GLP/GDP40VX5, GLP/GDP40VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/ GDP50VX, GLP/GDP55VX (F813) SERVICE MANUAL CONTENTS SECTION FRAME............................................................................................................................ OPERATOR'S CAB........................................................................................................ GM 4.3L V-6 ENGINES................................................................................................... COOLING SYSTEM........................................................................................................ LPG FUEL SYSTEM (GM 4.3L)...................................................................................... 1 AND 2-SPEED POWERSHIFT TRANSMISSION REPAIR......................................... DRIVE AXLE - DRY BRAKE........................................................................................... DRIVE AXLE AND DIFFERENTIAL ASSEMBLY REPAIR............................................ STEERING AXLE............................................................................................................ BRAKE SYSTEM............................................................................................................ HYDRAULIC GEAR PUMP............................................................................................. HYDRAULIC CLEANLINESS PROCEDURES............................................................... MAIN CONTROL VALVE................................................................................................ CYLINDER REPAIR (MAST S/N A551, A555, A559, A661, A662, A663, A66, B507, B508, B509, B551, B555, B559, B562, B563, B564, B661, B662, B663, C515, C551, C555, C559, D507, D508, D509, D515, D562, D563, D564, E509, AND E564).......................................................................................................................... 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...................................................................................... DIAGRAMS..................................................................................................................... PERIODIC MAINTENANCE............................................................................................ CAPACITIES AND SPECIFICATIONS........................................................................... DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................
PART NUMBER
YRM NUMBER
REV DATE
524262274 524306203 524265337 524223757 524262275 524223762 524262277 524262278 524223764 524262279 524223766 550073240 524223767
0100 YRM 1243 0100 YRM 1290 0600 YRM 1251 0700 YRM 1123 0900 YRM 1242 1300 YRM 1129 1400 YRM 1245 1400 YRM 1246 1600 YRM 1133 1800 YRM 1247 1900 YRM 1136 1900 YRM 1620 2000 YRM 1137
05/14 04/14 05/14 03/13 08/12 09/09 01/12 12/13 07/13 03/13 04/14 12/14 04/14
524223768 524208014 524223769 524223770 524223771 524223772
2100 YRM 1139 2200 YRM 1097 2200 YRM 1128 2200 YRM 1130 2200 YRM 1131 2200 YRM 1142
02/14 05/14 12/14 12/14 12/14 04/14
524265342 524150797 524223780 524223779 524262298 524262281 524221866
4000 YRM 1250 8000 YRM 0231 8000 YRM 1134 8000 YRM 1152 8000 YRM 1248 8000 YRM 1249 9000 YRM 1112
02/14 10/13 12/14 04/14 04/13 08/11 12/14
Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center. 9000 YRM 1112 ON CD PART NO. 524278309 (12/14)
1900 YRM 1136
General
General This section includes a description and the repair procedures for the hydraulic gear pump assembly and for the variable displacement pump (VDP) assembly.
Hydraulic Gear Pump Assembly Lift truck models listed below can be equipped with one of three different gear pumps: 24 cc/rev, 25.7 cc/ rev, or 29.4 cc/rev •
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)
Lift truck models listed below can be equipped with the 24 cc/rev gear pump •
GLC050LX (A967)
•
GLP20-25LX (GLP050LX) (A974)
Lift truck models listed below can be equipped with the 25.7 cc/rev gear pump •
Lift truck models listed below can be equipped with one of two different gear pumps: 41.3 cc/rev, or 51.6 cc/rev •
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)
Lift truck model listed below can also be equipped with a 46.5 cc/rev gear pump •
Lift truck models listed below can be equipped with one of two different tandem gear pumps: 63.3 cc/rev or 68.5 cc/rev •
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)
GDP20-25LX (GDP050LX) (A974)
Lift truck models listed below can be equipped with a 32.5 cc/rev gear pump •
GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (H813, J813)
•
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)
Lift truck model listed below is equipped with a tandem gear pump: 63.3 cc/rev •
GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909).
1
General
1900 YRM 1136
The repair procedures are similar for each type of gear pump. When the repair has been completed, see the Gear Pump Specifications section in this manual.
•
GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813)
Variable Displacement Pump Assembly
•
Lift truck models listed below can be equipped with one of three different variable displacement pumps: 24 cc/rev, 26 cc/rev, or 28 cc/rev
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).
•
GLP/GDP20-35VX (B875)
Lift truck models listed below can be equipped with one of two different variable displacement pumps: 42 cc/rev or 45 cc/rev •
GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (G813, H813)
The repair procedures are similar for each size of VDP. When the repair has been completed, see the section Variable Displacement Pump Specifications. Repair information for other components of the hydraulic system, equipped with either a hydraulic gear pump or variable displacement pump, are found in the following manuals
See Steering Axle 1600YRM1425 for lift truck models •
GLC050LX (A967)
•
GLP/GDP20-25LX (GLP/GDP050LX) (A974)
See Main Control Valve 2000YRM1137 for lift truck models •
GC/GLC030VX, GC/GLC035VX, GC/ GLC040SVX (C809)
•
GLP/GDP16VX, GLP/GDP18VX, GLP/ GDP20SVX, (G{/GLP/GDP030VX, GP/GLP/ GDP035VX, GP/GLP/GDP040SVX) (C810)
See Steering Axle 1600YRM1133 for lift truck models
2
•
GC/GLC030VX, GC/GLC035VX, GC/ GLC040SVX (C809)
•
GLC20-35VX (GC/GLC040-070VX, GC/ GLC055SVX) (A910)
•
GLP/GDP16VX, GLP/GDP18VX, GLP/ GDP20SVX, (GP/GLP/GDP030VX, GP/GLP/ GDP035VX, GP/GLP/GDP040SVX) (C810)
•
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)
•
GLC050LX (A967)
•
GLC20-35VX (GC/GLC040-070VX, GC/ GLC055SVX) (A910)
•
GLP/GDP20-25LX (GLP/GDP050LX) (A974)
•
•
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)
GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/ GLC120SVX; GC/GLC120VXPRS) (E818, F818)
1900 YRM 1136 •
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).
See Main Control Valve 2000YRM1457 for lift truck models •
GLP/GDP20-35VX (B875)
•
GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (G813, H813)
See Mast Repairs (S/N A551, A555, A559, A661, A662, A663, A664, B507, B508, B509, B551, B555, B559, B562, B563, B564, B661, B662, B663, C515, C551, C555, C559, D507, D508, D509, D515, D562, D563, D564, E509, and E564) 4000YRM1148 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)
•
GLC20-35VX (GC/GLC040-070VX, GC/ GLC055SVX) (A910)
General •
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)
See 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) 4000YRM1250 for lift truck models •
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)
See Mast Repair (S/N A513, A514, A613, A614, A643, A644, A683, A684) 4000YRM1406 for lift truck models •
GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)
See Mast Repair (S/N A698, A699, B551) 4000YRM1431 for lift truck models •
GLC050LX (A967)
•
GLP/GDP20-25LX (GLP/GDP050LX) (A974)
3
Single Gear Pump Assembly Repair
1900 YRM 1136
Single Gear Pump 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 following assemblies will cause large changes in the center of gravity: mast, drive axle, engine, transmission, and counterweight. When the lift truck is put on blocks, put additional blocks in the following positions to maintain stability: •
Before removing the mast and drive axle, put blocks under the counterweight so the lift truck cannot fall backward.
•
Before removing the counterweight, put blocks under the mast assembly so the lift truck cannot fall forward.
The surface must be solid, even, and level when the lift truck is put on blocks. Make sure any blocks used to support the lift truck are solid, one-piece units. NOTE: Worn or damaged seals are the most common cause of pump damage. The pump bushings, gears, and shafts also wear. They must be checked during disassembly. DO NOT make any repairs to the parts. To prevent more failures, always replace parts that are worn or damaged. If several main parts need replacing, replace the complete group.
4
1. Put the lift truck on blocks. See the Operating Manual or the Periodic Maintenance Manual for your lift truck for the procedures to put the lift truck on blocks. 2. Place a drain pan under the hydraulic tank, remove drain plug at the bottom of hydraulic oil tank, and drain oil from tank. a. Drain pan capacity approximately ter (8 gal) for lift truck models
30
li-
•
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)
•
GLC050LX (A967)
•
GLP/GDP20-35VX GDP040-070VX) (B875)
•
GLP/GDP20-25LX (A974)
(GP/GLP/
(GLP/GDP050LX)
NOTE: For lift trucks equipped with dual hudraulic tanks, place a second drain pan with same capacity under opposite hydraulic tank.
1900 YRM 1136 b. Drain pan capacity approximately ter (11 gal) for lift truck model •
40
li-
GLC40, 45, 55VX; GLC55SVX; (GC/ GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/ GLC120VXPRS) (E818, F818)
c. Drain pan capacity approximately ter (13.5 gal) for lift truck model •
Single Gear Pump Assembly Repair
51
li-
GLP/GDP40VX5/VX6; GLP/ GDP45SVX5, GLP/GDP45VX6; GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813)
NOTE: Perform Step 3 and Step 4 for lift trucks equipped with an iron transmission housing. 3. Put a drain pan under the pump assembly. Disconnect all hydraulic lines connected to the pump assembly. Remove the pump outlet fitting and suction adapter. Put caps on all the hose fittings and hydraulic pump ports. See Figure 1 for lift truck models •
GC/GLC030VX, GC/GLC035VX, GLC040SVX (C809)
GC/
•
GLP/GDP16VX, GLP/GDP18VX, (GLP/ GDP20SVX, (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/ GDP040SVX) (C810)
•
GLC20-35VX (GC/GLC040-070VX, GLC055SVX) (A910)
•
GLP/GDP20-35VX GDP040-070VX) (B875)
GC/
(GP/GLP/
See Figure 2 for lift truck models •
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)
See Figure 3 for lift truck model •
GLC40, 45, 55VX; GLC55SVX; (GC/ GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/ GLC120VXPRS) (F818) equipped with dual hydraulic tanks.
5
Single Gear Pump Assembly Repair
1900 YRM 1136
A. EARLY LIFT TRUCK MODELS
B. NEWER LIFT TRUCK MODELS
1. 2. 3. 4.
5. HYDRAULIC PUMP 6. TRANSMISSION 7. PUMP OUTLET FITTING
SUCTION HOSE HYDRAULIC INLET HOSE SUCTION ADAPTER SOCKET HEAD SCREW (2)
Figure 1. Hydraulic Pump for 1.5 to 3.5 Ton Lift Truck Models Equipped With an Iron Transmission Housing
6
1900 YRM 1136
Single Gear Pump Assembly Repair
A. FOR EARLY MODEL GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) LIFT TRUCKS ONLY B. FOR NEWER MODEL GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) LIFT TRUCKS ONLY AND FOR ALL GLP/GDP40VX5/ VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) LIFT TRUCKS 1. 2. 3. 4.
TRANSMISSION SOCKET HEAD SCREW HYDRAULIC PUMP SUCTION HOSE
5. SUCTION ADAPTER 6. PUMP OUTLET FITTING 7. HYDRAULIC INLET HOSE
Figure 2. Hydraulic Pump for 4 to 5.5 Ton Lift Truck Models
7
Single Gear Pump Assembly Repair
1. 2. 3. 4.
TRANSMISSION SOCKET HEAD SCREW HYDRAULIC PUMP SUCTION HOSE
1900 YRM 1136
5. SUCTION ADAPTER 6. PUMP OUTLET FITTING 7. HYDRAULIC INLET HOSE
Figure 3. Hydraulic Pump for Lift Truck Model GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/ GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) ( F818) with Dual Hydraulic Tanks
8
1900 YRM 1136
Single Gear Pump Assembly Repair
4. Hold the pump assembly to keep it from falling. Remove the two socket head screws and the lockwashers that fasten the pump to the transmission housing. Remove the pump assembly. NOTE: Perform Step 5 through Step 8 for lift trucks equipped with an aluminum transmission housing.
•
6. On lift truck models not equipped with a QuickLok™ hydraulic hose, disconnect all hydraulic lines connected to the pump assembly. Remove pump outlet fitting and suction adapter from hydraulic gear pump. Put caps on all hose fittings and hydraulic gear pump ports. See Figure 4 for lift truck models •
GC/GLC030VX, GC/GLC035VX, GLC040SVX (C809)
•
GLP/GDP16VX, GLP/GDP18VX, GLP/ GDP20SVX, (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/ GDP040SVX) (C810)
•
GLC20-35VX (GC/GLC040-070VX, GLC055SVX) (A910)
GC/
GC/
(GP/GLP/
See Figure 5 for lift truck models •
GC/GLC030VX, GC/GLC035VX, GLC040SVX (C809)
•
GLP/GDP16VX, GLP/GDP18VX, GLP/ GDP20SVX, (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/ GDP040SVX) (C810)
•
GLC20-35VX (GC/GLC040-070VX, GLC055SVX) (A910)
•
GLP/GDP20-35VX GDP040-070VX) (B875)
•
GLC050LX (A967)
•
GLP/GDP20-25LX (GLP/GDP050LX) (A974)
5. Put a drain pan under the pump assembly. Cover charge pump with liquid proof covering to prevent damage. NOTE: Lift truck models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), with a single speed transmission, electronic or manual control valve, and manufactured after January, 2011, may be equipped with an optional Quick-Lok™ hydraulic hose and adapters.
GLP/GDP20-35VX GDP040-070VX) (B875)
GC/
GC/
(GP/GLP/
7. On lift truck models GLP/GDP20-35VX (GP/GLP/ GDP040-070VX) (B875) equipped with a QuickLok™ hydraulic hose and single speed transmission, remove the adapter and hydraulic hose from gear pump assembly. Disconnect all other hydraulic hoses connected to gear pump assembly. Remove pump outlet fitting from hydraulic gear pump. Put caps on all hose fittings and hydraulic gear pump ports. See Figure 5 for lift truck model •
GLP/GDP20-35VX GDP040-070VX) (B875)
(GP/GLP/
See Figure 6 for lift truck models •
GLP/GDP20-35VX GDP040-070VX) (B875)
(GP/GLP/
9
Single Gear Pump Assembly Repair
1900 YRM 1136
8. Hold the pump assembly to keep it from falling. Remove the two flange head capscrews that fasten the pump to the transmission housing. Remove the pump assembly. See Figure 4 for lift truck models •
GC/GLC030VX, GC/GLC035VX, GLC040SVX (C809)
GC/
•
GLP/GDP16VX, GLP/GDP18VX, GLP/ GDP20SVX, (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/ GDP040SVX) (C810)
•
GLC20-35VX (GC/GLC040-070VX, GLC055SVX) (A910)
•
GLP/GDP20-35VX GDP040-070VX) (B875)
GC/
(GP/GLP/
See Figure 5 for lift truck models
10
•
GC/GLC030VX, GC/GLC035VX, GLC040SVX (C809)
GC/
•
GLP/GDP16VX, GLP/GDP18VX, GLP/ GDP20SVX, (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/ GDP040SVX) (C810)
•
GLC20-35VX (GC/GLC040-070VX, GLC055SVX) (A910)
•
GLP/GDP20-35VX GDP040-070VX) (B875)
•
GLC050LX (A967)
•
GLP/GDP20-25LX (GLP/GDP050LX) (A974)
GC/
(GP/GLP/
1. 2. 3. 4. 5. 6. 7.
SUCTION HOSE HYDRAULIC INLET HOSE SUCTION ADAPTER PUMP OUTLET FITTING FLANGE HEAD CAPSCREW (2) HYDRAULIC PUMP TRANSMISSION Figure 4. Hydraulic Pump for 1.5 to 3.5 Ton Lift Truck Models, Equipped With Aluminum Transmission Housing, Prior to January, 2011
1900 YRM 1136
Single Gear Pump Assembly Repair
NOTE: QUICK-LOKâ„¢ HYDRAULIC HOSE AND ADAPTERS NOT SHOWN. A. 1.5 TO 3.5 TON MODELS
B. LIFT TRUCK MODELS GLC050LX (A967) AND GLP/GDP20-25LX (GLP/GDP050LX) (A974)
1. 2. 3. 4.
5. SUCTION ADAPTER 6. HYDRAULIC PUMP 7. TRANSMISSION
SUCTION HOSE HYDRAULIC INLET HOSE FLANGE HEAD CAPSCREW (2) PUMP OUTLET FITTING
Figure 5. Hydraulic Pump for 1.5 to 3.5 Ton Lift Truck Models, and Lift Trucks GLC050LX (A967) and GLP/ GDP20-25LX (GLP/GDP050LX) (A974) Equipped with Aluminum Transmission Housing, After January, 2011
11
Single Gear Pump Assembly Repair
1900 YRM 1136
NOTE: ELECTRO-HYDRAULIC MAIN CONTROL VALVE SHOWN. 1. STEERING CONTROL UNIT 2. QUICK-LOK™ ADAPTER
3. QUICK-LOK™ HYDRAULIC HOSE 4. HYDRAULIC GEAR PUMP
Figure 6. Quick-LokQuick-Lok™ Hydraulic Supply Hose System, Lift Truck Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) With Single Speed and Aluminum Transmission, After January, 2011
DISASSEMBLE 1. Put the pump body in a vise. Put an alignment mark on each section of the pump body to aid in reassembly. 2. Remove the capscrews that hold the pump together. Remove the flange end housing. Remove the rear valve housing. DO NOT let the seals and gears fall. See Figure 7.
12
3. Make a note of the position of the plate seals and pressure plates. Carefully remove the plate seals, pressure plates, and gears from the housings. Discard plate seals and backup seals. Remove the snap ring and shaft seal from the flange end housing.
1900 YRM 1136
1. 2. 3. 4. 5. 6.
SNAP RING SHAFT SEAL FLANGE END HOUSING PLATE SEAL PRESSURE PLATE GEAR HOUSING
Single Gear Pump Assembly Repair
7. 8. 9. 10. 11.
DRIVEN GEAR DRIVE GEAR REAR VALVE HOUSING CAPSCREW BACKUP SEAL
Figure 7. Hydraulic Pump Assembly
13
Single Gear Pump Assembly Repair
CLEAN WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturers recommended safety precautions.
WARNING
1900 YRM 1136 move and that the seals stay in the correct position. Make sure the marks made during disassembly are aligned. Tighten the capscrews to 88 to 98 N•m (65 to 72 lbf ft).
INSTALL 1. Install pump outlet fitting and tighten to: a. 88 to 98 N•m (65 to 72 lbf ft) for lift truck models below
Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.
•
GC/GLC030VX, GC/GLC035VX, GC/ GLC040SVX (C809)
•
Clean all parts in solvent. Dry parts with compressed air. DO NOT dry the parts with a cloth. Make sure all surfaces are free of scratches and sharp edges.
GLP/GDP16VX, GLP/GDP18VX, GLP/ GDP20SVX, (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/ GDP040SVX) (C810)
•
GLC20-35VX (GC/GLC040-070VX, GC/ GLC055SVX) (A910)
•
GLC050LX (A967)
•
GLP/GDP20-35VX GDP040-070VX) (B875)
•
GLP/GDP20-25LX (A974)
•
GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/ GDP155VX) (C878, D878, E878)
INSPECT Check parts for wear and damage. If any parts are worn or damaged, replace the damaged parts. If the pump housing is damaged, replace the pump.
ASSEMBLE 1. Coat all pump components with hydraulic oil. Use hydraulic oil meeting specification ISO VG 46 hydraulic oil −15°C (5°F) and above. 2. Use new plate and backup seals and install the pressure plates and gears. Make sure to install the pressure plates as removed during disassembly. See the notes made during disassembly. Make sure all seals are complete and in the correct positions. See Figure 7. 3. Install a new shaft seal in the flange end housing. Carefully install the flange end housing. DO NOT move the pressure plates. Make sure the seals do not move out of the correct position. See Figure 7. 4. Carefully install the valve end housing on the pump body using the four capscrews and lockwashers. Make sure the pressure plates do not
14
(GP/GLP/
(GLP/GDP050LX)
b. 98 to 118 N•m (72 to 87 lbf ft) for lift truck models below •
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)
1900 YRM 1136 2. On lift truck models not equipped with a QuickLok™ hydraulic hose, install suction adapter and tighten to 78 to 88 N•m (58 to 65 lbf ft). NOTE: The information in Step 3 is used when the Quick-Lok™ hydraulic hose is installed for the first time. 3. For lift truck models GLP/GDP20-35VX (GP/GLP/ GDP040-070VX) (B875) equipped with a QuickLok™ hydraulic hose: a. Disconnect standard hydraulic hose from steering control unit (SCU) and remove fitting from SCU port. b. Install Quick-Lok™ adapters into the SCU and gear pump ports. See Figure 6. Tighten adapter at the gear pump to 59 to 69 N•m (44 to 51 lbf ft). Tighten the adapter at the SCU port to 170 to 183 N•m (125 to 135 lbf ft). c. Install hydraulic gear pump to transmission. Go to Step 6. NOTE: Once the Quick-Lok™ hydraulic hose clicks into place on the adapters, the adapters are permanently installed on the hose. To remove the QuickLok™ hydraulic hose again, remove the adapters from the SCU and gear pump ports. When replacing the Quick-Lok™ hydraulic hose, replace both adapters and the hose at the same time. See Parts Manual. d. Push each end of Quick-Lok™ hydraulic hose into adapters on the SCU and gear pump, until they click into place. Pull on the Quick-Lok™ hydraulic hose to ensure that it is securely in the adapters. e. Position the Quick-Lok™ hydraulic hose (inlet hose) as shown in Figure 11.
Single Gear Pump Assembly Repair 4. Clean the pump flange and transmission mounting surfaces and put a 3 to 5 mm (0.118 to 0.197 in.) bead of Loctite™ 515 (Yale Part No. 520042831) on the pump flange or transmission mounting surface. Hold the pump in the correct position on the transmission. Install the socket head screws and lockwashers that fasten the pump to the transmission housing. Tighten socket head screws to 38 N•m (28 lbf ft). See Figure 1 for lift truck models •
GC/GLC030VX, GC/GLC035VX, GLC040SVX (C809)
GC/
•
GLP/GDP16VX, GLP/GDP18VX, GLP/ GDP20SVX, (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/ GDP040SVX) (C810)
•
GLC20-35VX (GC/GLC040-070VX, GLC055SVX) (A910)
•
GLP/GDP20-35VX GDP040-070VX) (B875)
GC/
(GP/GLP/
See Figure 2 for lift truck models •
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)
See Figure 3 for lift truck model •
GLC40, 45, 55VX; GLC55SVX; (GC/ GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/ GLC120VXPRS) (F818) equipped with dual hydraulic tanks.
NOTE: Perform Step 4 and Step 5 for lift trucks equipped with an iron transmission housing.
15
Single Gear Pump Assembly Repair
1900 YRM 1136
5. Connect the hydraulic lines to the hydraulic pump assembly. Position the hydraulic inlet hose as shown in figures specified below: See Figure 8 for lift trucks models •
GC/GLC030VX, GC/GLC035VX, GLC040SVX (C809)
GC/
•
GLP/GDP16VX, GLP/GDP18VX, GLP/ GDP20SVX, (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/ GDP040SVX) (C810)
•
GLC20-35VX (GC/GLC040-070VX, GLC055SVX) (A910)
•
GLP/GDP20-35VX GDP040-070VX) (B875)
GC/
(GP/GLP/
See Figure 9 for lift truck models •
•
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)
NOTE: Perform Step 6, Step 7, and Step 8 for lift truck equipped with an aluminum transmission housing. 6. Make sure pump flange and transmission mounting surfaces are clean. Put a 3 to 5 mm (0.118 to 0.197 in.) bead of sealant on either pump or transmission housing face. Hold the pump in the correct position on the transmission and install flange head capscrews into pump and transmission housing. Tighten capscrews to 38 N•m (28 lbf ft).
A. Z = 60° ±5° FOR 1-SPEED TRANSMISSION, LIFT TRUCK MODELS GC/GLC030-035VX, GC/ GLC040SVX (C809), GLP/GDP16-18VX, GLP/ GDP20SVX (GP/GLP/GDP030-035VX, GP/GLP/ GDP040SVX) (C810), AND GLC20-35VX (GC/ GLC040-070VX, GC/GLC055SVX) (A910) B. Z = 75° ±5° FOR 2-SPEED TRANSMISSION, LIFT TRUCK MODELS GC/GLC040-070VX, GC/ GLC055SVX (A910) C. Z = 50° ±5° FOR LIFT TRUCK MODELS GLP/ GDP20-35VX (GP/GLP/GDP040-070VX) (B875) D. X = 10° ±5° 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); GLC20-35VX (GC/GLC040-070VX, GC/ GLC055SVX) (A910) GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 1. HYDRAULIC INLET HOSE 2. SUCTION HOSE Figure 8. Inlet Hose Orientation for Lift Truck Models, With Iron Transmission Housing,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), and GLP/GDP20-35VX (GP/GLP/ GDP040-070VX) (B875)
16
1900 YRM 1136
Single Gear Pump Assembly Repair •
GLP/GDP20-35VX GDP040-070VX) (B875)
(GP/GLP/
See Figure 5 for lift truck models
A. X = 32° ±5° FOR ALL LIFT TRUCK MODELS EXCEPT GLC40, 45, 55VX; GLC55SVX; (GC/ GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) AND GLP/GDP40VX5/VX6; GLP/ GDP45SVX5, GLP/GDP45VX6; GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) B. X = 30° ±5° FOR LIFT TRUCK MODELS GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/ GLC120SVX; GC/GLC120VXPRS) (E818, F818) AND GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) 1. HYDRAULIC INLET HOSE 2. SUCTION HOSE Figure 9. Inlet Hose Orientation for Lift Truck Models GLC40, 45, 55VX; GLC55SVX; (GC/ GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/ GLC120SVX; GC/GLC120VXPRS) (E818, F818) and GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) See Figure 4 for lift truck models •
GC/GLC030VX, GC/GLC035VX, GLC040SVX (C809)
GC/
•
GLP/GDP16VX, GLP/GDP18VX, GLP/ GDP20SVX, (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/ GDP040SVX) (C810)
•
GLC20-35VX (GC/GLC040-070VX, GLC055SVX) (A910)
•
GC/GLC030VX, GC/GLC035VX, GLC040SVX (C809)
GC/
•
GLP/GDP16VX, GLP/GDP18VX, GLP/ GDP20SVX, (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/ GDP040SVX) (C810)
•
GLC20-35VX (GC/GLC040-070VX, GLC055SVX) (A910)
•
GLP/GDP20-35VX GDP040-070VX) (B875)
•
GLC050LX (A967)
•
GLP/GDP20-25LX (GLP/GDP050LX) (A974)
GC/
(GP/GLP/
7. On lift truck models not equipped with a QuickLok™ hydraulic hose, connect hydraulic lines to hydraulic pump assembly. Position inlet hydraulic line as shown in Figure 10. NOTE: If the Quick-Lok™ hydraulic supply hose and adapter is being installed for the first time, go to Step 3 for procedures. 8. On lift truck models equipped with a Quick-Lok™ hydraulic hose and adapter, connect hydraulic lines, except for the Quick-Lok™ hydraulic hose, to hydraulic gear pump assembly. Install the Quick-Lok™ hydraulic hose and adapter into gear pump and position inlet hydraulic line as shown in Figure 11. Tighten adapter at the gear pump to 59 to 69 N•m (44 to 51 lbf ft). Tighten the adapter at the SCU port to 170 to 183 N•m (125 to 135 lbf ft). 9. Remove the lift truck from the blocks. See the Operating Manual or the Periodic Maintenance Manual for the procedures to remove lift truck from blocks. 10. Fill the tank using the hydraulic oil shown in the Maintenance Table located in the Operating Manual or the Periodic Maintenance Manual for your lift truck model. When the oil level is correct, operate the system and check for leaks. Check the hydraulic oil level and add hydraulic oil if necessary.
GC/
17
Single Gear Pump Assembly Repair
1900 YRM 1136
NOTE: QUICK-LOKâ„¢ HYDRAULIC HOSE AND ADAPTERS NOT SHOWN. 1. HYDRAULIC INLET HOSE
2. SUCTION HOSE
Figure 10. Inlet Hose Orientation 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), GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLC050LX (A967), GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) and GLP/GDP20-25LX (GLP050LX) (A974) With Aluminum Transmission Housing Before January, 2011 and Equipped With Mazda Engine
18
1900 YRM 1136
Single Gear Pump Assembly Repair
NOTE: ELECTRO-HYDRAULIC CONTROL VALVE SHOWN. ORIENTATION IS THE SAME ON MANUAL CONTROL VALVE. A. 40° ±5°
B. 15° ±5°
1. INLET HOSE
2. SUCTION HOSE
Figure 11. Inlet Hose Orientation for All Lift Truck Models With Single Speed and Aluminum Transmission After January, 2011 and Equipped With Quick-Lok™ Hydraulic Supply Hose and Adapters
19
Tandem Gear Pump Assembly
1900 YRM 1136
Tandem Gear Pump Assembly 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 following assemblies will cause large changes in the center of gravity: mast, drive axle, engine, transmission, and counterweight. When the lift truck is put on blocks, put additional blocks in the following positions to maintain stability: •
•
Before removing the mast and drive axle, put blocks under the counterweight so the lift truck cannot fall backward. Before removing the counterweight, put blocks under the mast assembly so the lift truck cannot fall forward.
The surface must be solid, even, and level when the lift truck is put on blocks. Make sure any blocks used to support the lift truck are solid, one-piece units. NOTE: Worn or damaged seals are the most common cause of pump damage. The pump bushings, gears, and shafts also wear. They must be checked during disassembly. DO NOT make any repairs to the parts. To prevent more failures, always replace parts that are worn or damaged. If several main parts need replacing, replace the complete group. 1. Put the lift truck on blocks. See the Operating Manual or the Periodic Maintenance Manual for your lift truck for the procedures to put the lift truck on blocks. The following lift trucks are equipped with the tandem gear pump assembly: •
20
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)
2. Place a drain pan under the hydraulic tank, remove the drain plug at the bottom of hydraulic oil tank, and drain oil from tank. a. Drain pan capacity approximately ter (16.9 gal) for lift truck models
64
li-
•
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)
3. Put a drain pan under the tandem gear pump assembly. Remove hydraulic outlet hoses at the fittings on the tandem gear pump assembly. Remove the inlet hose clamps and inlet hoses from the tandem gear pump assembly. Put caps on all the hose fittings and hydraulic pump ports. See Figure 12. 4. Support the tandem gear pump assembly to keep it from falling. Remove the two socket head screws and lock washers that fasten the tandem gear pump assembly to the transmission charge pump housing. Remove the tandem gear pump assembly.
1900 YRM 1136
1. 2. 3. 4.
OUTLET HOSES OUTLET HOSE FITTINGS INLET HOSE CLAMPS INLET HOSES
Tandem Gear Pump Assembly
5. 6. 7. 8.
HEX SOCKET CAPSCREW LOCK WASHER TRANSMISSION CHARGE PUMP TANDEM GEAR PUMP
Figure 12. Hydraulic Pump Removal for 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), and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/ GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909)
21
Tandem Gear Pump Assembly
DISASSEMBLE 1. Secure the tandem gear pump assembly in a vise. Put an alignment mark on each section of the pump body to aid in reassembly. NOTE: The tandem gear pump assembly consists of a driven pump attached to a drive pump. Each pump has an inlet adapter and outlet fitting. 2. Remove inlet adapters and outlet fittings from drive pump and driven pump of tandem gear pump assembly. See Figure 13.
1900 YRM 1136 3. Remove two capscrews and washers attaching driven pump to drive pump. See Figure 14. NOTE: Drive pump shaft and driven pump shaft are connected by a coupling. 4. Slowly remove driven pump from drive pump. Note position of O-rings on coupling. Remove Orings, and coupling. Discard O-rings. 5. Place driven pump on a clean work space and continue with disassembly of the drive pump. 6. Remove snap ring and oil seal from drive pump flange end housing. Discard snap ring. 7. Remove the socket head screws and washers that hold the pump together, and remove from vise. Remove adapter plate, cover plate and housing from drive pump flange end housing. DO NOT let the seals and gears fall. 8. Make a note of the position of the plate seals and pressure plates. Carefully remove the plate seals, back up seals, pressure plates, gear plate, cover plate, oil seal and gears from the housings. Discard plate seals and backup seals.
1. FITTING 2. DRIVEN PUMP
3. ADAPTER 4. DRIVE PUMP
Figure 13. Tandem Gear Pump Fittings
22
1900 YRM 1136
Tandem Gear Pump Assembly
Figure 14. Tandem Gear Pump Assembly
23
Tandem Gear Pump Assembly
1900 YRM 1136 Legend for Figure 14
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
SOCKET HEAD FLANGE SCREW MOUNTING FLANGE COVER PLATE SEAL BACKUP SEAL PRESSURE PLATE GEAR PLATE DOWEL PIN GEARS CAPSCREW WASHER
9. Secure the driven pump body in a vise. 10. Remove the socket head flange screws that hold the pump together. Remove the mounting flange cover. Remove the rear valve housing. DO NOT let the seals and gears fall. See Figure 14. 11. Make a note of the position of the plate seals and pressure plates. Carefully remove the plate seals, pressure plates, gear plate and gears from the housings. Discard plate seals and backup seals. Remove the snap ring from the flange end housing. Discard snap ring.
CLEAN WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturers recommended safety precautions.
WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.
24
11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
FLANGE END HOUSING SNAP RING O-RING COUPLING SOCKET HEAD SCREW ADAPTER PLATE COVER PLATE HOUSING OIL SEAL DRIVE PUMP FLANGE END HOUSING
Clean all parts in solvent. Dry parts with compressed air. DO NOT dry the parts with a cloth. Make sure all surfaces are free of scratches and sharp edges.
INSPECT Check parts for wear and damage. If any parts are worn or damaged, replace the damaged parts. If the pump housing is damaged, replace the pump.
ASSEMBLE 1. Coat all pump components with hydraulic oil. Use hydraulic oil meeting specification ISO VG 46 hydraulic oil −15°C (5°F) and above. 2. Begin assembly of the driven pump. Use new plate and backup seals and install the pressure plates, gear plate and gears. Make sure to install the pressure plates as removed during disassembly. See the notes made during disassembly. Make sure all seals are in the correct positions. See Figure 14. 3. Carefully install the mounting flange cover. DO NOT move the pressure plates. Make sure the seals do not move out of the correct position.
1900 YRM 1136
Tandem Gear Pump Assembly
4. Carefully install the flange end housing on the pump body using the four socket head flange screws. Make sure the pressure plates do not move and that the seals stay in the correct position. Make sure the marks made during disassembly are aligned. Tighten the capscrews to 88 to 98 N•m (65 to 72 lbf ft). Install new snap ring in flange end housing.
9. Reposition tandem gear pump in the vise and install two outlet hose fittings. See Figure 13. Tighten the fittings to 78 to 88 N•m (58 to 65 lbf ft).
5. Begin assembly of the drive pump. Use new plate and backup seals and install the pressure plates and gears. Make sure to install the pressure plates, cover plate, housing, oil seal and adapter plate as removed during disassembly. See the notes made during disassembly. Make sure all seals are in the correct positions.
INSTALL
6. Install a new shaft seal in the drive pump flange end housing. Carefully install the flange end housing. DO NOT move the pressure plates. Make sure the seals do not move out of the correct position. 7. Carefully install the adapter plate on the drive pump body using the four socket head screws and lock washers. Make sure the pressure plates do not move and that the seals stay in the correct position. Make sure the marks made during disassembly are aligned. Tighten the capscrews to 123 to 132 N•m (91 to 97 lbf ft). Install new snap ring in front of shaft seal. 8. Assemble tandem gear pump. Place drive pump in vise and install oil seal, adapter, sleeve and Oring to shaft of drive pump. Fit shaft of driven pump into adapter and install two capscrews and washers securing the driven pump to the drive pump. Tighten the capscrews to 42 to 46 N•m (31 to 34 lbf ft).
10. Install two inlet adapters, tighten to 88 to 98 N•m (65 to 72 lbf ft). Remove tandem gear pump from vise.
1. Clean the tandem gear pump flange and transmission charge pump mounting surfaces and put a 3-5 mm (0.118-0.197 in.) bead of Loctite™ 515 (Yale Part No. 520042831) on the pump flange or transmission charge pump mounting surface. Hold the pump in the correct position on the transmission. Install the socket head screws and lockwashers that fasten the pump to the transmission housing. Tighten socket head screws to 108 N•m (80 lbf ft). See Figure 12. 2. Loosen inlet hose clamps and install inlet hoses to inlet hose fittings. Tighten inlet hose clamps. Install outlet hoses to outlet hose fittings. 3. Remove the lift truck from the blocks. See the Operating Manual or the Periodic Maintenance Manual for the procedures to remove lift truck from blocks. 4. Fill the tank using the hydraulic oil shown in the Maintenance Table located in the Operating Manual or the Periodic Maintenance Manual for your lift truck model. When the oil level is correct, operate the system and check for leaks. Check the hydraulic oil level and add hydraulic oil if necessary.
25
Gear Pump Specifications
1900 YRM 1136
Gear Pump Specifications Table 1. Hydraulic Gear Pumps for Lift Truck Models GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) and GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX, (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) Model
Engine
Displacement
Governed Speed
Main Relief Valve Pressure Mpa (PSI)
Pump Flow Rate - LPM (GPM)
GC/GLC030VX, GC/GLC035VX, GC/ GLC040SVX (C809) GLP/ GDP16VX, GLP/ GDP18VX, GLP/ GDP20SVX (GP/GLP/ GDP030VX, GP/GLP/ GDP035VX, GP/GLP/ GDP040SVX) (C810)
Mazda 2.0L
24.0 cc/rev
2400 rpm
19.31 MPa (2800 psi)
56.1 liter/min (14.8 gal/min)
GC/GLC030VX, GC/GLC035VX, GC/ GLC040SVX (C809) GLP/ GDP16VX, GLP/ GDP18VX, GLP/ GDP20SVX (GP/GLP/ GDP030VX, GP/GLP/ GDP035VX, GP/GLP/ GDP040SVX) (C810)
Yanmar 2.6L
29.4 cc/rev
2400 rpm
19.31 MPa (2800 psi)
68.7 liter/min (18.1 gal/min)
26
1900 YRM 1136
Gear Pump Specifications
Table 2. Hydraulic Gear Pumps for Lift Truck Models GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLC050LX (A967), GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), and GLP/GDP20-25LX (GLP/ GDP050LX) (A974) Model
Engine
Displacement
Governed Speed
GLC050LX (A967)
Mazda 2.0L
24.0 cc/rev
2400 rpm
GLP20-25L (A974) GLP050LX (A974) GDP20-25LX (A974) GDP050LX (A974)
Mazda 2.0L
Yanmar 2.6L
GLC20-30VX Mazda 2.0L/2.2L (GC/ GLC040-060VX, GM 2.4L GC/ GLC055SVX) Yanmar 2.6L (A910) GLP/ GDP20-30VX (GP/GLP/ Yanmar 3.3L GDP040-060VX ) (B875) GLC35VX (GC/ Mazda 2.0L/2.2L GLC070VX) (A910) GLP/ GM 2.4L GDP35VX (GP/GLP/ Yanmar 2.6L GDP070VX) (B875) Yanmar 3.3L
24.0 cc/rev
25.7 cc/rev
2400 rpm
2400 rpm
Main Relief Valve Pressure Mpa (PSI)
Pump Flow Rate - LPM (GPM)
21.4 MPa (3104 psi)
57.6 liter/min (15.2 gal/min)
23.4 MPa (3394 psi) 21.4 MPa (3104 psi) 23.4 MPa (3394 psi) 21.4 MPa (3104 psi)
24.0 cc/rev 25.7 cc/rev
2700 rpm
2600 rpm
29.4 cc/rev
67.5 liter/min (17.8 gal/min) 77.3 liter/min (20.4 gal/min) 74.4 liter/min (19.7 gal/min)
24.0 cc/rev 25.7 cc/rev
61.7 liter/min (16.3 gal/min) 63.1 liter/min (16.7 gal/min)
21.37 MPa (3100 psi) 29.4 cc/rev
57.6 liter/min (15.2 gal/min)
63.1 liter/min (16.7 gal/min) 2700 rpm
2600 rpm
23.44 MPa (3400 psi)
67.5 liter/min (17.8 gal/min) 77.3 liter/min (20.4 gal/min) 74.4 liter/min (19.7 gal/min)
27
Gear Pump Specifications
1900 YRM 1136
Table 3. Hydraulic Gear Pumps for Lift Truck Model GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) Model
Engine
GLC40VX (GC/ GLC080VX, GC/ GLC080VXBCS) (E818, F818) GLC45, 55VX; GLC55SVX; (GC/ GLC100, 120VX; GC/ GLC100VXBCS; GC/GLC120SVX; GC/ GLC120VXPRS) (E818, F818)
Displacement
Governed Speed
Main Relief Pump Flow Rate Valve Pressure - LPM (GPM) Mpa (PSI)
32.5 cc/rev
75.9 liter/min (20.1 gal/min) 96.5 liter/min (25.5 gal/min)
41.3 cc/rev GM 4.3L
51.6 cc/rev
2400 rpm
22.06 MPa (3200 psi)
96.5 liter/min (25.5 gal/min) 120.5 liter/min (31.8 gal/min)
Table 4. Hydraulic Gear Pumps 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) Model
GLP/ GDP40VX5/VX6 (GP/GLP/ GDP080, 090VX) (F813, G813, H813, J813)
Engine
Displacement
Governed Speed
GM 4.3L / Kubota 3.8L (Paper Kit Industry)
32.5 cc/rev
2400 rpm
22.06 MPa (3200 psi)
75.9 liter/min (20.1 gal/min)
GM 4.3L
41.3 cc/rev
2400 rpm
22.06 MPa (3200 psi)
96.5 liter/min (25.5 gal/min)
Kubota
41.3 cc/rev
2450 rpm
22.1 MPa (3200 psi)
96.5 liter/min (25.5 gal/min)
Cummins 3.3L Turbo / Kubota 3.8L (Paper Kit Industry)
41.3 cc/rev
2200 rpm
22.06 MPa (3200 psi)
88.4 liter/min (23.4 gal/min)
Cummins 3.3L Turbo
46.5 cc/rev
2200 rpm
22.06 MPa (3200 psi)
99.6 liter/min (26.3 gal/min)
Kubota 3.8L
46.5 cc/rev
2450 rpm
22.06 MPa (3200 psi)
96.5 liter/min (25.5 gal/min)
41.3 cc/rev
2400 rpm
22.06 MPa (3200 psi)
96.5 liter/min (25.5 gal/min)
41.3 cc/rev
2450 rpm
22.1 MPa (3200 psi)
96.5 liter/min (25.5 gal/min)
GLP/ GM 4.3L (Paper GDP45SVX5, Kit Industry) GLP/GDP45VX6; Kubota GLP/ GDP50-55VX (GP/GLP/ GDP100, 110, 120VX) (F813,
28
Main Relief Pump Flow Rate Valve Pressure - LPM (GPM) Mpa (PSI)
1900 YRM 1136
Gear Pump Specifications
Table 4. Hydraulic Gear Pumps 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) (Continued) Model
Engine
Displacement
Governed Speed
Main Relief Pump Flow Rate Valve Pressure - LPM (GPM) Mpa (PSI)
G813, H813, J813)
GM 4.3L
51.6 cc/rev
2400 rpm
22.06 MPa (3200 psi)
120.5 liter/min (31.8 gal/min)
Cummins 3.3L Turbo (Paper Kit Industry)
51.6 cc/rev
2200 rpm
22.06 MPa (3200 psi)
110.5 liter/min (29.2 gal/min)
Cummins 3.3L Turbo
51.6 cc/rev
2200 rpm
22.06 MPa (3200 psi)
110.5 liter/min (29.2 gal/min)
Kubota 3.8L
51.6 cc/rev
2500 rpm
22.1 MPa (3200 psi)
96.5 liter/min (25.5 gal/min)
Table 5. Hydraulic Gear Pumps 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) Model
Engine
Displacement
Governed Speed
GLC/GDC60VX (GC/GLC/ GDC135VX) (C879, D879, E879, F879); GLP/GDP60VX (GP/GLP/ GDP135VX) (C878, D878, E878)
GM 4.3L
41.3 cc/rev
2500 rpm
22.06 MPa (3200 psi)
144.3 liter/min (38.1 gal/min)
Cummins 3.3L Turbo
41.3 cc/rev
2500 rpm
22.06 MPa (3200 psi)
132.3 liter/min (35.0 gal/min)
Kubota
41.3 cc/rev
2500 rpm
22.1 MPa (3200 psi)
96.5 liter/min (25.5 gal/min)
GM 4.3L
63.3 cc/rev
2400 rpm
22.06 MPa (3200 psi)
144.3 liter/min (38.1 gal/min)
GLC/GDC70VX, (GC/GLC/ GDC155VX) (C879, D879, E879, F879); GLP/GDP70VX (GP/GLP/ GDP155VX)
Main Relief Pump Flow Rate Valve Pressure - LPM (GPM) Mpa (PSI)
29
Gear Pump Specifications
1900 YRM 1136
Table 5. Hydraulic Gear Pumps 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) (Continued) Model
(C878, D878, E878)
Engine
Displacement
Governed Speed
Kubota
41.3 cc/rev
2500 rpm
Main Relief Pump Flow Rate Valve Pressure - LPM (GPM) Mpa (PSI) 22.1 MPa (3200 psi)
96.5 liter/min (25.5 gal/min)
Table 6. Hydraulic Gear Pumps for Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/ GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) Model
Engine
Displacement
Governed Speed
Main Relief Pump Flow Rate Valve Pressure - LPM (GPM) Mpa (PSI)
Cummins 3.3L Turbo
46.5cc/rev
2500 rpm
22.06 MPa (3200 psi)
177.2 liter/min (46.8 gal/min)
GM 5.7L
46.5 cc/rev
2500 rpm
22.06 MPa (3200 psi)
177.2 liter/min (46.8 gal/min)
GDP80VX (GDP170VX) (A909, B909) GDP80VX9 (GDP175VX36) (A909, B909) GDP90VX (GDP190VX) (A909, B909) GLP80VX (GLP170VX) (A909, B909) GLP80VX9 (GLP175VX36) (A909, B909) GLP90VX (GLP190VX) (A909, B909)
30
1900 YRM 1136
Variable Displacement Pump Repair
Variable Displacement Pump Repair REMOVE WARNING
Periodic Maintenance 8000YRM1248 for lift truck models •
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 following assemblies will cause large changes in the center of gravity: mast, drive axle, engine, transmission, and counterweight. When the lift truck is put on blocks, put additional blocks in the following positions to maintain stability: •
Before removing the mast and drive axle, put blocks under the counterweight so the lift truck cannot fall backward.
•
Before removing the counterweight, put blocks under the mast assembly so the lift truck cannot fall forward.
The surface must be solid, even, and level when the lift truck is put on blocks. Make sure any blocks used to support the lift truck are solid, one-piece units. NOTE: Worn or damaged seals and O-rings are the most common cause of pump damage. The pump shaft, plugs, and plates also wear. They must be checked during disassembly. DO NOT make any repairs to the parts. To prevent more failures, always replace parts that are worn or damaged. If several main parts need replacing, replace the with a new pump. 1. Put the lift truck on blocks. See the Operating Manual or one of the following service manuals for the procedures to put the lift truck on blocks:
GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (G813)
Periodic Maintenance 8000YRM1558 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 8000YRM1605 for lift truck model •
GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813)
2. Place a drain pan under the hydraulic tank, remove drain plug at bottom of hydraulic oil tank, and drain oil from tank. See Figure 15. a. Drain pan capacity approximately ter (11 gal) for lift truck models •
40
li-
62
li-
GLP/GDP20-35VX (B875)
b. Drain pan capacity approximately ter (16.5 gal) for lift truck models •
GLP/GDP40VX5/VX6, GLP/ GDP45SVX5, GLP/GDP45VX6, GLP/ GDP50-55VX (G813, H813, J813) with short wheel base.
•
GP/GLP/GDP080, 090, 100, 110, 120VX (J813) with short wheel base.
Periodic Maintenance 8000YRM1150 for lift truck models •
GLP/GDP20-35VX (B875)
31
Variable Displacement Pump Repair c. Drain pan capacity approximately ter (21 gal) for lift truck models •
•
1900 YRM 1136 78
li-
GLP/GDP40VX5/VX6, GLP/ GDP45SVX5, GLP/GDP45VX6, GLP/ GDP50-55VX (G813, H813, J813) with long wheel base. GP/GLP/GDP080, 090, 100, 110, 120VX (J813) with long wheel base.
3. Once hydraulic oil has finished draining from hydraulic tank, install drain plug.
See Figure 16 for lift truck models •
GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (G813, H813, J813)
See Figure 17 for lift truck model •
GP/GLP/GDP080, 090, 100, 110, 120VX (J813)
See Figure 18 or Figure 19 for lift truck models •
GLP/GDP20-35VX (B875)
4. Place drain pan under variable displacement pump (VDP).
7. Allow hydraulic oil to drain from VDP. Put caps on all hose fittings and VDP ports.
5. Disconnect all hydraulic lines connected to variable displacement pump and steering control unit.
8. Support the VDP assembly to prevent it from falling. Remove two flange head capscrews and VDP from transmission housing.
See Figure 16 for lift truck models •
GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (G813, H813, J813)
See Figure 16 for lift truck models •
See Figure 17 for lift truck model •
GP/GLP/GDP080, 090, 100, 110, 120VX (J813)
See Figure 17 for lift truck model •
See Figure 18 or Figure 19 for lift truck models •
GLP/GDP20-35VX (B875)
6. Remove the suction adapter from the VDP.
32
GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (G813, H813, J813)
GP/GLP/GDP080, 090, 100, 110, 120VX (J813)
See Figure 18 or Figure 19 for lift truck models •
GLP/GDP20-35VX (B875)
1900 YRM 1136
1. HYDRAULIC TANK
Variable Displacement Pump Repair
2. DRAIN PLUG Figure 15. Drain Hydraulic Oil
33
Variable Displacement Pump Repair
1900 YRM 1136
Figure 16. Variable Displacement Pump Arrangement, Lift Truck Models GLP/GDP40VX5/VX6, GLP/ GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (G813, H813, J813) 34
1900 YRM 1136
Variable Displacement Pump Repair Legend for Figure 16
A. FRONT VIEW
B. TOP VIEW
1. 2. 3. 4. 5. 6. 7.
8. 9. 10. 11. 12. 13.
HYDRAULIC INLET HOSE LOAD SENSE LINE DRAIN CASE LINE DRAIN CASE FILL PLUG VARIABLE DISPLACEMENT PUMP FLANGE HEAD CAPSCREWS SUCTION HOSE
MAIN CONTROL VALVE STEERING CONTROL UNIT ACCUMULATOR DRAIN CASE DRAIN PLUG TRANSMISSION SUCTION HOSE ADAPTER
35
Variable Displacement Pump Repair
1900 YRM 1136
Figure 17. Variable Displacement Pump Arrangement, Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (J813) 36
1900 YRM 1136
Variable Displacement Pump Repair Legend for Figure 17
A. FRONT VIEW
B. TOP VIEW
1. 2. 3. 4. 5. 6. 7.
8. 9. 10. 11. 12. 13.
HYDRAULIC INLET HOSE LOAD SENSE LINE DRAIN CASE LINE DRAIN CASE FILL PLUG VARIABLE DISPLACEMENT PUMP FLANGE HEAD CAPSCREWS SUCTION HOSE
MAIN CONTROL VALVE STEERING CONTROL UNIT ACCUMULATOR DRAIN CASE DRAIN PLUG TRANSMISSION SUCTION HOSE ADAPTER
37
Variable Displacement Pump Repair
1900 YRM 1136
Figure 18. Variable Displacement Pump Arrangement, Lift Truck Models GLP/GDP20-35VX (B875) With 1Speed Transmission 38
1900 YRM 1136
Variable Displacement Pump Repair Legend for Figure 18
A. FRONT VIEW
B. TOP VIEW
1. 2. 3. 4. 5. 6.
7. 8. 9. 10. 11. 12.
HYDRAULIC INLET HOSE LOAD SENSE LINE DRAIN CASE LINE VARIABLE DISPLACEMENT PUMP FLANGE HEAD CAPSCREWS SUCTION HOSE
MAIN CONTROL VALVE ACCUMULATOR STEERING CONTROL UNIT DRAIN CASE DRAIN PLUG TRANSMISSION SUCTION HOSE ADAPTER
39
Variable Displacement Pump Repair
1900 YRM 1136
Figure 19. Variable Displacement Pump Arrangement, Lift Truck Models GLP/GDP20-35VX (B875) With 2Speed Transmission 40
1900 YRM 1136
Variable Displacement Pump Repair Legend for Figure 19
A. FRONT VIEW
B. TOP VIEW
1. 2. 3. 4. 5. 6. 7.
8. 9. 10. 11. 12. 13.
HYDRAULIC INLET HOSE LOAD SENSE LINE DRAIN CASE LINE DRAIN CASE FILL PLUG VARIABLE DISPLACEMENT PUMP FLANGE HEAD CAPSCREWS SUCTION HOSE
MAIN CONTROL VALVE ACCUMULATOR STEERING CONTROL UNIT DRAIN CASE DRAIN PLUG TRANSMISSION SUCTION ADAPTER
DISASSEMBLE 1. Put the variable displacement pump in a vise.
CAUTION Protect the drive shaft from damage before removing the retaining ring and shaft seal. NOTE: Perform Step 2 ONLY if shaft seal is leaking. NOTE: Kits are available that include materials and tools to remove and install shaft seal. See the Parts Manual for kit part numbers. 2. Remove retaining ring and shaft seal from drive shaft as described below: a. Clean the shaft and shaft seal area. Wrap the pump drive shaft splines in tape or other protective material to protect drive shaft before removing retaining ring and shaft seal. See Figure 20. b. Remove the retaining ring. See Figure 20.
1. RETAINING RING 2. SHAFT SEAL
3. DRIVE SHAFT
Figure 20. Retaining Ring Removal
41
Variable Displacement Pump Repair c. Punch two holes into top surface of old shaft seal being replaced. Make sure holes are 180° apart from each other. Insert two screws into holes and into steel layer of the shaft seal. Pull on screws and remove existing shaft seal from drive shaft. See Figure 21.
1900 YRM 1136 d. Inspect and clean shaft and internal shaft sealing area. Remove any metal shavings created while inserting screws into old shaft seal. See Figure 21. NOTE: Be sure solid surface area of shaft seal is pointing outwards from pump. NOTE: On lift truck models GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813, H813, J813), use the end of the VDP shaft seal installation tool that has two rings to install the shaft seal. For lift truck models GLP/GDP20-35VX (B875), use the end of the VDP shaft seal installation tool that has one ring to install the shaft seal. See Figure 22. e. Install new shaft seal onto drive shaft. Use special VDP shaft seal installation tool, Yale Part Number 582016143, and seat shaft seal down onto pump stop ring. f.
1. SCREWS 2. SHAFT SEAL
3. DRIVE SHAFT
Figure 21. Shaft Seal Removal
42
Use rubber hammer and tap on VDP shaft seal tool until VDP shaft seal tool shoulder stops against the face of VDP housing. See Figure 22.
g. Install the retaining ring. Be sure retaining ring correctly rests in the groove. See Figure 20.
1900 YRM 1136
Variable Displacement Pump Repair Legend for Figure 22 NOTE: SHAFT SEAL INSTALLATION FOR VDP USED ON GLP/GDP20-35VX (B875) LIFT TRUCK MODELS SHOWN (ONE RING SIDE OF VDP SHAFT SEAL TOOL PUSHING DOWN ON SHAFT SEAL). TO INSTALL SHAFT SEAL ON LIFT TRUCKS GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (G813, H813, J813), USE PART OF VDP SHAFT SEAL TOOL WITH TWO RINGS. 1. 2. 3. 4. 5. 6. 7. 8.
VDP SHAFT SEAL TOOL TWO RINGS ONE RING VDP SHAFT SEAL TOOL SHOULDER STOP RING BEARING RETAINING RING DRIVE SHAFT
3. Remove four socket head screws from control valve and VDP. Remove seal from control valve. See Figure 23 for lift truck models •
GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (G813, H813, J813)
See Figure 24 for lift truck model • Figure 22. Shaft Seal Installation
GP/GLP/GDP080, 090, 100, 110, 120VX (J813)
See Figure 25 for lift truck models •
GLP/GDP20-35VX (B875)
43
Variable Displacement Pump Repair
1. 2. 3. 4. 5. 6.
SOCKET HEAD SCREW CONTROL VALVE SEAL VARIABLE DISPLACEMENT PUMP DRIVE SHAFT CONTROL VALVE ASSEMBLY Figure 23. Variable Displacement Pump Dissembly, Lift Truck Models GLP/GDP40VX5/ VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/ GDP50-55VX (G813, H813, J813)
44
1900 YRM 1136
1. 2. 3. 4. 5. 6.
SOCKET HEAD SCREW CONTROL VALVE SEAL VARIABLE DISPLACEMENT PUMP DRIVE SHAFT CONTROL VALVE ASSEMBLY Figure 24. Variable Displacement Pump Dissembly, Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (J813)
1900 YRM 1136
Variable Displacement Pump Repair
CLEAN WARNING Cleaning solvents can be flammable and toxic, can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer.
WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. Clean all components in solvent. Dry components with compressed air. DO NOT dry components with a cloth. Make sure all surfaces are free of scratches and sharp edges.
INSPECT
1. 2. 3. 4. 5. 6.
SOCKET HEAD SCREW CONTROL VALVE SEAL VARIABLE DISPLACEMENT PUMP DRIVE SHAFT CONTROL VALVE ASSEMBLY
Check the control valve seal, drive shaft seal, and retaining ring for wear or damage and replace if necessary. Check the rest of the variable displacement pump assembly. If any parts other than the control valve seal, drive shaft seal, and retaining ring are worn or damaged, replace with a new variable displacement pump.
Figure 25. Variable Displacement Pump Dissembly, Lift Truck Models GLP/GDP20-35VX (B875)
45
Variable Displacement Pump Repair
ASSEMBLE 1. Coat seal with clean hydraulic oil. Install seal, control valve, and four socket head screws on VDP. See Figure 23 for lift truck models •
GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (G813, H813, J813)
See Figure 24 for lift truck model •
GP/GLP/GDP080, 090, 100, 110, 120VX (J813)
See Figure 25 for lift truck models •
GLP/GDP20-35VX (B875)
1900 YRM 1136 See Figure 30 for lift truck model •
GP/GLP/GDP080, 090, 100, 110, 120VX (J813)
2. Clean the VDP flange and transmission mounting surface and put a 3 to 5 mm (0.118 to 0.197 in.) bead of Loctite™ 515 (Yale P/N 520042831) on the VDP flange or transmission mounting surface. Hold the pump in the correct position on the transmission. Install two socket head screws on VDP and transmission housing. Tighten socket head screws to 38 N•m (28 lbf ft). 3. Connect the hydraulic lines to the VDP and steering control unit. Tighten the flange head capscrews at the VDP, using sequence shown in Figure 26, to 70 to 77 N•m (52 to 57 lbf ft).
2. Apply clean hydraulic oil to shaft seal and retaining ring. Install shaft seal and retaining ring onto drive shaft. See Figure 23 for lift truck models •
GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (G813, H813, J813)
See Figure 25 for lift truck models •
GLP/GDP20-35VX (B875)
INSTALL 1. Install the suction adapter and tighten flange hardware 70 to 77 N•m (52 to 57 lbf ft). Position suction adapter as shown in: Figure 27 and Figure 28 for lift truck models •
GLP/GDP20-35VX (B875)
Figure 29 for lift truck models •
GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (G813, H813, J813)
Figure 26. Torque Tightening Sequence, Flange Head Capscrews 4. Position the hydraulic lines as shown in: Figure 27, Figure 28, and Figure 31 for lift truck models •
46
GLP/GDP20-35VX (B875)
1900 YRM 1136
Variable Displacement Pump Repair
Figure 29 and Figure 31 for lift truck models •
GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (G813, H813, J813)
Figure 30 and Figure 31for lift truck model •
GP/GLP/GDP080, 090, 100, 110, 120VX (J813)
A. X = 45° ±5° 1. 2. 3. 4. 5.
B. Y = 54° ±5°
HYDRAULIC INLET HOSE SUCTION HOSE LOAD SENSE LINE DRAIN CASE LINE VARIABLE DISPLACEMENT PUMP
Figure 27. Hydraulic Hose Orientation at the Variable Displacement Pump, Lift Truck Models GLP/GDP20-35VX (B875) Equipped With 1-Speed Transmission
NOTE: HYDRAULIC INLET HOSE OMITTED FROM VIEW D FOR CLARITY. A. X = 74° ±5° B. Y = 20° ±5° C. Z = 35° ±5° 1. 2. 3. 4. 5.
D. FRONT VIEW E. SIDE VIEW
LOAD SENSE LINE SUCTION HOSE DRAIN CASE LINE HYDRAULIC INLET HOSE VARIABLE DISPLACEMENT PUMP
Figure 28. Hydraulic Hose Orientation at the Variable Displacement Pump, Lift Truck Models GLP/GDP20-35VX (B875) Equipped With 2-Speed Transmission
47
Variable Displacement Pump Repair
A. X = 30° ±5° 1. 2. 3. 4.
B. Y = 12° ±5°
LOAD SENSE LINE SUCTION HOSE VARIABLE DISPLACEMENT PUMP DRAIN CASE LINE
Figure 29. Hydraulic Hose Orientation at the Variable Displacement Pump, Lift Truck Models GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/ GDP45VX6, GLP/GDP50-55VX (G813, H813, J813)
48
1900 YRM 1136
A. X = 30° ±5° 1. 2. 3. 4.
B. Y = 12° ±5°
LOAD SENSE LINE SUCTION HOSE VARIABLE DISPLACEMENT PUMP DRAIN CASE LINE
Figure 30. Hydraulic Hose Orientation at the Variable Displacement Pump, Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (J813)
1900 YRM 1136
Variable Displacement Pump Repair Legend for Figure 31 A. X = 10° ±5° FOR LIFT TRUCK MODELS GLP/ GDP40VX5/VX6, GLP/GDP45SVX5, GLP/ GDP45VX6, GLP/GDP50-55VX (G813, H813, J813) AND GLP/GDP20-35VX (B875), 1-SPEED TRANSMISSION B. X = 28° ±5° FOR LIFT TRUCK MODELS GLP/ GDP20-35VX (B875), 2-SPEED TRANSMISSION C. Y = 65° ±5° FOR LIFT TRUCK MODELS GLP/ GDP20-35VX (B875), 1-SPEED TRANSMISSION D. Y = 55° ±5° FOR LIFT TRUCK MODELS GLP/ GDP20-35VX (B875), 2-SPEED TRANSMISSION E. 1-SPEED TRANSMISSION F. 2-SPEED TRANSMISSION 1. 2. 3. 4.
STEERING CONTROL UNIT MAIN CONTROL VALVE HYDRAULIC INLET HOSE LOAD SENSE LINE
Figure 31. Hydraulic Hose Orientation at the Steering Control Unit
49
Variable Displacement Pump Repair
1900 YRM 1136
5. Remove the lift truck from the blocks. See the Operating Manual or one of the following service manuals for the procedures:
Periodic Maintenance 8000YRM1150 for lift truck models
Periodic Maintenance 8000YRM1150 for lift truck models
Periodic Maintenance 8000YRM1248 for lift truck models
•
GLP/GDP20-35VX (B875)
Periodic Maintenance 8000YRM1248 for lift truck models •
GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (G813)
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GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813)
Capacities and Specifications 8000YRM1605 for lift truck model •
GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813)
6. Fill the hydraulic tank using hydraulic oil specified in the Operating Manual or one of the following service manuals:
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GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (G813)
Periodic Maintenance 8000YRM1558 for lift truck model •
Periodic Maintenance 8000YRM1558 for lift truck model •
GLP/GDP20-35VX (B875)
GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813)
Capacities and Specifications 8000YRM1605 for lift truck model •
GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813)
7. When the hydraulic oil level is correct, operate the hydraulic system and check for leaks. Check the hydraulic oil level and add hydraulic oil if necessary.
1900 YRM 1136
Variable Displacement Pump Checks and Adjustments
Variable Displacement Pump Checks and Adjustments MARGIN PRESSURE CHECK The margin pressure is the difference between the pressure at the P-port and LS-port. If the margin pressure is not within the range shown in Table 7, the flow of hydraulic oil out of the variable displacement pump (VDP) will be either too low or too high. Table 7. Margin Pressure Lift Truck Model
Margin Pressure
GLP/GDP20-35VX (B875)
12.5 ±1 bar (180 ±15 psi)
GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/ GDP45VX6, GLP/ GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (G813, H813, J813)
14.0 ±1 bar (203 ±15 psi)
1. P-PORT
WARNING DO NOT operate the hydraulic functions while checking the margin pressure. Serious injury to personnel and damage to the lift truck can result if hydraulic functions are operated. 1. Install a 70 bar (1000 psi) gauge on the P-port and a 35 bar (500 psi) gauge on the LS-port on the main control valve. See Figure 32.
2. LS-PORT
Figure 32. Margin Pressure Check Ports 2. Start lift truck engine and keep truck at idle for five minutes. 3. Check the pressure on the gauges against those listed in Table 7.
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Variable Displacement Pump Checks and Adjustments
1900 YRM 1136
4. If the margin pressure is not within range specified in Table 7, go to Flow Compensator Adjustment section.
FLOW COMPENSATOR ADJUSTMENT WARNING DO NOT operate the hydraulic functions while adjusting the flow compensator. Serious injury to personnel and damage to the lift truck can result if hydraulic functions are operated. 1. Insert an allen wrench into flow compensator adjustment screw. Hold allen wrench in flow compensator screw and turn jam nut counter clockwise all the way. See Figure 33. 2. Turn the flow compensator adjustment screw to adjust the P-port pressure: •
Clockwise to increase the P-port pressure by 16 bar (232 psi) per turn.
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Counter clockwise to decrease the P-port pressure by 16 bar (232 psi) per turn.
3. Check the margin pressure as described in Margin Pressure Check. If margin pressure is not correct, perform Step 1 and Step 2 until correct margin pressure is reached.
1. 2. 3. 4. 5.
FLOW COMPENSATOR JAM NUT FLOW COMPENSATOR ADJUSTMENT SCREW PRESSURE COMPENSATOR PRESSURE COMPENSATOR ADJUSTMENT SCREW Figure 33. Flow and Pressure Compensators
1. Mark or measure the screw locations of the flow and pressure compensators. See Figure 34.
4. Tighten the jam nut to 21 N•m (186 lbf in). See Figure 33.
PRESSURE COMPENSATOR ADJUSTMENT WARNING DO NOT operate the hydraulic functions while adjusting the pressure compensator. Serious injury to personnel and damage to the lift truck can result if hydraulic functions are operated.
A. MEASURE AND NOTE THIS DISTANCE 1. PRESSURE COMPENSATOR 2. FLOW COMPENSATOR Figure 34. Screw Location
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1900 YRM 1136 NOTE: Be sure to count and note the number of turns on the jam nut. 2. Using an allen wrench, hold the flow compensator adjustment screw and turn the jam nut counterclockwise all the way. 3. Turn the flow compensator adjustment screw clockwise until it stops.
WARNING DO NOT operate the hydraulic functions while adjusting the pressure compensator. Serious injury to personnel and damage to the lift truck can result if hydraulic functions are operated. 4. Start lift truck engine and let it idle. DO NOT operate the hydraulic functions. Measure the pressure at the P-port of the SCU. See Figure 32. If pressure does not match what is shown in Table 8, adjust the pressure compensator as follows:
Variable Displacement Pump Checks and Adjustments Table 8. Pressure Compensator Adjustment Lift Truck Model
Pressure
GLP/GDP20-35VX (B875)
239 ±3 bar (3466 ±44 psi)
GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/ GDP45VX6, GLP/ GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (G813, H813, J813)
226 ±3 bar (3278 ±44 psi)
5. Put the pressure compensator adjustment screw back to its original position by turning the adjustment screw counter clockwise by the number of turns noted earlier. 6. Tighten jam nut on pressure compensator adjustment screw to 21 N•m (186 lbf in).
a. Turn pressure compensator adjustment screw clockwise to increase pressure by 50 bar (725 psi) per turn.
7. Put the flow compensator adjustment screw back to its original position by turning the adjustment screw counter clockwise by the number of turns noted earlier.
b. Turn pressure compensator adjustment screw counter clockwise to decrease pressure by 50 bar (725 psi) per turn.
8. Check the margin pressures as described in Margin Pressure Check. 9. If margin pressure is correct, tighten the flow compensator jam nut to 21 N•m (186 lbf in). If margin pressure is not correct, adjust margin pressure as outlined in Margin Pressure Check.
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Variable Displacement Pump Specifications
1900 YRM 1136
Variable Displacement Pump Specifications Table 9. Variable Displacement Pump for Lift Truck Models GLP/GDP20-35VX (B875) Displacement
Governed Speed
Pump Speed
Pressure Compensator Setting - Bar (PSI)
Load Sense Pump Flow Rate @ Pump Flow Rate @ Margin Setting - ≤ 30 Bar LPM (GPM) 210 Bar LPM (GPM) Bar (PSI)
24.0 cc/rev
3200 rpm
2765 ±5 rpm
239 ±3 bar (3466 ±44 psi)
12.5 ±1 bar (180 ±15 psi)
66.4 ±3.1 liter/min (17.5 ±0.82 gal/min)
64.0 ±3.0 liter/min (16.9 ±0.80 gal/min)
26.0 cc/rev
3200 rpm
2765 ±5 rpm
239 ±3 bar (3466 ±44 psi)
12.5 ±1 bar (180 ±15 psi)
71.9 ±3.1 liter/min (19.0 ±0.82 gal/min)
69.0 ±3.0 liter/min (18.2 ±0.80 gal/min)
28.0 cc/rev
3200 rpm
2765 ±5 rpm
239 ±3 bar (3466 ±44 psi)
12.5 ±1 bar (180 ±15 psi)
77.4 ±3.1 liter/min (20.4 ±0.82 gal/min)
75.0 ±3.0 liter/min (19.8 ±0.80 gal/min)
Table 10. Variable Displacement Pump for Lift Truck Models GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813, H813, J813) Displacement
Governed Speed
Pump Speed
Pressure Compensator Setting - Bar (PSI)
42.0 cc/rev
2900 rpm
2458 ±5 rpm
226 ±3 bar (3278 ±44 psi)
14.0 ±1 bar (203 ±15 psi)
103.2 ±4.4 liter/min (27.3 ±1.20 gal/min)
100.0 ±4.3 liter/min (26.4 ±1.10 gal/min)
45.0 cc/rev
2900 rpm
2458 ±5 rpm
226 ±3 bar (3278 ±44 psi)
14.0 ±1 bar (203 ±15 psi)
110.6 ±4.4 liter/min (29.2 ±1.20 gal/min)
107.0 ±4.3 liter/min (28.3 ±1.10 gal/min)
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Load Sense Pump Flow Rate @ Pump Flow Rate @ Margin Setting - ≤ 30 Bar LPM (GPM) 210 Bar LPM (GPM) Bar (PSI)
1900 YRM 1136
Torque Specifications
Torque Specifications HYDRAULIC GEAR PUMP Rear Valve End Housing to Gear Pump Body Capscrews - Lift Truck Models GC/GLC030-035VX, GC/GLC040SVX (C809); GLP/GDP16-18VX, GLP/ GDP20SVX (GP/GLP/GDP030-035VX, GP/GLP/ GDP040SVX) (C810); GLC20-35VX (GC/ GLC040-070VX, GC/GLC055SVX) (A910); GLC050LX (A967); GLP/GDP20-35VX (GP/GLP/ GDP040-070VX) (B875); GLP/GDP20-25LX (GLP/ GDP050LX) (A974); GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818); and GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) 46 to 49 N•m (34 to 36 lbf ft) Driven Pump Rear Valve End Housing to Gear Pump Body Capscrews - 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) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/ GDP190VX) (A909, B909) 88 to 98 N•m (65 to 72 lbf ft)
Drive Pump Rear Valve End Housing to Gear Pump Body Capscrews - 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) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/ GDP190VX) (A909, B909) 123 to 132 N•m (91 to 97 lbf ft) Driven Pump to Drive Pump Capscrews - 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) and GLP/GDP80VX, GLP/ GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909) 88 to 98 N•m (65 to 72 lbf ft)
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Torque Specifications Pump Outlet Fitting - Lift Truck Models GC/ GLC030-035VX, GC/GLC040SVX (C809); GLP/ GDP16-18VX, GLP/GDP20SVX (GP/GLP/ GDP030-035VX, GP/GLP/GDP040SVX) (C810); GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910); GLC050LX (A967); GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875); GLP/ GDP20-25LX (GLP/GDP050LX) (A974); 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) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/ GDP190VX) (A909, B909) 88 to 98 N•m (65 to 72 lbf ft) Pump Outlet Fitting - Lift Truck Models GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/ GLC080, 100VXBCS; GC/GLC120SVX; GC/ GLC120VXPRS) (E818, F818) and GLP/GDP40VX5/ VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) 98 to 118 N•m (72 to 87 lbf ft) Suction Adapter- All Lift Truck Models Not Equipped With Quick-Lok™ Hydraulic Supply Hose 78 to 88 N•m (58 to 65 lbf ft) Outlet Adapter - Lift Truck Models GLP/ GDP20-35VX (GP/GLP/GDP040-070VX) (B875) Equipped With Quick-Lok™ Hydraulic Supply Hose To Gear Pump 59 to 69 N•m (44 to 51 lbf ft) To SCU Port 170 to 183 N•m (125 to 135 lbf ft) Gear Pump to Transmission Socket Head Screws - Lift Truck Models With Iron Transmission Housing, GC/GLC030-035VX, GC/GLC040SVX (C809); GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/ GDP030-035VX, 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); and GLP/GDP40VX5/VX6; GLP/ GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) 38 N•m (28 lbf ft)
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1900 YRM 1136 Gear Pump to Transmission Flange Head Capscrews - Lift Truck Models With Aluminum Transmission Housing, GC/GLC030-035VX, GC/ GLC040SVX (C809); GLP/GDP16-18VX, GLP/ GDP20SVX (GP/GLP/GDP030-035VX, GP/GLP/ GDP040SVX) (C810); GLC20-35VX (GC/ GLC040-070VX, GC/GLC055SVX) (A910); GLC050LX (A967); GLP/GDP20-35VX (GP/GLP/ GDP040-070VX) (B875); GLP/GDP20-25LX (GLP/ GDP050LX) (A974) 38 N•m (28 lbf ft) Tandem Gear Pump To Transmission Charge Pump Socket Head Screws - 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) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909) 108 N•m (80 lbf ft)
VARIABLE DISPLACEMENT PUMP Suction Hose Adapter 70 to 77 N•m (52 to 57 lbf ft) Flange Head Capscrews 70 to 77 N•m (52 to 57 lbf ft) Flow Compensator Jam Nut 21 N•m (186 lbf in) Pressure Compensator Jam Nut 21 N•m (186 lbf in) Variable Displacement Pump to Transmission Socket Head Screws - All Transmissions 38 N•m (28 lbf ft)
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