Yale Forklift G807 (ERP15VT, 16VT, 18VT, 20VT) Service Manual – PDF DOWNLOAD

Yale Forklift G807 (ERP15VT, 16VT, 18VT, 20VT) Service Manual – PDF DOWNLOAD

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Yale Forklift G807 (ERP15VT, 16VT, 18VT, 20VT) Service Manual – PDF DOWNLOAD

Language : English
Pages : 3896
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift G807 (ERP15VT, 16VT, 18VT, 20VT) 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
524295629-0100YRM1329-(04-2023)-UK-EN 421
Introduction 427
General 427
Description of Operation 428
Discharging the Capacitors 429
Rapid Charge 429
Covers and Floor Plates 430
Overhead Guard Replacement 433
Remove 433
Install 438
Hood and Seat Assembly 439
Remove 442
Install 444
Ground Test 444
Counterweight Replacement 445
Remove 446
Install 451
Safety Labels 453
Painting Instructions 458
Battery Specifications 459
European Model Trucks ERP15-20VT (G807) 459
US Model Trucks ERP030-040VT (G807) 460
European Model Trucks ERP16-20VF (A955) 461
US Model Trucks ERP30-40VF (A955) 462
524295629-0100YRM1329-(09-2014)-UK-EN 465
524295630-1300YRM1330-(04-2023)-UK-EN 507
General 513
Discharging the Capacitors 514
Special Tools 514
Transaxle Assembly 515
Remove Transaxle From Frame 515
Remove the Parking Brake and Traction Motor 516
Install Parking Brake and Traction Motor 517
Install Transaxle to Frame 518
Maintenance and Repair 519
Speed Sensor Repair 519
Trunnion Cap Repair 520
Fluid Level Check 520
Fluid Change 521
Breather Repair 522
Stud Repair 523
Brake Cylinder Repair 524
Input Seal Repair 526
Cover to Housing Seal 526
During the Transaxle Warranty Period 526
After the Transaxle Warranty Period 527
Removing the Cover 527
Installing the Cover 528
Wet Brakes 529
Electronic Brake (E-Brake) 531
524295630-1300YRM1330-(10-2015)-UK-EN 533
General 537
Discharging the Capacitors 538
Special Tools 538
Transaxle Assembly 538
Remove Transaxle From Frame 539
Remove the Parking Brake and Traction Motor 540
Install Parking Brake and Traction Motor 541
Install Transaxle to Frame 542
Maintenance and Repair 542
Speed Sensor Repair 542
Trunnion Cap Repair 543
Fluid Level Check 544
Fluid Change 545
Breather Repair 546
Stud Repair 547
Brake Cylinder Repair 548
Input Seal Repair 549
Cover to Housing Seal 550
During the Transaxle Warranty Period 551
After the Transaxle Warranty Period 552
Removing the Cover 552
Installing the Cover 552
Wet Brakes 553
Electronic Brake (E-Brake) 555
524295631-1600YRM1331-(04-2023)-UK-EN 559
General 565
Introduction 565
Discharging The Capacitors 565
Steering Pressure Check, Lift Trucks Equipped With Hydraulic Steering 567
Operation Check 569
Steering Control Unit (SCU) Repair, Lift Trucks Equipped With Hydraulic Steering 570
Remove 570
Disassemble 573
Clean 578
Inspect 578
Assemble 578
Install 579
Steering Wheel and Fixed Steering Column Assembly Repair 581
Remove 581
Disassemble 584
Clean 586
Inspect 586
Assemble 586
Install 587
Gear Replacement for Lift Trucks Built Prior to 10/2008 588
Steering Wheel and Telescopic Column Assembly Repair 589
Remove 589
Disassemble 592
Clean 595
Inspect 596
Assemble 596
Install 597
Hydraulic Pump and Motor 604
Steering Actuator Components 604
Steer Tire and Wheel Assembly 604
Remove 604
Install 605
Wheel Hub Assembly, Lift Trucks Equipped With Hydraulic Steering 605
Remove 605
Clean 607
Inspect 608
Install 608
Wheel Hub Assembly, Lift Trucks Equipped With E-Steering 608
Remove 608
Clean 609
Inspect 610
Install 610
Steering Axle Assembly, Lift Trucks Equipped With Hydraulic Steering 610
Remove 610
Disassemble 611
Clean 612
Inspect 612
Assemble 612
Install 613
Steering Axle Assembly, Lift Trucks Equipped With E-Steering 613
Remove 613
Disassemble 616
Clean 618
Inspect 618
Assemble 618
Install 619
Torque Specifications 620
Fixed Steering Column 620
Telescopic Steering Column 620
Steering Control Unit 620
Steer Axle, Lift Trucks Equipped With Hydraulic Steering 620
Steer Axle, Lift Trucks Equipped With E-Steering 620
524295631-1600YRM1331-(07-2019)-UK-EN 623
General 627
Introduction 627
Discharging The Capacitors 627
Steering Pressure Check, Lift Trucks Equipped With Hydraulic Steering 628
Operation Check 630
Steering Control Unit (SCU) Repair, Lift Trucks Equipped With Hydraulic Steering 630
Remove 630
Disassemble 633
Clean 638
Inspect 638
Assemble 638
Install 639
Steering Wheel and Fixed Steering Column Assembly Repair 640
Remove 640
Disassemble 644
Clean 645
Inspect 646
Assemble 646
Install 646
Gear Replacement for Lift Trucks Built Prior to 10/2008 647
Steering Wheel and Telescopic Column Assembly Repair 648
Remove 648
Disassemble 651
Clean 655
Inspect 655
Assemble 655
Install 656
Hydraulic Pump and Motor 663
Steering Actuator Components 663
Steer Tire and Wheel Assembly 663
Remove 663
Install 664
Wheel Hub Assembly, Lift Trucks Equipped With Hydraulic Steering 664
Remove 664
Clean 666
Inspect 667
Install 667
Wheel Hub Assembly, Lift Trucks Equipped With E-Steering 667
Remove 667
Clean 668
Inspect 669
Install 669
Steering Axle Assembly, Lift Trucks Equipped With Hydraulic Steering 669
Remove 669
Disassemble 670
Clean 671
Inspect 671
Assemble 671
Install 672
Steering Axle Assembly, Lift Trucks Equipped With E-Steering 672
Remove 672
Disassemble 675
Clean 677
Inspect 677
Assemble 677
Install 678
Torque Specifications 678
Fixed Steering Column 678
Telescopic Steering Column 678
Steering Control Unit 678
Steer Axle, Lift Trucks Equipped With Hydraulic Steering 678
Steer Axle, Lift Trucks Equipped With E-Steering 678
524295632-1800YRM1332-(04-2023)-UK-EN 681
Introduction 687
General 687
Discharging the Capacitors 688
Brake Pedal Assembly Repair 689
Hydraulic Brake System 689
Remove 689
Disassemble 690
Assemble 690
Install 690
Electronic Brake (E-Brake) System 691
Remove 691
Disassemble 692
Assemble 693
Install 694
Adjustments 694
Brake Pedal Adjustment 694
Clevis Adjustment 694
Master Cylinder Repair 696
Remove 696
Disassemble 697
Clean and Inspect 699
Assemble 699
Install 699
Adjustments 700
Bleed the Brake System 700
Adjust Linkage 700
Brake Lines 702
Brake Line Replacement 702
Parking Brake 703
Manual Release Lever 703
Adjust Cable 703
Replace Cable 703
Remove 704
Install 705
524295632-1800YRM1332-(11-2015)-UK-EN 707
Introduction 711
General 711
Discharging the Capacitors 711
Brake Pedal Assembly Repair 712
Hydraulic Brake System 712
Remove 712
Disassemble 713
Assemble 714
Install 714
Electronic Brake (E-Brake) System 715
Remove 715
Disassemble 716
Assemble 717
Install 718
Adjustments 718
Brake Pedal Adjustment 718
Clevis Adjustment 718
Master Cylinder Repair 720
Remove 720
Disassemble 720
Clean and Inspect 724
Assemble 724
Install 724
Adjustments 724
Bleed the Brake System 724
Adjust Linkage 725
Brake Lines 725
Brake Line Replacement 726
Parking Brake 727
Manual Release Lever 727
Adjust Cable 727
Replace Cable 727
Remove 728
Install 729
524295633-1900YRM1333-(07-2023)-UK-EN 733
General 739
Hydraulic Pump Repair 740
Remove 740
Disassemble 744
Inspect 746
Clean 746
Assemble 746
Install 746
Hydraulic Tank Assembly 748
Remove 748
Disassemble 750
Clean 751
Steam Method 751
Chemical Method 751
Inspect 752
Assemble 752
Install 752
Hydraulic Filter Replacement 753
Breather Clean and Inspect 754
Add Hydraulic Oil 755
Steer Accumulator Replacement for Lift Truck Models ERP030-40VF (A955) 756
Remove 756
Install 758
Specifications 759
524295633-1900YRM1333-(10-2015)-UK-EN 761
General 765
Hydraulic Pump Repair 766
Remove 766
Disassemble 769
Inspect 771
Clean 771
Assemble 771
Install 771
Hydraulic Tank Assembly 772
Remove 772
Disassemble 775
Clean 775
Steam Method 776
Chemical Method 776
Inspect 776
Assemble 776
Install 777
Hydraulic Filter Replacement 778
Breather Clean and Inspect 779
Add Hydraulic Oil 779
Steer Accumulator Replacement for Lift Truck Models ERP030-40VF (A955) 780
Remove 780
Install 780
Specifications 783
524306565-8000YRM1340-(03-2017)-UK-EN 787
General 791
Lubrication Specifications 791
Hydraulic System 793
Steering System 794
Tire Sizes 796
Torque Specifications 797
Electrical 797
Steering SystemLift Truck Models ERP15-20VT (G807) Manufactured Before November, 2014 and ERP030-040VT (G807) 797
Steering SystemLift Truck Models ERP15-20VT (G807) Manufactured After November, 2014 798
Hydraulic System 798
E-Hydraulic Control Valve 798
Transaxle 798
Mast Speeds 798
Maximum Carriage and Tilt Creep Rates 803
Tilt Angles 804
Transaxle Assembly 804
Travel Speeds 804
Battery 806

ERP15-20VT (G807) European Model Trucks 806

ERP030-040VT (G807) US Model Trucks 807
Battery Discharge Rate 808
524319495-2000YRM1334-(03-2023)-UK-EN 811
General 819
Lift Trucks ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955) 819
Lift Trucks ERC22-35VG (ERC045-070VG) (A968), ERP22-35VL (ERP045-070VL) (A976), and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 821
Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 825
Discharging the Capacitors 827
Manual Hydraulic Control Valve Repair for 1 5-2 0T Trucks 828
Remove 828
Beginning Steps 828
Disassemble Handles and Levers 841
Disassemble Manual Control Valve 844
Spool Seal Replacement 854
Clean 857
Inspect 857
Assemble Manual Control Valve 859
Assemble Handles and Levers 870
Install 873
Ending Steps 885
Manual Hydraulic Control Valve Repair for 2 0-3 5T Trucks and 4 0-5 0T Pneumatic Trucks 887
Remove 887
Disassemble Handles and Levers 903
Disassemble Manual Control Valve 906
Disassemble Valve 906
Disassemble Inlet Section 909
Disassemble Lift, Tilt, and Auxiliary Sections 909
Spool Seal Replacement 911
Clean 912
Inspect 913
Assemble Manual Control Valve 913
Assemble Lift, Tilt, and Auxiliary Sections 913
Assemble Inlet Section 914
Assemble Valve 915
Assemble Handles and Levers 923
Install 927
Ending Steps 939
Manual Hydraulic Control Valve Repair for 4 0-5 5T Cushion Trucks 940
Remove 940
Disassemble Handles and Levers 954
Disassemble Manual Control Valve 956
Disassemble Valve 956
Disassemble Inlet Section 959
Disassemble Lift, Tilt, and Auxiliary Sections 960
Spool Seal Replacement 962
Clean 963
Inspect 963
Assemble Manual Control Valve 964
Assemble Lift, Tilt, and Auxiliary Sections 964
Assemble Inlet Section 965
Assemble Valve 966
Assemble Handles and Levers 973
Install 976
Ending Steps 988
E-Hydraulic Control Valve Repair for 1 5-2 0T Trucks 989
Remove 989
Disassemble 995
Clean 1002
Inspect 1002
Assemble 1002
Install 1010
E-Hydraulic Controls 1015
Replace E-Hydraulic Control Components 1016
E-Hydraulic Control Valve Repair for 2 0-3 5T Trucks and 4 0-5 0T Pneumatic Trucks 1017
Remove 1017
Initial Steps 1017
Fitting Removal for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1017
Fitting Removal for Lift Truck ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1019
Electrical Disconnect and Control Valve Dismount 1021
Disassemble 1023
Clean 1028
Inspect 1028
Assemble 1028
Install 1036
Electrical Connect and Control Valve Mount 1036
Fitting Installation for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1038
Fitting Installation for Lift Truck ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1040
Ending Steps 1041
E-Hydraulic Controls 1042
Replace E-Hydraulic Control Components 1042
E-Hydraulic Control Valve Repair for 4 0-5 5T Cushion Trucks 1043
Remove 1043
Initial Steps 1043
Fitting Removal 1043
Electrical Disconnect and Control Valve Dismount 1045
Disassemble 1047
Clean 1052
Inspect 1052
Assemble 1052
Install 1060
Electrical Connect and Control Valve Mount 1060
Fitting Installation 1062
Ending Steps 1063
E-Hydraulic Controls 1064
Replace E-Hydraulic Control Components 1064
Checks and Adjustments
for 1 5-2 0T Lift Trucks 1065
Manual Control Valve 1065
Primary Relief Valve 1065
Optional Auxiliary Port Relief Valve 1065
E-Hydraulic Control Valve 1066
Primary Relief Valve 1066
Optional Secondary Port Relief Valve 1067
Hydraulic System Air Removal 1068
Checks and Adjustments
2 0-5 5T Lift Trucks 1069
Manual Control Valve 1069
External Leakage 1069
Primary Relief Cartridge 1069
Secondary Relief Valve 1070
E-Hydraulic Control Valve 1070
Primary Relief Valve 1070
Secondary Relief Valve 1071
PPRV Pilot Pressure Test 1072
Hydraulic System Air Removal 1073
Position Sensor and OPS Check and Adjustment 1074
Position Sensor 1074
(OPS) Operator Presence Solenoid 1074
Manual Control Valve Re-Calibration 1074
Calibration Procedure 1075
Control Valve 1075
Torque Specifications
for 1 5-2 0T Lift Trucks 1076
Manual Hydraulic Control Valve 1076
Manual Control Valve Handles and Levers 1076
E-Hydraulic Control Valve 1076
Torque Specifications
for 2 2-5 5T Lift Trucks 1077
Manual Hydraulic Control Valve 1077
Manual Control Valve Handles and Levers 1077
Manual Control Valve Covers 1077
E-Hydraulic Control Valve 1077
524319495-2000YRM1334-(09-2014)-UK-EN 1079
524319496-2100YRM1382-(02-2018)-UK-EN 1329
Safety Procedures When Working Near Mast 1337
General 1339
Description 1340
Tilt Cylinder Repair for 2 0-5 5T Trucks 1340
Remove 1340
Disassemble 1342
Inspect 1343
Clean 1343
Assemble 1343
Install 1345
Tilt Cylinders, Adjust 1345
Tilt Cylinder Leak Check 1348
Tilt Cylinder Repair
for 1 0-2 0T Trucks 1349
Remove 1349
Disassemble 1351
Inspect 1353
Clean 1353
Assemble 1353
Install 1353
Tilt Cylinders, Adjust 1354
Tilt Cylinders Leak Check 1355
Lift Cylinder Repair
for 2 0-3 5T Trucks 1356
Main Lift Cylinders 1356
Remove 1356
Two-Stage FFL 1356
Three-Stage FFL 1358
Four-Stage FFL 1358
Two-Stage LFL 1359
Disassemble 1359
Two-Stage FFL 1359
Three-Stage FFL 1361
Four-Stage FFL 1361
Two-Stage LFL 1363
Clean 1364
Inspect 1364
Assemble 1364
Two-Stage FFL 1364
Three-Stage FFL 1364
Four-Stage FFL 1365
Two-Stage LFL 1365
Install 1366
Two-Stage FFL 1366
System Air Bleed Procedures 1366
Three-Stage FFL 1366
Four-Stage FFL 1367
Two-Stage LFL 1367
Lift Cylinder Repair for Lift Truck Model ERP15VT (G807) 1368
Main Lift Cylinder 1368
Remove 1368
Main Lift Cylinders – Two-Stage FFL Mast 1368
Left-Hand Main Lift Cylinder – Three-Stage FFL Mast 1370
Right-Hand Main Lift Cylinder – Three-Stage FFL Mast 1374
Main Lift Cylinder – Two-Stage LFL Mast 1374
Disassemble 1377
Main Lift Cylinders – Two-Stage FFL Mast 1377
Main Lift Cylinder – Three-Stage FFL Mast 1379
Main Lift Cylinder – Two-Stage LFL Mast 1379
Clean 1380
Inspect 1380
Assemble 1381
Main Lift Cylinder – Two-Stage FFL Mast 1381
Main Lift Cylinder – Three-Stage FFL Mast 1381
Main Lift Cylinder – Two-Stage LFL Mast 1381
Install 1382
Main Lift Cylinder – Two-Stage FFL Mast 1382
Left-Hand Main Lift Cylinder – Three-Stage FFL Mast 1382
Right-Hand Main Lift Cylinder – Three-Stage FFL Mast 1383
Main Lift Cylinder – Two-Stage LFL Mast 1384
System Air Bleed Procedures 1385
All Main Lift Cylinders 1385
Lift Cylinder Repair for 1 5-2 0T Trucks 1385
Main Lift Cylinder 1385
Remove 1385
Two-Stage FFL 1386
Three-Stage FFL 1386
Two-Stage LFL 1387
Four-Stage FFL 1389
Disassemble 1390
Two-Stage FFL 1390
Three-Stage FFL 1392
Two-Stage LFL 1392
Four-Stage FFL 1393
Clean 1396
Inspect 1396
Assemble 1396
Two-Stage FFL 1396
Three-Stage FFL 1397
Two-Stage LFL 1397
Four-Stage FFL 1398
Install 1399
Two-Stage FFL 1399
System Air Bleed Procedures 1399
Three-Stage FFL Mast 1399
Two-Stage LFL 1400
Four-Stage FFL 1400
Mast and Carriage Install for Two-Stage FFL, Three-Stage FFL, and Two-Stage LFL 1401
Mast and Carriage Installation for Four-Stage FFL 1401
Lift Cylinder Repair
for 4 0-5 5T Trucks 1402
Main Lift Cylinders 1402
Remove 1402
Two-Stage FFL 1402
Three-Stage FFL 1404
Two-Stage LFL 1404
Disassemble 1405
Two-Stage FFL 1405
Three-Stage FFL 1407
Two-Stage LFL 1408
Clean 1409
Inspect 1409
Assemble 1409
Two-Stage FFL 1409
Three-Stage FFL 1410
Two-Stage LFL 1410
Install 1411
Two-Stage FFL 1411
System Air Bleed Procedures 1411
Three-Stage FFL 1411
Two-Stage LFL 1412
Free-Lift Cylinder Repair
for 2 0-3 5T Trucks 1413
Free-Lift Cylinder 1413
Remove 1413
Two and Three-Stage FFL Mast 1413
Four-Stage FFL For Lift Truck ERC22-356VG (ERC045-070VG) (A968) 1414
Disassemble 1416
Two and Three-Stage FFL Mast 1416
Four-Stage FFL Mast for Lift Truck ERC22-356VG (ERC045-070VG) (A968) 1417
Clean 1417
Inspect 1417
Assemble 1418
Two and Three-Stage FFL Mast 1418
Four-Stage FFL Mast for Lift Truck ERC22-356VG (ERC045-070VG) (A968) 1418
Install 1419
Two and Three-Stage FFL Mast 1419
Four-Stage FFL Mast for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1419
Free Lift Cylinder Repair for Lift Truck Model ERP15VT (G807) 1420
Free-Lift Cylinder 1420
Remove 1420
Three-Stage FFL Mast 1420
Disassemble 1422
Clean 1423
Inspect 1423
Assemble 1423
Install 1423
Free Lift Cylinder Repair
for 1 5-2 0T Trucks 1424
Free-Lift Cylinder 1424
Remove 1424
Two and Three-Stage FFL Mast 1424
Four-Stage FFL Mast 1426
Disassemble 1428
Two-Stage and Three-Stage FFL Masts 1428
Four Stage FFL Mast 1429
Clean 1430
Inspect 1430
Assemble 1430
Two-Stage and Three-Stage FFL Masts 1430
Four-Stage FFL Mast 1431
Install 1431
Two-Stage and Three-Stage FFL Masts 1431
Four-Stage FFL Mast 1431
All Masts 1433
Free-Lift Cylinder Repair
for 4 0-5 5T Trucks 1434
Free-Lift Cylinder 1434
Remove 1434
Two and Three-Stage FFL Mast 1434
Disassemble 1435
Two and Three-Stage FFL Mast 1435
Clean 1436
Inspect 1436
Assemble 1436
Two and Three-Stage FFL Mast 1436
Install 1437
Two and Three-Stage FFL Mast 1437
Sideshift Cylinder Repair
for 1 5-3 5T Trucks Prior to December 2016 1437
Remove 1437
Disassemble 1441
Clean and Inspect 1443
Assemble and Install 1443
Sideshift Cylinder Repair
for 1 5-3 5T Trucks After December 2016 1444
Remove 1444
Disassemble 1448
Clean and Inspect 1450
Assemble and Install 1450
Integral Side-Shift Cylinder Gland Leak Checks 1452
Sideshift Cylinder Repair
for 4 0-5 5T Trucks 1453
Remove 1453
Disassemble 1453
Clean and Inspect 1455
Assemble and Install 1455
Fork Positioner Cylinder Repair Prior to December 2016 1455
Remove 1455
Disassemble 1456
Clean 1458
Inspect 1458
Assemble 1459
Install 1459
Fork Positioner Cylinder Adjustment 1459
Fork Positioner Cylinder Repair After December 2016 1460
Remove 1460
Disassemble 1460
Clean 1463
Inspect 1463
Assemble 1464
Install 1464
Fork Positioner Cylinder Adjustment 1464
Lift Cylinder Leak Check 1465
Seal Kit Installation 1465
External Installation (Seal and Back-Up Ring) 1466
Internal Installation (Piston Rod Assembly) 1466
Torque Specifications for Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-25VL (ERP045-070VL) (A976) 1466
Tilt Cylinders 1466
Piston Rod Nut 1466
Gland 1467
Tilt Cylinder Mounting Capscrew 1467
Tilt Cylinder Rod End Capscrew 1467
Main and Free-Lift Cylinder 1467
Sideshift Cylinder 1467
Fork Positioner Cylinder 1467
Torque Specifications for Lift Truck Model ERP15VT (G807) 1467
Tilt Cylinders 1467
Main and Free-Lift Cylinders 1467
Sideshift Cylinder 1468
Torque Specifications for Lift Truck Models ERP16-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), ESC030-40AC (B883),ESC030-40AD (C883) 1468
Tilt Cylinders 1468
Main and Free-Lift Cylinders 1468
Sideshift Cylinder 1469
Fork Positioner Cylinder 1469
Torque Specifications for Lift Truck Model ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1469
Tilt Cylinders 1469
Main and Free-Lift Cylinder 1469
Sideshift Cylinder 1469
Torque Specifications for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1469
Tilt Cylinder 1470
Main and Free Lift Cylinder 1470
Sideshift Cylinder 1470
524319496-2100YRM1382-(07-2023)-UK-EN 1473
Safety Procedures When Working Near Mast 1483
General 1486
Description 1486
Tilt Cylinder Repair for 2 0-5 5T Trucks 1487
Remove 1487
Disassemble 1489
Inspect 1490
Clean 1490
Assemble 1490
Install 1492
Tilt Cylinders, Adjust 1492
Tilt Cylinder Leak Check 1495
Tilt Cylinder Repair
for 1 0-2 0T Trucks 1496
Remove 1496
Disassemble 1499
Inspect 1501
Clean 1501
Assemble 1501
Install 1501
Tilt Cylinders, Adjust 1502
Tilt Cylinders Leak Check 1503
Lift Cylinder Repair
for 2 0-3 5T Trucks 1505
Main Lift Cylinders 1505
Remove 1505
Two-Stage FFL 1505
Three-Stage FFL 1507
Four-Stage FFL 1507
Two-Stage LFL 1508
Disassemble 1508
Two-Stage FFL 1508
Three-Stage FFL 1510
Four-Stage FFL 1512
Two-Stage LFL 1513
Clean 1514
Inspect 1514
Assemble 1514
Two-Stage FFL 1514
Three-Stage FFL 1515
Four-Stage FFL 1515
Two-Stage LFL 1516
Install 1516
Two-Stage FFL 1516
System Air Bleed Procedures 1516
Three-Stage FFL 1517
Four-Stage FFL 1517
Two-Stage LFL 1518
Lift Cylinder Repair for Lift Truck Model ERP15VT (G807) 1519
Main Lift Cylinder 1519
Remove 1519
Main Lift Cylinders – Two-Stage FFL Mast 1519
Left-Hand Main Lift Cylinder – Three-Stage FFL Mast 1521
Right-Hand Main Lift Cylinder – Three-Stage FFL Mast 1525
Main Lift Cylinder – Two-Stage LFL Mast 1525
Disassemble 1528
Main Lift Cylinders – Two-Stage FFL Mast 1528
Main Lift Cylinder – Three-Stage FFL Mast 1530
Main Lift Cylinder – Two-Stage LFL Mast 1531
Clean 1532
Inspect 1532
Assemble 1532
Main Lift Cylinder – Two-Stage FFL Mast 1532
Main Lift Cylinder – Three-Stage FFL Mast 1533
Main Lift Cylinder – Two-Stage LFL Mast 1533
Install 1533
Main Lift Cylinder – Two-Stage FFL Mast 1533
Left-Hand Main Lift Cylinder – Three-Stage FFL Mast 1534
Right-Hand Main Lift Cylinder – Three-Stage FFL Mast 1535
Main Lift Cylinder – Two-Stage LFL Mast 1536
System Air Bleed Procedures 1536
All Main Lift Cylinders 1537
Lift Cylinder Repair for 1 5-2 0T Trucks 1538
Main Lift Cylinder 1538
Remove 1538
Two-Stage FFL 1538
Three-Stage FFL 1538
Two-Stage LFL 1539
Four-Stage FFL 1541
Disassemble 1543
Two-Stage FFL 1543
Three-Stage FFL 1544
Two-Stage LFL 1545
Four-Stage FFL 1546
Clean 1548
Inspect 1549
Assemble 1549
Two-Stage FFL 1549
Three-Stage FFL 1549
Two-Stage LFL 1550
Four-Stage FFL 1550
Install 1551
Two-Stage FFL 1551
System Air Bleed Procedures 1552
Three-Stage FFL Mast 1552
Two-Stage LFL 1552
Four-Stage FFL 1553
Mast and Carriage Install for Two-Stage FFL, Three-Stage FFL, and Two-Stage LFL 1553
Mast and Carriage Installation for Four-Stage FFL 1554
Lift Cylinder Repair for 4 0-5 5T Trucks 1555
Main Lift Cylinders 1555
Remove 1555
Two-Stage FFL 1555
Three-Stage FFL 1557
Two-Stage LFL 1557
Disassemble 1558
Two-Stage FFL 1558
Three-Stage FFL 1560
Two-Stage LFL 1561
Clean 1562
Inspect 1562
Assemble 1562
Two-Stage FFL 1562
Three-Stage FFL 1563
Two-Stage LFL 1563
Install 1564
Two-Stage FFL 1564
System Air Bleed Procedures 1564
Three-Stage FFL 1564
Two-Stage LFL 1565
Free-Lift Cylinder Repair for 2 0-3 5T Trucks 1566
Free-Lift Cylinder 1566
Remove 1566
Two and Three-Stage FFL Mast 1566
Four-Stage FFL For Lift Truck ERC22-356VG (ERC045-070VG) (A968) 1567
Disassemble 1569
Two and Three-Stage FFL Mast 1569
Four-Stage FFL Mast for Lift Truck ERC22-356VG (ERC045-070VG) (A968) 1570
Clean 1570
Inspect 1571
Assemble 1571
Two and Three-Stage FFL Mast 1571
Four-Stage FFL Mast for Lift Truck ERC22-356VG (ERC045-070VG) (A968) 1571
Install 1572
Two and Three-Stage FFL Mast 1572
Four-Stage FFL Mast for Lift Truck ERC22-35VG (ERC045-070VG) (A968) 1572
Free Lift Cylinder Repair for Lift Truck Model ERP15VT (G807) 1574
Free-Lift Cylinder 1574
Remove 1574
Three-Stage FFL Mast 1574
Disassemble 1576
Clean 1577
Inspect 1577
Assemble 1577
Install 1577
Free Lift Cylinder Repair for 1 5-2 0T Trucks 1579
Free-Lift Cylinder 1579
Remove 1579
Two and Three-Stage FFL Mast 1579
Four-Stage FFL Mast 1581
Disassemble 1584
Two-Stage and Three-Stage FFL Masts 1584
Four Stage FFL Mast 1584
Clean 1585
Inspect 1585
Assemble 1585
Two-Stage and Three-Stage FFL Masts 1585
Four-Stage FFL Mast 1586
Install 1586
Two-Stage and Three-Stage FFL Masts 1586
Four-Stage FFL Mast 1587
All Masts 1590
Free-Lift Cylinder Repair
for 4 0-5 5T Trucks 1591
Free-Lift Cylinder 1591
Remove 1591
Two and Three-Stage FFL Mast 1591
Disassemble 1592
Two and Three-Stage FFL Mast 1592
Clean 1593
Inspect 1593
Assemble 1593
Two and Three-Stage FFL Mast 1593
Install 1594
Two and Three-Stage FFL Mast 1594
Sideshift Cylinder Repair
for 1 5-3 5T Trucks Prior to December 2016 1595
Remove 1595
Disassemble 1598
Clean and Inspect 1600
Assemble and Install 1600
Sideshift Cylinder Repair
for 1 5-3 5T Trucks After December 2016 1602
Remove 1602
Disassemble 1605
Clean and Inspect 1606
Assemble and Install 1607
Integral Side-Shift Cylinder Gland Leak Checks 1609
Sideshift Cylinder Repair
for 4 0-5 5T Trucks 1610
Remove 1610
Disassemble 1611
Clean and Inspect 1612
Assemble and Install 1612
Fork Positioner Cylinder Repair Prior to December 2016 1613
Remove 1613
Disassemble 1613
Clean 1616
Inspect 1616
Assemble 1617
Install 1617
Fork Positioner Cylinder Adjustment 1617
Fork Positioner Cylinder Repair After December 2016 1619
Remove 1619
Disassemble 1619
Clean 1622
Inspect 1622
Assemble 1623
Install 1623
Fork Positioner Cylinder Adjustment 1623
Lift Cylinder Leak Check 1625
Seal Kit Installation 1626
External Installation (Seal and Back-Up Ring) 1626
Internal Installation (Piston Rod Assembly) 1626
Torque Specifications for Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-25VL (ERP045-070VL) (A976) 1627
Tilt Cylinders 1627
Piston Rod Nut 1627
Gland 1627
Tilt Cylinder Mounting Capscrew 1627
Tilt Cylinder Rod End Capscrew 1627
Main and Free-Lift Cylinder 1627
Sideshift Cylinder 1627
Fork Positioner Cylinder 1627
Torque Specifications for Lift Truck Model ERP15VT (G807) 1628
Tilt Cylinders 1628
Main and Free-Lift Cylinders 1628
Sideshift Cylinder 1628
Torque Specifications for Lift Truck Models ERP16-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), ESC030-40AC (B883),ESC030-40AD (C883) 1629
Tilt Cylinders 1629
Main and Free-Lift Cylinders 1629
Sideshift Cylinder 1629
Fork Positioner Cylinder 1629
Torque Specifications for Lift Truck Model ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 1630
Tilt Cylinders 1630
Main and Free-Lift Cylinder 1630
Sideshift Cylinder 1630
Torque Specifications for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) 1630
Tilt Cylinder 1630
Main and Free Lift Cylinder 1630
Sideshift Cylinder 1630
524319497-2200YRM1335-(01-2023)-UK-EN 1633
General 1641
Description 1641
Display Panel Menu Access 1641
Menu Flowchart 1642
Supervisor Menu Flowchart 1642
Menu Navigation 1648
Icon Glossary 1652
Introduction 1652
Soft Key Icons 1652
Overlay Icons 1653
Icons on System Off Screen and Alert Screens 1653
Main Menu Title Screens 1657
Submenu Icons Grouped by Menu 1659
Operating Screen Icons 1659
Password Screen Icons 1660
Activity Log Submenu Icons 1660
Calibration Submenu Icons 1662
Display Submenu Icons 1664
Status Submenu Icons 1666
Truck Setup Submenu Icons 1669
Operating Screen 1676
Introduction 1676
Performance Mode Controls 1677
Status and Warning Icons 1677
Battery Discharge Indicator 1678
Direction and Parking Brake Indicators 1679
Hazard Flashers and Lighting Controls 1679
Steer Angle Indicator 1679
System Time 1679
Load Weight Indicator 1679
System Off/Alert Screens 1680
Introduction 1680
System Off Screen 1680
Alert Screens 1680
Password Screen 1682
Introduction 1682
Password Screen 1682
Service Technician Password Setup 1682
Adding/Removing/Changing Passwords 1683
Password Log 1686
Activity Log Menu 1687
Introduction 1687
Operator Checklist Log 1688
Password Log 1691
Impact Events Log 1693
Calibration Menu 1695
Introduction 1695
Load Weight Calibration 1695
Return to Set Tilt Stop Point Calibration 1696
E-Hydraulic and Manual Valve Threshold Calibration 1696
Steering Wheel Center Point Calibration 1697
Steer Axle Position Calibration 1697
Steer Axle Center Point Calibration 1698
Manual Hydraulics Calibration 1699
Display Menu 1700
Introduction 1700
Set Date and Time Format Menu 1700
Set Daylight Saving Time Menu 1701
Procedure for Setting Up Automatic Daylight Savings Time 1702
Set Time and Date Menu 1704
Procedure for Setting Time and Date 1704
Set Units Menu 1705
Status Menu 1706
Introduction 1706
VSM Versions 1706
Display Versions 1707
Truck Serial Number 1707
Hour Meters 1707
E-Hydraulic Controller Versions 1707
Pump Motor Controller Versions 1707
Traction Motor Controller 1 Versions 1707
Traction Motor Controller 2 Versions 1708
Light Controller Versions 1708
Impact Sensor Versions 1708
Truck Setup Menu 1709
Introduction 1709
Add/Remove Password 1709
Battery Settings 1709
Restore Default Settings 1710
Motion Alarm 1710
Impact Monitor Settings 1711
Impact Detection 1711
Setting Adjustments 1711
Initial Adjustment of Soft and Hard Impact Settings 1711
Readjustment of Soft and Hard Impact Settings 1711
Auto Power-Off Time Delay 1712
Return to Set Tilt 1712
Traction Speed Limit 1712
Scheduled Maintenance Reminder 1713
Minimum Pump Standby Flow Rate 1714
Operator Checklist 1714
Impact Monitor Shutdown 1715
Motor Braking 1716
Changing the Motor Braking Settings 1716
Steering Wheel Friction and Steering Turns Adjustment 1717
How to Adjust Settings 1717
Steering Friction Setting 1717
Steering Wheel Number of Turns 1718
524319497-2200YRM1335-(07-2020)-UK-EN 1721
General 1727
Description 1727
Display Panel Menu Access 1727
Menu Flowchart 1728
Supervisor Menu Flowchart 1728
Menu Navigation 1734
Icon Glossary 1738
Introduction 1738
Soft Key Icons 1738
Overlay Icons 1739
Icons on System Off Screen and Alert Screens 1739
Main Menu Title Screens 1743
Submenu Icons Grouped by Menu 1745
Operating Screen Icons 1745
Password Screen Icons 1746
Activity Log Submenu Icons 1746
Calibration Submenu Icons 1748
Display Submenu Icons 1750
Status Submenu Icons 1752
Truck Setup Submenu Icons 1755
Operating Screen 1762
Introduction 1762
Performance Mode Controls 1762
Status and Warning Icons 1763
Battery Discharge Indicator 1764
Direction and Parking Brake Indicators 1764
Hazard Flashers and Lighting Controls 1765
Steer Angle Indicator 1765
System Time 1765
Load Weight Indicator 1765
System Off/Alert Screens 1766
Introduction 1766
System Off Screen 1766
Alert Screens 1766
Password Screen 1768
Introduction 1768
Password Screen 1768
Service Technician Password Setup 1768
Adding/Removing/Changing Passwords 1769
Password Log 1772
Activity Log Menu 1773
Introduction 1773
Operator Checklist Log 1773
Password Log 1775
Impact Events Log 1777
Calibration Menu 1779
Introduction 1779
Load Weight Calibration 1779
Return to Set Tilt Stop Point Calibration 1780
E-Hydraulic and Manual Valve Threshold Calibration 1780
Steering Wheel Center Point Calibration 1781
Steer Axle Position Calibration 1781
Steer Axle Center Point Calibration 1782
Manual Hydraulics Calibration 1783
Display Menu 1784
Introduction 1784
Set Date and Time Format Menu 1784
Set Daylight Saving Time Menu 1785
Procedure for Setting Up Automatic Daylight Savings Time 1786
Set Time and Date Menu 1788
Procedure for Setting Time and Date 1788
Set Units Menu 1789
Status Menu 1790
Introduction 1790
VSM Versions 1790
Display Versions 1791
Truck Serial Number 1791
Hour Meters 1791
E-Hydraulic Controller Versions 1791
Pump Motor Controller Versions 1791
Traction Motor Controller 1 Versions 1791
Traction Motor Controller 2 Versions 1792
Light Controller Versions 1792
Impact Sensor Versions 1792
Truck Setup Menu 1793
Introduction 1793
Add/Remove Password 1793
Battery Settings 1793
Restore Default Settings 1794
Motion Alarm 1794
Impact Monitor Settings 1794
Impact Detection 1795
Setting Adjustments 1795
Initial Adjustment of Soft and Hard Impact Settings 1795
Readjustment of Soft and Hard Impact Settings 1795
Auto Power-Off Time Delay 1796
Return to Set Tilt 1796
Traction Speed Limit 1796
Scheduled Maintenance Reminder 1797
Minimum Pump Standby Flow Rate 1798
Operator Checklist 1798
Impact Monitor Shutdown 1799
Motor Braking 1800
Changing the Motor Braking Settings 1800
Steering Wheel Friction and Steering Turns Adjustment 1801
How to Adjust Settings 1801
Steering Friction Setting 1801
Steering Wheel Number of Turns 1802
524319498-2200YRM1336-(02-2023)-UK-EN 1805
General 1813
Description 1813
Display Panel Menu Access 1813
Menu Flowchart 1814
Technician Menu Flowchart 1814
Menu Navigation 1820
Icon Glossary 1824
Introduction 1824
Soft Key Icons 1824
Overlay Icons 1825
Heat Exchange Module Warning Indicator Screen 1825
System Off Screen and Alert Screens 1826
Main Menu Title Screens 1832
Submenu Icons Grouped by Menu 1833
Operating Screen Icons 1833
Password Screen Icons 1835
Activity Log Submenu Icons 1835
Calibration Submenu Icons 1836
Display Submenu Icons 1840
Status Submenu Icons 1842
Truck Setup Submenu Icons 1845
Diagnostics Submenu Icons 1857
Operating Screen 1867
Introduction 1867
Performance Mode Controls 1867
Status and Warning Icons 1868
Battery Discharge Indicator 1869
Direction and Parking Brake Indicators 1869
Hazard Flashers and Lighting Controls 1870
Steer Angle Indicator 1870
System Time 1870
Load Weight Indicator 1870
System Off/Alert Screens 1871
Introduction 1871
System Off Screen 1871
Alert Screens 1871
Password Screen 1873
Introduction 1873
Password Screen 1873
Service Technician Password Setup 1873
Adding/Removing/Changing Passwords 1874
Password Log 1877
Activity Log Menu 1878
Introduction 1878
Operator Checklist Log 1878
Password Log 1880
Impact Events Log 1882
Calibration Menu 1884
Introduction 1884
Load Weight Calibration 1884
Return to Set Tilt Stop Point Calibration 1885
E-Hydraulic and Manual Valve Threshold Calibration 1885
Steering Wheel Center Point Calibration 1886
Steer Axle Position Calibration 1887
Steer Axle Center Point Calibration 1888
Manual Hydraulics Calibration 1888
Display Menu 1889
Introduction 1889
Set Date and Time Format Menu 1889
Set Daylight Saving Time Menu 1890
Procedure for Setting Up Automatic Daylight Savings Time 1891
Set Time and Date Menu 1893
Procedure for Setting Time and Date 1893
Set Units Menu 1894
Status Menu 1895
Introduction 1895
VSM Versions 1895
Display Versions 1896
Truck Serial Number 1896
Hour Meters 1896
E-Hydraulic Controller Versions 1896
Pump Motor Controller Versions 1896
Traction Motor Controller 1 Versions 1896
Traction Motor Controller 2 Versions 1897
Light Controller Versions 1897
Impact Sensor Versions 1897
E-Steer Controller 1 Versions 1897
E-Steer Controller 2 Versions 1897
Truck Setup Menu 1898
Introduction 1898
Add/Remove Password 1899
Battery Settings 1899
Motor Braking 1899
Changing the Motor Braking Settings 1900
Battery Mode 1900
Battery Setup 1901
BDI Adjustment Setting 1902
Acceleration Rates 1903
Hour Meter Initialization 1904
Impact Monitor Shutdown 1904
Operator Checklist 1906
Minimum Pump Standby Flow Rate 1906
Scheduled Maintenance Reminder 1907
Traction Speed Limit 1908
Return to Set Tilt 1908
Auto Power-Off Time Delay 1909
Impact Monitor Settings 1909
Impact Detection 1910
Setting Adjustments 1910
Initial Adjustment of Soft and Hard Impact Settings 1910
Readjustment of Soft and Hard Impact Settings 1910
Motion Alarm 1910
Lift Hydraulic Function Maximum Speed and Ramp Times 1911
Lower Hydraulic Function Maximum Speed and Ramp Times 1911
Tilt Forward Hydraulic Function Maximum Speed and Ramp Times 1912
Tilt Backward Hydraulic Function Maximum Speed and Ramp Times 1912
Auxiliary 1A Hydraulic Function Maximum Speed and Ramp Times 1912
Auxiliary 1B Hydraulic Function Maximum Speed and Ramp Times 1912
Auxiliary 2A Hydraulic Function Maximum Speed and Ramp Times 1912
Auxiliary 2B Hydraulic Function Maximum Speed and Ramp Times 1912
Optional Hydraulic Functions 1912
Rear Lights Control 1913
Restore Default Settings 1913
Steering Wheel Friction and Steering Turns Adjustment 1914
Navigation 1915
How to Adjust Settings 1915
Steering Friction 1915
Steering Wheel Number of Turns 1916
Diagnostics Menu 1918
Introduction 1918
Fault Code Log 1918
Fault Log Details 1919
Speedometer 1920
Direction Switch 1920
Traction Motor 1 Status 1921
Traction Motor 2 Status 1921
Occupancy Sensor 1921
Brake System Sensors 1921
Pump Status 1922
Hydraulic Control Inputs 1923
E-Hydraulic Valves 1923
Hydraulic Sensors 1924
System Voltages 1924
Steering Position Sensors 1926
E-Steering Position Sensors 1926
Electric Brake 1927
Navigation 1928
ESS Diagnostics Menus A, B, and C 1929
Menu A 1929
Menu B 1930
Menu C 1932
524319498-2200YRM1336-(07-2020)-UK-EN 1935
General 1941
Description 1941
Display Panel Menu Access 1941
Menu Flowchart 1942
Technician Menu Flowchart 1942
Menu Navigation 1948
Icon Glossary 1952
Introduction 1952
Soft Key Icons 1952
Overlay Icons 1953
Heat Exchange Module Warning Indicator Screen 1953
System Off Screen and Alert Screens 1954
Main Menu Title Screens 1959
Submenu Icons Grouped by Menu 1961
Operating Screen Icons 1961
Password Screen Icons 1962
Activity Log Submenu Icons 1962
Calibration Submenu Icons 1964
Display Submenu Icons 1967
Status Submenu Icons 1969
Truck Setup Submenu Icons 1973
Diagnostics Submenu Icons 1984
Operating Screen 1994
Introduction 1994
Performance Mode Controls 1994
Status and Warning Icons 1995
Battery Discharge Indicator 1996
Direction and Parking Brake Indicators 1997
Hazard Flashers and Lighting Controls 1997
Steer Angle Indicator 1997
System Time 1997
Load Weight Indicator 1997
System Off/Alert Screens 1998
Introduction 1998
System Off Screen 1998
Alert Screens 1998
Password Screen 2000
Introduction 2000
Password Screen 2000
Service Technician Password Setup 2000
Adding/Removing/Changing Passwords 2001
Password Log 2003
Activity Log Menu 2004
Introduction 2004
Operator Checklist Log 2004
Password Log 2006
Impact Events Log 2008
Calibration Menu 2010
Introduction 2010
Load Weight Calibration 2010
Return to Set Tilt Stop Point Calibration 2011
E-Hydraulic and Manual Valve Threshold Calibration 2011
Steering Wheel Center Point Calibration 2012
Steer Axle Position Calibration 2013
Steer Axle Center Point Calibration 2013
Manual Hydraulics Calibration 2014
Display Menu 2015
Introduction 2015
Set Date and Time Format Menu 2015
Set Daylight Saving Time Menu 2016
Procedure for Setting Up Automatic Daylight Savings Time 2017
Set Time and Date Menu 2019
Procedure for Setting Time and Date 2019
Set Units Menu 2020
Status Menu 2021
Introduction 2021
VSM Versions 2021
Display Versions 2022
Truck Serial Number 2022
Hour Meters 2022
E-Hydraulic Controller Versions 2022
Pump Motor Controller Versions 2022
Traction Motor Controller 1 Versions 2022
Traction Motor Controller 2 Versions 2023
Light Controller Versions 2023
Impact Sensor Versions 2023
E-Steer Controller 1 Versions 2023
E-Steer Controller 2 Versions 2023
Truck Setup Menu 2024
Introduction 2024
Add/Remove Password 2025
Battery Settings 2025
Motor Braking 2025
Changing the Motor Braking Settings 2026
Battery Mode 2026
Battery Setup 2027
BDI Adjustment Setting 2028
Acceleration Rates 2029
Hour Meter Initialization 2030
Impact Monitor Shutdown 2030
Operator Checklist 2031
Minimum Pump Standby Flow Rate 2032
Scheduled Maintenance Reminder 2032
Traction Speed Limit 2034
Return to Set Tilt 2034
Auto Power-Off Time Delay 2034
Impact Monitor Settings 2035
Impact Detection 2035
Setting Adjustments 2035
Initial Adjustment of Soft and Hard Impact Settings 2035
Readjustment of Soft and Hard Impact Settings 2036
Motion Alarm 2036
Lift Hydraulic Function Maximum Speed and Ramp Times 2036
Lower Hydraulic Function Maximum Speed and Ramp Times 2037
Tilt Forward Hydraulic Function Maximum Speed and Ramp Times 2037
Tilt Backward Hydraulic Function Maximum Speed and Ramp Times 2037
Auxiliary 1A Hydraulic Function Maximum Speed and Ramp Times 2037
Auxiliary 1B Hydraulic Function Maximum Speed and Ramp Times 2038
Auxiliary 2A Hydraulic Function Maximum Speed and Ramp Times 2038
Auxiliary 2B Hydraulic Function Maximum Speed and Ramp Times 2038
Optional Hydraulic Functions 2038
Rear Lights Control 2038
Restore Default Settings 2039
Steering Wheel Friction and Steering Turns Adjustment 2039
Navigation 2040
How to Adjust Settings 2040
Steering Friction 2040
Steering Wheel Number of Turns 2041
Diagnostics Menu 2043
Introduction 2043
Fault Code Log 2043
Fault Log Details 2044
Speedometer 2045
Direction Switch 2045
Traction Motor 1 Status 2045
Traction Motor 2 Status 2046
Occupancy Sensor 2046
Brake System Sensors 2046
Pump Status 2047
Hydraulic Control Inputs 2047
E-Hydraulic Valves 2047
Hydraulic Sensors 2048
System Voltages 2048
Steering Position Sensors 2049
E-Steering Position Sensors 2049
Electric Brake 2050
Navigation 2051
524319503-8000YRM1341-(10-2015)-UK-EN 2053
524319504-9000YRM1377-(09-2019)-UK-EN 2093
SECTION 9010 Operational Diagnostic Procedures 2109
Group 05 – Operational Checkout 2111
SECTION 9025 Traction Motor 2121
Group 10 – Principles of Operation 2123
Group 30 – Observed Symptoms 2129
SECTION 9030 Electrical System 2131
Group 03 – General Maintenance and Diagnostic Data 2141
Group 10 – Principles of Operation 2185
Group 20 – Diagnostic Trouble Codes 2217
Group 30 – Observed Symptoms 2829
Group 55 – Icons and Graphics 2873
SECTION 9035 Drive Axle/Unit 2881
Group 10 – Principles of Operation 2883
Group 30 – Observed Symptoms 2893
Group 20 – Diagnostic Trouble Codes 2905
SECTION 9050 Hydraulic Systems 2907
Group 10 – Principles of Operation 2911
Group 33 – Observed Symptoms-Gear Pump 2949
Group 43 – Tests and Adjustments-Gear Pump 3029
SECTION 9060 Operators Station 3059
Group 10 – Principles of Operation 3061
SECTION 9070 Front End (Mast) and Chassis 3101
Group 10 – Principles of Operation 3103
Group 30 – Observed Symptoms 3121
SECTION 9080 Supplementary Data 3165
Group 50 – Abbreviations and Acronyms 3167
524320282-2200YRM1337-(01-2020)-UK-EN 3175
General 3183
Discharging the Capacitors 3184
Display Panel and Key or Keyless Switch Replacement 3184
Display Panel, Replace 3184
Remove 3184
Install 3187
Electronic and Manual Hydraulic Controls 3190
General 3190
Manual Hydraulic Controls 3191
Upper Front Cover 3191
Direction Control Switch 3191
Remove 3191
Install 3194
Clamp Button 3194
Remove 3194
Install 3194
Return To Set Tilt (RTST) Button 3194
Remove 3194
Install 3194
Emergency Disconnect Switch 3195
Remove 3195
Install 3195
E-Hydraulic Controls – Test 3196
Mini-Levers 3196
Full Stroke Test 3196
Function Returns to Neutral Test 3196
Push (Override) Button 3197
E-Hydraulic Controls 3197
Mini-levers, Remove and Install 3197
Armrest Assembly 3198
Remove 3198
Install 3200
Horn Button 3200
Remove 3200
Install 3201
Direction Control Switch 3201
Remove 3201
Install 3202
Emergency Disconnect Switch 3202
Remove 3203
Install 3203
Push (Override) Buttons and Function Selection Button 3203
Remove 3204
Install 3206
Electronic-Hydraulic Controls, After January, 2020 3206
General 3206
E-Hydraulic Controls – TEST 3207
Mini-Levers 3207
Full Stroke Test 3208
Function Returns to Neutral Test 3208
Push Button (push (override) button) 3208
Mini-levers, Remove and Install 3209
Armrest Assembly 3209
Remove 3209
Install 3212
Horn Button 3212
Remove 3212
Install 3212
Direction Control Switch 3213
Remove 3213
Install 3213
Emergency Disconnect Switch 3213
Remove 3214
Install 3214
Push (Override) Buttons 3215
Remove 3215
Install 3216
Sensors and Switches 3217
General 3217
Synchronous Steering Valve 3217
Steering Axle Sensor 3217
Lift Truck Models ERP15-20VT (G807) Manufactured Before November, 2014 and ERP030-040VT (G807) 3217
Remove 3217
Install 3221
Lift Truck Models ERP15-20VT (G807) Manufactured After November, 2014 3221
Remove 3221
Install 3222
Lift Truck Models ERP16-20VF (ERP30-40VF) (A955) 3223
Remove 3223
Install 3224
Hydraulic Motor Speed Sensor 3225
Remove 3225
Install 3225
Hydraulic Motor Temperature Sensor 3226
Transmission Speed Sensor 3226
Remove 3226
Install 3228
Traction Motor Temperature Sensor 3229
Tilt Position Sensor 3229
Remove 3229
Install 3229
Low Level Brake Fluid Switch 3230
Remove 3230
Install 3232
Service Brake Pressure Sensor, Lift truck models , and , manufactured before February, 2016ERP030-040VT (G807)ERP30-40VF (A955) ERP15-20VT (G807)ERP16-20VF (A955) 3232
Remove 3232
Install 3232
Service Brake Pressure Sensor, Lift Truck Models and Manufactured After February, 2016ERP15-20VT (G807) ERP16-20VF (A955) 3232
Remove 3232
Install 3233
Accelerator Pedal Position Sensor 3234
Remove 3234
Install 3236
Seat Belt Sequence Module 3236
Remove 3236
Install 3236
Seat Sensor (Operator Presence System) 3237
Non-Suspension Seat 3237
Remove 3237
Install 3237
Full Suspension and Swivel Seats 3238
Remove 3238
Install 3238
Steering Wheel Position Sensor 3238
Remove 3238
Install 3241
Load Weight Sensor 3241
Remove 3241
Install 3242
Battery Gate Switch 3242
Remove, for Lift Truck Models, and, Manufactured Before December, 2015ERP15-20VT (G807)ERP16-20VF (A955)ERP030-040VT (G807)ERP030-040VF (A955) 3242
Install, for Lift Truck Models, and, Manufactured Before December, 2015ERP15-20VT (G807)ERP16-20VF (A955)ERP030-040VT (G807)ERP030-040VF (A955) 3244
Remove, for Lift Truck Models and Manufactured After December, 2015ERP030-040VT (G807) ERP030-040VF (A955) 3245
Install, for Lift Truck Models and Manufactured After December, 2015ERP030-040VT (G807) ERP030-040VF (A955) 3246
Horn Switch 3247
Remove 3247
Install 3248
Rear Horn Button Switch 3248
Remove 3248
Install 3249
Impact Sensor 3249
Remove 3249
Install 3250
Steering Motor Speed Sensor 3250
Remove 3250
Install 3251
Hydraulic Tank Level Sensor 3252
Remove 3252
Install 3252
Hydraulic Filter Pressure Switch 3254
Remove 3254
Install 3254
Hydraulic Oil Temperature Sensor 3254
Remove 3254
Install 3254
Motor Controllers Replacement 3255
General 3255
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) 3255
Remove 3255
Fan, Remove 3258
Fan, Install 3260
Install 3260
Hydraulic Pump and Motor Controller, Lift Truck Models Manufactured After November, 2014ERP15-20VT (G807) 3260
Remove 3260
Fan, Remove 3261
Fan, Install 3261
Install 3262
Traction Motor Controllers 3262
Remove 3262
Fan, Remove 3266
Fan, Install 3267
Install 3268
Line Contactor, Lift Truck Models ERP15-20VT (G807) Manufactured Before November, 2014, ERP030-040VT (G807), and ERP16-20VF (ERP30-40VF) (A955) 3268
Remove 3268
Install 3270
Line Contactor, Lift Truck Models Manufactured After November, 2014ERP15-20VT (G807) 3270
Remove 3270
Install 3271
Steering Motor Controller 3271
Remove 3271
Install 3272
Vehicle Systems Manager 3273
General 3273
Remove 3273
Install 3274
Programming a New VSM and/or Display Panel 3275
PC Service Tool Software 3275
Fuses 3276
Audible Alarm 3280
Battery Connection 3281
Inspect 3281
Replacing Cables 3281
Cab Heater 3283
Lights 3283
General 3283
Work Lights (Front and Rear) 3285
Halogen Bulb Lights 3285
Remove 3285
Install 3285
LED Lights 3285
Remove 3285
Install 3286
Strobe Light 3286
Remove 3286
Install 3287
LED Tail, Backup, and Brake Lights 3287
Remove 3287
Install 3288
Front Marker/Turn Signal Lights 3288
Remove 3288
Install 3290
Converter 3290
Remove 3290
Install 3290
524320287-8000YRM1339-(01-2018)-UK-EN 3293
Introduction 3299
General 3299
Serial Number 3300
Discharging the Capacitors 3300
Rapid Charge 3300
How to Tow a Disabled Lift Truck 3301
How to Put Lift Truck on Blocks 3302
How to Raise Drive Tires 3302
How to Raise Steer Tires 3303
How to Clean a Lift Truck 3304
Safety Procedures When Working Near Mast 3304
WHEN WORKING NEAR THE MAST ALWAYS: 3305
Maintenance Schedule 3307
Maintenance Procedures Every 8 Hours or Daily 3312
How to Make Checks With the Key or Keyless Switch OFF 3312
Wheels and Tires 3312
Safety Labels 3312
Frame and Covers 3312
Forks 3314
General 3314
Inspect 3314
Remove 3315
Install 3318
Adjust 3318
Inspection of Mast, Carriage, Header Hoses, Lift Chains, and Attachments 3319
Hydraulic Oil Level and Leaks 3320
Operator Restraint System 3320
Emergency Locking Retractor (ELR) 3321
Seat Adjustments 3322
Seat Position Adjustment (Swivel Seat) 3322
Seat Adjustment for Operator Weight 3322
Battery Restraint System 3324
Steering Column Adjustments 3330
Tilt Adjust Feature 3330
Tilt Memory Feature 3330
Telescopic Feature 3330
Battery Check 3330
How to Make Checks With the Key or Keyless Switch ON 3331
Control Levers and Pedals 3331
Direction and Speed Controls 3331
Electrical Components 3331
Steering System 3332
Hydraulic System 3332
Service Brakes 3333
Automatic Parking Brake 3333
Operator Presence System 3333
Oil Leaks 3334
Maintenance Procedures After First 100 Hours or 2 Months of Service 3334
Tire and Wheel Assemblies 3334
Mast Sliding Surfaces 3334
Mast Pivot Pins and Mounting Hardware 3335
Fork Guides and Pins 3336
Integral Sideshift Carriage 3336
Check Upper and Lower Bearings 3336
Header Hoses, Hose Fittings, and Clamps 3338
Maintenance Procedures Every 500 Hours or Three Months 3338
Tire and Wheel Assemblies 3338
Forks, Inspect 3339
Mast and Carriage 3340
Mast Sliding Surfaces 3340
Mast Pivot Pins, Bushings, and Mounting Hardware 3341
Header Hoses 3341
Fourth Function Mini Rollers Lubrication 3342
Lift Chain Lubrication 3343
Lift Chain Wear Check 3343
Integral Sideshift Carriage 3344
Check Upper and Lower Bearings 3344
Fork Positioner 3345
Fork Guides and Pins 3346
Check Lower Mounting Hook 3346
Tilt Cylinder Rod End Pins 3347
Control Levers, Pedals, and Hinges 3347
Direction and Speed Control Pedals 3347
Hydraulic Hoses, Fittings, and Clamps 3347
Hydraulic Breather Cap 3348
Service Brakes 3348
Master Cylinder Oil Check 3348
Parking Brake 3349
Manual Override Handle 3349
Electrical Inspection 3350
Contactors 3350
Maintenance Procedures Every 2000 Hours or Yearly 3350
Hydraulic System 3351
Hydraulic Oil Filter, Change 3351
Hydraulic Breather, Check 3353
Steering Axle 3354
Steering Actuator and Steering Plate Torque Check 3354
Transaxle Oil Change 3354
Transaxle Breather Check 3356
Brake Oil Change 3356
Forks, Inspect 3356
Integral Sideshift Carriage 3357
Lift Chains 3357
Maintenance Procedures Every 4000 Hours or Two Years 3358
Hydraulic Oil Change 3358
Steering Wheel Position Sensor Inspection 3360
Fixed Steering Column 3360
Telescopic Steering Column 3361
Telescopic Steering Column Lubrication 3362
Welding Repairs 3363
Lift and Tilt System Leak Check 3363
Lift Cylinders Leak Check 3364
Tilt Cylinder Leak Check 3364
Battery Maintenance 3364
How to Charge Battery 3364
Rapid Charge 3366
How to Change Battery 3366
Remove the Battery 3366
Install the Battery 3368
Optional Side Removal of Battery 3370
Battery Size Specifications 3370
Wheels and Tires 3370
General 3371
Pneumatic Tires Repair 3371
Remove Wheels From Lift Truck 3371
Remove Tire From Wheel 3372
Install Wheel in Tire 3375
Add Air to Tires 3378
Wheels, Install 3378
Solid Rubber Tires on Pneumatic Wheels, Change 3378
Install the Wheels 3382
Solid Rubber (Cushioned) Tire Repair 3382
Remove Wheels From Lift Truck 3382
Remove and Install Tire on Wheel 3382
Lift Chain Adjustments 3383
524320290-8000YRM1339-(12-2019)-UK-EN 3387
Introduction 3393
General 3393
Serial Number 3393
Discharging the Capacitors 3394
Rapid Charge 3394
How to Tow a Disabled Lift Truck 3395
How to Put Lift Truck on Blocks 3396
How to Raise Drive Tires 3396
How to Raise Steer Tires 3397
How to Clean a Lift Truck 3398
Safety Procedures When Working Near Mast 3398
WHEN WORKING NEAR THE MAST ALWAYS: 3399
Maintenance Schedule 3401
Maintenance Procedures Every Shift 3408
How to Make Checks With the Key or Keyless Switch OFF 3408
Wheels and Tires 3408
Safety Labels 3409
Frame and Covers 3409
Forks 3410
General 3410
Inspect 3410
Remove 3412
Install 3415
Adjust 3415
Inspection of Mast, Carriage, Header Hoses, Lift Chains, and Attachments 3416
Hydraulic Oil Level and Leaks 3417
Operator Restraint System 3417
Emergency Locking Retractor (ELR) 3418
Seat Adjustments 3419
Seat Position Adjustment (Swivel Seat) 3419
Seat Position Adjustment (Full Suspension, High Back Seat) 3419
Seat Adjustment for Operator Weight 3420
Battery Restraint System 3421
Steering Column Adjustments 3429
Tilt Adjust Feature 3429
Tilt Memory Feature 3430
Telescopic Feature 3430
Battery Check 3430
How to Make Checks With the Key or Keyless Switch ON 3430
Control Levers and Pedals 3430
Direction and Speed Controls 3430
Electrical Components 3431
Steering System 3432
Hydraulic System 3432
Service Brakes 3432
Automatic Parking Brake 3433
Operator Presence System 3433
Oil Leaks 3433
Maintenance Procedures After First 100 Hours or 2 Months of Service 3433
Tire and Wheel Assemblies 3433
Mast Sliding Surfaces 3433
Mast Pivot Pins and Mounting Hardware 3434
Fork Guides and Pins 3435
Integral Sideshift Carriage 3435
Check Upper and Lower Bearings 3435
Header Hoses, Hose Fittings, and Clamps 3437
Maintenance Procedures Every 1000 Hours or 6 Months 3437
Tire and Wheel Assemblies 3437
Forks, Inspect 3438
Mast and Carriage 3439
Mast Sliding Surfaces 3439
Mast Pivot Pins, Bushings, and Mounting Hardware 3440
Header Hoses 3440
Fourth Function Mini Rollers Lubrication 3440
High Visibility Mast 3441
High Visibility and Heavy Duty Masts 3441
Lift Chain Lubrication 3443
Lift Chain Wear Check 3443
Integral Sideshift Carriage 3444
Check Upper and Lower Bearings 3444
Fork Positioner 3445
Check Lower Mounting Hook 3446
Fork Guides and Pins 3447
Tilt Cylinder Rod End Pins 3447
Control Levers, Pedals, and Hinges 3448
Direction and Speed Control Pedals 3448
Hydraulic Hoses, Fittings, and Clamps 3448
Hydraulic Breather Cap 3448
Service Brakes 3449
Master Cylinder Oil Check 3449
Parking Brake 3450
Manual Override Handle 3450
Electrical Inspection 3451
Contactors 3451
Cab Heater 3452
Maintenance Procedures Every 2000 Hours or Yearly 3452
Hydraulic System 3452
Hydraulic Oil Filter, Change 3452
Hydraulic Breather, Check 3455
Steering Axle 3457
Steering Actuator and Steering Plate Torque Check 3457
Transaxle Oil Change 3458
Transaxle Breather Check 3459
Brake Oil Change 3459
Forks, Inspect 3460
Integral Sideshift Carriage 3461
Lift Chains 3461
Maintenance Procedures Every 4000 Hours or Two Years 3461
Hydraulic Oil Change 3461
Steering Wheel Position Sensor Inspection 3463
Fixed Steering Column 3464
Telescopic Steering Column 3465
Telescopic Steering Column Lubrication 3466
Welding Repairs 3468
Lift and Tilt System Leak Check 3468
Lift Cylinders Leak Check 3468
Tilt Cylinder Leak Check 3469
Battery Maintenance 3469
How to Charge Battery 3469
Rapid Charge 3470
How to Change Battery 3471
Remove the Battery 3471
Install the Battery 3473
Optional Side Removal of Battery 3475
Lift Trucks Manufactured Before March, 2015 3475
Lift Trucks Manufactured After February, 2015 3476
Optional Removable Battery Tray, Battery Remove 3481
Optional Removable Battery Tray, Battery Install 3483
Battery Exchange Stacker Option 3483
Optional Battery Roller Extraction 3484
Battery Size Specifications 3484
Wheels and Tires 3484
Snap-On Solid Rubber Tires 3484
Install Snap-On Solid Tire and Wheel on Lift Truck 3487
Lift Chain Adjustments 3487
524327054-4000YRM1386-(10-2017)-UK-EN 3491
General 3495
Safety Procedures When Working Near Mast 3496
Fork Replacement 3499
Remove 3500
Install 3501
Checks 3501
Carriages Repair 3503
Standard Carriage 3503
Remove 3503
Clean and Inspect 3505
Install 3505
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 3506
Remove 3506
Disassemble 3508
Clean and Inspect 3508
Assemble 3509
Install 3510
Integral Sideshift Carriage, Lift Trucks Manufactured After December, 2016 3510
Remove 3510
Disassemble 3513
Clean and Inspect 3513
Assemble 3513
Install 3514
Two-Stage Mast With Limited Free-Lift Repair 3514
Remove 3515
Disassemble 3521
Clean and Inspect 3524
Assemble 3526
Install 3526
Header Hose Installation and Adjustment 3528
Installation 3528
Adjustment 3535
Three-Stage Mast With Full Free-Lift Repair 3535
Remove 3535
Disassemble 3541
Clean and Inspect 3546
Assemble 3548
Install 3549
Header Hose Installation and Adjustment 3550
Installation 3550
Adjustment 3558
Lift Chains Adjustment 3558
Carriage Adjustments 3560
Tilt Cylinders Adjustment 3560
Mast Adjustments 3561
Load Roller, Adjust 3561
Mast Side Kicking, Adjust 3563
524333799-4000YRM1405-(06-2019)-UK-EN 3567
General 3571
Safety Procedures When Working Near Mast 3572
Fork Replacement 3577
Remove 3577
Install 3579
Checks 3579
Carriages Repair 3580
Standard Carriage 3580
Remove 3580
Clean and Inspect 3584
Install 3584
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 3585
Remove 3585
Disassemble 3588
Clean and Inspect 3588
Assemble 3589
Install 3590
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 3590
Remove 3590
Disassemble 3593
Clean and Inspect 3593
Assemble 3594
Install 3595
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 3595
Remove 3595
Disassemble 3598
Clean and Inspect 3598
Assemble 3599
Install 3600
Fork Positioner, Lift Trucks Manufactured Prior To December, 2016 3600
Remove 3600
Clean and Inspect 3604
Disassemble and Assemble 3604
Install 3604
Fork Positioner Hydraulic Hose Adjustment 3605
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 3607
Remove 3607
Clean and Inspect 3610
Disassemble and Assemble 3610
Install 3610
Fork Positioner Hydraulic Hose Adjustment 3611
Fork Positioner Carriage, Lift Trucks Manufactured June, 2018 and After 3612
Remove 3613
Clean and Inspect 3616
Disassemble and Assemble 3616
Install 3616
Fork Positioner Hydraulic Hose Adjustment 3617
Two-Stage Mast With Limited Free-Lift Repair 3618
Remove 3618
Disassemble 3630
Clean and Inspect 3632
Assemble 3635
Install 3636
Header Hose Installation and Adjustment 3638
Install 3638
Adjust 3646
Two-Stage Mast With Full Free-Lift Repair 3646
Remove 3647
Disassemble 3657
Clean and Inspect 3662
Assemble 3665
Install 3666
Header Hose Installation and Adjustment 3667
Install 3667
Adjust 3676
Three-Stage Mast With Full Free-Lift Repair 3677
Remove 3677
Disassemble 3688
Clean and Inspect 3695
Assemble 3697
Install 3699
Header Hose Installation and Adjustment 3700
Install 3700
Adjust 3709
Four-Stage Mast With Full Free-Lift Repair 3709
Remove 3709
Disassemble 3714
Clean and Inspect 3719
Assemble 3720
Install 3721
Header Hose Installation and Adjustment 3723
Lift Chains Adjustment 3728
Carriage Adjustments 3729
Tilt Cylinders Adjustment 3730
Mast Adjustments 3730
Load Roller, Adjust 3730
Mast Side Kicking, Adjust 3732
550025937-0100YRM1446-(02-2023)-UK-EN 3735
General 3741
Discharging the Capacitors 3742
Window Replacement 3743
Front Panel 3743
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) 3743
Remove, Lift Truck Models ERP13VC, ERP15VC (B888) 3744
Clean 3746
Inspect 3746
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) 3746
Install, Lift Truck Models ERP13VC, ERP15VC (B888) 3746
Rear Panel 3746
Remove 3746
Clean 3750
Inspect 3750
Install 3750
Door Window 3751
Disassemble Window 3751
Clean 3752
Inspect 3752
Assemble Window 3752
Window Wipers Replacement 3753
Front Wiper Assembly 3753
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) 3753
Remove, Lift Truck Models ERP13VC, ERP15VC (B888) 3758
Clean 3759
Inspect 3760
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) 3760
Install, Lift Truck Models ERP13VC, ERP15VC (B888) 3761
Cab Component Repair 3762
Roof Liner 3762
Remove 3762
Clean 3763
Inspect 3763
Install 3763
Top Panel 3764
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) 3764
Remove, Lift Truck Models ERP13VC, ERP15VC (B888) 3766
Clean 3767
Inspect 3767
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) 3767
Install, Lift Truck Models ERP13VC, ERP15VC (B888) 3767
Cab Door Assembly 3768
Door Assembly 3768
Remove 3768
Lift Truck Models and ERP22-35VL (ERP045-070VL) (A976)ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 3768
Lift Truck Models and ERP15-20VT (ERP030-040VT) (G807)ERP16-20VF (ERP30-40VF) (A955) 3770
Disassemble Left Door 3772
Disassemble Right Door 3774
Clean 3776
Inspect 3776
Assemble Right Door 3776
Assemble Left Door 3776
Install 3777
Lift Truck Models and ERP22-35VL (ERP045-070VL) (A976)ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 3777
Lift Truck Models and ERP15-20VT (ERP030-040VT) (G807)ERP16-20VF (ERP30-40VF) (A955) 3777
Cab Heater 3778
Cab Heater 3778
Remove 3778
Clean 3785
Inspect 3785
Install 3785
Troubleshooting 3787
Weather Panel Replacement 3790
Remove 3790
Roof Panels 3790
Front Screen Panel 3793
Install 3794
Front Screen Panel 3794
Roof Panels 3794
550025937-0100YRM1446-(09-2014)-UK-EN 3797
550073240-1900YRM1620-(01-2023)-UK-EN 3851
Proper Flushing after Major Hydraulic Repairs 3857
Introduction 3857
The Phases of Wear 3857
Causes of Hydraulic System Failure 3857
Progression of Contaminant Caused Hydraulic System Failure 3858
Hydraulic System Flushing Techniques 3858
Double Oil and Filter Change 3858
Mechanical Cleaning 3859
Cleaning of Components 3859
How to Clean Tubes and Hoses 3859
Filter Caddy 3859
Start-Up Procedure for Cleaned System 3860
Contaminated Oil Coolers 3860
Additional Filter Caddy Functions 3861
How to Handle Different Fluids 3861
Water Removal Filters 3861
Fluid Conditioning and System Flushing Procedures 3862
Operation of the Filter Caddy 3862
Filter Caddy operation 3862
Fluid Conditioning Procedure 3862
Filter Caddy Start-Up 3863
System Flushing Procedure 3863
Component Cleaning Procedure 3864
Reservoir Cleaning Procedure 3864
Cylinder Cleaning Procedure 3864
Hose and Tube Cleaning Procedure 3864
Valve Cleaning Procedure 3865
Front-End Attachment Cleaning Procedure 3866
System Flushing Procedure 3866
Filter Caddy Start-Up 3867
System Start-Up and Flushing 3867
Reservoir Fluid Cleaning Times 3868
Dealing With Different Fluid Types 3869
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 3869
Filter Caddy Maintenance 3869
Servicing the Strainer 3869
DC Motor 3869
Hydraulic Oil Sampling Method and Procedure 3870
Hydraulic Oil Sampling Method 3870
Objective 3870
General Guidelines 3870
Synopsis 3871
Hydraulic Oil Analysis Report Guidelines 3872
Sampling Conditions 3872
Equipment 3872
Sampling Procedure 3873
Hydraulic Oil Sampling 3873
Sample Labeling 3873
Results Documentation 3873
550073240-1900YRM1620-(03-2020)-UK-EN 3875
Proper Flushing after Major Hydraulic Repairs 3879
Introduction 3879
The Phases of Wear 3879
Causes of Hydraulic System Failure 3879
Progression of Contaminant Caused Hydraulic System Failure 3880
Hydraulic System Flushing Techniques 3880
Double Oil and Filter Change 3880
Mechanical Cleaning 3881
Cleaning of Components 3881
How to Clean Tubes and Hoses 3881
Filter Caddy 3881
Start-Up Procedure for Cleaned System 3882
Contaminated Oil Coolers 3882
Additional Filter Caddy Functions 3882
How to Handle Different Fluids 3882
Water Removal Filters 3883
Fluid Conditioning and System Flushing Procedures 3883
Operation of the Filter Caddy 3883
Filter Caddy operation 3883
Fluid Conditioning Procedure 3884
Filter Caddy Start-Up 3884
System Flushing Procedure 3885
Component Cleaning Procedure 3885
Reservoir Cleaning Procedure 3885
Cylinder Cleaning Procedure 3885
Hose and Tube Cleaning Procedure 3886
Valve Cleaning Procedure 3886
Front-End Attachment Cleaning Procedure 3887
System Flushing Procedure 3887
Filter Caddy Start-Up 3888
System Start-Up and Flushing 3888
Reservoir Fluid Cleaning Times 3889
Dealing With Different Fluid Types 3889
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 3889
Filter Caddy Maintenance 3890
Servicing the Strainer 3890
DC Motor 3890
Hydraulic Oil Sampling Method and Procedure 3890
Hydraulic Oil Sampling Method 3890
Objective 3890
General Guidelines 3890
Synopsis 3891
Hydraulic Oil Analysis Report Guidelines 3892
Sampling Conditions 3893
Equipment 3893
Sampling Procedure 3893
Hydraulic Oil Sampling 3893
Sample Labeling 3894
Results Documentation 3894