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GLP/GDP60VX, GLP/GDP70VX (E878) SERVICE MANUAL CONTENTS SECTION OPERATOR'S CAB........................................................................................................ FRAME............................................................................................................................ GM 4.3L V-6 ENGINES................................................................................................... KUBOTA DIESEL 3.6L ENGINE.................................................................................... KUBOTA ENGINE REPAIR 3.8L DIESEL W/DPF......................................................... COOLING SYSTEM........................................................................................................ LPG FUEL SYSTEM GM 4.3L ENGINE WITH PSI........................................................ THREE-SPEED POWERSHIFT TRANSMISSION REPAIR........................................... TRANSMISSION REPAIR (DANA SPICER) 2X2........................................................... DRIVE AXLE WET BRAKE (SPICER)............................................................................ STEERING AXLE............................................................................................................ BRAKE SYSTEM............................................................................................................ HYDRAULIC GEAR PUMP............................................................................................. HYDRAULIC CLEANLINESS PROCEDURES............................................................... MAIN CONTROL VALVE................................................................................................ CYLINDER REPAIR (MAST S/N A513, A514, A613, A614, B513, B514)..................... HIGH VOLTAGE SWITCH (HVS) IGNITION.................................................................. WIRE HARNESS REPAIR.............................................................................................. USER INTERFACE......................................................................................................... USER INTERFACE......................................................................................................... ELECTRICAL SYSTEM.................................................................................................. MAST REPAIRS (S/N A513, A514, A613, A614, A702, A703, A704, A705, A706, A707, A751, A752, B513, B514, B586, B587, B588, B589, B590, B591, B749, B750, B751, B752, B753, B754)................................................................................ METRIC AND INCH (SAE) FASTENERS....................................................................... CALIBRATION PROCEDURES...................................................................................... PERIODIC MAINTENANCE............................................................................................ CAPACITIES AND SPECIFICATIONS........................................................................... DIAGRAMS AND SCHEMATICS.................................................................................... DIAGRAMS AND SCHEMATICS.................................................................................... DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................

PART NUMBER

YRM NUMBER

REV DATE

524306203 550055278 524265337 550055279 550059479 524223757 550043871 524288194 524294873 524296605 524223764 524262279 524223766 550073240 524223767 524294878 524208014 524223769 524223770 524223771 524223772

0100 YRM 1290 0100 YRM 1581 0600 YRM 1251 0600 YRM 1579 0600 YRM 1590 0700 YRM 1123 0900 YRM 1556 1300 YRM 1317 1300 YRM 1343 1400 YRM 1344 1600 YRM 1133 1800 YRM 1247 1900 YRM 1136 1900 YRM 1620 2000 YRM 1137 2100 YRM 1328 2200 YRM 1097 2200 YRM 1128 2200 YRM 1130 2200 YRM 1131 2200 YRM 1142

04/14 08/13 05/14 01/14 09/13 03/13 04/14 03/13 03/14 12/13 07/13 03/13 04/14 12/14 04/14 02/14 05/14 12/14 12/14 12/14 04/14

524265342 524150797 524223780 550055296 550055282 550055283 550096331 524221866

4000 YRM 1250 8000 YRM 0231 8000 YRM 1134 8000 YRM 1583 8000 YRM 1584 8000 YRM 1585 8000 YRM 1689 9000 YRM 1112

02/14 10/13 12/14 01/14 02/14 04/14 04/14 12/14

Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center. 9000 YRM 1112 ON CD PART NO. 550055273 (12/14)


SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product. Updated technical service information may be available from your local authorized Yale® dealer. Service Manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in damage to the products, personal injury, property damage or death. • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, 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 hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage. On the lift truck, the WARNING symbol and word are on orange background. The CAUTION symbol and word are on yellow background.


Steering Axle

Table of Contents

TABLE OF CONTENTS General................................................................................................................................................................ Steering Axle Assembly Repair ........................................................................................................................... Remove ........................................................................................................................................................... Disassemble.................................................................................................................................................... Clean............................................................................................................................................................... Inspect............................................................................................................................................................. Assemble ........................................................................................................................................................ Install............................................................................................................................................................... Spindles, Bearings, and Tie Rods Repair............................................................................................................ Spindles and Bearings .................................................................................................................................... GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813), GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879), GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878), GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP170VX36, GLP/GDP190VX) (A909, B909).................................................................................................................. Remove .................................................................................................................................................. Disassemble ........................................................................................................................................... Clean ...................................................................................................................................................... Inspect .................................................................................................................................................... Assemble................................................................................................................................................ Install ...................................................................................................................................................... Spindles and Bearings .................................................................................................................................... GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC/GLC040SVX (C809) and GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/GDP030-035VX, GP/GLP/GDP040SVX) (C810) ................................................................................................................... Remove and Disassemble...................................................................................................................... Assemble and Install .............................................................................................................................. Tie Rods.......................................................................................................................................................... GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), and GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) ............................................................................................................................................... Remove .................................................................................................................................................. Install ...................................................................................................................................................... Tie Rods.......................................................................................................................................................... GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC/GLC040SVX (C809), GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/GDP030-035VX, GP/GLP/GDP040SVX) (C810), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813), GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879), GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878), and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP170VX36, GLP/GDP190VX) (A909, B909).................................................................................................................. Remove .................................................................................................................................................. Install ...................................................................................................................................................... Steering Cylinder Repair ..................................................................................................................................... Remove and Disassemble .............................................................................................................................. Clean and Inspect ........................................................................................................................................... Assemble and Install .......................................................................................................................................

©2013 Yale Materials Handling Corp.

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Table of Contents

Steering Axle

TABLE OF CONTENTS (Continued) Torque Specifications .......................................................................................................................................... This section is for the following models: GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX [C809]; GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) [C810]; GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) [A910]; GLP/GDP20-35VX (GP/GLP/GDP040-070VX) [B875]; GLC40, 45, 55VX; GLC55SVX (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) [E818, F818]; GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) [F813, G813, H813, J813]; GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) [C879, D879, E879, F879]; GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) [C878, D878, E878]; GLP/GDP80VX, GLP/GDP80VX9,GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) [A909, B909]

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1600 YRM 1133

General

General This section has the description and repair procedures for the steering axle. The steering axle assembly includes an axle frame, steering cylinder, and two spindle and hub assemblies. See Figure 1. The steering axle is articulated and is connected to the frame by center pivot mounts. The center pivot mounts permit the steering axle to move in the frame mount when the lift truck travels over rough surfaces.

The end caps of the steering cylinder are also the mounts for the cylinder and are held to the shell by the mount capscrews. There are O-rings, seals, and wipers in the end caps to seal the caps to the shell and rod. The ends of the piston rod extend from both ends of the cylinder. A single piston and the seal are at the center of the rod. Oil pressure on one side of the piston moves the piston in the bore. The piston pushes an equal amount of oil from the opposite side of the cylinder.

1


General

1600 YRM 1133

A. CUSHION TRUCKS ONLY

B. PNEUMATIC TRUCKS ONLY

1. 2. 3. 4.

5. 6. 7. 8.

AXLE FRAME MOUNT BRACKET STEERING CYLINDER

TIE ROD SPINDLE MOUNT HUB ASSEMBLIES

Figure 1. Steering Axle

2


1600 YRM 1133

Steering Axle Assembly Repair

When the piston reaches the end of the stroke, a relief valve in the steering circuit controls the oil pressure. The tie rods that connect the spindle arms to the cylinder are not adjustable. Each spindle turns on two tapered roller bearings in mounts in the axle frame. The preload on the bearings is controlled by shims at the lower bearing cap.

The wheels rotate on two tapered roller bearings and are held on the spindles by a castle nut. The bearing preload of the wheels is adjusted by the castle nut. The grease seals protect the bearings from dirt and water. Wear sleeves protect the hub from wear by the seals.

Steering Axle Assembly Repair REMOVE WARNING PUTTING THE LIFT TRUCK ON BLOCKS The lift truck must be put on blocks for some types of maintenance and repair. The removal of the mast, drive axle, battery, or counterweight assemblies will cause large changes in the center of gravity. When the lift truck is put on blocks, put additional blocks in the following positions: • If the mast and drive axle are removed, put blocks under the counterweight so the lift truck cannot fall backward. • If the counterweight is removed, put blocks under the mast so that the lift truck cannot fall forward. Put the lift truck on blocks on a solid, even, and level surface. Verify the blocks or stands have enough capacity to hold the lift truck. Use additional blocks next to the tires as necessary to prevent movement of the lift truck. Verify the lifting devices used during repairs can lift the weight of the parts and assemblies. See the Operating Manual or Periodic Maintenance section for your lift truck model, for the procedures to put the lift truck on blocks. The steering axle can be removed without removing the counterweight. 1. Verify wheels are set for straight travel. Put lift truck on blocks so the steering axle will have enough clearance to be removed. The top of the axle frame must have clearance under the bottom of the frame at the rear of the lift truck. 2. Disconnect hydraulic lines at steering cylinder. Install plug fittings in cylinder and put caps on hydraulic lines. Plug fittings will prevent spindles from turning as axle is removed from under the lift truck.

NOTE: Steering Axle Assembly may be mounted to the frame with brackets or plates. 3. Slide floor jack or forks of another lift truck under steering axle. Raise lifting device until it holds the weight of the axle assembly. a. To remove bracket type mounts, remove four capscrews and nuts that fasten two brackets under rubber mounts. See Figure 2 for lift truck model • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) See Figure 3 for lift truck models • GLP/GDP20-35VX (GP/GLP/GDP040070VX) (B875) See Figure 5 for lift truck model • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) See Figure 6 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) b. To remove plate type mounts, remove four capscrews and washers from two plates. See Figure 4 for lift truck models • GC/GLC030-035VX, GC/GLC040SVX (C809) • GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/GDP030-035VX, GP/GLP/ GDP040SVX) (C810)

3


Steering Axle Assembly Repair See Figure 7 for lift truck models • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) See Figure 8 for lift truck models • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP170VX36, GLP/GDP190VX) (A909, B909) c. Remove plates and slowly lower steering axle assembly onto wheels. Carefully roll steering axle assembly away from lift truck.

DISASSEMBLE 1. Remove ring seal, shims, flange, stub shaft and bushing from steering axle assembly for lift truck models below. See Figure 8 for lift truck models • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP170VX36, GLP/GDP190VX) (A909, B909) 2. Put axle on blocks so the wheels just touch the floor. Remove hub cap. Remove cotter pin, washer, and castle nut. Remove bearing cone and discard cotter pin.

1600 YRM 1133 See Figure 2 for lift truck model • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) See Figure 3 for lift truck model • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) See Figure 4 for lift truck models • GC/GLC030-035VX, GC/GLC040SVX (C809) • GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/ GDP030-035VX, GP/GLP/GDP040SVX) (C810) See Figure 5 for lift truck model • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) See Figure 6 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) See Figure 7 for lift truck models • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) See Figure 8 for lift truck models • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP170VX36, GLP/GDP190VX) (A909, B909)

NOTE: Identify and tag the outer and inner bearing cones so they can be reassembled in their original locations.

NOTE: If the bearing is replaced, then the associated bearing cup must be replaced also.

NOTE: The wear ring may not be present on all steering axles.

4. If the bearings must be replaced, use a brass drift pin to remove the bearing cups and wear ring.

3. Slide wheel from spindle. Remove inner bearing cone, wear ring, and oil seal from spindle.

5. Repeat Step 1 through Step 4 for the other wheel.

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1600 YRM 1133

1. 2. 3. 4. 5. 6. 7. 8. 9.

MOUNT STEER AXLE ASSEMBLY MOUNT PLATE WASHER LOCK NUT CAPSCREW STEERING CYLINDER ROD LUBRICATION FITTING

Steering Axle Assembly Repair

10. 11. 12. 13. 14. 15. 16. 17. 18.

COTTER PIN OIL SEAL WEAR RING BEARING CONE BEARING CUP WASHER CASTLE NUT HUB CAP STEERING CYLINDER

Figure 2. Spindle to Tie Rod Assembly for Lift Truck Models GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910)

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Steering Axle Assembly Repair

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

MOUNT STEERING AXLE ASSEMBLY MOUNT BRACKET NUT WASHER WASHER CAPSCREW STEERING CYLINDER ROD LUBRICATION FITTING OIL SEAL

1600 YRM 1133

12. 13. 14. 15. 16. 17. 18. 19. 20. 21.

WEAR RING BEARING CONE BEARING CUP HUB BEARING CUP BEARING CONE CASTLE NUT HUB CAP COTTER PIN STEERING CYLINDER

Figure 3. Spindle to Tie Rod Assembly for Lift Truck Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)

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1600 YRM 1133

Steering Axle Assembly Repair

A. PNEUMATIC TRUCKS ONLY 1. 2. 3. 4. 5. 6. 7. 8.

MOUNT STEER AXLE ASSEMBLY MOUNT PLATE CAPSCREW STEERING CYLINDER ROD LUBRICATION FITTING OIL SEAL

9. 10. 11. 12. 13. 14. 15. 16.

BEARING HUB BEARING WASHER CASTLE NUT HUB CAP COTTER PIN STEERING CYLINDER

Figure 4. Spindle to Tie Rod Assembly for Lift Truck Models GC/GLC030-035VX, GC/GLC040SVX (C809) and GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/GDP030-035VX, GP/GLP/GDP040SVX) (C810)

7


Steering Axle Assembly Repair

1. 2. 3. 4. 5. 6. 7. 8. 9.

HUB CAP CASTLE NUT COTTER PIN WASHER BEARING CONE (OUTER) BEARING CUP (OUTER) BEARING CUP (INNER) BEARING CONE (INNER) WEAR RING

1600 YRM 1133

10. 11. 12. 13. 14. 15. 16. 17. 18.

OIL SEAL STEERING CYLINDER ROD STEERING CYLINDER PADS MOUNT CAPSCREW WASHER PLATE NUTS

Figure 5. Spindle to Tie Rod Assembly for Lift Truck Models GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818)

8


1600 YRM 1133

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

HUB CAP CASTLE NUT COTTER PIN WASHER BEARING CONE BEARING CUP HUB WEAR RING OIL SEAL LUBE FITTING

Steering Axle Assembly Repair

11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

MOUNT STEERING AXLE ASSEMBLY MOUNT CAPSCREW WASHER NUT STEERING CYLINDER ROD SPINDLE (LEFT SIDE SHOWN) TIE ROD STEERING CYLINDER

Figure 6. Spindle to Tie Rod Assembly for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813)

9


Steering Axle Assembly Repair

1. 2. 3. 4. 5. 6. 7. 8. 9.

HUB CAP COTTER PIN CASTLE NUT WASHER BEARING CONE (OUTER) BEARING CUP (OUTER) BEARING CONE (INNER) BEARING CUP (INNER) SEAL

1600 YRM 1133

10. 11. 12. 13. 14. 15. 16. 17.

WEAR RING PAD MOUNT PLATE CAPSCREW LUBE FITTING STEERING CYLINDER ROD STEERING CYLINDER

Figure 7. Spindle to Tie Rod Assembly for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

10


1600 YRM 1133

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

STEER AXLE ASSEMBLY TIE ROD PLATE WASHER CAPSCREW RING SEAL SHIM FLANGE SHIM BUSHING STUB SHAFT STEERING CYLINDER STEERING CYLINDER ROD GREASE FITTING

Steering Axle Assembly Repair

15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27.

COTTER PIN HUB CAP CASTLE NUT WASHER HUB BEARING CUP (OUTER) BEARING CONE (OUTER) BEARING CUP (INNER) BEARING CONE (INNER) WEAR RING OIL SEAL SPINDLE LUBE FITTING

Figure 8. Spindle to Tie Rod Assembly for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP170VX36, GLP/GDP190VX) (A909, B909)

11


Steering Axle Assembly Repair

CLEAN WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures.

WARNING Compressed air is used for cleaning or drying purposes, or for clearing restrictions. Wear protective clothing (goggles/shield, gloves, etc.) to avoid injury to personnel. 1. Clean bearings by placing them in a wire basket and immersing in a container of fresh solvent. Agitate the bearings in the solvent to remove all traces of old lubricant. 2. After cleaning the bearings, dry them with clean compressed air. Take care to prevent spinning the bearings when using a compressed air jet. 3. Immediately wrap bearings in a lint-free cloth to protect them from dust and other foreign matter.

INSPECT 1. Inspect for loose, burned, missing, cracked or damaged hardware. 2. Inspect all parts for dents, holes, bends, burrs, rust, corrosion or marred finish. NOTE: If the spindle, bearings or tie rods need to be repaired, go to Spindles, Bearings, and Tie Rods Repair.

ASSEMBLE NOTE: For specified lubricant to use, refer to one of the following sections: Periodic Maintenance 8000 YRM 1150 for lift truck models • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910 • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) Periodic Maintenance 8000 YRM 1207 for lift truck models • GC/GLC030-035VX, GC/GLC040SVX (C809) • GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/ GDP030-035VX, GP/GLP/GDP040SVX) (C810)

12

1600 YRM 1133 Periodic Maintenance 8000 YRM 1248 for lift truck models • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813) Periodic Maintenance 8000 YRM 1558 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) Periodic Maintenance 8000 YRM 1604 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) Periodic Maintenance 8000 YRM 1319 for lift truck models • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879) Periodic Maintenance 8000 YRM 1571 for lift truck models • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (E879) Periodic Maintenance 8000 YRM 1606 for lift truck models • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (F879) Periodic Maintenance 8000 YRM 1322 for lift truck models • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878) Periodic Maintenance 8000 YRM 1407 for lift truck model • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP170VX36, GLP/ GDP190VX) (A909) Periodic Maintenance 8000 YRM 1586 for lift truck model • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (B909) Periodic Maintenance 8000 YRM 1583 for lift truck model • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (E878)


1600 YRM 1133

Steering Axle Assembly Repair Lubricate bearing cones with multipurpose grease. Verify bearings are filled with grease. Install oil seal, wear ring (if removed) and inner bearing cone on spindle.

Periodic Maintenance 8000 YRM 1598 for lift truck model • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (F818) 1. If necessary, use a press to install new bearing cups in wheel or hub. See Figure 9 for lift truck model • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910)

CAUTION DO NOT damage the seals during installation. 2. Carefully slide wheel onto spindle. Install outer bearing cone and install washer.

See Figure 10 for lift truck model • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) See Figure 11 for lift truck model • GC/GLC030-035VX, GC/GLC040SVX (C809) See Figure 12 for lift truck model • GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/ GDP030-035VX, GP/GLP/GDP040SVX) (C810) See Figure 13 for lift truck model • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) See Figure 14 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) See Figure 15 for lift truck models • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) See Figure 16 for lift truck models • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP170VX36, GLP/GDP190VX) (A909, B909)

1. 2. 3. 4. 5. 6. 7. 8.

WASHER COTTER PIN HUB CAP CASTLE NUT OUTER BEARING CUP AND CONE INNER BEARING CUP AND CONE WEAR RING OIL SEAL

Figure 9. Bearing Arrangement for Lift Truck Models GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910)

13


Steering Axle Assembly Repair

1. 2. 3. 4. 5.

SPINDLE HUB CAP COTTER PIN CASTLE NUT BEARING CONE

6. 7. 8. 9. 10.

1600 YRM 1133

BEARING CUP BEARING CONE BEARING CUP OIL SEAL WEAR RING

Figure 10. Bearing Arrangement for Lift Truck Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)

14

1. 2. 3. 4.

HUB OIL SEAL BEARING BEARING

5. 6. 7. 8.

WASHER CASTLE NUT COTTER PIN HUB CAP

Figure 11. Bearing Arrangement for Lift Truck Models GC/GLC030-035VX, GC/GLC040SVX (C809)


1600 YRM 1133

1. 2. 3. 4.

BEARING BEARING CASTLE NUT COTTER PIN

Steering Axle Assembly Repair

5. WASHER 6. HUB CAP 7. OIL SEAL

Figure 12. Bearing Arrangement for Lift Truck Models GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/GDP030-035VX, GP/GLP/GDP040SVX) (C810)

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

WEAR RING BEARING CONE (INNER) BEARING CUP (INNER) BEARING CONE (OUTER) BEARING CUP (OUTER) HUB CAP COTTER PIN CASTLE NUT WASHER OIL SEAL

Figure 13. Bearing Arrangement for Lift Truck Models GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818)

15


Steering Axle Assembly Repair

1600 YRM 1133

NOTE: RIGHT SIDE IS SHOWN 1. 2. 3. 4. 5. 6. 7. 8.

OIL SLEEVE OUTER BEARING CUP AND CONE HUB INNER BEARING CUP AND CONE CASTLE NUT COTTER PIN HUB CAP WASHER

Figure 14. Bearing Arrangement for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813)

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

BEARING CONE (OUTER) BEARING CUP (OUTER) WASHER HUB CAP COTTER PIN CASTLE NUT BEARING CONE (INNER) BEARING CUP (INNER) WEAR RING OIL SEAL

Figure 15. Bearing Arrangement for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

16


1600 YRM 1133

Steering Axle Assembly Repair NOTE: Ensure that the washer is seated properly against the bearing cone and not against the shaft shoulder before tightening the castle nut. 3. Install the castle nut and tighten as follows for your lift truck: a. GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) - Tighten the castle nut to 68 N•m (50 lbf ft) while rotating the wheel in both directions to properly seat the bearings. Loosen the castle nut 1/4 turn. Tighten nut to 3 N•m (27 lbf in). Pull on the wheel axially to ensure that there is no end play. If there is excessive end play, reassemble washer and repeat Step 1 through Step 3.

NOTE: RIGHT SIDE IS SHOWN 1. 2. 3. 4. 5. 6. 7. 8.

HUB ASSEMBLY HUB CAP COTTER PIN CASTLE NUT WASHER OUTER BEARING CUP AND CONE INNER BEARING CUP AND CONE SEAL

Figure 16. Bearing Arrangement for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP170VX36, GLP/GDP190VX) (A909, B909)

b. GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) - Tighten the castle nut to 200 N•m (147.5 lbf ft) while rotating the wheel in both directions to properly seat the bearings. Loosen the castle nut until wheel turns freely with no end play. Tighten nut to 15 N•m (133 lbf in). c. GC/GLC030-035VX, GC/GLC040SVX (C809) - Tighten the castle nut to 200 N•m (147.5 lbf ft) while rotating the wheel in both directions to properly seat the bearings. Loosen the castle nut until wheel turns freely with no end play. Tighten nut to 12 N•m (106 lbf in). d. GLP/GDP16-18VX, GLP/GDP20SVX (GP/ GLP/GDP030-035VX, GP/GLP/GDP040SVX) (C810) - Tighten the castle nut to 200 N•m (147.5 lbf ft) while rotating the wheel in both directions to properly seat the bearings. Loosen the castle nut until wheel turns freely with no end play. Tighten nut to 12 N•m (106 lbf in).

17


Steering Axle Assembly Repair e. GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) - Tighten the castle nut to 203 N•m (150 lbf ft) while rotating the wheel in both directions to properly seat the bearings. Loosen the castle nut until wheel turns freely with no end play. Tighten nut to 34 N•m (25 lbf ft). f.

GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/ GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) - Tighten castle nut to 200 to 220 N•m (148 to 162 lbf ft) while rotating the wheel in both directions to properly seat the bearings. Loosen the castle nut until wheel turns freely with no end play. Tighten castle nut to 35 to 40 N•m (26 to 30 lbf ft).

g. GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) - Tighten castle nut to 203 N•m (150 lbf ft) while rotating the wheel in both directions to properly seat the bearings. Loosen the castle nut until wheel turns freely with no end play. Tighten castle nut to 34 N•m (25 lbf ft). h. GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP170VX36, GLP/GDP190VX) (A909, B909) - Tighten castle nut to 203 N•m (150 lbf ft) while rotating the wheel in both directions to properly seat the bearings. Loosen the castle nut until wheel turns freely with no end play. Tighten castle nut to 34 N•m (25 lbf ft). i.

GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) - Tighten castle nut to 203 N•m (150 lbf ft) while rotating the wheel in both directions to properly seat the bearings. Loosen the castle nut until wheel turns freely with no end play. Tighten castle nut to 34 N•m (25 lbf ft).

4. Install new cotter pin in castle nut. If cotter pin cannot be installed, tighten castle nut to the first alignment position where the cotter pin can be installed. 5. Install hub cap. 6. Repeat Step 1 through Step 5 for other wheel.

18

1600 YRM 1133 NOTE: Apply multipurpose grease to stub shaft prior to installing. 7. Install stub shaft, bushing, shims, flange, and rig seal to steering axle assembly. See Figure 8 for lift truck models • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP170VX36, GLP/GDP190VX) (A909, B909)

INSTALL 1. Install rubber mounts and top mount(s) on axle. Verify face of rubber mount with the part number is away from the axle. Verify part number will be right side up after axle assembly is installed. See Figure 2 for lift truck model • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) See Figure 3 for lift truck model • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) See Figure 4 for lift truck models • GC/GLC030-035VX, GC/GLC040SVX (C809) • GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/ GDP030-035VX, GP/GLP/GDP040SVX) (C810) See Figure 5 for lift truck model • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) See Figure 6 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) See Figure 7 for lift truck models • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 2. Apply lubricant that is approved for use with rubber to rubber mount. The lubricant is used to ease assembly of the mount into frame and brackets.


1600 YRM 1133

Steering Axle Assembly Repair

3. Use floor jack or another lift truck to put steering axle into position in frame. Verify rubber mounts fit inside frame brackets for mounts.

a. GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) - tighten four bracket bolts and nuts to 90 N•m (66.4 lbf ft).

NOTE: Steering axle assembly may be attached to frame with brackets or plates.

b. GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) - tighten four bracket bolts and nuts to 88 N•m (65 lbf ft).

a. Install bottom brackets. See Figure 2 for lift truck models • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910)

c. GC/GLC030-035VX, GC/GLC040SVX (C809) - tighten four flange bolts to 41 to 49 N•m (30 to 36 lbf ft).

See Figure 3 for lift truck models • GLP/GDP20-35VX (GP/GLP/GDP040070VX) (B875)

d. GLP/GDP16-18VX, GLP/GDP20SVX (GP/ GLP/GDP030-035VX, GP/GLP/GDP040SVX) (C810) - tighten four flange bolts to 41 to 49 N•m (30 to 36 lbf ft).

See Figure 5 for lift truck models • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818)

e. GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) - tighten four flange bolts to 215 N•m (159 lbf ft).

See Figure 6 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813)

f.

b. Install mount plates. See Figure 4 for lift truck models • GC/GLC030-035VX, GC/GLC040SVX (C809) • GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/GDP030-035VX, GP/GLP/ GDP040SVX) (C810) See Figure 7 for lift truck models • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) See Figure 8 for lift truck models • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP170VX36, GLP/GDP190VX) (A909, B909) 4. Proceed as follows for your lift truck:

GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/ GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) - tighten four bracket bolts and nuts to 90 N•m (66 lbf ft).

g. GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) - apply thread lock and washers and tighten four capscrews to 250 to 275 N•m (184 to 203 lbf ft). h. GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) - apply thread lock and washers and tighten four capscrews to 270 N•m (199 lbf ft). i.

GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP170VX36, GLP/GDP190VX) (A909) - apply thread lock and washers and tighten four capscrews to 270 N•m (199 lbf ft).

5. Remove plugs and caps and connect hydraulic lines to steering cylinder. 6. Operate steering system to remove air from system. Turn steering wheel several times from one stop to the other. Check for hydraulic leaks.

19


Spindles, Bearings, and Tie Rods Repair

1600 YRM 1133

Spindles, Bearings, and Tie Rods Repair SPINDLES AND BEARINGS GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813), GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879), GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878), GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP170VX36, GLP/GDP190VX) (A909, B909) Remove

WARNING PUTTING THE LIFT TRUCK ON BLOCKS The lift truck must be put on blocks for some types of maintenance and repair. The removal of the mast, drive axle, battery, or counterweight assemblies will cause large changes in the center of gravity. When the lift truck is put on blocks, put additional blocks in the following positions:

20

• If the mast and drive axle are removed, put blocks under the counterweight so the lift truck cannot fall backward. • If the counterweight is removed, put blocks under the mast so that the lift truck cannot fall forward. Put the lift truck on blocks on a solid, even, and level surface. Verify the blocks or stands have enough capacity to hold the lift truck. Use additional blocks next to the tires as necessary to prevent movement of the lift truck. Verify the lifting devices used during repairs can lift the weight of the parts and assemblies. See the Operating Manual or Periodic Maintenance section for your lift truck model, for the procedures to put the lift truck on blocks. 1. Put the lift truck on blocks. 2. Remove the wheel and bearings. See Steering Axle Assembly Repair, Disassemble. NOTE: To remove the spindle from the steering rod, the tie rod can be disconnected at the retaining pin inside the dust cover. 3. Loosen the clamps on the dust cover and slide the dust cover off the steering cylinder rod. See Figure 17 for lift truck models • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818)


1600 YRM 1133

1. 2. 3. 4.

CLAMP DUST COVER CLAMP SNAP RING

Spindles, Bearings, and Tie Rods Repair

5. STEERING CYLINDER ROD 6. PIN 7. TIE ROD

Figure 17. Tie Rod for Lift Truck Models and GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818)

21


Spindles, Bearings, and Tie Rods Repair

1600 YRM 1133

4. Remove two snap rings from the pin holding the tie rod to steering cylinder rod and remove pin.

GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813)

See Figure 17 for lift truck models • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818)

See Figure 22 or Figure 27 for lift truck models • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

See Figure 26 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) See Figure 27 for lift truck models • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909)

CAUTION DO NOT hit the threads or the nut of the tie rod. NOTE: Rod end may be attached to spindle arm by one of two methods, castle nut and cotter pin or by snap ring, washer and pin. 5. Remove the cotter pin and castle nut. Discard cotter pin. Use a puller to remove the tie rod end from the spindle arm. See Figure 19 for lift truck model • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) See Figure 20 for lift truck model • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) 6. Remove snap rings, washers and pin. Remove tie rod end from spindle arm. See Figure 21 or Figure 26 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/

22

See Figure 23 for lift truck models • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP170VX36, GLP/GDP190VX) (A909, B909) 7. Remove the snap rings from the pin retaining the tie rod to the steering cylinder rod, then remove the pin. If necessary, use a hammer and brass drift to remove pin. Remove tie rod from steering cylinder rod. 8. If necessary, repeat the procedure for the other spindle and tie rod.

Disassemble 1. Remove the grease cap from the spindle. Remove the capscrews from the bearing cap. Remove the bearing cap and shims. If necessary, remove the bearing cup from the bearing cap as shown in Figure 18, for the following lift truck models: • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/ GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP170VX36, GLP/GDP190VX) (A909, B909) 2. Tilt the spindle and lift the spindle from the axle. If necessary, remove the bearing and seals from the spindle. If necessary, remove the wear sleeve and bearing cup from the axle frame.


1600 YRM 1133 3. If necessary, repeat the procedure for the other spindle and tie rod.

Clean

WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures.

WARNING Compressed air is used for cleaning or drying purposes, or for clearing restrictions. Wear protective clothing (goggles/shield, gloves, etc.) to avoid injury to personnel. 1. Clean bearings by placing them in a wire basket and immersing in a container of fresh solvent. Agitate the bearings in the solvent to remove all traces of old lubricant. 2. After cleaning the bearings, dry them with clean compressed air. Take care to prevent spinning the bearings when using a compressed air jet. 3. Immediately wrap bearings in a lint-free cloth to protect them from dust and other foreign matter.

Inspect 1. Inspect for loose, missing, cracked, burned or damaged hardware. 2. Inspect all parts for dents, holes, bends, burrs, rust, corrosion, or marred finish.

Assemble 1. Install new seals on the spindle. Lubricate the seals with grease. If necessary, press new bearing cones on the spindle. 2. Lubricate the bearings with wheel bearing grease. Verify the bearings are filled with grease. If necessary, press the new bearing cups into the steering axle frame and bearing cap. Install the wear sleeve in the steering axle frame. 3. Install the spindle in the steering axle. Install the bearing cap without the O-rings. See Figure 19 for lift truck model • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910)

Spindles, Bearings, and Tie Rods Repair See Figure 20 for lift truck models • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) See Figure 21 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) See Figure 22 for lift truck models • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) See Figure 23 for lift truck models • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP170VX36, GLP/GDP190VX) (A909, B909) Measure the clearance between the bearing cap and the axle. Remove the bearing cap and install enough shims to give a preload of 0.00 to 0.13 mm (0.000 to 0.005 in.). NOTE: The spindle bearings must have no clearance. Install shims 0.00 to 0.13 mm (0.000 to 0.005 in.) less than the measured gap. 4. Install the O-ring on the bearing cap. Apply Loctite® 242 to threads of capscrews. Install the bearing cap and capscrews. a. GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) - tighten capscrews to 44 N•m (32 lbf ft). b. GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) - tighten the capscrews to 52 N•m (38 lbf ft). c. GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) - tighten the capscrews to 52 N•m (38 lbf ft).

23


Spindles, Bearings, and Tie Rods Repair

1600 YRM 1133

Install NOTE: Tie rod end may be attached to spindle arm by one of two methods, castle nut and cotter pin or with snap rings, washers and pins. 1. Install the tie rod to the spindle arm and steering cylinder. If removed, tighten the castle nut to 163 N•m (120 lbf ft) for lift truck models • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) If removed, tighten the castle nut to 175 N•m (129 lbf ft) for lift truck models • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) 2. Tighten the castle nut until the new cotter pin can be installed. 3. Install tie rod end to spindle arm and steering cylinder with pins, seals and snap rings.

1. PRY BAR 2. BEARING CUP

3. BEARING CAP 4. O-RING

Figure 18. Bearing Cup Removal d. GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/ GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) - tighten capscrews to 45 to 50 N•m (33 to 37 lbf ft). e. GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) - tighten capscrews to 47 N•m (35 lbf ft). f.

GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP170VX36, GLP/GDP190VX) (A909, B909) - tighten capscrews to 47 N•m (35 lbf ft).

5. If necessary, repeat the procedure for the other spindle and tie rod.

See Figure 26 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) See Figure 27 for lift truck models • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP170VX36, GLP/GDP190VX) (A909, B909) 4. Install the grease cap on the top of the steering axle. 5. Install the bearings and wheel. See section Steering Axle Assembly Repair, Assemble. 6. If necessary, repeat the procedure for the other spindle and tie rod. 7. Remove the lift truck from blocks.

24


1600 YRM 1133

Spindles, Bearings, and Tie Rods Repair

NOTE: THE LUBRICATION FITTING NEEDS TO BE ORIENTED 45° TO CENTERLINE AND REAR OF LIFT TRUCK.

NOTE: THE LUBRICATION FITTING NEEDS TO BE ORIENTED TOWARDS THE CENTERLINE OF THE LIFT TRUCK. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

GREASE CAP BEARING ASSEMBLY WEAR SLEEVE SEAL SPINDLE OIL SEAL BEARING CONE BEARING CUP WASHER CASTLE NUT COTTER PIN HUB CAP O-RING SHIMS (AS REQUIRED) CAPSCREW AND LOCKWASHER ASSEMBLY LUBRICATION FITTING BEARING CAP TIE ROD CASTLE NUT COTTER PIN

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

HUB CAP WASHER BEARING CONE (OUTER) BEARING CUP (OUTER) BEARING CONE (INNER) BEARING CUP (INNER) WEAR SLEEVE OIL SEAL CAPSCREW LUBE FITTING CAP ASSEMBLY SHIM BEARING CUP BEARING CONE SEAL O-RING CAP CASTLE NUT COTTER PIN TIE ROD

Figure 20. Spindle Assembly for Lift Truck Models GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818)

Figure 19. Spindle Assembly for Lift Truck Models GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910)

25


Spindles, Bearings, and Tie Rods Repair

1600 YRM 1133

NOTE: THE LUBRICATION FITTING NEEDS TO BE ORIENTED 45° TO CENTERLINE AND REAR OF LIFT TRUCK.

NOTE: LEFT SIDE SPINDLE ASSEMBLY SHOWN 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

HUB CAP CASTLE NUT COTTER PIN WASHER BEARING CONE BEARING CUP HUB WEAR SLEEVE OIL SEAL SPINDLE LUBE FITTING CAP TIE ROD SEAL O-RING SHIM CAP ASSEMBLY LOCKWASHER CAPSCREW

Figure 21. Spindle Assembly for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813)

26

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.

PLUG BEARING CONE (UPPER) BEARING CUP (UPPER) WEAR SLEEVE OIL SEAL PIN SNAP RING SPHERICAL BEARING TIE ROD BEARING CONE (LOWER) O-RING BEARING CUP (LOWER) SHIM BEARING CAP CAPSCREW LUBE FITTING HUB CAP CASTLE NUT COTTER PIN WASHER BEARING CONE (OUTER) BEARING CUP (OUTER BEARING CONE (INNER) BEARING CUP (INNER)

Figure 22. Spindle Assembly for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)


1600 YRM 1133

Spindles, Bearings, and Tie Rods Repair

SPINDLES AND BEARINGS GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC/GLC040SVX (C809) and GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/GDP030-035VX, GP/GLP/GDP040SVX) (C810) Remove and Disassemble

WARNING PUTTING THE LIFT TRUCK ON BLOCKS

NOTE: THE LUBRICATION FITTING NEEDS TO BE ORIENTED 45° TO CENTERLINE AND REAR OF LIFT TRUCK. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.

SNAP RING PIN SEAL TIE ROD SEAL BEARING CONE (LOWER) O-RING BEARING CUP (LOWER) SEAL SHIM BEARING CAP CAPSCREW LUBE FITTING OIL SEAL WEAR SLEEVE BEARING CONE (INNER) BEARING CUP (INNER) BEARING CONE (OUTER) BEARING CUP (OUTER) HUB COTTER PIN WASHER CASTLE NUT HUB CAP SEAL WEAR SLEEVE BEARING CUP (UPPER) BEARING CONE (UPPER) PLUG

Figure 23. Spindle Assembly for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP170VX36, GLP/GDP190VX) (A909, B909)

The lift truck must be put on blocks for some types of maintenance and repair. The removal of the mast, drive axle, battery, or counterweight assemblies will cause large changes in the center of gravity. When the lift truck is put on blocks, put additional blocks in the following positions: • If the mast and drive axle are removed, put blocks under the counterweight so the lift truck cannot fall backward. • If the counterweight is removed, put blocks under the mast so that the lift truck cannot fall forward. Put the lift truck on blocks on a solid, even, and level surface. Verify the blocks or stands have enough capacity to hold the lift truck. Use additional blocks next to the tires as necessary to prevent movement of the lift truck. Verify the lifting devices used during repairs can lift the weight of the parts and assemblies. See the Operating Manual or Periodic Maintenance section for your lift truck model, for the procedures to put the lift truck on blocks. 1. Put the lift truck on blocks. 2. Remove the wheel and if necessary, the bearings. See Steering Axle Assembly Repair, Disassemble. 3. If the tie rod is to be replaced, remove the two snap rings and pin. To loosen and remove the pin, use a brass punch and hammer. 4. Disassemble the bottom half of the spindle as follows: a. Remove and discard cotter pin from castle nut and remove castle nut from kingpin. See Figure 24. b. Remove the oil seal, sleeve, and bearing cone.

27


Spindles, Bearings, and Tie Rods Repair NOTE: If the bearing cone is being replaced, the bearing cup must be replaced. c. If necessary, remove the bearing cup. 5. Disassemble the top half of the spindle as follows:

GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) Remove

WARNING

a. Remove pin and O-ring from kingpin.

PUTTING THE LIFT TRUCK ON BLOCKS

b. Remove spacer, seal, and bearing cone.

The lift truck must be put on blocks for some types of maintenance and repair. The removal of the mast, drive axle, battery, or counterweight assemblies will cause large changes in the center of gravity. When the lift truck is put on blocks, put additional blocks in the following positions: • If the mast and drive axle are removed, put blocks under the counterweight so the lift truck cannot fall backward. • If the counterweight is removed, put blocks under the mast so that the lift truck cannot fall forward.

NOTE: If the bearing cone is being replaced, the bearing cup must be replaced. c. If necessary, remove the bearing cup. 6. Repeat the procedure for the other spindle and tie rod.

Assemble and Install 1. If new spindle bearings are installed, use a press to install new bearing cups into spindle. See Figure 24. Lubricate bearing cones and seal lips with grease. 2. Install bearings, seals, sleeves, and O-rings into spindle. If the groove pin was removed from the kingpin, install new groove pin. Apply grease to kingpin. Position spindle in axle and install kingpin. 3. Install lock nut onto kingpin and tighten lock nut to 90 N•m (66.4 lbf ft). Completely loosen lock nut, then tighten to 34 N•m (25 lbf ft). Tighten castle nut until new cotter pin can be installed. 4. Install tie rod to spindle housing. Align holes and place lubricated pin into the spindle and tie rod. Install the two snap rings on top and bottom of pin. 5. If removed, install the bearings and install the wheel. See section Steering Axle Assembly Repair, Assemble. 6. Repeat the procedure for the other spindle and tie rod. 7. Remove the lift truck from blocks.

TIE RODS GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), and GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS;

28

1600 YRM 1133

Put the lift truck on blocks on a solid, even, and level surface. Verify the blocks or stands have enough capacity to hold the lift truck. Use additional blocks next to the tires as necessary to prevent movement of the lift truck. Verify the lifting devices used during repairs can lift the weight of the parts and assemblies. See the Operating Manual or Periodic Maintenance section for your lift truck model, for the procedures to put the lift truck on blocks. 1. Put the lift truck on blocks. 2. Remove the wheel and bearings. See Steering Axle Assembly Repair, Disassemble.

CAUTION DO NOT hit the threads or the nut of the tie rod. 3. Remove the cotter pin and castle nut. Discard cotter pin. Use a puller to remove the tie rod end from the spindle arm. To loosen the tie rod end, place a hammer behind the arm to hold the arm. Hit the spindle arm with another large hammer. See Figure 19 for lift truck models • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) See Figure 20 for lift truck models • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818)


1600 YRM 1133

Spindles, Bearings, and Tie Rods Repair 4. Loosen the clamps on the dust cover and slide the dust cover off the steering cylinder rod. See Figure 17. 5. Remove the snap rings from the pin retaining the tie rod to the steering cylinder rod, then remove the pin. 6. Slide the tie rod from the cylinder rod. 7. Remove the dust cover from the tie rod. 8. If necessary, remove the clamps from the dust cover.

Install 1. Install the tie rod to the spindle arm. Install the castle nut. a. GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) - tighten castle nut to 163 N•m (120 lbf ft). b. GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) - tighten castle nut to 175 N•m (129 lbf ft) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.

PIN O-RING SPACER SEAL BEARING CONE BEARING CUP SLEEVE OIL SEAL CASTLE NUT COTTER PIN HUB CAP WASHER BEARING (OUTER) BEARING (INNER) OIL SEAL SPINDLE KINGPIN SNAP RING WASHER TIE ROD PIN

Figure 24. Spindle Assembly for Lift Truck Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC/GLC040SVX (C809) and GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/GDP030-035VX, GP/GLP/GDP040SVX) (C810)

c. Tighten castle nut until new cotter pin can be installed. 2. If removed, slide the clamps onto the dust cover. 3. Slide the dust cover on the tie rod. See Figure 17. 4. Slide the tie rod into the steering cylinder rod. 5. Lubricate and install the pin to retain the tie rod and steering cylinder rod together. 6. Install the snap rings. 7. Slide the dust cover on to the steering rod cylinder, against the rod-end shoulder. 8. Slide the clamps flush with the ends of the dust cover and tighten clamps. 9. Install the bearings and wheel. See section Steering Axle Assembly Repair, Assemble.

29


Spindles, Bearings, and Tie Rods Repair 10. Repeat the procedure for the other tie rod. 11. Remove the lift truck from blocks.

1600 YRM 1133

Remove

WARNING

TIE RODS

PUTTING THE LIFT TRUCK ON BLOCKS

GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC/GLC040SVX (C809), GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/GDP030-035VX, GP/GLP/GDP040SVX) (C810), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813), GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879), GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878), and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP170VX36, GLP/GDP190VX) (A909, B909)

The lift truck must be put on blocks for some types of maintenance and repair. The removal of the mast, drive axle, battery, or counterweight assemblies will cause large changes in the center of gravity. When the lift truck is put on blocks, put additional blocks in the following positions: • If the mast and drive axle are removed, put blocks under the counterweight so the lift truck cannot fall backward. • If the counterweight is removed, put blocks under the mast so that the lift truck cannot fall forward.

30

Put the lift truck on blocks on a solid, even, and level surface. Verify the blocks or stands have enough capacity to hold the lift truck. Use additional blocks next to the tires as necessary to prevent movement of the lift truck. Verify the lifting devices used during repairs can lift the weight of the parts and assemblies. See the Operating Manual or Periodic Maintenance section for your lift truck model, for the procedures to put the lift truck on blocks.


1600 YRM 1133 1. Put the lift truck on blocks. 2. Remove the wheel and if necessary, the bearings. See Steering Axle Assembly Repair, Disassemble. 3. Remove the snap rings from the pin retaining the tie rod to the spindle. Remove the pin. To loosen and remove the pin, use a brass punch and hammer. See Figure 25 for lift truck models • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) See Figure 26 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/

Spindles, Bearings, and Tie Rods Repair GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) See Figure 27 for lift truck models • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 4. Remove the snap rings from the pin retaining the tie rod to the steering cylinder rod. Remove the pin. 5. Slide the tie rod and washers from the spindle housing and steering cylinder rod.

31


Spindles, Bearings, and Tie Rods Repair

1600 YRM 1133

Legend for Figure 25 A. GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) B. GC/GLC030-035VX, GC/GLC040SVX (C809) AND GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/GDP030-035VX, GP/GLP/GDP040SVX) (C810) 1. SNAP RINGS 2. STEERING CYLINDER ROD 3. WASHERS

32

4. TIE ROD 5. PIN 6. SPINDLE


1600 YRM 1133

Spindles, Bearings, and Tie Rods Repair

Figure 25. Tie Rod for Lift Truck Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC/GLC040SVX (C809) and GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/GDP030-035VX, GP/GLP/GDP040SVX) (C810) 33


Spindles, Bearings, and Tie Rods Repair

1. SPINDLE (LEFT SIDE SHOWN) 2. SNAP RING 3. SEAL

1600 YRM 1133

4. TIE ROD ASSEMBLY 5. PIN 6. STEERING CYLINDER ROD

Figure 26. Tie Rod Assembly for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813)

34


1600 YRM 1133

1. SNAP RING 2. PIN 3. STEERING CYLINDER ROD

Spindles, Bearings, and Tie Rods Repair

4. SEAL 5. TIE ROD ASSEMBLY 6. SPINDLE (LEFT SIDE SHOWN)

Figure 27. Tie Rod Assembly for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879); GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878); and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP170VX36, GLP/GDP190VX) (A909, B909)

35


Steering Cylinder Repair

1600 YRM 1133

Install 1. Place the tie rod and washers in position in the spindle and steering cylinder rod.

• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909)

See Figure 25 for lift truck models • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)

2. Align holes and place lubricated pin into the spindle and tie rod. Install the two snap rings on top and bottom of pin.

See Figure 26 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813)

4. If removed, install the bearings and install the wheel. See Steering Axle Assembly Repair, Assemble.

See Figure 27 for lift truck models • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

3. Align holes and place lubricated pin into the steering cylinder rod and tie rod. Install the two snap rings on top and bottom of pin.

5. Repeat the procedure for the other tie rod. 6. Remove the lift truck from blocks.

Steering Cylinder Repair REMOVE AND DISASSEMBLE NOTE: The end caps of the steering cylinder are held in the shell by the installation of cylinder mount capscrews into the axle frame. To prevent oil leaks at the caps, hold the caps on the shell during removal. NOTE: Hydraulic oil is to be disposed of in accordance with local directives. 1. Disconnect and tag hydraulic lines at steering cylinder. See Figure 28. Install caps in fittings on cylinder and put fittings on hydraulic lines. 2. Remove the tie rods. See Spindles, Bearings, and Tie Rods Repair, Tie Rods.

36

3. Remove capscrews that fasten cylinder to axle frame. Hold end caps on shell and remove steering cylinder. 4. Hold end of steering cylinder over a container. Remove plug for hydraulic fitting from each end cap. Push rod toward end of shell that is over container. Oil will drain from cylinder. Repeat procedure for other end. 5. Carefully remove one end cap from shell and slide off of rod. Carefully pull rod out of shell, keeping rod centered in shell during removal. Remove other end cap from shell. Remove all seals, wipers, and O-rings. See Figure 28.


1600 YRM 1133

Steering Cylinder Repair

6. Remove piston seal. If present, remove two guide rings.

CLEAN AND INSPECT WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures. 1. Clean all metal parts in solvent. 2. Inspect piston rod for grooves or damage. Remove small scratches with fine emery cloth. 3. Inspect cylinder bore for damage

ASSEMBLE AND INSTALL CAUTION Do not damage the O-rings, seals, or wipers during installation.

ROD WIPER END CAP O-RING BACKUP RING SHELL

2. Lubricate O-rings, seals, and wipers with O-ring lubricant and carefully install one end cap on cylinder rod. 3. Carefully slide cylinder rod into shell and end onto into shell. Keep cylinder rod aligned in center of shell during installation so the parts are not damaged. Install other end cap into shell. Put caps on hydraulic fittings of end caps. 4. Hold end caps and install cylinder on axle frame using capscrews. Tighten capscrews to 225 N•m (166 lbf ft). 5. Install tie rods. See section Spindles, Bearings, and Tie Rods Repair, Tie Rods.

4. Inspect mounts for cracks.

1. 2. 3. 4. 5. 6.

1. Put O-rings, seals, guide rings, and wipers in warm hydraulic oil. Install O-rings, seals, guide rings, and wipers as shown in Figure 28.

6. Remove plugs and caps and connect hydraulic lines as tagged during removal, to steering cylinder. Operate steering system to remove air from cylinders and system. Turn steering wheel several times from one stop to the other. Check that the steer cylinder operates lock to lock.

7. 8. 9. 10. 11.

PISTON SEAL ROD SEAL O-RING HYDRAULIC LINE PORT GUIDE RING

Figure 28. Steering Cylinder

37


Torque Specifications

1600 YRM 1133

Torque Specifications Axle Mounting Bolts and Nuts GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) 90 N•m (66.4 lbf ft) GLP/GDP20-35VX (GP/GLP/GDP040070VX) (B875) 88 N•m (65 lbf ft) GC/GLC030-035VX, GC/GLC040SVX (C809) and GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/ GDP030-035VX, GP/GLP/GDP040SVX) (C810) 41 to 49 N•m (30 to 36 lbf ft) GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818), F818 215 N•m (159 lbf ft) GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) 90 N•m (66.4 lbf ft) GLP/GDP40VX5/VX6; GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 250 to 275 N•m (184 to 203 lbf ft) GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 270 N•m (199 lbf ft) GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 270 N•m (199 lbf ft) Hub Nut (Initial) GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) 68 N•m (50 lbf ft)

38

GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC/GLC040SVX (C809), and GLP/GDP16-18VX, GLP/ GDP20SVX (GP/GLP/GDP030-035VX, GP/GLP/GDP040SVX) (C810) 200 N•m (147.5 lbf ft) GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) 203 N•m (150 lbf ft) GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) 200 to 220 N•m (148 to 162 lbf ft) GLP/GDP40VX5/VX6; GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 203 N•m (150 lbf ft) GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 203 N•m (150 lbf ft) GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 203 N•m (150 lbf ft) Hub Nut (Final) GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) 3 N•m (27 lbf in) GLP/GDP20-35VX (GP/GLP/GDP040070VX) (B875) 15 N•m (133 lbf ft) GC/GLC030-035VX, GC/GLC040SVX (C809) and GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/ GDP030-035VX, GP/GLP/GDP040SVX) (C810) 12 N•m (106 lbf in)


1600 YRM 1133 GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) 34 N•m (25 lbf ft) GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) 35 N•m (26 lbf ft) GLP/GDP40VX5/VX6; GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 35 N•m (26 lbf ft) GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 34 N•m (25 lbf ft) GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, b909) 34 N•m (25 lbf ft) King Pin Lock Nut (Initial) GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC/GLC040SVX (C809), and GLP/GDP16-18VX, GLP/ GDP20SVX (GP/GLP/GDP030-035VX, GP/GLP/GDP040SVX) (C810) 90 N•m (66.4 lbf ft) King Pin Lock Nut (Final) GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC/GLC040SVX (C809), and GLP/GDP16-18VX, GLP/ GDP20SVX (GP/GLP/GDP030-035VX, GP/GLP/GDP040SVX) (C810) 34 N•m (25 lbf ft) Spindle Bearing Cap Capscrews GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) 44 N•m (32 lbf ft)

Torque Specifications GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) 45 to 50 N•m (33 to 37 lbf ft) GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 52 N•m (38 lbf ft) GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 47 N•m (35 lbf ft) GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 47 N•m (35 lbf ft) Tie Rod Nut GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) 163 N•m (120 lbf ft) GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) 175 N•m (129 lbf ft) Steer Cylinder Mounting Bolts GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 225 N•m (166 lbf ft) GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 225 N•m (166 lbf ft) GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 225 N•m (166 lbf ft)

GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) 52 N•m (38 lbf ft)

39


NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

40


1800 YRM 1247

General

General DRY BRAKE SYSTEM NOTE: The dry brake system is used only on lift truck models • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813) This section has service procedures for the dry brake system. The dry brake system includes the following parts: master cylinder and parking brake system (see Figure 1) and brake shoes and wheel cylinders (see Figure 6).

WET BRAKE SYSTEM NOTE: The wet brake system is used on all lift truck models covered in this YRM. The wet brake system in this section includes the following parts: master cylinder and parking brake system. See Figure 2 for lift truck models • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) See Figure 3 for lift truck models • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) See Figure 4 for lift truck models • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/ GDP190VX) (A909, B909) See Figure 5 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX ) (F813, G813, H813)

1. 2. 3. 4. 5. 6. 7.

PARK BRAKE HANDLE ASSEMBLY ADJUSTMENT KNOB PARK BRAKE CABLES INCHING/BRAKE PEDAL MASTER CYLINDER AND BOOSTER BRAKE ASSEMBLY BRAKE POSITION SENSOR (RIGHT-HAND SIDE)

Figure 1. Dry Brake System Drive Axle and Differential Assembly Repair, (Wet Brake) 1400 YRM 1246 for lift truck models • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813)

The wet disc brakes are a component of the wet brake drive axle. The brake discs are located inside the planetary carrier housing at each end of the drive axle. For the removal, assembly and installation procedures see:

1


General

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

PARK BRAKE HANDLE ASSEMBLY INCH/BRAKE PEDAL BOOSTER ASSEMBLY PARK BRAKE LEVERS PLANETARY CARRIER HOUSING (LEFT-HAND SIDE SHOWN) WET DISC BRAKE HOUSING PARK BRAKE CABLES ADJUSTMENT KNOB BRAKE POSITION SENSOR (LEFT-HAND SIDE SHOWN) MASTER CYLINDER CYLINDER BLOCK

Figure 2. Wet Brake System for Lift Truck Models GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) Drive Axle and Differential Assembly Repair, (Wet Brake) 1400 YRM 1318 for lift truck models • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) Drive Axle and Differential Assembly Repair, (Wet Brake) 1400 YRM 1344 for lift truck models • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/ GDP190VX) (A909, B909)

2

1800 YRM 1247

NOTE: LIFT TRUCK MODEL GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (C879, D879, E879, F879) SHOWN. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

PARK BRAKE HANDLE ASSEMBLY INCH/BRAKE PEDAL BOOSTER ASSEMBLY ADJUSTMENT KNOB PLANETARY CARRIER HOUSING (LEFT-HAND SIDE SHOWN) WET DISC BRAKE HOUSING PARK BRAKE CABLES BRAKE POSITION SENSOR MASTER CYLINDER CYLINDER BLOCK PARK BRAKE LEVERS

Figure 3. Wet Brake System for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)


1800 YRM 1247

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

PARK BRAKE HANDLE ASSEMBLY INCH/BRAKE PEDAL ADJUSTMENT KNOB BRAKE POSITION SENSOR PARK BRAKE CABLE PARK BRAKE LEVER CHARGE VALVE ACCUMULATOR MODULATING BRAKE VALVE DRIVE AXLE ASSEMBLY

Figure 4. Wet Brake System for Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909. B909)

General

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

PARK BRAKE HANDLE ASSEMBLY INCH/BRAKE PEDAL BOOSTER ASSEMBLY PARK BRAKE LEVERS PLANETARY CARRIER HOUSING (LEFT-HAND SIDE SHOWN) WET DISC BRAKE HOUSING PARK BRAKE CABLES ADJUSTMENT KNOB BRAKE POSITION SENSOR (LEFT-HAND SIDE SHOWN) MASTER CYLINDER

Figure 5. Wet Brake System for Lift Truck Model GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813)

3


Service Brakes Repair (Dry Brake)

1800 YRM 1247

Service Brakes Repair (Dry Brake) NOTE: The procedures in this section apply only to lift truck models • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813) equipped with the dry brake system.

REMOVE AND DISASSEMBLE WARNING Brake linings can contain dangerous fibers. Breathing the dust from these brake linings is a cancer or lung disease hazard. DO NOT create dust! DO NOT clean brake parts with compressed air or by brushing. Use vacuum equipment approved for brake dust or follow the cleaning procedure in this section. When the brake drums are removed, DO NOT create dust. DO NOT sand, grind, chisel, hammer, or change linings in any way that will create dust. Any changes to brake linings must be done in a restricted area with special ventilation. Protective clothing and a respirator must be used. 1. See the procedure How to Put Lift Truck on Blocks in the Operating Manual or Periodic Maintenance section for your lift truck. Start the engine and tilt the mast fully backward. Put blocks under the mast. Tilt the mast forward until the wheels just touch the floor. Stop the engine. Put blocks under the frame of the lift truck. 2. Remove the capscrews that hold the axle shaft to the hub. Remove the axle shaft. 3. Bend the lock plate tab and remove the nut, lockplate, washer and bearing cone.

4

4. Pull the wheel assembly from the lift truck. If the wheel assembly cannot be removed easily, use a small screwdriver to push the adjuster actuator away from the adjuster wheel. Use a brake adjustment tool or a screwdriver to turn the adjuster wheel to loosen the brake shoes. Remove the hub and drum assembly. Do not damage the grease seal when removing the hub. NOTE: During disassembly, note the arrangement of parts to aid in re-assemble of the brake system. 5. Remove the primary, secondary return springs and tension spring with spring pliers and remove the anchor pin from the primary brake shoe. See Figure 6. 6. Remove the pressure springs that hold the brake shoes to the backing plate. 7. Disconnect the parking brake cable from park brake lever. See Figure 6.

WARNING When the brake shoes are removed, DO NOT create dust in the air. See the Clean procedure in this section. 8. Remove brake shoes. 9. Remove the auto adjuster assembly from the backing plate. See Figure 7. 10. Disconnect the brake line from the wheel cylinder. Remove wheel cylinder from backing plate. See Figure 7. 11. If damaged, remove the backing plate from the axle housing. Discard the eight mounting lock bolts.


1800 YRM 1247

1. 2. 3. 4. 5. 6. 7. 8.

Service Brakes Repair (Dry Brake)

RETAINER SECONDARY RETURN SPRING SECONDARY BRAKE SHOE PRESSURE SPRING AUTO ADJUSTER LINK ADJUSTER WHEEL AUTO ADJUSTMENT ASSEMBLY PARKING BRAKE CABLE

9. 10. 11. 12. 13. 14. 15. 16.

TENSION SPRING PRIMARY BRAKE SHOE PARK BRAKE LEVER STRUT PRIMARY RETURN SPRING ANCHOR PIN BACKING PLATE WHEEL CYLINDER

Figure 6. Brake Assembly (Left-Hand Shown)

5


Service Brakes Repair (Dry Brake)

1800 YRM 1247 Small amounts of water in the brake system can cause reduced braking if the water reaches the wheel cylinders and is subject to high temperatures. DO NOT allow water entry into the brake system. If water is present, remove all water and refill the system with Dexron III from a sealed container. Unfiltered shop air can contain substantial amounts of water. DO NOT use unfiltered shop air to blow out brake components. Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the safety instructions of the solvent manufacturer.

CAUTION DO NOT permit brake cleaning fluid to contact the master cylinder or wheel cylinder. Brake cleaning fluid will cause damage and leaks in seals of the brake system. 1. DO NOT release brake lining dust from the brake linings into the air when the brake drum is removed.

CAUTION DO NOT permit oil or grease on the brake linings. Use a brake cleaning fluid as necessary to clean linings that will not be replaced.

1. 2. 3. 4.

WHEEL CYLINDER CAPSCREWS AUTO ADJUSTER CAPSCREW ADJUSTER WHEEL ACCESS PLUGS BRAKE LINE

Figure 7. Auto Adjuster and Wheel Cylinder Mount Location

CLEAN WARNING DO NOT use an oil solvent to clean the brake linings, use a solvent approved for cleaning of brake parts. Do not permit oil or grease on the brake linings, the brakes will not operate correctly if oil, grease, or brake cleaning fluid is on the brake linings. Oil and grease will cause damage and leaks in the seals of a brake system.

6

2. Use a solvent approved for cleaning of brake parts to wet the brake lining dust. Follow the instructions and cautions of the manufacturer for the use of the solvent. If a solvent spray is used, spray at a distance so that the dust is not released into the air. 3. When the brake lining dust is wet, clean the parts. Put any cloth or towels in a plastic bag or an airtight container while they are still wet. Put a DANGEROUS FIBERS warning label on the plastic bag or airtight container. 4. Any cleaning cloths that will be washed must be cleaned so that fibers are not released into the air.


1800 YRM 1247

INSPECT WARNING Small amounts of water in the brake system can cause reduced braking if the water reaches the wheel cylinders and is subject to high temperatures. DO NOT allow water entry into the brake system. If water is present, remove all water and refill the system with Dexron III from a sealed container. Unfiltered shop air can contain substantial amounts of water. DO NOT use unfiltered shop air to blow out brake components. Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the safety instructions of the solvent manufacturer.

CAUTION DO NOT permit brake cleaning fluid to contact the master cylinder or wheel cylinder. Brake cleaning fluid will cause damage and leaks in seals of the brake system. 1. Inspect the bore of the wheel cylinder for holes or scratches. Replace the wheel cylinder assembly if there is any damage. 2. Inspect wheel cylinder parts for dirt or water. Clean any dirt or water present in the wheel cylinder parts using a lint free cloth. 3. Inspect the primary, secondary and tension springs for wear and damage. Inspect the back plate for wear where the brake shoes touch the back plate. Remove any grooves or replace a worn or damaged back plate. 4. Inspect the park brake lever and strut. If damaged, replace primary and secondary brake shoe assembly.

Service Brakes Repair (Dry Brake)

WARNING The brake shoes on both wheels must be replaced if any shoe is damaged. The brake performance on both ends of an axle must be equal, or the lift truck can be difficult to steer when the brakes are applied. 5. Inspect the brake shoes for cracks or damage. If the linings or shoes are worn or damaged, replace the brake shoes. Maximum wear is to within 1 mm (0.039 in.) of contact with the rivets, or the metal shoe on bonded linings. Brake shoes must be replaced in complete sets. Inspect the brake drums for cracks or damage. Replace any damaged parts. 6. Inspect the brake drum for deep grooves or other damage. NOTE: If grooves must be removed from the brake drums, do not grind more than 1.5 mm (0.060 in.) from the internal diameter of the brake drum. The maximum limit of the internal diameter of the brake drum is 319.5 mm (12.6 in.). If the internal diameter is larger than the limit, replace the brake drum. 7. The teeth of the adjuster wheels must not be worn. The adjuster wheel must turn freely. Check the adjuster links for damage. Replace the auto adjuster assembly if there is any damage. See Figure 6 and Figure 7. 8. Make sure the parking brake cables are in good condition. Replace parking brake cables if worn or damaged. 9. Check the grease seals and the surfaces of the seals for wear or damage. Replace damaged seals.

ASSEMBLE AND INSTALL 1. If removed, install backing plate using eight new lock bolts to the axle housing using tightening sequence. Tighten bolts to 340 to 375 N•m (251 to 277 lbf ft). See Figure 8.

7


Service Brakes Repair (Dry Brake)

1800 YRM 1247 5. Install the primary and secondary brake shoes on the push rod of wheel cylinder and auto adjuster link. See Figure 6. 6. Connect the parking brake cable to park brake lever. 7. Install pressure springs to hold the brake shoes to the backing plate. 8. Install the primary and secondary return springs, and tension spring to the brake shoe. See Figure 6. 9. Coat threads of the adjuster wheels with antiseize compound. Turn the adjuster wheels so that the adjuster assembly is in its shortest position. This action permits the brake drum to be easily installed over the brake shoes. NOTE: Seal and bearings are to be installed flush with the hub. Seal is to be installed with no grease or oil on outside surface.

Figure 8. Backing Plate to Axle Housing Tightening sequence NOTE: Replace wheel cylinder if there is any damage or it is not working properly. 2. Install the wheel cylinder on the backing plate and tighten capscrews to 20 to 25 N•m (15 to 19 lbf ft). Connect the brake line to the wheel cylinder. See Figure 7. NOTE: Replace auto adjuster assembly if there is any damage or it is not working properly. 3. Install the auto adjuster assembly on the backing plate between the two brake shoes and tighten capscrew to 120 to 140 N•m (89 to 103 lbf ft). See Figure 6 and Figure 7. 4. Lubricate the backing plate with small amount of lithium grease where the brake shoes touch. NOTE: The park brake lever and strut are a component of the primary brake shoe. If damaged, replace primary and secondary brake shoe assembly.

8

10. Clean the bearings and lubricate them with wheel bearing grease. Install the bearings and seals in the wheel hub. Install the assembly on the axle housing. See Figure 9 and Figure 10. NOTE: To prevent damage to the inner oil seal when installing the hub, the hub and drum assembly can be temporarily fastened to the wheel. 11. Align the height of the axle housing with hub bearings. Install the outer bearing and nut. 12. Install the washer, lock plate and wheel adjustment nut. See Figure 11. a. To align the bearing rollers, tighten the wheel adjustment nut to 28 to 32 N•m (21 to 24 lbf ft) and rotate the hub 2 revolutions in both directions. b. To seat the wheel bearings, tighten the wheel adjustment nut to 400 to 480 N•m (295 to 354 lbf ft). Back off the wheel adjustment nut to zero end play. c. Preload the wheel bearings by tightening the wheel adjustment nut to 28 to 32 N•m (21 to 24 lbf ft).


1800 YRM 1247

1. INNER SEAL 2. OUTER SEAL 3. BRAKE DRUM

Service Brakes Repair (Dry Brake)

4. INNER BEARING 5. OUTER BEARING

Figure 9. Grease Seals and Bearing Locations

9


Service Brakes Repair (Dry Brake)

1800 YRM 1247

Figure 10. Inner Grease Seal Installation

1. ADJUSTER LEVER 2. ADJUSTER WHEEL

3. ADJUSTER LINK

Figure 12. Auto Adjuster Assembly NOTE: If the brake shoes were not replaced, loosen the two adjuster wheels equally, approximately 20 teeth.

1. 2. 3. 4. 5.

AXLE SHAFT WHEEL ADJUSTMENT NUT LOCK PLATE WASHER HUB

Figure 11. Wheel Adjustment d. Rotate the hub 3 complete revolutions in both directions. Verify the wheel adjustment nut torque is 28 to 32 N•m (21 to 24 lbf ft) and that the torque stabilizes at that specification.

CAUTION If there is too much clearance, the automatic adjusters will not operate. If the clearance is too small, the automatic adjuster cannot turn the adjuster wheel to increase the clearance, and the adjuster wheel will not turn until the brake shoes wear. If the adjuster wheel does not move for a long operating period, the adjuster link can wear a spot on the adjuster wheel so that it will not turn correctly.

10

13. To manually adjust the brakes, it is necessary to turn the adjuster wheels. See Figure 6. a. Remove the two access plugs in the adjustment slots located on the back side of the backing plate. Place an adjuster tool and screwdriver through the slot in the backing plate. See Figure 7. b. Push the adjuster lever away from the adjuster wheel, in the direction indicated in Figure 12 and turn the adjuster wheel until the brake shoe just touches the brake drum. c. Use the adjuster tool to loosen the adjuster wheel approximately 20 teeth. Adjust the brake shoe for the other adjuster wheel using the same method. See Figure 12. d. Install the access plugs after the adjustment is complete. See Figure 7. 14. Install the drive wheels. Remove the lift truck from the blocks. 15. Operate the lift truck in the FORWARD and REVERSE directions. Stop the lift truck 10 times in each direction. This procedure causes the brake shoes to wear a small amount and fit the brake drum better.


1800 YRM 1247

Parking Brake Repair and capscrews. Tighten the capscrews in the sequence shown in Figure 13 to 90 to 99 N•m (66 to 73 lbf ft).

ADJUST 1. Remove the air from the brake hydraulic system. See Brake System Air Removal. 2. Install the wheel on the hub. Tighten the wheel nuts to 610 to 680 N•m (450 to 502 lbf ft). 3. Start the engine and tilt the mast backward to remove the blocks. Push on the brake pedal. The pedal must not touch the floor plate. Move the lift truck in REVERSE and push on the brake pedal to permit adjusting mechanism to operate. Repeat this operation several times.

Figure 13. Axle Shaft Tightening Sequence 16. Coat the flange of the axle shaft with liquid sealant, Yale Part Number 520042831. Install the axle shaft

4. The service brakes must be adjusted before the parking brake can be adjusted. See Figure 15 and the following paragraphs in this section for the correct adjustment of the parking brake.

Parking Brake Repair REMOVE AND DISASSEMBLE NOTE: For removal and disassembly procedures for a dry brake system use Step 1 through Step 5. For the wet brake system use Step 1 through Step 4 and Step 6. If the handle assembly for the parking brake must be removed from the cowl, use the following procedures. For dry brake system, see Figure 15. For wet brake system, see Figure 16 for lift truck models • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX ) (F813, G813, H813)

Figure 17 for lift truck models • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) Figure 18 for lift truck models • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/ GDP190VX) (A909, B909) 1. Block the front and rear side of the wheels to make sure the lift truck cannot move. Release the parking brake handle assembly. 2. Remove the four capscrews that fasten the bracket for the parking brake to the cowl. Remove the bracket and parking brake handle assembly.

11


Parking Brake Repair

1800 YRM 1247

3. Loosen the jam nuts that fasten the threaded ends of the parking brake cables to the parking brake handle assembly. 4. Turn the adjustment knob counterclockwise until the parking brake cables are loosened. Disconnect the cables from the equalizer links. 5. The service brake assembly must be removed before the parking brake cable can be removed from the back plate of the service brake. A snap ring holds the sheath of the parking brake cable in the back plate of the service brake. Remove the snap ring and remove the parking brake cable from the back plate. See Figure 14. 6. The cotter pin, clevis pin, and cable clamps must be removed from the parking brake levers before the parking brake cables can be removed. See Figure 16 for lift truck models • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX ) (F813, G813, H813) See Figure 17 for lift truck models • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

1. 2. 3. 4. 5.

PARKING BRAKE CABLE SHEATH SNAP RING SERVICE BRAKE ASSEMBLY BACK PLATE

Figure 14. Parking Brake Cable Removal for Lift Truck Models GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) and GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813) With Dry Brake System

See Figure 18 for lift truck models • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909)

Legend for Figure 15 A. RIGHT HAND SIDE

B. LEFT HAND SIDE

1. 2. 3. 4. 5. 6. 7.

8. 9. 10. 11. 12. 13. 14.

12

PARKING BRAKE HANDLE ASSEMBLY ADJUSTMENT KNOB PARKING BRAKE CABLES INCHING/BRAKE PEDAL MASTER CYLINDER AND BOOSTER BRAKE ASSEMBLY BRAKE POSITION SENSOR

ADJUSTMENT SLOT (UNDERNEATH SPRING) EQUALIZER LINK NUT CAPSCREW PARKING BRAKE BRACKET JAM NUTS PARKING BRAKE CABLE BRACKET


1800 YRM 1247

Parking Brake Repair

Figure 15. Parking Brake Lever Adjustment for Lift Truck Models GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) and GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813) With Dry Brake System

13


Parking Brake Repair

1800 YRM 1247

Figure 16. Parking Brake Lever Adjustment for Lift Truck Models GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) and GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813) With Wet Brake System

14


1800 YRM 1247

Parking Brake Repair

Legend for Figure 16 A. GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813)

B. GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818)

1. 2. 3. 4. 5. 6. 7.

9. 10. 11. 12. 13. 14. 15. 16. 17.

PARKING BRAKE HANDLE ASSEMBLY ADJUSTMENT KNOB EQUALIZER LINKS PARKING BRAKE CABLES NUT CAPSCREW BRAKE POSITION SENSOR (RIGHT SIDE SHOWN) 8. ADJUSTMENT SLOT (UNDERNEATH SPRING)

INCHING/BRAKE PEDAL MASTER CYLINDER AND BOOSTER CLEVIS PIN COTTER PIN PARKING BRAKE LEVER CABLE CLAMPS PARKING BRAKE BRACKET JAM NUTS PARKING BRAKE CABLE BRACKET

15


Parking Brake Repair

1800 YRM 1247

Figure 17. Parking Brake Lever Adjustment for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) (Wet Brake System) 16


1800 YRM 1247

Parking Brake Repair

Legend for Figure 17 A. GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 1. 2. 3. 4. 5. 6. 7. 8.

PARKING BRAKE HANDLE ASSEMBLY ADJUSTMENT KNOB EQUALIZER LINKS PARKING BRAKE CABLES NUT CAPSCREW BRAKE POSITION SENSOR ADJUSTMENT SLOT (UNDERNEATH SPRING)

B. GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 9. 10. 11. 12. 13. 14. 15.

INCHING/BRAKE PEDAL MASTER CYLINDER AND BOOSTER CLEVIS PIN COTTER PIN PARKING BRAKE LEVER CABLE CLAMPS/MOUNTING BRACKET JAM NUTS

17


Parking Brake Repair

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

PARK BRAKE HANDLE ASSEMBLY ADJUSTMENT KNOB EQUALIZER LINKS PARK BRAKE CABLE NUT CAPSCREW BRAKE POSITION SENSOR ADJUSTMENT SLOT (UNDER SPRING) INCH/BRAKE PEDAL ACCUMULATOR CHARGE VALVE

1800 YRM 1247

11. 12. 13. 14. 15. 16. 17. 18. 19.

ACCUMULATOR MODULATING BRAKE VALVE CLEVIS PIN COTTER PIN PARKING BRAKE LEVER CLEVIS CABLE CLAMP/MOUNTING BRACKET JAM NUTS BRAKE BRACKET

Figure 18. Parking Brake Lever Adjustment for Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) (Wet Brake System)

18


1800 YRM 1247

ASSEMBLE AND INSTALL NOTE: For assemble and install procedures for a dry brake system use Step 1, Step 3, Step 4, Step 6 and Step 7. For the wet brake system use Step 2, Step 3, and Step 5 through Step 7. If the lever assembly for the parking brake was removed from the cowl, use the following procedure for installation: 1. The parking brake cables must be installed in the back plate before the service brake is installed. A snap ring holds the sheath of the parking brake cable in the back plate of the service brake. Install the parking brake cable in the back plate and install the snap ring that holds the sheath of the parking brake cable in the back plate. See Figure 14. 2. The parking brake cables must be installed on the parking brake levers located on the wet brake drive axle and the cables loosely clamped to the frame and axle in the correct position before connecting cables to the equalizer links located on the parking brake handle assembly. See Figure 16 for lift truck models • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX ) (F813, G813, H813) See Figure 17 for lift truck models • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) See Figure 18 for lift truck models • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3. Make sure the parking brake handle is in the released position. Turn the adjustment knob until the equalizer link is adjusted to the bottom of the adjustment slot. For dry brake system, see Figure 15. For wet brake system: See Figure 16 for lift truck models

Parking Brake Repair • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX ) (F813, G813, H813) See Figure 17 for lift truck models • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) See Figure 18 for lift truck models • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 4. Adjust the jam nuts on the ends of the cable assemblies so that the threads of the cable sheaths extend 23 to 26 mm (0.90 to 1.02 in.) above their support plate in the lever assembly. See Figure 15. 5. Adjust the jam nuts on the ends of the parking cables so that the threads of the cable are level in the parking brake handle assembly and not pulling on the equalizer links with the parking brake handle assembly in the released position. See Figure 16 for lift truck models • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX ) (F813, G813, H813) See Figure 17 for lift truck models • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) See Figure 18 for lift truck models • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909)

19


Parking Brake Repair 6. Install the round ends of the parking brake cables in their slots in the equalizer link. Tighten the upper jam nuts to hold the sheaths of the parking brake cables in the parking brake cable bracket. 7. Use the four capscrews, washers, and nuts and fasten the bracket to the inside of the cowl. Tighten park brake cable clamps on frame and axle.

1800 YRM 1247

CAUTION On lift trucks equipped with the wet brake system, check the dash display to verify the transmission oil is at operating temperature, 49 to 66°C (120 to 150°F) before adjusting the parking brake adjustment knob. 1. To adjust the parking brake, perform the following:

ADJUST Dry Brake System Make sure the service brakes are adjusted and the operation of the automatic adjuster mechanism is correct before the parking brake cables are adjusted.

Wet Brake System Make sure the park brake levers are adjusted before the parking brake cables are adjusted. For park brake lever adjustment procedures, see: Drive Axle and Differential Assembly Repair, (Wet Brake) 1400 YRM 1246 for lift truck models • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813) Drive Axle and Differential Assembly Repair, (Wet Brake) 1400 YRM 1318 for lift truck models • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) Drive Axle and Differential Assembly Repair, (Wet Brake) 1400 YRM 1344 for lift truck models • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/ GDP190VX) (A909, B909)

Lift Trucks With a Foot Directional Control Pedal or Forward Reverse Lever The switch energizes the seat warning circuit when hand lever is released. This switch puts the transmission in NEUTRAL by de-energizing the direction solenoid. There is also a switch on the left-hand side of bracket. This switch prevents engine from starting unless parking brake is applied.

20

a. Turn the adjustment knob to raise the equalized link and tighten the parking brake cables. DO NOT tighten the adjustment knob so that the brake is applied when the lever is released. For dry brake system, see Figure 15. For wet brake system: See Figure 16 for lift truck models • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX ) (F813, G813, H813) See Figure 17 for lift truck models • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) See Figure 18 for lift truck models • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) b. The lever for the parking brake has a lock. Use your thumb or finger to release the lock on the lever when the parking brake is released. NOTE: Before doing Step 2 and Step 3, make sure the parking brake is correctly adjusted. For lift truck models GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) the parking brake is correctly adjusted when it takes 125 N (28 lbf) (wet brakes) or 200 N (45 lbf) (dry brakes) force to fully apply the parking brake.


1800 YRM 1247

Master Cylinder Repair

For lift truck models GLP/GDP40VX5/VX6; GLP/ GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813) the parking brake is correctly adjusted when it takes 200 N (45 lbf) (wet and dry brakes) force to fully apply the parking brake.

For lift truck models GLP/GDP80VX, GLP/ GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) the parking brake is correctly adjusted when it takes 175 N (39 lbf) (wet brakes) force to fully apply the parking brake.

For lift truck models GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) the parking brake is correctly adjusted when it takes 200 N (45 lbf) (wet and dry brakes) force to fully apply the parking brake.

2. For new brakes, test the operation of the parking brake. The lift truck, with a capacity load, must not move when parking brake is applied on a 7.5 percent grade [a slope that increases .75 m in 10 m (9 in. in 10 ft)].

For lift truck models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) the parking brake is correctly adjusted when it takes 175 N (39 lbf) (wet brakes) force to fully apply the parking brake.

3. For burnished brakes, test the operation of the parking brake. The lift truck, with a capacity load, must not move when parking brake is applied on a 15 percent grade [a slope that increases 1.5 m in 10 m (1.5 ft in 10 ft)].

Master Cylinder Repair REMOVE NOTE: The removal procedure in this section is the same for both dry and wet brake systems. 1. Remove the floor plate, kick plate, and seal plate from the lift truck for access to the master cylinder and booster assembly. 2. Remove master cylinder hoses and brake pressure transducer: a. Remove and tag the brake booster supply and return hoses from the master cylinder and booster assembly. Plug hoses to prevent hoses from draining. Disconnect the connector at the brake pressure transducer, and remove brake pressure transducer. See Figure 19 for lift truck models • GLC40, 45, 55VX; GLC55SVX (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813)

b. Remove and tag the accumulator to booster hose, the booster and accumulator supply hose, the brake hose, and booster return hose. Plug hoses to prevent hoses from draining. Disconnect the connector at the brake pressure transducer, and remove brake pressure transducer. See Figure 20 for lift truck models • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) c. Remove and tag the accumulator to booster line, the booster and accumulator supply hose and the brake hose. Plug hoses to prevent hoses from draining. Disconnect the connector at the brake pressure transducer, and remove brake pressure transducer. See Figure 21 for lift truck models • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3. Disconnect and cap the lower brake oil supply hose from nipple at the master cylinder. See Figure 19. 4. Remove the cotter pin and rod end pin from the clevis that is attached to the brake linkage lever arm. 5. Remove capscrews and nuts that hold master cylinder and booster assembly to bracket assembly.

21


Master Cylinder Repair

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

CAPSCREW BRAKE OIL RESERVOIR CLAMP UPPER BRAKE OIL SUPPLY HOSE CYLINDRICAL BLOCK MOUNT LOWER BRAKE OIL SUPPLY HOSE INSERT FITTING FOR BOOSTER RETURN HOSE BRAKE HOSE

1800 YRM 1247

11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

BRAKE PRESSURE TRANSDUCER BOOSTER SUPPLY HOSE BOOSTER ASSEMBLY MOUNTING BOLT MANIFOLD MOUNT BRACKET COTTER PIN ROD END PIN MASTER CYLINDER NIPPLE

Figure 19. Master Cylinder and Reservoir Assembly, Lift Truck Models GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) and GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813)

22


1800 YRM 1247

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

BOOSTER MASTER CYLINDER BOOSTER RETURN HOSE MANIFOLD BOOSTER AND ACCUMULATOR SUPPLY HOSE ACCUMULATOR TO BOOSTER HOSE FITTING ACCUMULATOR MOUNTING CLAMP/BRACKET BRAKE HOSE BRAKE PRESSURE TRANSDUCER

Figure 20. Accumulator and Boosted Master Cylinder, Lift Truck Models GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

Master Cylinder Repair

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

BOOSTER BOOSTER RETURN HOSE MANIFOLD MASTER CYLINDER ACCUMULATOR TO BOOSTER LINE BOOSTER AND ACCUMULATOR SUPPLY HOSE TEE FITTING MOUNTING CLAMP/BRACKET ACCUMULATOR BRAKE HOSE BRAKE PRESSURE TRANSDUCER

Figure 21. Accumulator and Boosted Master Cylinder, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/ GDP155VX) (C878, D878, E878)

23


Master Cylinder Repair

DISASSEMBLE CAUTION

1800 YRM 1247 Inspect the bore of the master cylinder for holes and scratches. Replace the master cylinder and booster assembly if there is damage. See Figure 22.

When the piston is removed or installed, make sure the cylinder bore and piston are not scratched or damaged.

Inspect master cylinder parts for dirt or water. Clean any dirt or water present in master cylinder parts using a clean lint free cloth.

1. Place master cylinder and booster assembly into a soft jawed vise.

ASSEMBLE

2. Remove three mounting capscrews and master cylinder from booster. See Figure 22.

WARNING

NOTE: Install new seals when the master cylinder is being assembled. 1. Install the new retaining seal on the piston, as noted during removal.

Piston is under extreme pressure. Use care when removing snap ring to avoid possible injury.

2. Install the washer between the pressure seal and the piston.

3. Remove the snap ring holding the piston.

3. Install the new pressure seal and retainer over the spring end of the plunger.

4. Remove piston. 5. Remove the spring and retainer from the bore.

4. Install the spring and piston into the bore of the master cylinder.

6. Remove and discard the pressure seal from the spring end of the piston.

5. Install the snap ring holding the piston.

7. Remove the washer between the pressure seal and the piston.

6. Install the master cylinder on the booster assembly with three capscrews and tighten to 49 to 59 N•m (36 to 43 lbf ft).

NOTE: Note the position of the seal. 8. Remove and discard the retaining seal from the piston.

CLEAN AND INSPECT WARNING Small amounts of water in the brake system can cause reduced braking performance if the water reaches the wheel cylinders and is subject to high temperatures. DO NOT allow water entry into the brake system. If water is present, remove all water and refill the system with Dexron III from a sealed container. Unfiltered shop air can contain substantial amounts of water, therefore, DO NOT use unfiltered shop air to blow out components.

CAUTION DO NOT permit brake cleaning fluid to contact master cylinder. Brake cleaning fluid will cause damage and leaks in seals of the brake system.

24

INSTALL AND ADJUST WARNING Small amounts of water in the brake system can cause reduced braking performance if the water reaches the wheel cylinders and is subject to high temperatures. DO NOT allow water entry into the brake system. If water is present, remove all water and refill the system with Dexron III from a sealed container. Unfiltered shop air can contain substantial amounts of water, therefore, DO NOT use unfiltered shop air to blow out components. NOTE: The install and adjust procedure is the same for both dry and wet brake systems. NOTE: The master cylinder uses Dexron III brake oil. For the correct amount oil used see the Maintenance Schedule. 1. Using capscrews and nuts, install the master cylinder and brake booster assembly on the bracket assembly. See Figure 19.


1800 YRM 1247

1. 2. 3. 4. 5.

Master Cylinder Repair

BOOSTER ASSEMBLY HOUSING (MASTER CYLINDER) SNAP RING PISTON RETAINING SEAL

6. 7. 8. 9. 10.

PRESSURE SEAL WASHER RETAINER SPRING CAPSCREW

Figure 22. Master Cylinder and Booster

25


Master Cylinder Repair 2. Attach the clevis to the bracket using the rod end pin and cotter pin. 3. Uncap and install the lower brake oil supply hose onto the nipple at the master cylinder. 4. Connect hoses to master cylinder booster assembly: a. Connect the brake booster supply and return hoses to the master cylinder and booster assembly. See Figure 19 for lift truck models • GLC40, 45, 55VX; GLC55SVX (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813) b. Connect the accumulator to booster hose, the booster, and accumulator supply hose, the brake hose, and booster return hose. See Figure 20 for lift truck models • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) c. Connect the accumulator to booster line, the booster, accumulator supply hose, and the brake hose. See Figure 21 for lift truck models • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 5. Install the brake pressure transducer into master cylinder and tighten to 23 to 28 N•m (16.9 to 20.6 lbf ft). See Figure 19 for lift truck models • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX ) (F813, G813, H813)

26

1800 YRM 1247 See Figure 20 for lift truck models • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) See Figure 21 for lift truck models • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 6. Orient master cylinder side of brake supply and return lines parallel with brake pressure transducer. 7. Tighten fitting nuts at each end of brake hose assembly to 13 to 18 N•m (84 to 117 lbf in). 8. Apply a layer of multipurpose grease to the rod end pin and, with twisting motion, insert through clevis and the inching/brake pedal. Install cotter pin into the rod end pin. 9. Adjust free pedal per the following procedure: a. Loosen nut and screw it away from yoke. b. Turn push rod counterclockwise, as viewed from top, until push rod can be moved from side to side. c. Turn push rod clockwise until it can no longer be moved from side to side. d. Turn push rod counterclockwise 1.5 to 1.75 turns. e. Tighten nut to 17 to 23 N•m (12.5 to 17 lbf ft). f.

Verify free pedal is 10 to 12 mm (0.39 to 0.47 in.). See Figure 36.

10. Flush with Dexron III brake oil from a sealed container, and air bleed system. See Brake System Air Removal. 11. Adjust oil level until level is within 2.5 mm (0.098 in.) of MAX line or 5 to 7.5 mm (0.19 to 0.29 in.) above large rib on reservoir if MAX line is not present. 12. Verify all connections are leak-free.


1800 YRM 1247

Accumulator

13. Check the brake booster input pressure. The brake booster input pressure is found in the Transmission Oil Pressures section and listed under Port 1, Transmission Pump in the service manuals listed below: Capacities and Specifications 8000 YRM 1249, for lift truck models • GLC40, 45, 55VX; GLC55SVX (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS (E818) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813) Capacities and Specifications 8000 YRM 1559, for lift truck model • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (H813) Capacities and Specifications 8000 YRM 1320, for lift truck models • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX (C878, D878)

• GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879) Capacities and Specifications 8000 YRM 1572, for lift truck model • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (E879) Capacities and Specifications 8000 YRM 1584 for lift truck model • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX (E878) Capacities and Specifications 8000 YRM 1607 for lift truck model • 14. Install floor plate, kick plate, and seal plate on lift truck. 15. Check adjustment of brake pedal as described in Brake Pedal Adjustment.

Accumulator This accumulator is used only on the following lift truck models: • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

PRE-CHARGE CHECK NOTE: During service, the pre-charge pressure will decrease as a result of the natural diffusion of nitrogen gas. Therefore, the pre-charge pressure must be checked every 12 months and recharged if required. NOTE: For checking of the pre-charge value, proceed as follows:

2. Switch the engine OFF. 3. To access the accumulator a. Remove the floor mats, floor plates and raise the hood for lift truck models • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) b. Remove the floor mats and floor plates for lift truck models • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4. Remove the cap from the accumulator. See Figure 23.

1. Lower the forks completely.

27


Accumulator

1. CAP 2. O-RING

1800 YRM 1247

3. CHECK VALVE 4. ACCUMULATOR

Figure 23. Accumulator 5. Connect a 0 to 34 bar (0 to 500 psi) gauging assembly to the accumulator check valve. See Figure 23. 6. Apply brake pedal ten times until the pressure stabilizes and observe the gauge reading. This reading in pressure represents the pre-charge of the accumulator. 7. Recharge with nitrogen gas to the required precharge pressure of 4 ±0.35 bar (58 ±5 psi). 8. Disconnect gauging assembly and install cap.

28

1. 2. 3. 4. 5. 6. 7. 8. 9.

BOOSTER MASTER CYLINDER BOOSTER RETURN HOSE MANIFOLD BOOSTER AND ACCUMULATOR SUPPLY HOSE ACCUMULATOR TO BOOSTER HOSE FITTING ACCUMULATOR MOUNTING CLAMP/BRACKET

Figure 24. Accumulator and Boosted Master Cylinder, GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)


1800 YRM 1247

Accumulator

REMOVE WARNING The accumulator has a pressure charge and can cause an injury if the pressure is released too fast. Follow the manufacturer’s instructions during removal and installation. Before disconnecting any hydraulic lines, release pressure from hydraulic circuit as follows:

• Shut OFF the engine and completely lower the forks. Install blocks at the wheels to prevent the lift truck from moving. • Operate the lift/lower lever and the brake pedals until the hydraulic pressure is released. 1. Perform the following step that applies to your lift truck. NOTE: Position of accumulator may vary. a. Release pressure from the accumulator by slowly disconnecting the fitting on the accumulator from the hose between the accumulator and booster. See Figure 24 for lift truck models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) b. To release system pressure, slowly disconnect the line between the booster and accumulator from the tee fitting on the accumulator. Slowly disconnect the hose between the manifold on the drive axle and accumulator from the tee fitting on the accumulator. See Figure 25 for lift truck models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 2. Place caps on all disconnected lines and hoses. 3. Loosen the nut on the accumulator mounting clamp/bracket and remove accumulator. See Figure 26.

1. 2. 3. 4. 5. 6. 7. 8. 9.

BOOSTER BOOSTER RETURN HOSE MANIFOLD MASTER CYLINDER ACCUMULATOR TO BOOSTER LINE BOOSTER AND ACCUMULATOR SUPPLY HOSE TEE FITTING MOUNTING CLAMP/BRACKET ACCUMULATOR

Figure 25. Accumulator and Boosted Master Cylinder, GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

4. If necessary, remove tee fitting from the accumulator. See Figure 26.

29


Accumulator

1800 YRM 1247

A. GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) B. GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

C. GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (E879, F879)

1. ACCUMULATOR 2. FITTING

3. CLAMP/BRACKET 4. NUT

Figure 26. Accumulator and Mounting Clamp/Bracket

INSTALL 1. If removed, install the fitting to accumulator. See Figure 26. 2. Place the accumulator in position in the mounting clamp/bracket and tighten nut to 17 N•m (150 lbf in). 3. Perform the following step that applies to your lift truck. a. Connect the hose between the booster and accumulator to the elbow fitting on the accumulator. See Figure 24 for lift truck models • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) b. Connect the line between the booster and accumulator to the tee fitting on the accumulator. Connect the hose between the manifold on the drive axle and accumulator to the tee fitting on the accumulator.

30

See Figure 25 for lift truck models • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4. Perform the following: a. Install the floor plates, floor mats and close the hood for lift truck models • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) b. Install the floor plates and floor mats for lift truck models • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 5. Operate the system and check for leaks.


1800 YRM 1247

Modulating Brake Valve, Accumulator Charge Valve, and Accumulator

Modulating Brake Valve, Accumulator Charge Valve, and Accumulator WARNING DO NOT continue to operate the lift truck if the light and audible alarm are on during operation. Low accumulator pressure will prevent the service brakes from stopping the lift truck. Serious injury to personnel can result. During operation of the lift truck, if the red, low accumulator pressure light illuminates and an audible alarm sounds (see Operating Manual) the hydraulic pressure is below 7240 kPa (1050 psi). Move lift truck to level ground and/or apply the parking brake. Turn lift truck power OFF immediately and do not restart the engine until the low pressure condition has been corrected.

REMOVE The modulating brake valve, accumulator charge valve, and accumulator in this section are used on lift truck model GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909).

WARNING Before disconnecting any hydraulic lines, release pressure from the hydraulic circuit as follows: a. Turn key or keyless switch to the OFF position. Completely lower carriage. Install blocks at the wheels to prevent the lift truck from moving. b. Operate the lift/lower lever and the brake pedal(s) until the hydraulic pressure is released. 1. Remove floor mats and floor plates for access to valves and accumulator. 2. Remove cotter pin and clevis pin from push rod clevis and plate. Remove push rod clevis from plate. NOTE: Tag hydraulic lines during disassembly to aid in assembly. 3. Disconnect and cap hydraulic lines from modulating brake valve and accumulator charge valve. See Figure 27.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

NUT PUSH ROD BOOT TUBE ASSEMBLY WASHER ACCUMULATOR CHARGE VALVE CAPSCREW BRAKE BRACKET HYDRAULIC LINE MODULATING BRAKE VALVE

Figure 27. Modulating Brake Valve and Accumulator Charge Valve

31


Modulating Brake Valve, Accumulator Charge Valve, and Accumulator

1. ACCUMULATOR 2. ACCUMULATOR CHARGE VALVE

Figure 28. Accumulator Charge Valve and Accumulator 4. Disconnect tube assembly from accumulator charge valve fitting. See Figure 27. 5. Remove two capscrews and accumulator charge valve from brake bracket. See Figure 27. 6. Remove two capscrews, two washers, and modulating brake valve from brake bracket. See Figure 27. 7. Remove accumulator from accumulator charge valve. See Figure 28.

MODULATING BRAKE VALVE Disassemble 1. Remove push rod from modulating brake valve. See Figure 27. 2. Remove brake pressure transducer from modulating brake valve. See Figure 29. 3. Remove tube assembly from fitting. See Figure 29. 4. Remove fittings from modulating brake valve. Remove and discard O-rings from fittings. See Figure 29. 5. Remove and discard boot from piston and housing. See Figure 30.

1. 2. 3. 4. 5.

1800 YRM 1247

MODULATING BRAKE VALVE FITTING O-RING TUBE ASSEMBLY BRAKE PRESSURE TRANSDUCER

Figure 29. Modulating Brake Valve Fittings NOTE: Note order of springs removed during disassembly to aid in assembly. NOTE: Note number of shims removed during disassembly to aid in assembly. 6. Remove piston, springs, shim(s), and retainer from housing. See Figure 30.

CAUTION Care must be taken not to scratch or mar housing bore. 7. Carefully remove cup and seal from housing. See Figure 30. 8. Remove end plug and spring from housing. Remove and discard O-ring from end plug. See Figure 30.

CAUTION Care must be taken not to damage spool or housing bore. NOTE: Housing and spool are manufactured as a matched set. Be sure to keep housing and spool together after disassembly to aid in assembly. 9. Carefully remove spool from end plug side of housing. See Figure 30.

32


1800 YRM 1247

Modulating Brake Valve, Accumulator Charge Valve, and Accumulator

Clean and Inspect WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures.

WARNING Compressed air can move particles so they cause injury to the user or to other personnel. Make sure the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.

CAUTION Clean only metal components with solvent and dry using compressed air. 1. Clean metal valve components with solvent and dry with compressed air. 2. Clean plastic or rubber components with warm soapy water and dry with a lint free cloth. DO NOT submerge components with electrical connections in water. 3. Inspect spool and housing for damage. Replace modulating brake valve assembly if either is damaged. 1. 2. 3. 4. 5. 6.

BOOT HOUSING PISTON SPRING SHIM RETAINER

7. 8. 9. 10. 11.

CUP SEAL END PLUG O-RING SPOOL

Figure 30. Modulating Brake Valve Assembly

4. Inspect all other components for damage. Replace if damaged.

Assemble CAUTION Care must be taken not to damage spool or housing bore. NOTE: Be sure housing and spool are a matched set. 1. Carefully install spool into end plug side of housing. See Figure 30. 2. Install new O-ring onto end plug. Install spring and end plug into housing. See Figure 30.

33


Modulating Brake Valve, Accumulator Charge Valve, and Accumulator

1800 YRM 1247

CAUTION Care must be taken not to scratch or mar housing bore. 3. Carefully install seal and cup into housing. See Figure 30. NOTE: Be sure to install the same number of shims noted in Step 6 of disassembly. NOTE: Be sure to install springs in the order removed as noted in Step 6 of disassembly. 4. Install retainer, shim(s), springs, and piston into housing. See Figure 30. 5. Install new boot onto piston and housing. See Figure 30. 6. Install push rod into modulating brake valve. NOTE: Nipple fitting to be place at 45° ±3° angle toward charge valve. 7. Install new O-rings onto fittings. Install fittings into modulating brake valve. See Figure 29.

ACCUMULATOR CHARGE VALVE Disassemble WARNING Due to allowable operating temperature of accumulator charge valve, avoid contact or burn injury may occur.

1. 2. 3. 4.

1. Remove pressure switch from accumulator charge valve. See Figure 31.

Figure 31. Accumulator Charge Valve Fittings and Pressure Switch

2. Remove fittings from accumulator charge valve. Remove and discard O-rings from fittings. See Figure 31.

NOTE: Note placement and orientation of components indicated in Step 4 through Step 6 during disassembly to aid in assembly.

CAUTION

ACCUMULATOR CHARGE VALVE FITTING O-RING PRESSURE SWITCH

4. Remove spacer (4) from housing (1). See Figure 32.

Step 3 through Step 20 must be performed in the order presented. If steps are performed out of order components may be damaged.

5. Using a 1/4-20UNC bolt, remove seat (5) from housing (1). See Figure 32.

3. Remove plug (2) from housing (1). Remove and discard O-ring (3) from plug. See Figure 32.

6. Remove ball (6), spring (7), and stop (8) from housing (1). See Figure 32.

34


1800 YRM 1247

1. 2. 3. 4. 5. 6.

HOUSING PLUG O-RING SPACER SEAT BALL

Modulating Brake Valve, Accumulator Charge Valve, and Accumulator

7. 8. 9. 10. 11. 12.

SPRING STOP BACKUP RING SCREW SPRING RETAINER

13. 14. 15. 16. 17. 18.

PIN STOP INSERT SPOOL SPOOL PLUG

19. 20. 21. 22. 23.

PLUG PLUG PLUG PLUG PLUG

Figure 32. Accumulator Charge Valve Assembly 7. Remove and discard backup ring (9) and O-ring (3) from seat (5). See Figure 32.

12. Remove plug (22) from housing (1). Remove and discard O-ring (3) from plug. See Figure 32.

8. Remove plug (18) from housing (1). Remove and discard O-ring (3) from plug. See Figure 32.

13. Remove spring (11), stop (14), and ball (6) from housing (1). See Figure 32.

NOTE: Before moving screw, accurately measure and record its depth from the end of housing to aid in assembly. 9. Remove screw (10) from housing (1). See Figure 32. NOTE: Note orientation of retainer during disassembly to aid in assembly. 10. Remove spring (11), retainer (12), and ball (6) from housing (1). See Figure 32.

CAUTION Be careful not to damage threads. 11. Remove pin (13) from screw (10). See Figure 32.

CAUTION Be careful not to scratch or mar valve seats on insert. NOTE: Insert must be removed from plug (22) end of housing. NOTE: Note orientation of insert during disassembly to aid in assembly. 14. Using a 6.4 to 7.9 mm (0.25 to 0.31 in.) diameter wood or plastic dowel, carefully remove insert (15) from housing (1). See Figure 32. NOTE: Note orientation of spool during disassembly to aid in assembly.

35


Modulating Brake Valve, Accumulator Charge Valve, and Accumulator

1800 YRM 1247

15. Remove spool (16), backup rings (9), and O-rings (3) from insert (15). Discard backup rings and O-rings. See Figure 32.

Assemble

16. Remove plug (23) from housing (1). Remove and discard O-ring from plug. See Figure 32.

Step 1 through Step 21 must be performed in the order presented. If steps are performed out of order components may be damaged.

17. Remove plug (21) from housing (1). Remove and discard O-ring from plug. See Figure 32. NOTE: Note orientation of spool during disassembly to aid in assembly. 18. Remove spring (11) and spool (17) from housing (1). See Figure 32. 19. Remove plug (19) from housing (1). Remove and discard O-ring (3) from plug. See Figure 32. 20. Remove plug (20) from housing (1). Remove and discard O-ring (3) from plug. See Figure 32.

CAUTION

NOTE: Lubricate parts with clean hydraulic oil prior to assembly. Make sure parts remain clear of contaminates during assembly procedure. 1. Install new O-ring (3) onto plug (20). Install plug into housing (1). See Figure 32. Tighten plug to 13.6 to 19.0 N•m (120 to 168 lbf in). 2. Install new O-ring (3) onto plug (19). Install plug into housing (1). See Figure 32. Tighten plug to 13.6 to 19.0 N•m (120 to 168 lbf in). 3. Install spool (17), as noted in Step 18 of disassembly, and spring (11) into housing (1). See Figure 32.

Clean and Inspect WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures.

WARNING Compressed air can move particles so they cause injury to the user or other personnel. Make sure the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.

4. Install new O-ring (3) onto plug (21). Install plug into housing (1). See Figure 32. Tighten plug to 13.6 to 19.0 N•m (120 to 168 lbf in). 5. Install new O-ring (3) onto plug (23). Install plug into housing (1). See Figure 32. Tighten plug to 67.8 to 81.4 N•m (50 to 60 lbf ft). 6. Install new O-rings (3) and new backup rings (9) onto insert (15). See Figure 32. 7. Install insert (15) into housing (1) as noted in Step 14 of disassembly. Seat insert using a 12.7 mm (0.50 in.) diameter word or plastic dowel. NOTE: Orientation of spool is with long shoulder end toward plug (22).

CAUTION Clean only metal components with solvent and dry using compressed air.

8. Install spool (16) into insert (15) as noted in Step 15 of disassembly. See Figure 32.

1. Clean metal valve components and dry with compressed air.

9. Install ball (6) into insert (15). See Figure 32.

2. Clean plastic or rubber components with warm soapy water and dry with a lift free cloth. DO NOT submerge components with electrical connections in water. 3. Inspect spools and housing bores for damage. Replace if damaged. 4. Inspect all other components for damage. Replace if damaged.

36

10. Install stop (8) onto ball (6). See Figure 32. 11. Install spring (11) over stop (8). See Figure 32. 12. Install new O-ring (3) onto plug (22). Install plug into housing (1) centered over spring (11). See Figure 32. Tighten plug to 47.5 to 61.0 N•m (35 to 45 lbf ft). 13. Turn housing (1) so hole for plug (18) is vertically upward. Install ball (6) into center of hole at bottom of housing. See Figure 32.


1800 YRM 1247

Modulating Brake Valve, Accumulator Charge Valve, and Accumulator

14. Install retainer (12) into housing (1) as noted in Step 10 of disassembly. See Figure 32.

3. Install accumulator onto accumulator charge valve. See Figure 28.

15. Install spring (11) into housing (1). See Figure 32.

4. Install brake pressure transducer into modulating brake valve. See Figure 29. Tighten transducer to 23 to 28 N•m (204 to 248 lbf in).

CAUTION DO NOT damage threads. 16. Install new pin (13) into screw (10). Be sure pin is aligned properly and is evenly driven into screw. See Figure 32. 17. Thread screw (10) into housing (1) to the depth recorded in Step 9 of disassembly. See Figure 32. 18. Install new O-ring (3) onto plug (18). Install plug into housing (1). See Figure 32. Tighten plug to 47.5 to 54.2 N•m (35 to 40 lbf ft). 19. Install new O-ring (3) and new backup ring (9) onto seat (5) as shown in Figure 32. 20. Install stop (8), spring (7), ball (6), seat (5), and spacer (4) into housing (1) as noted in Step 4 through Step 6 of disassembly. See Figure 32. 21. Install new O-ring (3) onto plug (2). Install plug into housing (1). See Figure 32. Tighten plug to 94.9 to 108.5 N•m (70 to 80 lbf ft). 22. Install new O-rings onto fittings. Install fittings into charge valve. See Figure 31. 23. Install pressure switch into charge valve. See Figure 31.

INSTALL 1. Install modulating brake valve and two capscrews onto brake bracket. See Figure 27. 2. Install accumulator charge valve and two capscrews onto brake bracket. See Figure 27.

5. Install tube assembly onto fittings in modulating brake valve and accumulator charge valve. See Figure 27 and Figure 29. 6. Connect hydraulic lines, as tagged during disassembly, to modulating brake valve and accumulator charge valve. See Figure 27. 7. Install push rod clevis onto plate. Install clevis pin into push rod clevis and plate. Install cotter pin through clevis pin. NOTE: Perform Step 8 and Step 9 to adjust brake pedal. 8. Depress and hold brake pedal firmly to down-stop. 9. Loosen nut and turn push rod clockwise until plunger is fully depressed to a hard contact. Turn push rod counterclockwise 1/4 turn and tighten nut to 30 ±3 N•m (22 ±2 lbf ft). See Figure 27. 10. Install floor plates and floor mats.

PRESSURE CHECKS NOTE: These checks and adjustments are to be performed after installation.

Accumulator Charge Valve Check 1. Install tee and pressure gauge between accumulator charge valve and accumulator. 2. Start pump and monitor high limit value. See Table 1.

Table 1. Accumulator Charge Valve Pressure Accumulator Charge Low Limit

Accumulator Charge High Limit

8966 ±345 kPa (1300 ±50 psi)

10686 ±345 kPa (1550 ±50 psi)

37


Service Brakes Adjustment (Dry Brake)

1800 YRM 1247

3. Discharge hydraulic pressure slowly by actuating brake pedal repeatedly. 4. Note pressure value when charge event begins, this is the low limit. See Table 1. 5. If limit values are not met, accumulator charge valve must be replaced.

DO NOT exceed the high limit pressure setting, 106.9 bar (1550 psi), or system damage or failure or injury to personnel could occur. 1. Install tee and pressure gauge or similar device to monitor pressure at accumulator. 2. Fill accumulator with hydraulic fluid to high limit.

Accumulator Check

3. Discharge hydraulic fluid slowly by actuating brake pedal repeatedly.

WARNING

4. Monitor pressure gauge closely while discharging hydraulic fluid. The pressure in the gauge will drop suddenly to zero; the pressure indicated immediately prior to this sudden drop is the gas pre-charge pressure. See Table 2.

Due to allowable operating temperature of accumulator charge valve avoid contact or burn injury may occur. Pressure in the accumulator is limited by the system pressure limiting device. Adjustment outside of the allowable range may result in system damage or failure or injury to personnel could occur.

Table 2. Accumulator Specifications Volume

Maximum Work Pressure

0.50 liter (30 in. 3 )

210 bar (3000 psi)

Operating Temp Range 29 to 121°C ( 20 to 250°F)

Pre-Charge Gas

Pre-Charge Pressure

Nitrogen

55 bar (800 psi)

Service Brakes Adjustment (Dry Brake) SERVICE BRAKES ADJUSTMENT The following procedure is for newly-installed brake shoes. If the lift truck has been operated for more than 25 hours and has correct pedal height, the brakes normally will not need adjustment. 1. See the procedure How to Put Lift Truck on Blocks in the Operating Manual or Periodic Maintenance section for your lift truck. Put the lift truck on blocks so the drive wheels can be removed. Remove the drive wheels. 2. To manually adjust the brakes it is necessary to turn adjuster wheels: a. Remove two access plugs in adjustment slots located on back side of backing plate. b. Place an adjuster tool and screwdriver through slot in backing plate. See Figure 7.

38

c. Push adjuster lever away from adjuster wheel and turn adjuster wheel, in the direction indicated in Figure 33 until brake shoe just touches brake drum. d. Use adjuster tool to loosen adjuster wheel approximately 20 teeth. e. Adjust brake shoe for opposite adjuster wheel using the same method. See Figure 33. f.

Install access plugs after adjustment is complete.

3. Install the drive wheels. Remove the lift truck from the blocks. Operate the lift truck in the FORWARD and REVERSE directions. Stop the lift truck 10 times in each direction. This procedure causes the brake shoes to wear a small amount and fit the brake drum better.


1800 YRM 1247

Service Brakes Adjustment (Dry Brake)

1. ADJUSTER LEVER 2. ADJUSTER WHEEL

3. ADJUSTER LINK

Figure 34. Auto Adjuster Assembly

1. 2. 3. 4.

WHEEL CYLINDER CAPSCREWS AUTO ADJUSTER CAPSCREW ADJUSTER WHEEL ACCESS PLUGS BRAKE LINE

Figure 33. Auto Adjuster and Wheel Cylinder Mount Location

39


Brake System Air Removal

1800 YRM 1247

Brake System Air Removal There are two commonly used methods to remove air from the brake system. The preferred method is using a pressure bleed system. The other method is by applying pressure using the brake pedal. NOTE: Two people are required for the two procedures below to properly bleed the brake system.

E879, F879) equipped with a Standard Powershift (2-speed) transmission • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) equipped with a Standard Powershift (2-speed) transmission See Figure 35.

USING PRESSURE BLEED SYSTEM WARNING On lift trucks with wet brake and dry brake drive axles, only use Dexron III brake oil in the master cylinder. NOTE: Adjust the service brakes before the air is removed from the brake system. 1. Fill the brake oil reservoir with Dexron III brake oil from a sealed container. 2. Place one end of a rubber hose on the bleeder screw of each wheel cylinder for lift trucks equipped with dry brakes or on the bleeder screws located on the drive axle for lift trucks equipped with wet brakes. Place the other end of rubber hose into a clear container of Dexron III brake oil. 3. Connect a pressure bleeder to the brake oil reservoir. NOTE: While applying air pressure to the pressure bleeder, check the level of the brake oil in the reservoir for the master cylinder. Make sure to maintain the brake oil at the correct level to avoid forcing more air into the brake system. 4. Apply 103.5 kPa (15 psi) of air pressure to the pressure bleeder, forcing oil through the lines until all air is removed from the system. Close the bleeder screws.

1. CAP 2. BLEED PORT FITTING 3. CONTROL VALVE

4. INCHING ACTUATOR 5. TRANSMISSION

Figure 35. Bleeding The Transmission 7. Check the level of the brake oil in the reservoir for the master cylinder. Fill the brake oil reservoir to the correct level.

USING BRAKE PEDAL PRESSURE Lift Truck Models with Master Cylinder WARNING

5. Loosen the bleeder screw, at the wheel cylinder for lift trucks equipped with dry brakes or on the drive axle for lift trucks equipped with wet brakes, one turn so that the air can be removed from the brake system.

On lift trucks with wet brake and dry brake drive axles, only use Dexron III brake oil in the master cylinder.

6. Loosen the bleed port fitting on the inching actuator and allow oil to run out until it is air free for lift truck models: • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879,

1. Fill the brake oil reservoir with Dexron III brake oil from a sealed container.

40

NOTE: Adjust the service brakes before the air is removed from the brake system.


1800 YRM 1247 2. Place one end of a rubber hose on the bleeder screw of the wheel cylinder furthest from the master cylinder for lift trucks equipped with dry brakes or on the bleeder screws located on the drive axle for lift trucks equipped with wet brakes. Place the other end of rubber hose into a clear container of Dexron III brake oil. NOTE: Check the level of the brake oil in the reservoir for the master cylinder during the procedure. Make sure to obtain the brake oil at the correct level. 3. Loosen the bleeder screw at the wheel cylinder for lift trucks equipped with dry brakes and loosen the bleeder screw on the drive axle for lift trucks equipped with wet brakes one turn so that the air can be removed from the brake system. Slowly push the brake pedal and hold it at the end of its stroke. Close the bleeder screw. 4. Repeat the procedures in Step 1 through Step 3 until there are no air bubbles in the container. 5. Repeat the procedures in Step 1 through Step 4 for the remaining wheel cylinder for lift trucks equipped with dry brakes. Repeat the procedures Step 1 through Step 4 for the other side of drive axle for lift trucks equipped with wet brakes.

Brake System Air Removal See Figure 35. 7. Check the level of the brake oil in the reservoir for the master cylinder. Fill the brake oil reservoir to the correct level.

Lift Truck Models with Modulating Brake Valve WARNING Remove air from the brake system after each installation or repair of hydraulic or brake system components or hydraulic lines. The brakes will not operate correctly with air in the system and can cause injury or damage. 1. Fill hydraulic tank to the correct level. NOTE: Keep engine operating at idle speed to maintain the pressure. 2. Operate engine to charge accumulator to maximum pressure. 3. Connect bleed hose to service brake bleed fittings (one on each end of axle). 4. Push brake pedal(s) down as far as possible.

NOTE: Both wheel cylinders (for lift trucks equipped with dry brakes), or both sides of the drive axle (for lift trucks equipped with wet brakes) must be completed before doing Step 6.

5. Repeat Step 4 until no air is expelled from bleed hose.

6. Slowly push the brake pedal and hold it at the end of its stroke. Loosen the bleed port fitting on the inching actuator and allow oil to run out until it is air free for lift truck models: • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) equipped with a Standard Powershift (2-speed) transmission only • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) equipped with a Standard Powershift (2-speed) transmission only

7. Check hydraulic tank oil level, add hydraulic oil if necessary.

6. Disconnect bleed hose from bleed fittings.

See Periodic Maintenance 8000 YRM 1407 for type of oil required and fill procedure for lift truck model • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (B909)

41


Brake Pedal Adjustment

1800 YRM 1247

Brake Pedal Adjustment FOR LIFT TRUCK MODELS GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813), GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879), AND GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

NOTE: The brake pedal adjustment procedure for this section is the same for both dry and wet brake systems.

1. 2. 3. 4.

5. SENSOR MOUNT 6. BRAKE POSITION SENSOR 7. BUMPER

INCH/BRAKE PEDAL UPSTOP BOLT NUT PEDAL PAD

NOTE: Measurements are made with the floor mats removed. 1. Adjust the height (dimension R) of the inching/brake pedal to 31 ±0.4 mm (1.22 ±0.01 in.). Use the upstop bolt to change the pedal height. Tighten the nut while keeping the upstop bolt fixed. See Figure 36. 2. Depress arm V until it stops. Verify gap S between arm V and tab W is 1.5 to 2.0 mm (0.06 to 0.08 in.) for wet brake, and 3.0 to 3.5 mm (0.11 to 0.13 in.) for dry brake. If it is not, then Tab W may require bending to obtain the proper gap of S. See Figure 36.

Figure 36. Brake Pedal Adjustment

42


1800 YRM 1247

Brake Pedal Adjustment

FOR LIFT TRUCK MODEL GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 1. Adjust pedal down-stop:

b. Adjust to 26.5 ±1.0 mm (1.04 ±0.04 in.) and tighten nut while keeping stop screw fixed. See Figure 37. 2. Adjust pedal up-stop: a. Turn stop screw through hole in brake pedal

a. Turn stop screw through hole in brake bracket.

b. Adjust to 16.5 ±0.4 mm (0.65 ±0.02 in.) and tighten nut while keeping stop screw fixed. See Figure 37.

NOTE: SECTION A-A SHOWS ADJUSTMENT FOR PEDAL UP-STOP NOTE: SECTION B-B SHOWS ADJUSTMENT FOR PEDAL DOWN-STOP 1. BRAKE PEDAL 2. BRAKE BRACKET

3. STOP SCREW 4. NUT

Figure 37. Brake Pedal Adjustment 43


Free Pedal Adjustment

1800 YRM 1247

Free Pedal Adjustment NOTE: The free pedal adjustment procedure is the same for both dry and wet brake systems. After the brake pedal adjustment is completed, see Brake Pedal Adjustment. Perform the following procedure for the free pedal adjustment. 1. Loosen nut and screw it away from clevis. See Figure 38. 2. Turn push rod counterclockwise, as viewed from the top of the push rod, until push rod can be moved from side to side. 3. Turn push rod clockwise until it just begins to no longer be moved from side to side. 4. Turn push rod counterclockwise 1.5 to 1.75 turns. 5. Tighten nut to 17 to 23 N•m (13 to 17 lbf ft). 6. Verify the free pedal is 10 to 12 mm (0.39 to 0.47 in.). See Figure 36.

NOTE: DRY BRAKE SYSTEM SHOWN 1. 2. 3. 4. 5. 6.

ROD END PIN COTTER PIN CLEVIS NUT PUSH ROD MASTER CYLINDER AND BOOSTER

Figure 38. Free Pedal Adjustment

44


1800 YRM 1247

Torque Specifications

Torque Specifications For Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX ) (F813, G813, H813)GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) Backing Plate to Axle Mount Capscrews 340 to 375 N•m (251 to 277 lbf ft) Wheel Cylinder Capscrews 20 to 25 N•m (15 to 19 lbf ft) Axle Shaft Capscrews

Auto Adjuster Assembly Capscrew 120 to 140 N•m (89 to 103 lbf ft) Wheel Nuts 610 to 680 N•m (450 to 502 lbf ft) Wheel Adjustment Nut Initial 400 to 480 N•m (295 to 354 lbf ft) Final 28 to 32 N•m (21 to 24 lbf ft) Master Cylinder to Booster Capscrews 49 to 59 N•m (36 to 43 lbf ft)

For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) Brake Pressure Transducer 23 to 28 N•m (204 to 248 lbf in) Push Rod Nut 30 ±3 N•m (22 ±2 lbf ft)

90 to 99 N•m (66 to 73 lbf ft)

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Yale e878 gdp70vx lift truck service repair manual  
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