YALE A839 ERC070HG, ERC080HG, ERC100HG, ERC120HG Lift Truck Service Repair Manual
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Maintenance
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ERC70-120HD, ERC70-120HG [A839];
GC/GLC70-120LG/MG [B818];
GP/GLP/GDP70-120LG/MG [B813]
PART NO. 524166837 1800 YRM 338
HM040042
SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fas-
tened, and that the load being lifted is balanced. Make sure the crane, cables, and chains
have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on
electric lift trucks.
• Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE
LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use YALE APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using
force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or
if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels
and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away
from the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this manual:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!
Brake System Table of Contents
TABLE OF CONTENTS
General ................................................................................................................................................................ 1
Description and Operation ................................................................................................................................... 1
Brake Booster and Master Cylinder ................................................................................................................ 1
Master Cylinder ............................................................................................................................................... 1
Service Brake Assembly ................................................................................................................................. 1
Parking Brake .................................................................................................................................................. 4
Brake Shoe Assemblies Repair ........................................................................................................................... 5
Remove and Disassemble .............................................................................................................................. 5
Clean and Inspect ........................................................................................................................................... 5
Assemble and Install ....................................................................................................................................... 7
Master Cylinder Repair ........................................................................................................................................ 10
Master Cylinder GC/GLC70-120LG/MG and GP/GLP/GDP70-120LG/MG .................................................... 10
Remove....................................................................................................................................................... 10
Disassemble ............................................................................................................................................... 11
Assemble .................................................................................................................................................... 11
Install .......................................................................................................................................................... 11
Master Cylinder ERC70-120HD and ERC70-120HG ...................................................................................... 12
Remove and Disassemble .......................................................................................................................... 12
Clean and Inspect ....................................................................................................................................... 14
Assemble and Install ................................................................................................................................... 14
Brake Booster Repair .......................................................................................................................................... 14
Remove ........................................................................................................................................................... 14
Disassemble.................................................................................................................................................... 14
Clean and Inspect ........................................................................................................................................... 15
Assemble ........................................................................................................................................................ 15
Install ............................................................................................................................................................... 15
Brake System Air Removal .................................................................................................................................. 16
Brake Pedal Adjustment ...................................................................................................................................... 16
Brake Pedal GP/GLP/GDP70-120LG/MG with Manual Transmission and ERC70-120HD and
ERC70-120HG ................................................................................................................................................ 16
Brake Shoes Adjustment ..................................................................................................................................... 17
Parking Brake Adjustment ................................................................................................................................... 18
Parking Brake Adjustment GC/GLC70-120LG/MG and GP/GLP/GDP70-120LG/MG .................................... 18
Parking Brake Lever and Switch Adjustment ERC70-120HD and ERC70-120HG ......................................... 18
Brake Booster Relief Valve Check ....................................................................................................................... 18
Troubleshooting ................................................................................................................................................... 19
This section is for the following models:
ERC70-120HD, ERC70-120HG [A839];
GC/GLC70-120LG/MG [B818];
GP/GLP/GDP70-120LG/MG [B813]
©2002 Yale Materials Handling Corp. i
1800 YRM 338 Description and Operation
General
This section has a description and the repair proce-
dures for the parts of the hydraulic brake system. These
parts include the brake booster, master cylinder, and
brake shoe assemblies.
Description and Operation
The master cylinder is actuated by a brake booster
on the GC/GLC70-120LG/MG and GP/GLP/GDP70-
120LG/MG lift trucks. The brake booster is a hydraulic
valve actuated by the brake pedal. The brake booster
uses the oil that flows from the steering control unit
to multiply the force of the brake pedal. The system
allows braking without hydraulic pressure at the brake
booster.
Lift trucks of the ERC70-120HD and ERC70-120HG se-
ries have a different master cylinder that is not actuated
by a brake booster.
BRAKE BOOSTER AND MASTER
CYLINDER
These parts are for the GC/GLC70-120LG/MG and
GP/GLP/GDP70-120LG/MG models. See Figure 1.
The operation of the parts is described in Figure 2.
MASTER CYLINDER
This master cylinder is for the ERC70-120HD and
ERC70-120HG models. See Figure 3. The master
cylinder has a housing and a piston assembly. The
housing has two ports between the bore for the piston
and the reservoir for the fluid. The compensator
port in front of the piston is open when the piston is
fully retracted. The compensator port lets fluid move
to or from the brake system when the temperature
changes. Another port keeps fluid in the cavity around
the piston. The piston moves in the housing when the
operator pushes the brake pedal. A small movement
of the piston closes the compensator port. Hydraulic
pressure actuates the wheel cylinders as the piston
pushes fluid through the check valve. A return spring
pushes the piston back to the stop plate when the
pedal is released. Fluid can flow through passages
in the piston and past the primary cup as the piston
returns. Fluid flows across the piston to prevent a
vacuum while fluid returns through the check valve.
When the piston passes the compensator port, excess
fluid from the system can return to the reservoir. The
check valve keeps a very small amount of pressure
in the brake system. The pressure helps to keep the
system effectively sealed.
SERVICE BRAKE ASSEMBLY
A service brake assembly is installed at each end of the
housing for the drive axle. See Figure 4. Each service
brake assembly has a single wheel cylinder at the top
of each back plate. The support plate has an anchor
for each shoe. When the wheel cylinder is actuated by
fluid pressure from the master cylinder, the shoes touch
the drum. The primary shoe starts to turn with the drum.
This action pushes the secondary shoe tight against the
drum and the anchor. This servo action increases the
force applied to the brake drums. When the lift truck is
traveling in reverse, the primary shoe is pushed against
the anchor and the drum by the secondary shoe.
NOTE: GC/GLC70-120LG/MG AND GP/GLP/GDP70-
120LG/MG.
1. BRAKE BOOSTER
2. INLET FROM STEERING CONTROL UNIT
3. OUTLET TO HYDRAULIC TANK
4. MASTER CYLINDER
5. INLET FROM RESERVOIR
6. OUTLET TO WHEEL CYLINDERS
Figure 1. Brake Booster and Master Cylinder
1
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