Page 1

GC/GLC080VX & 080VX-BCS, GC/GLC100VX & 100VX-BCS, GC/GLC120VX & SVX & PRS (F818) SERVICE MANUAL CONTENTS SECTION FRAME............................................................................................................................ GM 4.3L V-6 ENGINES................................................................................................... COOLING SYSTEM........................................................................................................ LPG FUEL SYSTEM GM 4.3L ENGINE WITH PSI........................................................ GASOLINE FUEL SYSTEM............................................................................................ 1 AND 2 SP PS TRANSMISSION REPAIR.................................................................... DRIVE AXLE AND DIFFERENTIAL ASSEMBLY REPAIR............................................ DRIVE AXLE AND DIFFERENTIAL ASSEMBLY REPAIR............................................ STEERING AXLE............................................................................................................ WET BRAKES - NMHG.................................................................................................. 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 AND SCHEMATICS.................................................................................... PERIODIC MAINTENANCE............................................................................................ CAPACITIES AND SPECIFICATIONS........................................................................... DIAGRAMS AND SCHEMATICS.................................................................................... DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................

PART NUMBER

YRM NUMBER

REV DATE

524262274 524265337 524223757 550043871 550048401 550048681 524262278 550055280 524223764 550064329 524223766 550073240 524223767

0100 YRM 1243 0600 YRM 1251 0700 YRM 1123 0900 YRM 1556 0900 YRM 1570 1300 YRM 1569 1400 YRM 1246 1400 YRM 1582 1600 YRM 1133 1800 YRM 1597 1900 YRM 1136 1900 YRM 1620 2000 YRM 1137

05/14 05/14 03/13 04/14 09/13 08/13 12/13 12/13 07/13 12/13 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 550055283 550064334 550064342 550096331 524221866

4000 YRM 1250 8000 YRM 0231 8000 YRM 1134 8000 YRM 1585 8000 YRM 1598 8000 YRM 1599 8000 YRM 1689 9000 YRM 1112

02/14 10/13 12/14 04/14 04/14 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. 550064306 (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.


Table of Contents

TABLE OF CONTENTS General ..................................................................................................................................................................... 1 Hydraulic Gear Pump Assembly ...................................................................................................................... 1 Variable Displacement Pump Assembly .......................................................................................................... 2 Single Gear Pump Assembly Repair ........................................................................................................................ 4 Remove ................................................................................................................................................................ 4 Disassemble ....................................................................................................................................................... 12 Clean .................................................................................................................................................................. 14 Inspect ................................................................................................................................................................ 14 Assemble ............................................................................................................................................................14 Install .................................................................................................................................................................. 14 Tandem Gear Pump Assembly ...............................................................................................................................20 Remove .............................................................................................................................................................. 20 Disassemble ....................................................................................................................................................... 22 Clean .................................................................................................................................................................. 24 Inspect ................................................................................................................................................................ 24 Assemble ............................................................................................................................................................24 Install .................................................................................................................................................................. 25 Gear Pump Specifications ...................................................................................................................................... 26 Variable Displacement Pump Repair ......................................................................................................................31 Remove .............................................................................................................................................................. 31 Disassemble ....................................................................................................................................................... 41 Clean .................................................................................................................................................................. 45 Inspect ................................................................................................................................................................ 45 Assemble ............................................................................................................................................................46 Install .................................................................................................................................................................. 46 Variable Displacement Pump Checks and Adjustments .........................................................................................51 Margin Pressure Check ...................................................................................................................................... 51 Flow Compensator Adjustment .......................................................................................................................... 52 Pressure Compensator Adjustment ....................................................................................................................52 Variable Displacement Pump Specifications .......................................................................................................... 54 Torque Specifications ............................................................................................................................................. 55 Hydraulic Gear Pump ......................................................................................................................................... 55 Variable Displacement Pump ............................................................................................................................. 56

Š2014 Yale Materials Handling Corp.

i


Table of Contents

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, GCGLC055SVX) [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]; GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) [F813, G813, H813, J813]; 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]; GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) [A909, B909]

ii


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)

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:

50

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.

51


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.

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

52


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.

53


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)

54

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)

55


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)

56

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)


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.

4


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)

5


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)

6


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.

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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.

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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

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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)

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

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Yale f818 gc glc100vx bcs lift truck service repair manual  
Yale f818 gc glc100vx bcs lift truck service repair manual  
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