Yale Forklift C839 (ERC070HH, ERC080HH, ERC100HH, ERC120HH) Service Manual PDF

Yale Forklift C839 (ERC070HH, ERC080HH, ERC100HH, ERC120HH) Service Manual – PDF DOWNLOAD

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Yale Forklift C839 (ERC070HH, ERC080HH, ERC100HH, ERC120HH) Service Manual – PDF DOWNLOAD

Language : English
Pages : 1298
Downloadable : Yes
File Type : PDF

PART NO. 524150783

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift C839 (ERC070HH, ERC080HH, ERC100HH, ERC120HH) Service Manual – PDF DOWNLOAD

524150783-1600YRM0326-(03-2007)-UK-EN 1
toc 1
Steering Axle 1
Safety Precautions Maintenance and Repair 2
General 5
Description 5
Steering Axle Assembly Repair 10
Steering Axle GP/GLP/GDP070-110LG/MG (B813), GC/GLC070-120LG/MG 10
Remove 10
Install 10
Steering Axle GDP60-70CA (GP/GLP/GDP135-155CA) (A878, B878), GLP 11
Remove 11
Install 11
Wheels and Hubs Repair (All Units) 12
Remove and Disassemble 12
Clean 12
Inspect 12
Assemble and Install 12
Spindles and Bearings Repair (All Units) 14
Remove 14
Clean 14
Assemble and Install 15
Tie Rods Repair (All Units) 16
Remove 16
Clean 16
Install 16
Steering Cylinder Repair 19
Remove and Disassemble 19
Clean and Inspect 19
Assemble and Install 19
Troubleshooting 20
524150797-8000YRM0231-(02-2023)-UK-EN 25
General 31
Threaded Fasteners 31
Nomenclature, Threads 31
Strength Identification 32
Cotter (Split) Pins 33
Fastener Torque Tables 38
Conversion Table 40
524150797-8000YRM0231-(03-2020)-UK-EN 47
General 51
Threaded Fasteners 51
Nomenclature, Threads 51
Strength Identification 52
Cotter (Split) Pins 53
Fastener Torque Tables 58
Conversion Table 60
524153920-4000YRM0736-(07-2010)-UK-EN 67
toc 67
Masts 67
Safety Precautions Maintenance and Repair 68
General 71
Description and Operation 71
Carriages 71
Two-Stage Mast With Limited Free-Lift 71
Two-Stage Mast With Full Free-Lift 72
Three-Stage Mast With Full Free-Lift 73
Safety Procedures When Working Near Mast 75
Fork Replacement 77
Remove 78
Install 78
Carriage Repair 79
Remove 79
Sideshift Carriage Repair 81
Remove 81
Disassemble 81
Assemble 81
Install 81
Two-Stage Mast With Limited Free-Lift Repair 83
Remove, GLP/GDP3 5-5 5LJ/MJ (GP/GLP/GDP070-120LJ/MJ) Model Lift 83
Remove, GC070-120LJ/MJ, ERC070-120HG (A839), and ERC35-55HG (ERC 85
Disassemble 88
Clean and Inspect 88
Assemble 89
Install, GLP/GDP3 5-5 5LJ/MJ (GP/GLP/GDP070-120LJ/MJ) Lift Truck 90
Install, GC070-120LJ/MJ, ERC070-120HG (A839), and ERC35-55HG (ER 92
Two-Stage Mast With Full Free-Lift Repair 94
Remove 94
Disassemble 94
Clean and Inspect 96
Assemble 96
Install 96
Three-Stage Mast With Full Free-Lift Repair 98
Remove 98
Disassemble 98
Clean and Inspect 102
Assemble 102
Install 103
Mast Operation Check 109
Lift and Tilt System Leak Check 110
Lift System 110
Tilt System 111
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment 112
Lift Chain Adjustments 114
Mast Adjustments 116
Carriage Adjustment 118
Troubleshooting 119
tables 67
Table 1 Tilt Cylinder Leak Check Specifications, GC070-120LJ/MJ 111
Table 2 Hook-Type Carriage Chain Adjustment 114
Table 3 Pin-Type Carriage Chain Adjustment 115
524158040-2240YRM0001-(01-2023)-UK-EN 125
General 131
Battery Type 131
Lead-Acid Batteries 131
Lithium-Ion Batteries 132
Specific Gravity 132
Chemical Reaction in a Cell 132
Electrical Terms 134
Battery Selection 135
Battery Voltage 136
Battery as a Counterweight 136
Battery Ratings 136
Kilowatt-Hours 136
Battery Maintenance 137
Safety Procedures 137
Maintenance Records 137
New Battery 137
Cleaning Battery 138
Adding Water to Battery 140
Hydrometer 140
Battery Temperature 141
Charging Battery 142
Types of Battery Charges 143
Methods of Charging 144
Troubleshooting Charger 145
Knowing When Battery Is Fully Charged 145
Where to Charge Batteries 145
Equipment Needed 145
Battery Connectors 146
Battery Care 146
Troubleshooting 148
524158040-2240YRM0001-(03-2020)-UK-EN 153
General 157
Battery Type 157
Lead-Acid Batteries 157
Lithium-Ion Batteries 158
Specific Gravity 158
Chemical Reaction in a Cell 158
Electrical Terms 160
Battery Selection 160
Battery Voltage 161
Battery as a Counterweight 162
Battery Ratings 162
Kilowatt-Hours 162
Battery Maintenance 162
Safety Procedures 162
Maintenance Records 163
New Battery 163
Cleaning Battery 163
Adding Water to Battery 165
Hydrometer 166
Battery Temperature 167
Charging Battery 168
Types of Battery Charges 168
Methods of Charging 170
Troubleshooting Charger 170
Knowing When Battery Is Fully Charged 171
Where to Charge Batteries 171
Equipment Needed 171
Battery Connectors 172
Battery Care 172
Troubleshooting 174
524158753-1600YRM0720-(11-2006)-UK-EN 179
toc 179
Steering Housing and Control Unit 179
Safety Precautions Maintenance and Repair 180
General 183
Description 183
Operation 184
Steering Wheel and Column Assembly Repair 185
Assembly Components, Remove 185
Steering Control Unit, Disassemble 190
Steering Control Unit, Clean 190
Steering Control Unit, Assemble 190
Assembly Components, Install 192
System Air Removal 194
Troubleshooting 194
524166834-1400YRM0413-(11-2006)-UK-EN 199
toc 199
Drive Axle, Speed Reducer, and Differential 199
Safety Precautions Maintenance and Repair 200
General 203
Description 203
Drive Axle, Speed Reducer, and Differential Repair 204
Remove 204
General 204
Traction Motor, Speed Reducer, and Differential 205
Motor, Speed Reducer, and Differential, Remove 205
Disassemble 208
Speed Reducer 208
Differential 209
Clean 210
Inspect 210
Assemble 210
Speed Reducer 210
Input Gear, Install 210
New Pinion, Install 210
Differential 213
Drive Axle Housing 216
Remove 216
Clean 217
Inspect 217
Assemble 217
Troubleshooting 220
tables 199
Table 1 Pinion Assembly Shims Adjustment 212
Table 2 Ring and Pinion Tooth Contact Adjustment 214
524166837-1800YRM0338-(05-2009)-UK-EN 223
toc 223
Brake System 223
Safety Precautions Maintenance and Repair 224
General 227
Description and Operation 227
Brake Booster and Master Cylinder 227
Master Cylinder 227
Service Brake Assembly 227
Parking Brake 231
Seat Brake 232
Brake Shoe Assemblies Repair 233
Remove and Disassemble 233
Clean and Inspect 233
Assemble and Install 235
Master Cylinder Repair 239
Master Cylinder For Lift Truck Models GC/GLC70-120LG/MG (B818) a 239
Remove 239
Disassemble 239
Assemble 240
Install 240
Master Cylinder For Lift Truck Models ERC70-120HD, ERC70-120HG ( 241
Remove and Disassemble 241
Clean and Inspect 242
Assemble and Install 242
Brake Booster Repair 242
Remove 242
Disassemble 242
Clean and Inspect 243
Assemble 244
Install 244
Brake System Air Removal 244
Brake Pedal Adjustment 244
Brake Pedal GP/GLP/GDP70-120LG/MG (B813) With Manual Transmissio 244
Brake Shoes Adjustment 246
Parking Brake Adjustment 246
Parking Brake Adjustment, Lift Truck Models GC/GLC70-120LG/MG (B 246
Parking Brake Lever and Switch Adjustment ERC70-120HD and ERC70- 247
Seat Brake Assembly 248
Remove 248
Clean and Inspect 248
Install 248
Adjustments 250
Solenoid Adjustment 250
Traction cutoff Switch Adjustment 250
Cable Adjustment 250
Brake Booster Relief Valve Check 253
Troubleshooting 253
524166839-2000YRM0077-(02-2009)-UK-EN 259
toc 259
Manual hydraulic Control Valve 259
Safety Precautions Maintenance and Repair 260
General 263
Description 263
Operation 265
Lift Section 267
Tilt Section 268
Tilt Backward 268
Tilt Forward 268
Relief Valve 270
Solenoid Valve for Auxiliary Function 271
Main Control Valve Repair 272
Remove and Disassemble – Control Valve Without OPS Solenoid 272
Remove and Disassemble – Control Valve With OPS Solenoid 272
Clean and Inspect 274
Assemble – Control Valve Without OPS 274
Assemble – Control Valve With OPS 274
Install 275
Solenoid Valve for Auxiliary Function Repair 275
Remove and Disassemble 275
Assemble and Install 277
Troubleshooting 277
Pressure Relief Valve Check and Adjustment 278
Primary Relief Valve 278
Secondary Relief Valve 278
Control Lever Arrangement and Adjustment 279
Specifications 281
Troubleshooting 281
524179945-1900YRM0559-(04-2009)-UK-EN 287
toc 287
Hydraulic System 287
Safety Precautions Maintenance and Repair 288
General 291
Description 291
Hydraulic System 291
Operation 299
Hydraulic System 299
Hydraulic Gear Pump 305
Steering Pump 305
Hydraulic Tank Repair 313
Tank, Remove [ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814); ERC/P1 313
Tank, Remove [ERP20-30ALF (B216) and ERP20-30ALF (ERP040-060DH) 315
Tank, Remove [ERP20-32ALF (ERP040-065DH) (E216)] 316
Hydraulic Tank [ERC35-55HG (ERC70-120HH) (B839/C839)] 316
Inspect 317
Small Leaks, Repair 318
Large Leaks, Repair 318
Clean 318
Steam Method 318
Chemical Solution Method 319
Additional Methods for Tank Repair 319
Tank, Install [ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814); ERC/P 319
Tank, Install [ERP20-30ALF (B216) and ERP20-30ALF (ERP040-060DH) 320
Tank, Install [ERP20-32ALF (ERP040-065DH) (E216)] 320
Filter Replacement 321
All Lift Trucks Except [ERC35-55HG (ERC70-120HH) (B839/C839); ER 321
Remove 321
Install 322
Lift Truck Models [ERC35-55HG (ERC70-120HH) (B839/C839)] 322
Remove 322
Install 322
Lift truck Models [ERC20-32AGF (ERC040-065GH) (A908) and ERC/P16 323
Remove 323
Install 323
Lift Truck Models [ERP20-32ALF (ERP040-065DH) (E216)] 325
Remove 325
Install 325
Hydraulic Pump Repair 328
Hydraulic Pump, Remove [ERC/P16-20AAF (ERC030-040AF, AG/BG) (A81 328
Hydraulic Pump, Disassemble ERC/P16-20AAF (ERC030-040AF, AG/BG) 328
Inspect 330
Clean 330
Pump Seal Replace and Pump Assemble 330
Assemble Pump on Motor 330
Hydraulic Pump and Motor, Install [ERC/P16-20AAF (ERC030-040AF, 332
Hydraulic Pump, Remove [ERP20-30ALF (B216); ERP20-30ALF (ERP040- 333
Hydraulic Pump, Disassemble [ERC35-55HG (ERC70-120HH) (B839/C839 334
Hydraulic Pump, Inspect [ERC35-55HG (ERC70-120HH) (B839/C839) an 336
Hydraulic Pump, Clean [ERC35-55HG (ERC70-120HH) (B839/C839) and 336
Hydraulic Pump, Assemble [ERC35-55HG (ERC70-120HH) (B839/C839) a 336
Hydraulic Pump and Motor, Install [ERP20-30ALF (B216); ERP20-30A 336
Main Control Valve Repair 338
Steering Pump Repair 338
Pump, Remove and Disassemble [ERC/P16-20AAF (ERC030-040AF, ERC03 338
Pump, Remove and Disassemble [ERP20-30ALF (B216); ERP20-30ALF (E 340
Pump, Assemble and Install 342
Steering Control Unit Replacement 343
Remove 343
Install 343
Steering Cylinder Repair 349
Main Control Valve Check and Adjust 349
Steering Relief Valve Check and Adjust 350
Specifications 350
Relief Valve Pressures* 350
Hydraulic Tank Capacity (dipstick full mark) 351
Hydraulic Pump Capacities – All Models Except ERC35-55HG (ERC70- 351
Hydraulic Pump Capacities – Models ERC35-55HG (ERC70-120HH) (B83 351
Troubleshooting 351
Steering 351
Steering Housing and Steering Control Unit 352
Hydraulic System 353
524183081-1600YRM1054-(11-2006)-UK-EN 359
toc 359
Steering System for AC Electric Lift Trucks 359
Safety Precautions Maintenance and Repair 360
General 363
Description 364
Steering Wheel and Column Assembly Repair 365
General 365
Assembly Components, Remove 367
Assembly Components, Install 368
Power Steering Motor and Pump 369
Description 369
Remove 369
Disassemble 372
Install 372
Power Steering Pump, Repair 372
Seal, Replace 373
Steering System Air Removal 374
Steering Pressure Check 374
Steering Motor Circuits Check 375
Troubleshooting 376
524183082-2200YRM1055-(10-2009)-UK-EN 381
toc 381
Electrical System (Trucks With AC Controllers) 381
Safety Precautions Maintenance and Repair 382
General 385
Description 386
Features of the Display Panels 386
Other Control Components 387
Display Panel and Key Switch Replacement 388
Display Panel, Replace 388
Key Switch, Replace 390
Controller Replacement 390
Traction and Pump Motor Controller Replacement 390
Master Controller, Replace 396
Master Controller, Remove ERP20-30ALF (ERP040-060DH) (D216), ERP 396
Master Controller, Install ERP20-30ALF (ERP040-060DH) (D216), ER 396
Master Controller, Remove ERC/P16-20AAF (ERC030-040AH) (B814/C81 398
Master Controller, Install ERC/P16-20AAF (ERC030-040AH) (B814/C8 398
Master Controller, Remove ERC35-55HG (ERC070-120HH) (B839/C839) 400
Master Controller, Install ERC35-55HG (ERC070-120HH) (B839/C839) 400
Control Components Replacement 401
General 401
Start Switch, Replace 401
Brake Light Switch, Replace 402
Seat Switch, Replace 402
Parking Brake Switch, Replace 403
Foot Directional Control Pedal Direction Switches, Replace 405
Steering Column Direction Control Switches, Replace 408
Remove 408
Install 408
Brake Fluid Switch, Replace 410
Brush Wear and Over Temperature Sensors (DC Pump Motor Only) 410
Rocker Switches for Lights, Replace 410
Accelerator Position Sensor, Replace 411
On-Demand Steering Sensor, Replace 412
Lights, Converter, Relay, and Reverse Alarm 412
Brake, Tail, and Reverse Light Assembly, Replace 413
Incandescent Assembly 413
LED Assembly – Remove 415
LED Assembly – Install 415
Strobe Light Assembly, Replace 418
Wire Harness Repair 419
Del-City Crimp-Solder-Shrink Splice 419
Front, Rear Driving Light or Spot Light Assemblies, Replace 420
Converter, Replace 420
Remove, Lift Truck Models ERP20-30ALF (ERP040-060DH) (D216), ERP 420
Install, Lift Truck Models ERP20-30ALF (ERP040-060DH) (D216), ER 422
Remove, Lift Truck Models ERC20-32AGF (ERC040-065GH) (A908) and 422
Install, Lift Truck Models ERC20-32AGF (ERC040-065GH) (A908) and 422
Remove, Lift Truck Models ERC35-55HG (ERC70-120HH) (B839/C839) 424
Install, Lift Truck Models ERC35-55HG (ERC70-120HH) (B839/C839) 424
Reverse Relay, Replace 425
Lift Truck Models ERC20-32AGF (ERC040-065GH) (A908), ERC/P16-20A 425
Lift Truck Models ERC35-55HG (ERC70-120HH) (B839/C839) 425
Backup Alarm, Replace 427
Horn and Horn Button, Replace 427
Horn Replacement for Lift Trucks ERP20-30ALF (ERP040-060DH) (D21 427
Horn Replacement for Lift Trucks ERC35-55HG (ERC70-120HH) (B839/ 429
Horn Switch and Cover, Replace 430
Hydraulic Pump Switches 431
Fan Power Supply, Replace 431
Remove, Lift Truck Models ERC35-55HG (ERC70-120HH) (B839/C839) 431
Install, Lift Truck Models ERC35-55HG (ERC70-120HH) (B839/C839) 431
Remove, Lift Truck Models ERP20-30ALF (ERP040-060DH) (D216) and 432
Install, Lift Truck Models ERP20-30ALF (ERP040-060DH) (D216) and 433
Remove, Lift Truck Models ERC20-32AGF (ERC040-065GH) (A908) 433
Install, Lift Truck Models ERC20-32AGF (ERC040-065GH) (A908) 433
Control and Power Fuse Check 434
Fuse Locations 434
Brake Light Switch Adjustment 440
Seat Switch Check 441
Seat Brake Adjustment 441
Parking Brake Switch Adjustment 442
Direction Switches Check 442
Foot Directional Control Pedal 442
Steering Column 443
Foot Directional Control Pedal or Accelerator Pedal Adjustment 443
Accelerator Position Sensor Adjustment and Start Switch Adjustme 444
Acceleration Position Sensor, Adjust 444
Start Switch, Adjust 446
tables 381
Table 1 Wire Splice Size 419
524183083-2200YRM1056-(03-2009)-UK-EN 449
toc 449
AC Motor Controllers/Display Panel 449
Safety Precautions Maintenance and Repair 450
Description 453
General 453
AC Motors 453
Motor Controllers 453
Master Controller 453
Dash Display 453
Controller Area Network Bus (CANbus) 453
Master Controller Checks and Adjustments 454
Function Settings 455
General 455
Function Numbers 455
Function Descriptions 458
General 458
Function Number 1 BATTERY VOLTAGE 458
Function Number 2 EXTENDED SHIFT 458
Function Number 3 ACCELERATION 1 458
Function Number 4 ACCELERATION 2 458
Function Number 5 TOP SPEED LIMIT 458
Function Number 6 REGEN BRAKING 458
Function Number 7 AUTO DECELERATION 459
Function Number 8 BDI ADJUSTMENT 459
Function Number 9 LIFT INTERRUPT 459
Function Number 10 POWER STEERING TIME DELAY 459
Function Number 11 SERVICE REMINDER 459
Function Number 12 CUSTOM 459
Function Number 13 PUMP SPEED 1 459
Function Number 14 PUMP SPEED 2 460
Function Number 15 PUMP SPEED 3 460
Function Number 16 PUMP ACCELERATION 460
Troubleshooting 460
General 460
Controller Status Light Emitting Diodes (LEDs) 461
Master Controller 461
AC Motor Controllers 461
Status Codes 467
AC Motor Controllers Status Code Charts 469
Troubleshooting When Dash and/or Lift Truck is not Operational 490
Typical Symptoms 490
Truck Runs but Dash Display is not Operational, or Only Displays 490
Truck Does Not Run and Dash is Not Operational or Only Displays 491
Hydraulics Operate Normally, Traction Does Not Operate Correctly 492
Traction Operates Normally, Hydraulics do Not Operate Correctly, 492
AC Transistor Motor Controller Replacement 492
General 492
General Maintenance Instructions 498
Special Precautions 498
Fuses 499
Fan Test 499
Contactors 499
Repair 499
Thermal Sensors 503
Motor Controller, Replace 503
Display Panel 504
General 504
Premium Display Panel 504
Standard Display Panel 504
Display Functions and Features 505
Key-On Initialization 505
Standard Display 506
Premium Display 506
Lift Truck Inspection Function 507
Access to Service Functions 507
Service Functions 507
Service Functions 508
Performance Modes 510
Battery Discharge Indicator (BDI) 510
Hourmeter 511
Dash Display Service Menu Navigation 517
General 517
Moving Through Menu Selections 517
Editing and Adding Information 517
tables 449
Table 1 Factory Parameters for ERP20-30ALF (ERP040-060DH) (D216 455
Table 2 Factory Setting for ERC020-032AGF (ERC40-65GH) (A908) 456
Table 3 Factory Setting for ERC/P16-20AAF (ERC030-040AH) (B814/ 456
Table 4 Factory Parameters for ERC35-55HG (ERC70-120HH) (B839/C 457
Table 5 List of Status Codes 467
Table 6 42-Pin Connections/Descriptions for Master Controller 500
Table 7 Pin Connections/Descriptions for 72/80 (Gen IV) Volt Mo 502
Table 8 Pin Connections/Descriptions for 36/48 and 72v/80v (Gen 502
524183085-2200YRM1058-(04-2011)-UK-EN 521
toc 521
Troubleshooting and Adjustments Using the AC Controls Program (E 521
Safety Precautions Maintenance and Repair 522
General 525
Computer Requirements 525
Software, Install 525
Language Selection 525
Demo Mode 526
Connect PC to Lift Truck 530
Starting AC Controls Program 532
Lift Truck Control Setup 537
Change Lift Truck Serial Number or Hourmeter 537
Setting Factory Default Values or Changing Lift Truck Parameters 538
Create New Custom Lift Truck Configuration 544
Lift Truck Configuration Properties 547
Import New Lift Truck Configuration From Disk 550
Delete Custom Lift Truck Configuration or Password File 552
Dash Display 555
Custom Display Languages 555
Download Display Language 557
Clear Operator Log 557
Password Functions 560
Enable/Disable Password and Lift Truck Inspection Functions 560
Truck Inspection Checklist 560
Password 560
Password Properties 560
Create New Password File 565
Download Passwords 566
Upload Passwords 568
Reports Menu 570
Devices Report 570
Custom Report 570
Password Report 570
Operator Report 577
Current Settings Report 580
Status Code Report 584
Status Codes Log 587
Troubleshooting 589
Diagnostics 589
Help Menu 592
General 592
Contents 592
Technical Support 592
About Electric Truck AC Controls Program 592
524205680-0620YRM1098-(03-2010)-UK-EN 599
toc 599
AC Motor Repair 599
Safety Precautions Maintenance and Repair 600
General 603
AC Motor Repair 603
Disassemble 603
Assemble 607
Troubleshooting 609
524223768-2100YRM1139-(02-2014)-UK-EN 613
524238572-0100YRM1200-(11-2006)-UK-EN 661
toc 661
Frame 661
Safety Precautions Maintenance and Repair 662
General 665
Description 665
Overhead Guard Replacement 667
Remove 667
Install 668
Battery and Operator Restraint, Hood and Seat Brake Repair 669
Battery Restraint and Hood Repair 669
Operator Restraint System and Seat Assembly 672
Automatic Locking Retractor (ALR) 672
Emergency Locking Retractor (ELR) 672
Seat Brake Repair 673
Counterweight Replacement 673
Remove 673
Install 674
Traction Motor Repair 674
Remove 674
Install 675
Hydraulic Tank Repair 676
Inspect 676
Small Leaks, Repair 676
Large Leaks, Repair 676
Clean 676
Steam Method 677
Chemical Solution Method 677
Additional Preparations For Repair 677
Safety Label Replacement 678
Battery Specifications 680
tables 661
Table 1 Torque Values 668
Table 2 Weight of Counterweights 673
Table 3 Battery Specifications* 680
524238574-8000YRM1201-(02-2010)-UK-EN 683
toc 683
Periodic Maintenance 683
Safety Precautions Maintenance and Repair 684
General 689
How to Move Disabled Lift Truck 689
How to Tow Lift Truck 689
How to Put Lift Trucks on Blocks 690
How to Raise Drive Tires 690
How to Raise Steering Tires 690
How to Clean a Lift Truck 691
Maintenance Schedule 692
Maintenance Procedures Every 8 Hours or Daily 696
General 696
How to Make Checks With Key Switch OFF 697
Tires and Wheels 697
Forks 697
Remove 697
Inspect 697
Install 698
Adjust 698
Inspection of Mast, Mast Pivots, Header Hoses and Lift Chains 699
Safety Labels 699
Steering Column Latch 699
Operator Restraint System 700
Automatic Locking Retractor (ALR) 700
Emergency Locking Retractor (ELR) 700
Battery Restraint System 701
Battery 702
Hydraulic System 703
How to Make Checks With Key Switch ON 704
Horn, Lights, and Alarm 704
Steering System 705
Service Brakes 705
Parking Brake 705
Seat Brake 705
Control Levers and Pedals 705
Direction and Speed Control Pedals 705
Lift System Operation 705
Oil Leaks 706
First Service After First 100 Hours of Operation 706
Change Hydraulic Oil and Filter 706
Lift Truck Models ERC35-55HG (ERC70-120HH) (C839) 706
Remove 706
Install 708
Lift Truck Models ERC35-55HG (ERC70-120HH) (B839) 709
Remove 709
Install 710
Maintenance Procedures Every 500 Hours or 3 Months 711
Wheel Nuts 711
Header Hose Checks 711
Mast Lubrication 711
Integral Sideshift Carriage 714
Brake Fluid 715
Other Lubrication 715
Maintenance Procedures Every 1000 Hours or 6 Months 715
Differential and Speed Reducer 715
Lift Chains 715
Wear Check 715
Lubrication 716
Forks 716
Parking Brake 716
Brake Linkage Shafts 717
Steering Spindles and Tie Rod Ends 717
Seat Rails 717
Seat Plate Hinges 717
Electrical Inspection 718
Contactors 718
Maintenance Procedures Every 2000 Hours or Yearly 720
Brake Fluid 720
Hydraulic System 721
Hydraulic Tank Breather, Lift Truck Models ERC35-55HG (ERC70-120 721
Change Hydraulic Oil and Hydraulic Oil Filter, Lift Truck Models 721
Remove 721
Install 722
Hydraulic Tank Breather, Lift Truck Models ERC35-55HG (ERC70-120 723
Remove 723
Install 723
Change Hydraulic Oil and Hydraulic Oil Filter, Lift Truck Models 723
Remove 723
Install 725
Differential and Speed Reducer 725
Service Brakes 726
Wheel Bearings 726
Steer Wheels, Lubrication 726
Drive Wheels, Lubrication 726
Lift Chains 726
Battery Maintenance 727
How to Charge Battery 727
How to Change Battery 728
Safety Procedures When Working Near Mast 731
Lift and Tilt System Leak Check 734
Check Lift Cylinders for Leaks 734
Check Tilt Cylinders for Leaks 734
Lift Chain Adjustments 735
Welding Repairs 736
Overhead Guard Changes 737
Wheels and Tires 737
General 737
Remove Wheels From Lift Truck 737
Remove Tire From Wheel and Install Tire on Wheel 737
Remove 737
Install 737
Install Wheels 738
tables 683
Table 1 Maintenance Schedule 693
Table 2 Battery Specifications* 731
Table 3 Hook-Type Carriage Chain Adjustment 736
524238575-8000YRM1202-(11-2006)-UK-EN 741
toc 741
Capacities and Specifications 741
Safety Precautions Maintenance and Repair 742
Lift Truck Lifting Capacity 745
Counterweight Weights 745
Tire Sizes 745
Capacities 746
Hydraulic System 746
Steering System 747
Specifications 747
Turning Radius 747
Mast Speeds 748
Maximum Carriage and Tilt Creep Rates 749
Battery Specifications 749
Traction Motor Speed 750
Battery Current at Hoist Relief 750
Torque Specifications 750
Brake System 750
Differential 751
Drive Axle 751
Frame 751
Mast 751
Main Control Valve 751
Steering System 751
Tilt Cylinders 752
Hydraulic System 752
Electrical System 752
tables 741
Table 1 Manual Control Valve 746
Table 2 E-Hydraulic Control Valve 746
524238576-8000YRM1203-(02-2009)-UK-EN 755
toc 755
Diagrams 755
Safety Precautions Maintenance and Repair 756
524256687-2000YRM1224-(04-2008)-UK-EN 795
toc 795
Electro-hydraulic Control Valve 795
Safety Precautions Maintenance and Repair 796
General 799
Description 799
Electro-Hydraulic Control System 799
Electro-Hydraulic Control Valve 802
Electro-Hydraulic Valve Driver Module 818
Mini-Lever Module (MLM) 818
Joystick 819
Electro-Hydraulic Control Valve Repair 820
Remove 820
Disassemble 829
Solenoid Coil Replacement 831
Cartridge Replacement 833
Electro-Hydraulic Pressure Reducing Valve (EHPR) Replacement 834
Lift Circuit Check Valve Replacement 835
Compensator Cartridge Replacement 835
Primary and Secondary Relief Valves Replacement 835
Tilt Counterbalance Valve Replacement 836
Flow Regulator Valve Replacement 836
Assemble 836
Install 836
E-Hydraulics Calibration 845
Mini-Lever Module 847
Mini-Lever Module (MLM) 847
Remove 847
Install 847
Mini-Lever Replacement 847
Remove 847
Clean and Inspect 848
Install 848
Push Button Switch Replacement 849
Remove 849
Install 850
Test 851
Mini-levers 851
Full Stroke Test 851
Function Returns to Neutral Test 851
Push Button Switch 852
Joystick 852
Remove and Disassemble 852
Inspect 852
Assemble and Install 852
Troubleshooting 853
tables 795
Table 1 Primary and Secondary Relief Valve Values 805
Table 2 Solenoid Resistance Values 831
Table 3 Cartridge and Solenoid Coil Nut Torque for Lift truck M 834
Table 4 Cartridge and Solenoid Coil Nut Torque for Lift truck M 834
524265342-4000YRM1250-(06-2021)-UK-EN 865
Safety Procedures When Working Near Mast 871
Fork Replacement 874
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 874
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 875
Remove, Lift Truck Models Equipped With Fork Positioner and Manufactured After March, 2017GLC40, 45, 55VX, GLC55SVX (GC/GLC080, 100, 120VX, GC/GLC80, 100VXBCS, GC/GLC120SVX, GC/GLC120VXPRS (G818) and GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX (K813) 877
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 878
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 879
Install, Lift Truck Models Equipped With Fork Positioner and Manufactured After March, 2017 GLC40, 45, 55VX, GLC55SVX (GC/GLC080, 100, 120VX, GC/GLC80, 100VXBCS, GC/GLC120SVX, GC/GLC120VXPRS (G818) and GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX (K813) 880
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 880
Checks, Lift Truck Models Equipped With Fork Positioner and Manufactured After March, 2017GLC40, 45, 55VX, GLC55SVX (GC/GLC080, 100, 120VX, GC/GLC80, 100VXBCS, GC/GLC120SVX, GC/GLC120VXPRS (G818) and GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX (K813) 881
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 882
Fixed Carriage Replacement 884
Remove, Carriage With Hook Forks 884
Remove, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 892
Install, Carriage With Hook Forks 893
Install, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 893
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 894
Connecting Attachment Hydraulic Quick Disconnect Hoses 894
Integral Sideshift Carriage Repair 895
Remove, for lift truck models ERC35-55HG (ERC70-120HH) (C839), GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818) and GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813) 895
Disassemble 895
Clean and Inspect 898
Assemble 898
Install, for lift truck models ERC35-55HG (ERC70-120HH) (C839), GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818) and GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813) 899
Hang On Sideshift Carriage Repair 900
Remove, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879, G879) 900
Disassemble 912
Clean and Inspect 921
Assemble 922
Install 923
Hang-On Sideshift Carriage Repair 925
Remove 925
Disassemble Carriage 927
Clean and Inspect 930
Assemble 930
Install 933
Fork Positioner 936
Two-Stage Mast With Limited Free-Lift Repair 937
Remove 937
Disassemble 940
Clean and Inspect 943
Assemble 961
Install, Lift Truck ModelsGLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813) and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 963
Install, Lift Trucks ModelsGLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818) GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879, G879), and ERC35-55HG (ERC70-120HH) (C839) 965
Header Hose Alignment 976
Two-Stage Mast With Full Free-Lift Repair 987
Remove 987
Disassemble 989
Clean and Inspect 1000
Assemble 1001
Install, Lift Truck ModelsGLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813) 1003
Install, Lift Trucks ModelsGLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818) and ERC35-55HG (ERC70-120HH) (C839) 1006
Header Hose Installation and Adjustment 1010
Installation 1010
Adjustment 1011
Three-Stage Mast With Full Free-Lift Repair 1012
Remove 1012
Disassemble 1014
Clean and Inspect 1044
Assemble 1046
Install, Lift Truck ModelsGLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813) and GLP/GDP60VX, GLP/GDP70VX, (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 1049
Install, Lift Trucks ModelsGLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818), GC/GLC/GDC60VX, GC/GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879, G879), and ERC35-55HG (ERC70-120HH) (C839) 1054
Header Hose Alignment for GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813), and ERC35-55HG (ERC70-120HH) (C839) 1061
Header Hose Alignment for GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GC/GLC/GDC60VX, GC/GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879, G879) 1068
Mast Operation Check 1072
Tilt Cylinder Adjustment 1073
Lift Chains Adjustment 1073
Mast Adjustments 1075
Load Roller Adjustment 1075
Mast Side Kicking Adjustment 1077
Shimming The Mast Mounting Pin, Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813, H813, K813) 1078
Carriage Adjustments 1080
Series Code / Model Designation Reference Table 1081
524265342-4000YRM1250-(09-2018)-UK-EN 1085
Safety Procedures When Working Near Mast 1091
Fork Replacement 1093
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 1093
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 1095
Remove, Lift Truck Models Equipped With Fork Positioner and Manufactured After March, 2017GLC40, 45, 55VX, GLC55SVX (GC/GLC080, 100, 120VX, GC/GLC80, 100VXBCS, GC/GLC120SVX, GC/GLC120VXPRS (G818) and GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX (K813) 1096
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 1097
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 1098
Install, Lift Truck Models Equipped With Fork Positioner and Manufactured After March, 2017 GLC40, 45, 55VX, GLC55SVX (GC/GLC080, 100, 120VX, GC/GLC80, 100VXBCS, GC/GLC120SVX, GC/GLC120VXPRS (G818) and GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX (K813) 1099
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 1099
Checks, Lift Truck Models Equipped With Fork Positioner and Manufactured After March, 2017GLC40, 45, 55VX, GLC55SVX (GC/GLC080, 100, 120VX, GC/GLC80, 100VXBCS, GC/GLC120SVX, GC/GLC120VXPRS (G818) and GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX (K813) 1101
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 1101
Fixed Carriage Replacement 1103
Remove, Carriage With Hook Forks 1103
Remove, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 1112
Install, Carriage With Hook Forks 1113
Install, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 1113
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 1114
Connecting Attachment Hydraulic Quick Disconnect Hoses 1114
Integral Sideshift Carriage Repair 1115
Remove, for lift truck models ERC35-55HG (ERC70-120HH) (C839), GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818) and GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813) 1115
Disassemble 1115
Clean and Inspect 1118
Assemble 1118
Install, for lift truck models ERC35-55HG (ERC70-120HH) (C839), GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818) and GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813) 1119
Hang On Sideshift Carriage Repair 1119
Remove, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 1119
Disassemble 1131
Clean and Inspect 1140
Assemble 1141
Install 1142
Bolzoni Hang-On Sideshift Carriage Repair 1144
Remove 1144
Disassemble Carriage 1146
Clean and Inspect 1149
Assemble 1149
Install 1152
Fork Positioner 1154
Two-Stage Mast With Limited Free-Lift Repair 1155
Remove 1155
Disassemble 1159
Clean and Inspect 1162
Assemble 1179
Install, Lift Truck ModelsGLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813) and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 1181
Install, Lift Trucks ModelsGLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818) GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879), and ERC35-55HG (ERC70-120HH) (C839) 1182
Header Hose Alignment 1194
Two-Stage Mast With Full Free-Lift Repair 1204
Remove 1204
Disassemble 1206
Clean and Inspect 1218
Assemble 1219
Install, Lift Truck ModelsGLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813) 1221
Install, Lift Trucks ModelsGLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818) and ERC35-55HG (ERC70-120HH) (C839) 1224
Header Hose Installation and Adjustment 1228
Installation 1228
Adjustment 1228
Three-Stage Mast With Full Free-Lift Repair 1229
Remove 1229
Disassemble 1231
Clean and Inspect 1261
Assemble 1262
Install, Lift Truck ModelsGLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813) and GLP/GDP60VX, GLP/GDP70VX, (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 1266
Install, Lift Trucks ModelsGLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818), GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879), and ERC35-55HG (ERC70-120HH) (C839) 1271
Header Hose Alignment for GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813), and ERC35-55HG (ERC70-120HH) (C839) 1278
Header Hose Alignment for GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 1284
Mast Operation Check 1288
Tilt Cylinder Adjustment 1288
Lift Chains Adjustment 1289
Mast Adjustments 1290
Load Roller Adjustment 1290
Mast Side Kicking Adjustment 1292
Shimming The Mast Mounting Pin, Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813, H813, K813) 1293
Carriage Adjustments 1296