585
Two-Stage LFL 1586
Disassemble 1586
Two-Stage FFL 1586
Three-Stage FFL 1588
Four-Stage FFL 1590
Two-Stage LFL 1591
Clean 1592
Inspect 1592
Assemble 1592
Two-Stage FFL 1592
Three-Stage FFL 1593
Four-Stage FFL 1593
Two-Stage LFL 1594
Install 1594
Two-Stage FFL 1594
System Air Bleed Procedures 1594
Three-Stage FFL 1595
Four-Stage FFL 1595
Two-Stage LFL 1596
Lift Cylinder Repair for Lift Truck Model ERP15VT (G807) 1597
Main Lift Cylinder 1597
Remove 1597
Main Lift Cylinders – Two-Stage FFL Mast 1597
Left-Hand Main Lift Cylinder – Three-Stage FFL Mast 1599
Right-Hand Main Lift Cylinder – Three-Stage FFL Mast 1603
Main Lift Cylinder – Two-Stage LFL Mast 1603
Disassemble 1606
Main Lift Cylinders – Two-Stage FFL Mast 1606
Main Lift Cylinder – Three-Stage FFL Mast 1608
Main Lift Cylinder – Two-Stage LFL Mast 1609
Clean 1610
Inspect 1610
Assemble 1610
Main Lift Cylinder – Two-Stage FFL Mast 1610
Main Lift Cylinder – Three-Stage FFL Mast 1611
Main Lift Cylinder – Two-Stage LFL Mast 1611
Install 1611
Main Lift Cylinder – Two-Stage FFL Mast 1611
Left-Hand Main Lift Cylinder – Three-Stage FFL Mast 1612
Right-Hand Main Lift Cylinder – Three-Stage FFL Mast 1613
Main Lift Cylinder – Two-Stage LFL Mast 1614
System Air Bleed Procedures 1614
All Main Lift Cylinders 1615
Lift Cylinder Repair for 1 5-2 0T Trucks 1616
Main Lift Cylinder 1616
Remove 1616
Two-Stage FFL 1616
Three-Stage FFL 1616
Two-Stage LFL 1617
Four-Stage FFL 1619
Disassemble 1621
Two-Stage FFL 1621
Three-Stage FFL 1622
Two-Stage LFL 1623
Four-Stage FFL 1624
Clean 1626
Inspect 1627
Assemble 1627
Two-Stage FFL 1627
Three-Stage FFL 1627
Two-Stage LFL 1628
Four-Stage FFL 1628
Install 1629
Two-Stage FFL 1629
System Air Bleed Procedures 1630
Three-Stage FFL Mast 1630
Two-Stage LFL 1630
Four-Stage FFL 1631
Mast and Carriage Install for Two-Stage FFL, Three-Stage FFL, and Two-Stage LFL 1631
Mast and Carriage Installation for Four-Stage FFL 1632
Lift Cylinder Repair for 4 0-5 5T Trucks 1633
Main Lift Cylinders 1633
Remove 1633
Two-Stage FFL 1633
Three-Stage FFL 1635
Two-Stage LFL 1635
Disassemble 1636
Two-Stage FFL 1636
Three-Stage FFL 1638
Two-Stage LFL 1639
Clean 1640
Inspect 1640
Assemble 1640
Two-Stage FFL 1640
Three-Stage FFL 1641
Two-Stage LFL 1641
Install 1642
Two-Stage FFL 1642
System Air Bleed Procedures 1642
Three-Stage FFL 1642
Two-Stage LFL 1643
Free-Lift Cylinder Repair for 2 0-3 5T Trucks 1644
Free-Lift Cylinder 1644
Remove 1644
Two and Three-Stage FFL Mast 1644
Four-Stage FFL For Lift Truck ERC22-356VG (ERC045-070VG) (A968) 1645
Disassemble 1647
Two and Three-Stage FFL Mast 1647
Four-Stage FFL Mast for Lift Truck ERC22-356VG (ERC045-070VG) (A968) 1648
Clean 1648
Inspect 1649
Assemble 1649
Two and Three-Stage FFL Mast 1649
Four-Stage FFL Mast for Lift Truck ERC22-356VG (ERC045-070VG) (A968) 1649
Install 1650
Two and Three-Stage FFL Mast 1650
Four-Stage FFL Mast for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1650
Free Lift Cylinder Repair for Lift Truck Model ERP15VT (G807) 1652
Free-Lift Cylinder 1652
Remove 1652
Three-Stage FFL Mast 1652
Disassemble 1654
Clean 1655
Inspect 1655
Assemble 1655
Install 1655
Free Lift Cylinder Repair for 1 5-2 0T Trucks 1657
Free-Lift Cylinder 1657
Remove 1657
Two and Three-Stage FFL Mast 1657
Four-Stage FFL Mast 1659
Disassemble 1662
Two-Stage and Three-Stage FFL Masts 1662
Four Stage FFL Mast 1662
Clean 1663
Inspect 1663
Assemble 1663
Two-Stage and Three-Stage FFL Masts 1663
Four-Stage FFL Mast 1664
Install 1664
Two-Stage and Three-Stage FFL Masts 1664
Four-Stage FFL Mast 1665
All Masts 1668
Free-Lift Cylinder Repair
for 4 0-5 5T Trucks 1669
Free-Lift Cylinder 1669
Remove 1669
Two and Three-Stage FFL Mast 1669
Disassemble 1670
Two and Three-Stage FFL Mast 1670
Clean 1671
Inspect 1671
Assemble 1671
Two and Three-Stage FFL Mast 1671
Install 1672
Two and Three-Stage FFL Mast 1672
Sideshift Cylinder Repair
for 1 5-3 5T Trucks Prior to December 2016 1673
Remove 1673
Disassemble 1676
Clean and Inspect 1678
Assemble and Install 1678
Sideshift Cylinder Repair
for 1 5-3 5T Trucks After December 2016 1680
Remove 1680
Disassemble 1683
Clean and Inspect 1684
Assemble and Install 1685
Integral Side-Shift Cylinder Gland Leak Checks 1687
Sideshift Cylinder Repair
for 4 0-5 5T Trucks 1688
Remove 1688
Disassemble 1689
Clean and Inspect 1690
Assemble and Install 1690
Fork Positioner Cylinder Repair Prior to December 2016 1691
Remove 1691
Disassemble 1691
Clean 1694
Inspect 1694
Assemble 1695
Install 1695
Fork Positioner Cylinder Adjustment 1695
Fork Positioner Cylinder Repair After December 2016 1697
Remove 1697
Disassemble 1697
Clean 1700
Inspect 1700
Assemble 1701
Install 1701
Fork Positioner Cylinder Adjustment 1701
Lift Cylinder Leak Check 1703
Seal Kit Installation 1704
External Installation (Seal and Back-Up Ring) 1704
Internal Installation (Piston Rod Assembly) 1704
Torque Specifications for Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-25VL (ERP045-070VL) (A976) 1705
Tilt Cylinders 1705
Piston Rod Nut 1705
Gland 1705
Tilt Cylinder Mounting Capscrew 1705
Tilt Cylinder Rod End Capscrew 1705
Main and Free-Lift Cylinder 1705
Sideshift Cylinder 1705
Fork Positioner Cylinder 1705
Torque Specifications for Lift Truck Model ERP15VT (G807) 1706
Tilt Cylinders 1706
Main and Free-Lift Cylinders 1706
Sideshift Cylinder 1706
Torque Specifications for Lift Truck Models ERP16-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), ESC030-40AC (B883),ESC030-40AD (C883) 1707
Tilt Cylinders 1707
Main and Free-Lift Cylinders 1707
Sideshift Cylinder 1707
Fork Positioner Cylinder 1707
Torque Specifications for Lift Truck Model ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1708
Tilt Cylinders 1708
Main and Free-Lift Cylinder 1708
Sideshift Cylinder 1708
Torque Specifications for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1708
Tilt Cylinder 1708
Main and Free Lift Cylinder 1708
Sideshift Cylinder 1708
524319497-2200YRM1335-(01-2023)-UK-EN 1711
General 1719
Description 1719
Display Panel Menu Access 1719
Menu Flowchart 1720
Supervisor Menu Flowchart 1720
Menu Navigation 1726
Icon Glossary 1730
Introduction 1730
Soft Key Icons 1730
Overlay Icons 1731
Icons on System Off Screen and Alert Screens 1731
Main Menu Title Screens 1735
Submenu Icons Grouped by Menu 1737
Operating Screen Icons 1737
Password Screen Icons 1738
Activity Log Submenu Icons 1738
Calibration Submenu Icons 1740
Display Submenu Icons 1742
Status Submenu Icons 1744
Truck Setup Submenu Icons 1747
Operating Screen 1754
Introduction 1754
Performance Mode Controls 1755
Status and Warning Icons 1755
Battery Discharge Indicator 1756
Direction and Parking Brake Indicators 1757
Hazard Flashers and Lighting Controls 1757
Steer Angle Indicator 1757
System Time 1757
Load Weight Indicator 1757
System Off/Alert Screens 1758
Introduction 1758
System Off Screen 1758
Alert Screens 1758
Password Screen 1760
Introduction 1760
Password Screen 1760
Service Technician Password Setup 1760
Adding/Removing/Changing Passwords 1761
Password Log 1764
Activity Log Menu 1765
Introduction 1765
Operator Checklist Log 1766
Password Log 1769
Impact Events Log 1771
Calibration Menu 1773
Introduction 1773
Load Weight Calibration 1773
Return to Set Tilt Stop Point Calibration 1774
E-Hydraulic and Manual Valve Threshold Calibration 1774
Steering Wheel Center Point Calibration 1775
Steer Axle Position Calibration 1775
Steer Axle Center Point Calibration 1776
Manual Hydraulics Calibration 1777
Display Menu 1778
Introduction 1778
Set Date and Time Format Menu 1778
Set Daylight Saving Time Menu 1779
Procedure for Setting Up Automatic Daylight Savings Time 1780
Set Time and Date Menu 1782
Procedure for Setting Time and Date 1782
Set Units Menu 1783
Status Menu 1784
Introduction 1784
VSM Versions 1784
Display Versions 1785
Truck Serial Number 1785
Hour Meters 1785
E-Hydraulic Controller Versions 1785
Pump Motor Controller Versions 1785
Traction Motor Controller 1 Versions 1785
Traction Motor Controller 2 Versions 1786
Light Controller Versions 1786
Impact Sensor Versions 1786
Truck Setup Menu 1787
Introduction 1787
Add/Remove Password 1787
Battery Settings 1787
Restore Default Settings 1788
Motion Alarm 1788
Impact Monitor Settings 1789
Impact Detection 1789
Setting Adjustments 1789
Initial Adjustment of Soft and Hard Impact Settings 1789
Readjustment of Soft and Hard Impact Settings 1789
Auto Power-Off Time Delay 1790
Return to Set Tilt 1790
Traction Speed Limit 1790
Scheduled Maintenance Reminder 1791
Minimum Pump Standby Flow Rate 1792
Operator Checklist 1792
Impact Monitor Shutdown 1793
Motor Braking 1794
Changing the Motor Braking Settings 1794
Steering Wheel Friction and Steering Turns Adjustment 1795
How to Adjust Settings 1795
Steering Friction Setting 1795
Steering Wheel Number of Turns 1796
524319497-2200YRM1335-(07-2020)-UK-EN 1799
General 1805
Description 1805
Display Panel Menu Access 1805
Menu Flowchart 1806
Supervisor Menu Flowchart 1806
Menu Navigation 1812
Icon Glossary 1816
Introduction 1816
Soft Key Icons 1816
Overlay Icons 1817
Icons on System Off Screen and Alert Screens 1817
Main Menu Title Screens 1821
Submenu Icons Grouped by Menu 1823
Operating Screen Icons 1823
Password Screen Icons 1824
Activity Log Submenu Icons 1824
Calibration Submenu Icons 1826
Display Submenu Icons 1828
Status Submenu Icons 1830
Truck Setup Submenu Icons 1833
Operating Screen 1840
Introduction 1840
Performance Mode Controls 1840
Status and Warning Icons 1841
Battery Discharge Indicator 1842
Direction and Parking Brake Indicators 1842
Hazard Flashers and Lighting Controls 1843
Steer Angle Indicator 1843
System Time 1843
Load Weight Indicator 1843
System Off/Alert Screens 1844
Introduction 1844
System Off Screen 1844
Alert Screens 1844
Password Screen 1846
Introduction 1846
Password Screen 1846
Service Technician Password Setup 1846
Adding/Removing/Changing Passwords 1847
Password Log 1850
Activity Log Menu 1851
Introduction 1851
Operator Checklist Log 1851
Password Log 1853
Impact Events Log 1855
Calibration Menu 1857
Introduction 1857
Load Weight Calibration 1857
Return to Set Tilt Stop Point Calibration 1858
E-Hydraulic and Manual Valve Threshold Calibration 1858
Steering Wheel Center Point Calibration 1859
Steer Axle Position Calibration 1859
Steer Axle Center Point Calibration 1860
Manual Hydraulics Calibration 1861
Display Menu 1862
Introduction 1862
Set Date and Time Format Menu 1862
Set Daylight Saving Time Menu 1863
Procedure for Setting Up Automatic Daylight Savings Time 1864
Set Time and Date Menu 1866
Procedure for Setting Time and Date 1866
Set Units Menu 1867
Status Menu 1868
Introduction 1868
VSM Versions 1868
Display Versions 1869
Truck Serial Number 1869
Hour Meters 1869
E-Hydraulic Controller Versions 1869
Pump Motor Controller Versions 1869
Traction Motor Controller 1 Versions 1869
Traction Motor Controller 2 Versions 1870
Light Controller Versions 1870
Impact Sensor Versions 1870
Truck Setup Menu 1871
Introduction 1871
Add/Remove Password 1871
Battery Settings 1871
Restore Default Settings 1872
Motion Alarm 1872
Impact Monitor Settings 1872
Impact Detection 1873
Setting Adjustments 1873
Initial Adjustment of Soft and Hard Impact Settings 1873
Readjustment of Soft and Hard Impact Settings 1873
Auto Power-Off Time Delay 1874
Return to Set Tilt 1874
Traction Speed Limit 1874
Scheduled Maintenance Reminder 1875
Minimum Pump Standby Flow Rate 1876
Operator Checklist 1876
Impact Monitor Shutdown 1877
Motor Braking 1878
Changing the Motor Braking Settings 1878
Steering Wheel Friction and Steering Turns Adjustment 1879
How to Adjust Settings 1879
Steering Friction Setting 1879
Steering Wheel Number of Turns 1880
524319498-2200YRM1336-(02-2023)-UK-EN 1883
General 1891
Description 1891
Display Panel Menu Access 1891
Menu Flowchart 1892
Technician Menu Flowchart 1892
Menu Navigation 1898
Icon Glossary 1902
Introduction 1902
Soft Key Icons 1902
Overlay Icons 1903
Heat Exchange Module Warning Indicator Screen 1903
System Off Screen and Alert Screens 1904
Main Menu Title Screens 1910
Submenu Icons Grouped by Menu 1911
Operating Screen Icons 1911
Password Screen Icons 1913
Activity Log Submenu Icons 1913
Calibration Submenu Icons 1914
Display Submenu Icons 1918
Status Submenu Icons 1920
Truck Setup Submenu Icons 1923
Diagnostics Submenu Icons 1935
Operating Screen 1945
Introduction 1945
Performance Mode Controls 1945
Status and Warning Icons 1946
Battery Discharge Indicator 1947
Direction and Parking Brake Indicators 1947
Hazard Flashers and Lighting Controls 1948
Steer Angle Indicator 1948
System Time 1948
Load Weight Indicator 1948
System Off/Alert Screens 1949
Introduction 1949
System Off Screen 1949
Alert Screens 1949
Password Screen 1951
Introduction 1951
Password Screen 1951
Service Technician Password Setup 1951
Adding/Removing/Changing Passwords 1952
Password Log 1955
Activity Log Menu 1956
Introduction 1956
Operator Checklist Log 1956
Password Log 1958
Impact Events Log 1960
Calibration Menu 1962
Introduction 1962
Load Weight Calibration 1962
Return to Set Tilt Stop Point Calibration 1963
E-Hydraulic and Manual Valve Threshold Calibration 1963
Steering Wheel Center Point Calibration 1964
Steer Axle Position Calibration 1965
Steer Axle Center Point Calibration 1966
Manual Hydraulics Calibration 1966
Display Menu 1967
Introduction 1967
Set Date and Time Format Menu 1967
Set Daylight Saving Time Menu 1968
Procedure for Setting Up Automatic Daylight Savings Time 1969
Set Time and Date Menu 1971
Procedure for Setting Time and Date 1971
Set Units Menu 1972
Status Menu 1973
Introduction 1973
VSM Versions 1973
Display Versions 1974
Truck Serial Number 1974
Hour Meters 1974
E-Hydraulic Controller Versions 1974
Pump Motor Controller Versions 1974
Traction Motor Controller 1 Versions 1974
Traction Motor Controller 2 Versions 1975
Light Controller Versions 1975
Impact Sensor Versions 1975
E-Steer Controller 1 Versions 1975
E-Steer Controller 2 Versions 1975
Truck Setup Menu 1976
Introduction 1976
Add/Remove Password 1977
Battery Settings 1977
Motor Braking 1977
Changing the Motor Braking Settings 1978
Battery Mode 1978
Battery Setup 1979
BDI Adjustment Setting 1980
Acceleration Rates 1981
Hour Meter Initialization 1982
Impact Monitor Shutdown 1982
Operator Checklist 1984
Minimum Pump Standby Flow Rate 1984
Scheduled Maintenance Reminder 1985
Traction Speed Limit 1986
Return to Set Tilt 1986
Auto Power-Off Time Delay 1987
Impact Monitor Settings 1987
Impact Detection 1988
Setting Adjustments 1988
Initial Adjustment of Soft and Hard Impact Settings 1988
Readjustment of Soft and Hard Impact Settings 1988
Motion Alarm 1988
Lift Hydraulic Function Maximum Speed and Ramp Times 1989
Lower Hydraulic Function Maximum Speed and Ramp Times 1989
Tilt Forward Hydraulic Function Maximum Speed and Ramp Times 1990
Tilt Backward Hydraulic Function Maximum Speed and Ramp Times 1990
Auxiliary 1A Hydraulic Function Maximum Speed and Ramp Times 1990
Auxiliary 1B Hydraulic Function Maximum Speed and Ramp Times 1990
Auxiliary 2A Hydraulic Function Maximum Speed and Ramp Times 1990
Auxiliary 2B Hydraulic Function Maximum Speed and Ramp Times 1990
Optional Hydraulic Functions 1990
Rear Lights Control 1991
Restore Default Settings 1991
Steering Wheel Friction and Steering Turns Adjustment 1992
Navigation 1993
How to Adjust Settings 1993
Steering Friction 1993
Steering Wheel Number of Turns 1994
Diagnostics Menu 1996
Introduction 1996
Fault Code Log 1996
Fault Log Details 1997
Speedometer 1998
Direction Switch 1998
Traction Motor 1 Status 1999
Traction Motor 2 Status 1999
Occupancy Sensor 1999
Brake System Sensors 1999
Pump Status 2000
Hydraulic Control Inputs 2001
E-Hydraulic Valves 2001
Hydraulic Sensors 2002
System Voltages 2002
Steering Position Sensors 2004
E-Steering Position Sensors 2004
Electric Brake 2005
Navigation 2006
ESS Diagnostics Menus A, B, and C 2007
Menu A 2007
Menu B 2008
Menu C 2010
524319498-2200YRM1336-(07-2020)-UK-EN 2013
General 2019
Description 2019
Display Panel Menu Access 2019
Menu Flowchart 2020
Technician Menu Flowchart 2020
Menu Navigation 2026
Icon Glossary 2030
Introduction 2030
Soft Key Icons 2030
Overlay Icons 2031
Heat Exchange Module Warning Indicator Screen 2031
System Off Screen and Alert Screens 2032
Main Menu Title Screens 2037
Submenu Icons Grouped by Menu 2039
Operating Screen Icons 2039
Password Screen Icons 2040
Activity Log Submenu Icons 2040
Calibration Submenu Icons 2042
Display Submenu Icons 2045
Status Submenu Icons 2047
Truck Setup Submenu Icons 2051
Diagnostics Submenu Icons 2062
Operating Screen 2072
Introduction 2072
Performance Mode Controls 2072
Status and Warning Icons 2073
Battery Discharge Indicator 2074
Direction and Parking Brake Indicators 2075
Hazard Flashers and Lighting Controls 2075
Steer Angle Indicator 2075
System Time 2075
Load Weight Indicator 2075
System Off/Alert Screens 2076
Introduction 2076
System Off Screen 2076
Alert Screens 2076
Password Screen 2078
Introduction 2078
Password Screen 2078
Service Technician Password Setup 2078
Adding/Removing/Changing Passwords 2079
Password Log 2081
Activity Log Menu 2082
Introduction 2082
Operator Checklist Log 2082
Password Log 2084
Impact Events Log 2086
Calibration Menu 2088
Introduction 2088
Load Weight Calibration 2088
Return to Set Tilt Stop Point Calibration 2089
E-Hydraulic and Manual Valve Threshold Calibration 2089
Steering Wheel Center Point Calibration 2090
Steer Axle Position Calibration 2091
Steer Axle Center Point Calibration 2091
Manual Hydraulics Calibration 2092
Display Menu 2093
Introduction 2093
Set Date and Time Format Menu 2093
Set Daylight Saving Time Menu 2094
Procedure for Setting Up Automatic Daylight Savings Time 2095
Set Time and Date Menu 2097
Procedure for Setting Time and Date 2097
Set Units Menu 2098
Status Menu 2099
Introduction 2099
VSM Versions 2099
Display Versions 2100
Truck Serial Number 2100
Hour Meters 2100
E-Hydraulic Controller Versions 2100
Pump Motor Controller Versions 2100
Traction Motor Controller 1 Versions 2100
Traction Motor Controller 2 Versions 2101
Light Controller Versions 2101
Impact Sensor Versions 2101
E-Steer Controller 1 Versions 2101
E-Steer Controller 2 Versions 2101
Truck Setup Menu 2102
Introduction 2102
Add/Remove Password 2103
Battery Settings 2103
Motor Braking 2103
Changing the Motor Braking Settings 2104
Battery Mode 2104
Battery Setup 2105
BDI Adjustment Setting 2106
Acceleration Rates 2107
Hour Meter Initialization 2108
Impact Monitor Shutdown 2108
Operator Checklist 2109
Minimum Pump Standby Flow Rate 2110
Scheduled Maintenance Reminder 2110
Traction Speed Limit 2112
Return to Set Tilt 2112
Auto Power-Off Time Delay 2112
Impact Monitor Settings 2113
Impact Detection 2113
Setting Adjustments 2113
Initial Adjustment of Soft and Hard Impact Settings 2113
Readjustment of Soft and Hard Impact Settings 2114
Motion Alarm 2114
Lift Hydraulic Function Maximum Speed and Ramp Times 2114
Lower Hydraulic Function Maximum Speed and Ramp Times 2115
Tilt Forward Hydraulic Function Maximum Speed and Ramp Times 2115
Tilt Backward Hydraulic Function Maximum Speed and Ramp Times 2115
Auxiliary 1A Hydraulic Function Maximum Speed and Ramp Times 2115
Auxiliary 1B Hydraulic Function Maximum Speed and Ramp Times 2116
Auxiliary 2A Hydraulic Function Maximum Speed and Ramp Times 2116
Auxiliary 2B Hydraulic Function Maximum Speed and Ramp Times 2116
Optional Hydraulic Functions 2116
Rear Lights Control 2116
Restore Default Settings 2117
Steering Wheel Friction and Steering Turns Adjustment 2117
Navigation 2118
How to Adjust Settings 2118
Steering Friction 2118
Steering Wheel Number of Turns 2119
Diagnostics Menu 2121
Introduction 2121
Fault Code Log 2121
Fault Log Details 2122
Speedometer 2123
Direction Switch 2123
Traction Motor 1 Status 2123
Traction Motor 2 Status 2124
Occupancy Sensor 2124
Brake System Sensors 2124
Pump Status 2125
Hydraulic Control Inputs 2125
E-Hydraulic Valves 2125
Hydraulic Sensors 2126
System Voltages 2126
Steering Position Sensors 2127
E-Steering Position Sensors 2127
Electric Brake 2128
Navigation 2129
524319503-8000YRM1341-(10-2015)-UK-EN 2131
524319504-9000YRM1377-(09-2019)-UK-EN 2171
SECTION 9010 Operational Diagnostic Procedures 2187
Group 05 – Operational Checkout 2189
SECTION 9025 Traction Motor 2199
Group 10 – Principles of Operation 2201
Group 30 – Observed Symptoms 2207
SECTION 9030 Electrical System 2209
Group 03 – General Maintenance and Diagnostic Data 2219
Group 10 – Principles of Operation 2263
Group 20 – Diagnostic Trouble Codes 2295
Group 30 – Observed Symptoms 2907
Group 55 – Icons and Graphics 2951
SECTION 9035 Drive Axle/Unit 2959
Group 10 – Principles of Operation 2961
Group 30 – Observed Symptoms 2971
Group 20 – Diagnostic Trouble Codes 2983
SECTION 9050 Hydraulic Systems 2985
Group 10 – Principles of Operation 2989
Group 33 – Observed Symptoms-Gear Pump 3027
Group 43 – Tests and Adjustments-Gear Pump 3107
SECTION 9060 Operators Station 3137
Group 10 – Principles of Operation 3139
SECTION 9070 Front End (Mast) and Chassis 3179
Group 10 – Principles of Operation 3181
Group 30 – Observed Symptoms 3199
SECTION 9080 Supplementary Data 3243
Group 50 – Abbreviations and Acronyms 3245
524320282-2200YRM1337-(01-2020)-UK-EN 3253
General 3261
Discharging the Capacitors 3262
Display Panel and Key or Keyless Switch Replacement 3262
Display Panel, Replace 3262
Remove 3262
Install 3265
Electronic and Manual Hydraulic Controls 3268
General 3268
Manual Hydraulic Controls 3269
Upper Front Cover 3269
Direction Control Switch 3269
Remove 3269
Install 3272
Clamp Button 3272
Remove 3272
Install 3272
Return To Set Tilt (RTST) Button 3272
Remove 3272
Install 3272
Emergency Disconnect Switch 3273
Remove 3273
Install 3273
E-Hydraulic Controls – Test 3274
Mini-Levers 3274
Full Stroke Test 3274
Function Returns to Neutral Test 3274
Push (Override) Button 3275
E-Hydraulic Controls 3275
Mini-levers, Remove and Install 3275
Armrest Assembly 3276
Remove 3276
Install 3278
Horn Button 3278
Remove 3278
Install 3279
Direction Control Switch 3279
Remove 3279
Install 3280
Emergency Disconnect Switch 3280
Remove 3281
Install 3281
Push (Override) Buttons and Function Selection Button 3281
Remove 3282
Install 3284
Electronic-Hydraulic Controls, After January, 2020 3284
General 3284
E-Hydraulic Controls – TEST 3285
Mini-Levers 3285
Full Stroke Test 3286
Function Returns to Neutral Test 3286
Push Button (push (override) button) 3286
Mini-levers, Remove and Install 3287
Armrest Assembly 3287
Remove 3287
Install 3290
Horn Button 3290
Remove 3290
Install 3290
Direction Control Switch 3291
Remove 3291
Install 3291
Emergency Disconnect Switch 3291
Remove 3292
Install 3292
Push (Override) Buttons 3293
Remove 3293
Install 3294
Sensors and Switches 3295
General 3295
Synchronous Steering Valve 3295
Steering Axle Sensor 3295
Lift Truck Models ERP15-20VT (G807) Manufactured Before November, 2014 and ERP030-040VT (G807) 3295
Remove 3295
Install 3299
Lift Truck Models ERP15-20VT (G807) Manufactured After November, 2014 3299
Remove 3299
Install 3300
Lift Truck Models ERP16-20VF (ERP30-40VF) (A955) 3301
Remove 3301
Install 3302
Hydraulic Motor Speed Sensor 3303
Remove 3303
Install 3303
Hydraulic Motor Temperature Sensor 3304
Transmission Speed Sensor 3304
Remove 3304
Install 3306
Traction Motor Temperature Sensor 3307
Tilt Position Sensor 3307
Remove 3307
Install 3307
Low Level Brake Fluid Switch 3308
Remove 3308
Install 3310
Service Brake Pressure Sensor, Lift truck models , and , manufactured before February, 2016ERP030-040VT (G807)ERP30-40VF (A955) ERP15-20VT (G807)ERP16-20VF (A955) 3310
Remove 3310
Install 3310
Service Brake Pressure Sensor, Lift Truck Models and Manufactured After February, 2016ERP15-20VT (G807) ERP16-20VF (A955) 3310
Remove 3310
Install 3311
Accelerator Pedal Position Sensor 3312
Remove 3312
Install 3314
Seat Belt Sequence Module 3314
Remove 3314
Install 3314
Seat Sensor (Operator Presence System) 3315
Non-Suspension Seat 3315
Remove 3315
Install 3315
Full Suspension and Swivel Seats 3316
Remove 3316
Install 3316
Steering Wheel Position Sensor 3316
Remove 3316
Install 3319
Load Weight Sensor 3319
Remove 3319
Install 3320
Battery Gate Switch 3320
Remove, for Lift Truck Models, and, Manufactured Before December, 2015ERP15-20VT (G807)ERP16-20VF (A955)ERP030-040VT (G807)ERP030-040VF (A955) 3320
Install, for Lift Truck Models, and, Manufactured Before December, 2015ERP15-20VT (G807)ERP16-20VF (A955)ERP030-040VT (G807)ERP030-040VF (A955) 3322
Remove, for Lift Truck Models and Manufactured After December, 2015ERP030-040VT (G807) ERP030-040VF (A955) 3323
Install, for Lift Truck Models and Manufactured After December, 2015ERP030-040VT (G807) ERP030-040VF (A955) 3324
Horn Switch 3325
Remove 3325
Install 3326
Rear Horn Button Switch 3326
Remove 3326
Install 3327
Impact Sensor 3327
Remove 3327
Install 3328
Steering Motor Speed Sensor 3328
Remove 3328
Install 3329
Hydraulic Tank Level Sensor 3330
Remove 3330
Install 3330
Hydraulic Filter Pressure Switch 3332
Remove 3332
Install 3332
Hydraulic Oil Temperature Sensor 3332
Remove 3332
Install 3332
Motor Controllers Replacement 3333
General 3333
Hydraulic Pump and Motor Controller, Lift Truck Models Manufactured Before November, 2014 and and ERP15-20VT (G807) ERP030-040VT (G807) ERP16-20VF (ERP30-40VF) (A955) 3333
Remove 3333
Fan, Remove 3336
Fan, Install 3338
Install 3338
Hydraulic Pump and Motor Controller, Lift Truck Models Manufactured After November, 2014ERP15-20VT (G807) 3338
Remove 3338
Fan, Remove 3339
Fan, Install 3339
Install 3340
Traction Motor Controllers 3340
Remove 3340
Fan, Remove 3344
Fan, Install 3345
Install 3346
Line Contactor, Lift Truck Models ERP15-20VT (G807) Manufactured Before November, 2014, ERP030-040VT (G807), and ERP16-20VF (ERP30-40VF) (A955) 3346
Remove 3346
Install 3348
Line Contactor, Lift Truck Models Manufactured After November, 2014ERP15-20VT (G807) 3348
Remove 3348
Install 3349
Steering Motor Controller 3349
Remove 3349
Install 3350
Vehicle Systems Manager 3351
General 3351
Remove 3351
Install 3352
Programming a New VSM and/or Display Panel 3353
PC Service Tool Software 3353
Fuses 3354
Audible Alarm 3358
Battery Connection 3359
Inspect 3359
Replacing Cables 3359
Cab Heater 3361
Lights 3361
General 3361
Work Lights (Front and Rear) 3363
Halogen Bulb Lights 3363
Remove 3363
Install 3363
LED Lights 3363
Remove 3363
Install 3364
Strobe Light 3364
Remove 3364
Install 3365
LED Tail, Backup, and Brake Lights 3365
Remove 3365
Install 3366
Front Marker/Turn Signal Lights 3366
Remove 3366
Install 3368
Converter 3368
Remove 3368
Install 3368
524320287-8000YRM1339-(01-2018)-UK-EN 3371
Introduction 3377
General 3377
Serial Number 3378
Discharging the Capacitors 3378
Rapid Charge 3378
How to Tow a Disabled Lift Truck 3379
How to Put Lift Truck on Blocks 3380
How to Raise Drive Tires 3380
How to Raise Steer Tires 3381
How to Clean a Lift Truck 3382
Safety Procedures When Working Near Mast 3382
WHEN WORKING NEAR THE MAST ALWAYS: 3383
Maintenance Schedule 3385
Maintenance Procedures Every 8 Hours or Daily 3390
How to Make Checks With the Key or Keyless Switch OFF 3390
Wheels and Tires 3390
Safety Labels 3390
Frame and Covers 3390
Forks 3392
General 3392
Inspect 3392
Remove 3393
Install 3396
Adjust 3396
Inspection of Mast, Carriage, Header Hoses, Lift Chains, and Attachments 3397
Hydraulic Oil Level and Leaks 3398
Operator Restraint System 3398
Emergency Locking Retractor (ELR) 3399
Seat Adjustments 3400
Seat Position Adjustment (Swivel Seat) 3400
Seat Adjustment for Operator Weight 3400
Battery Restraint System 3402
Steering Column Adjustments 3408
Tilt Adjust Feature 3408
Tilt Memory Feature 3408
Telescopic Feature 3408
Battery Check 3408
How to Make Checks With the Key or Keyless Switch ON 3409
Control Levers and Pedals 3409
Direction and Speed Controls 3409
Electrical Components 3409
Steering System 3410
Hydraulic System 3410
Service Brakes 3411
Automatic Parking Brake 3411
Operator Presence System 3411
Oil Leaks 3412
Maintenance Procedures After First 100 Hours or 2 Months of Service 3412
Tire and Wheel Assemblies 3412
Mast Sliding Surfaces 3412
Mast Pivot Pins and Mounting Hardware 3413
Fork Guides and Pins 3414
Integral Sideshift Carriage 3414
Check Upper and Lower Bearings 3414
Header Hoses, Hose Fittings, and Clamps 3416
Maintenance Procedures Every 500 Hours or Three Months 3416
Tire and Wheel Assemblies 3416
Forks, Inspect 3417
Mast and Carriage 3418
Mast Sliding Surfaces 3418
Mast Pivot Pins, Bushings, and Mounting Hardware 3419
Header Hoses 3419
Fourth Function Mini Rollers Lubrication 3420
Lift Chain Lubrication 3421
Lift Chain Wear Check 3421
Integral Sideshift Carriage 3422
Check Upper and Lower Bearings 3422
Fork Positioner 3423
Fork Guides and Pins 3424
Check Lower Mounting Hook 3424
Tilt Cylinder Rod End Pins 3425
Control Levers, Pedals, and Hinges 3425
Direction and Speed Control Pedals 3425
Hydraulic Hoses, Fittings, and Clamps 3425
Hydraulic Breather Cap 3426
Service Brakes 3426
Master Cylinder Oil Check 3426
Parking Brake 3427
Manual Override Handle 3427
Electrical Inspection 3428
Contactors 3428
Maintenance Procedures Every 2000 Hours or Yearly 3428
Hydraulic System 3429
Hydraulic Oil Filter, Change 3429
Hydraulic Breather, Check 3431
Steering Axle 3432
Steering Actuator and Steering Plate Torque Check 3432
Transaxle Oil Change 3432
Transaxle Breather Check 3434
Brake Oil Change 3434
Forks, Inspect 3434
Integral Sideshift Carriage 3435
Lift Chains 3435
Maintenance Procedures Every 4000 Hours or Two Years 3436
Hydraulic Oil Change 3436
Steering Wheel Position Sensor Inspection 3438
Fixed Steering Column 3438
Telescopic Steering Column 3439
Telescopic Steering Column Lubrication 3440
Welding Repairs 3441
Lift and Tilt System Leak Check 3441
Lift Cylinders Leak Check 3442
Tilt Cylinder Leak Check 3442
Battery Maintenance 3442
How to Charge Battery 3442
Rapid Charge 3444
How to Change Battery 3444
Remove the Battery 3444
Install the Battery 3446
Optional Side Removal of Battery 3448
Battery Size Specifications 3448
Wheels and Tires 3448
General 3449
Pneumatic Tires Repair 3449
Remove Wheels From Lift Truck 3449
Remove Tire From Wheel 3450
Install Wheel in Tire 3453
Add Air to Tires 3456
Wheels, Install 3456
Solid Rubber Tires on Pneumatic Wheels, Change 3456
Install the Wheels 3460
Solid Rubber (Cushioned) Tire Repair 3460
Remove Wheels From Lift Truck 3460
Remove and Install Tire on Wheel 3460
Lift Chain Adjustments 3461
524327049-0620YRM1385-(02-2023)-UK-EN 3465
General 3473
Discharging the Capacitors for Lift Truck Models ESC030-040AC (B883), ESC030-040AD (C883) 3479
Discharging the Capacitors (All Other Models) 3481
Traction Motor Repair 3482
For Lift Truck Models , and ERP15-20VT (ERP030-040VT) (G807)ERP16-20VF (ERP30-40VF) (A955), ESC030-040AC (B883) 3482
Remove 3482
Disassemble 3483
Electrical Connector Repair or Replacement 3485
Clean 3485
Inspect 3485
Assemble 3486
Install 3488
For Lift Truck ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 3490
Remove 3490
Disassemble 3490
Electrical Connector Repair or Replacement 3493
Clean 3493
Inspect 3493
Assemble 3494
Install 3494
For Lift Truck ERP2 2-3 5VL (ERP045-070VL) (A976) 3494
Remove 3494
Disassemble 3494
Clean 3496
Inspect 3496
Assemble 3497
Install 3497
For Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080120VM, ERP100VML) (A985) 3497
Remove 3497
Clean 3499
Install 3499
For Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 3499
Remove 3499
Disassemble 3499
Electrical Connector Repair or Replacement 3501
Clean 3501
Inspect 3501
Assemble 3502
Install 3503
Traction Motor Repair for 4-5 5T Lift Trucks 3504
For Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080120VM, ERP100VML) (A985) 3504
Remove 3504
Clean 3506
Install 3506
Hydraulic Motor Repair 3507
For Lift Trucks and ERP15-20VT (ERP030-040VT) (G807)ERP16-20VF (ERP30-40VF) (A955)ESC030-040AC (B883), ESC030-040AD (C883) 3507
Remove 3507
Disassemble 3508
Electrical Connector Repair or Replacement 3510
Clean 3510
Inspect 3510
Assemble 3511
Install 3513
For Lift Truck ERC22-35VG (ERC045-070VG) (A968) 3514
Remove 3514
Disassemble 3516
Standard Motor 3516
Enhanced Motor 3518
Electrical Connector Repair or Replacement 3519
Clean 3520
Inspect 3520
Assemble 3521
Standard Motor 3521
Enhanced Motor 3521
Install 3522
For Lift Truck Models ERP2 2-3 5VL (ERP045-070VL) (A976) and ERC16-20VA (ERC030-040VA) (A969) 3522
Remove 3522
Disassemble 3522
Electrical Connector Repair or Replacement 3528
Clean 3529
Inspect 3529
Assemble 3530
Install 3531
For Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 3531
Remove 3531
Disassemble 3531
Electrical Connector Repair or Replacement 3534
Clean 3534
Inspect 3535
Assemble 3535
Install 3536
Hydraulic Motor Repair For 4 0-5 5T Lift Trucks 3536
Remove 3536
Disassemble 3536
Electrical Connector Repair or Replacement 3538
Clean 3538
Inspect 3539
Assemble 3539
Install 3540
Torque Specifications 3541
Traction Motor for Lift Trucks and ERP15-20VT (ERP030-040VT) (G807)ERP16-20VF (ERP30-40VF) (A955) 3541
Traction Motor for Lift Truck and ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969),ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 3541
Traction Motor for Lift Truck ESC030-040AC (B883), ESC030-040AD (C883) 3541
Hydraulic Motor for Lift Trucks and ERP15-20VT (ERP030-040VT) (G807)ERP16-20VF (ERP30-40VF) (A955) 3541
Hydraulic Motor for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 3541
Hydraulic Motor for Lift Truck ERP22-35VG (ERP045-070VG) (A976) 3541
Hydraulic Motor for Lift Truck ERC16-20VA (ERC030-040VA) (A969) 3541
Hydraulic Motor for Lift Truck ESC030-040AC (B883), ESC030-040AD (C883) 3541
Hydraulic Motor for Lift Truck and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 3542
524327049-0620YRM1385-(06-2015)-UK-EN 3545
General 3549
Discharging the Capacitors for Lift Truck Models ESC030-040AC (B883), ESC030-040AD (C883) 3556
Discharging the Capacitors (All Other Models) 3557
Traction Motor Repair 3557
For Lift Truck Models ERP15-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), and ESC030-040AC (B883) 3558
Remove 3558
Disassemble 3559
Electrical Connector Repair or Replacement 3562
Clean 3562
Inspect 3562
Assemble 3563
Install 3566
For Lift Truck ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) 3568
Remove 3568
Disassemble 3568
Electrical Connector Repair or Replacement 3572
Clean 3572
Inspect 3572
Assemble 3573
Install 3573
For Lift Truck ERP2 2-3 5VL (ERP045-070VL) (A976) 3573
Remove 3573
Disassemble 3573
Clean 3575
Inspect 3575
Assemble 3576
Install 3576
For Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 3576
Remove 3576
Disassemble 3577
Electrical Connector Repair or Replacement 3578
Clean 3578
Inspect 3579
Assemble 3579
Install 3580
3580
Traction Motor Repair For Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 3580
Remove 3580
Clean 3582
Install 3582
Hydraulic Motor Repair 3582
For Lift Trucks ERP15-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), and ESC030-040AC (B883), ESC030-040AD (C883) 3582
Remove 3582
Disassemble 3584
Electrical Connector Repair or Replacement 3586
Clean 3586
Inspect 3586
Assemble 3587
Install 3589
For Lift Truck ERC22-35VG (ERC045-070VG) (A968) 3591
Remove 3591
Disassemble 3592
Standard Motor 3592
Enhanced Motor 3593
Electrical Connector Repair or Replacement 3595
Clean 3596
Inspect 3597
Assemble 3597
Standard Motor 3597
Enhanced Motor 3598
Install 3599
For Lift Truck Models ERP2 2-3 5VL (ERP045-070VL) (A976) and ERC16-20VA (ERC030-040VA) (A969) 3600
Remove 3600
Disassemble 3600
Electrical Connector Repair or Replacement 3606
Clean 3607
Inspect 3607
Assemble 3608
Install 3609
3609
Hydraulic Motor Repair For 4 0-5 5T Lift Trucks 3609
Remove 3609
Disassemble 3609
Electrical Connector Repair or Replacement 3612
Clean 3613
Inspect 3613
Assemble 3614
Install 3614
Torque Specifications 3615
Traction Motor for Lift Trucks ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955) 3615
Traction Motor for Lift Truck ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 3615
Traction Motor for Lift Truck ESC030-040AC (B883), ESC030-040AD (C883) 3615
Hydraulic Motor for Lift Trucks ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955) 3615
Hydraulic Motor for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 3615
Hydraulic Motor for Lift Truck ERP22-35VG (ERP045-070VG) (A976) 3615
Hydraulic Motor for Lift Truck ERC16-20VA (ERC030-040VA) (A969) 3615
Hydraulic Motor for Lift Truck ESC030-040AC (B883), ESC030-040AD (C883) 3615
Hydraulic Motor for Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 3616
524327054-4000YRM1386-(10-2017)-UK-EN 3619
General 3623
Safety Procedures When Working Near Mast 3624
Fork Replacement 3627
Remove 3628
Install 3629
Checks 3629
Carriages Repair 3631
Standard Carriage 3631
Remove 3631
Clean and Inspect 3633
Install 3633
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 3634
Remove 3634
Disassemble 3636
Clean and Inspect 3636
Assemble 3637
Install 3638
Integral Sideshift Carriage, Lift Trucks Manufactured After December, 2016 3638
Remove 3638
Disassemble 3641
Clean and Inspect 3641
Assemble 3641
Install 3642
Two-Stage Mast With Limited Free-Lift Repair 3642
Remove 3643
Disassemble 3649
Clean and Inspect 3652
Assemble 3654
Install 3654
Header Hose Installation and Adjustment 3656
Installation 3656
Adjustment 3663
Three-Stage Mast With Full Free-Lift Repair 3663
Remove 3663
Disassemble 3669
Clean and Inspect 3674
Assemble 3676
Install 3677
Header Hose Installation and Adjustment 3678
Installation 3678
Adjustment 3686
Lift Chains Adjustment 3686
Carriage Adjustments 3688
Tilt Cylinders Adjustment 3688
Mast Adjustments 3689
Load Roller, Adjust 3689
Mast Side Kicking, Adjust 3691
524333799-4000YRM1405-(06-2019)-UK-EN 3695
General 3699
Safety Procedures When Working Near Mast 3700
Fork Replacement 3705
Remove 3705
Install 3707
Checks 3707
Carriages Repair 3708
Standard Carriage 3708
Remove 3708
Clean and Inspect 3712
Install 3712
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 3713
Remove 3713
Disassemble 3716
Clean and Inspect 3716
Assemble 3717
Install 3718
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 3718
Remove 3718
Disassemble 3721
Clean and Inspect 3721
Assemble 3722
Install 3723
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 3723
Remove 3723
Disassemble 3726
Clean and Inspect 3726
Assemble 3727
Install 3728
Fork Positioner, Lift Trucks Manufactured Prior To December, 2016 3728
Remove 3728
Clean and Inspect 3732
Disassemble and Assemble 3732
Install 3732
Fork Positioner Hydraulic Hose Adjustment 3733
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 3735
Remove 3735
Clean and Inspect 3738
Disassemble and Assemble 3738
Install 3738
Fork Positioner Hydraulic Hose Adjustment 3739
Fork Positioner Carriage, Lift Trucks Manufactured June, 2018 and After 3740
Remove 3741
Clean and Inspect 3744
Disassemble and Assemble 3744
Install 3744
Fork Positioner Hydraulic Hose Adjustment 3745
Two-Stage Mast With Limited Free-Lift Repair 3746
Remove 3746
Disassemble 3758
Clean and Inspect 3760
Assemble 3763
Install 3764
Header Hose Installation and Adjustment 3766
Install 3766
Adjust 3774
Two-Stage Mast With Full Free-Lift Repair 3774
Remove 3775
Disassemble 3785
Clean and Inspect 3790
Assemble 3793
Install 3794
Header Hose Installation and Adjustment 3795
Install 3795
Adjust 3804
Three-Stage Mast With Full Free-Lift Repair 3805
Remove 3805
Disassemble 3816
Clean and Inspect 3823
Assemble 3825
Install 3827
Header Hose Installation and Adjustment 3828
Install 3828
Adjust 3837
Four-Stage Mast With Full Free-Lift Repair 3837
Remove 3837
Disassemble 3842
Clean and Inspect 3847
Assemble 3848
Install 3849
Header Hose Installation and Adjustment 3851
Lift Chains Adjustment 3856
Carriage Adjustments 3857
Tilt Cylinders Adjustment 3858
Mast Adjustments 3858
Load Roller, Adjust 3858
Mast Side Kicking, Adjust 3860
550025937-0100YRM1446-(02-2023)-UK-EN 3863
General 3869
Discharging the Capacitors 3870
Window Replacement 3871
Front Panel 3871
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) 3871
Remove, Lift Truck Models ERP13VC, ERP15VC (B888) 3872
Clean 3874
Inspect 3874
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) 3874
Install, Lift Truck Models ERP13VC, ERP15VC (B888) 3874
Rear Panel 3874
Remove 3874
Clean 3878
Inspect 3878
Install 3878
Door Window 3879
Disassemble Window 3879
Clean 3880
Inspect 3880
Assemble Window 3880
Window Wipers Replacement 3881
Front Wiper Assembly 3881
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) 3881
Remove, Lift Truck Models ERP13VC, ERP15VC (B888) 3886
Clean 3887
Inspect 3888
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) 3888
Install, Lift Truck Models ERP13VC, ERP15VC (B888) 3889
Cab Component Repair 3890
Roof Liner 3890
Remove 3890
Clean 3891
Inspect 3891
Install 3891
Top Panel 3892
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) 3892
Remove, Lift Truck Models ERP13VC, ERP15VC (B888) 3894
Clean 3895
Inspect 3895
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) 3895
Install, Lift Truck Models ERP13VC, ERP15VC (B888) 3895
Cab Door Assembly 3896
Door Assembly 3896
Remove 3896
Lift Truck Models and ERP22-35VL (ERP045-070VL) (A976)ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 3896
Lift Truck Models and ERP15-20VT (ERP030-040VT) (G807)ERP16-20VF (ERP30-40VF) (A955) 3898
Disassemble Left Door 3900
Disassemble Right Door 3902
Clean 3904
Inspect 3904
Assemble Right Door 3904
Assemble Left Door 3904
Install 3905
Lift Truck Models and ERP22-35VL (ERP045-070VL) (A976)ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 3905
Lift Truck Models and ERP15-20VT (ERP030-040VT) (G807)ERP16-20VF (ERP30-40VF) (A955) 3905
Cab Heater 3906
Cab Heater 3906
Remove 3906
Clean 3913
Inspect 3913
Install 3913
Troubleshooting 3915
Weather Panel Replacement 3918
Remove 3918
Roof Panels 3918
Front Screen Panel 3921
Install 3922
Front Screen Panel 3922
Roof Panels 3922
550025937-0100YRM1446-(09-2014)-UK-EN 3925
550073240-1900YRM1620-(01-2023)-UK-EN 3979
Proper Flushing after Major Hydraulic Repairs 3985
Introduction 3985
The Phases of Wear 3985
Causes of Hydraulic System Failure 3985
Progression of Contaminant Caused Hydraulic System Failure 3986
Hydraulic System Flushing Techniques 3986
Double Oil and Filter Change 3986
Mechanical Cleaning 3987
Cleaning of Components 3987
How to Clean Tubes and Hoses 3987
Filter Caddy 3987
Start-Up Procedure for Cleaned System 3988
Contaminated Oil Coolers 3988
Additional Filter Caddy Functions 3989
How to Handle Different Fluids 3989
Water Removal Filters 3989
Fluid Conditioning and System Flushing Procedures 3990
Operation of the Filter Caddy 3990
Filter Caddy operation 3990
Fluid Conditioning Procedure 3990
Filter Caddy Start-Up 3991
System Flushing Procedure 3991
Component Cleaning Procedure 3992
Reservoir Cleaning Procedure 3992
Cylinder Cleaning Procedure 3992
Hose and Tube Cleaning Procedure 3992
Valve Cleaning Procedure 3993
Front-End Attachment Cleaning Procedure 3994
System Flushing Procedure 3994
Filter Caddy Start-Up 3995
System Start-Up and Flushing 3995
Reservoir Fluid Cleaning Times 3996
Dealing With Different Fluid Types 3997
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 3997
Filter Caddy Maintenance 3997
Servicing the Strainer 3997
DC Motor 3997
Hydraulic Oil Sampling Method and Procedure 3998
Hydraulic Oil Sampling Method 3998
Objective 3998
General Guidelines 3998
Synopsis 3999
Hydraulic Oil Analysis Report Guidelines 4000
Sampling Conditions 4000
Equipment 4000
Sampling Procedure 4001
Hydraulic Oil Sampling 4001
Sample Labeling 4001
Results Documentation 4001
550073240-1900YRM1620-(03-2020)-UK-EN 4003
Proper Flushing after Major Hydraulic Repairs 4007
Introduction 4007
The Phases of Wear 4007
Causes of Hydraulic System Failure 4007
Progression of Contaminant Caused Hydraulic System Failure 4008
Hydraulic System Flushing Techniques 4008
Double Oil and Filter Change 4008
Mechanical Cleaning 4009
Cleaning of Components 4009
How to Clean Tubes and Hoses 4009
Filter Caddy 4009
Start-Up Procedure for Cleaned System 4010
Contaminated Oil Coolers 4010
Additional Filter Caddy Functions 4010
How to Handle Different Fluids 4010
Water Removal Filters 4011
Fluid Conditioning and System Flushing Procedures 4011
Operation of the Filter Caddy 4011
Filter Caddy operation 4011
Fluid Conditioning Procedure 4012
Filter Caddy Start-Up 4012
System Flushing Procedure 4013
Component Cleaning Procedure 4013
Reservoir Cleaning Procedure 4013
Cylinder Cleaning Procedure 4013
Hose and Tube Cleaning Procedure 4014
Valve Cleaning Procedure 4014
Front-End Attachment Cleaning Procedure 4015
System Flushing Procedure 4015
Filter Caddy Start-Up 4016
System Start-Up and Flushing 4016
Reservoir Fluid Cleaning Times 4017
Dealing With Different Fluid Types 4017
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 4017
Filter Caddy Maintenance 4018
Servicing the Strainer 4018
DC Motor 4018
Hydraulic Oil Sampling Method and Procedure 4018
Hydraulic Oil Sampling Method 4018
Objective 4018
General Guidelines 4018
Synopsis 4019
Hydraulic Oil Analysis Report Guidelines 4020
Sampling Conditions 4021
Equipment 4021
Sampling Procedure 4021
Hydraulic Oil Sampling 4021
Sample Labeling 4022
Results Documentation 4022