YALE E878 GLP60VX LIFT TRUCK Service Repair Manual

GLP/GDP60VX, GLP/GDP70VX (E878)
SERVICE MANUAL CONTENTS
SECTION
PART
NUMBER
YRM
NUMBER
REV
DATE
OPERATOR'S CAB........................................................................................................ 524306203 0100 YRM 1290 04/14
FRAME............................................................................................................................ 550055278 0100 YRM 1581 08/13
GM 4.3L V-6 ENGINES................................................................................................... 524265337 0600 YRM 1251 05/14
KUBOTA DIESEL 3.6L ENGINE.................................................................................... 550055279 0600 YRM 1579 01/14
KUBOTA ENGINE REPAIR 3.8L DIESEL W/DPF......................................................... 550059479 0600 YRM 1590 09/13
COOLING SYSTEM........................................................................................................ 524223757 0700 YRM 1123 03/13
LPG FUEL SYSTEM GM 4.3L ENGINE WITH PSI........................................................ 550043871 0900 YRM 1556 04/14
THREE-SPEED POWERSHIFT TRANSMISSION REPAIR........................................... 524288194 1300 YRM 1317 03/13
TRANSMISSION REPAIR (DANA SPICER) 2X2........................................................... 524294873 1300 YRM 1343 03/14
DRIVE AXLE WET BRAKE (SPICER)............................................................................ 524296605 1400 YRM 1344 12/13
STEERING AXLE............................................................................................................ 524223764 1600 YRM 1133 07/13
BRAKE SYSTEM............................................................................................................ 524262279 1800 YRM 1247 03/13
HYDRAULIC GEAR PUMP............................................................................................. 524223766 1900 YRM 1136 04/14
HYDRAULIC CLEANLINESS PROCEDURES............................................................... 550073240 1900 YRM 1620 12/14
MAIN CONTROL VALVE................................................................................................ 524223767 2000 YRM 1137 04/14
CYLINDER REPAIR (MAST S/N A513, A514, A613, A614, B513, B514)..................... 524294878 2100 YRM 1328 02/14
HIGH VOLTAGE SWITCH (HVS) IGNITION.................................................................. 524208014 2200 YRM 1097 05/14
WIRE HARNESS REPAIR.............................................................................................. 524223769 2200 YRM 1128 12/14
USER INTERFACE......................................................................................................... 524223770 2200 YRM 1130 12/14
USER INTERFACE......................................................................................................... 524223771 2200 YRM 1131 12/14
ELECTRICAL SYSTEM.................................................................................................. 524223772 2200 YRM 1142 04/14
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)................................................................................ 524265342 4000 YRM 1250 02/14
METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13
CALIBRATION PROCEDURES...................................................................................... 524223780 8000 YRM 1134 12/14
PERIODIC MAINTENANCE............................................................................................ 550055296 8000 YRM 1583 01/14
CAPACITIES AND SPECIFICATIONS........................................................................... 550055282 8000 YRM 1584 02/14
DIAGRAMS AND SCHEMATICS.................................................................................... 550055283 8000 YRM 1585 04/14
DIAGRAMS AND SCHEMATICS.................................................................................... 550096331 8000 YRM 1689 04/14
DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................ 524221866 9000 YRM 1112 12/14
Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center.
9000 YRM 1112 ON CD
PART NO. 550055273 (12/14)

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product.
Updated technical service information may be available from your local authorized Yale® dealer. Service Manuals
provide general guidelines for maintenance and service and are intended for use by trained and experienced techni-
cians. 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. Discon-
nect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS
in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications
of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to
follow the necessary safety precautions when handling these fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure
the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange background.
The CAUTION symbol and word are on yellow background.

Steering Axle Table of Contents
TABLE OF CONTENTS
General................................................................................................................................................................ 1
Steering Axle Assembly Repair........................................................................................................................... 3
Remove........................................................................................................................................................... 3
Disassemble.................................................................................................................................................... 4
Clean............................................................................................................................................................... 12
Inspect............................................................................................................................................................. 12
Assemble ........................................................................................................................................................ 12
Install............................................................................................................................................................... 18
Spindles, Bearings, and Tie Rods Repair............................................................................................................ 20
Spindles and Bearings .................................................................................................................................... 20
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).................................................................................................................. 20
Remove .................................................................................................................................................. 20
Disassemble ........................................................................................................................................... 22
Clean ...................................................................................................................................................... 23
Inspect.................................................................................................................................................... 23
Assemble................................................................................................................................................ 23
Install ...................................................................................................................................................... 24
Spindles and Bearings .................................................................................................................................... 27
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) ................................................................................................................... 27
Remove and Disassemble...................................................................................................................... 27
Assemble and Install .............................................................................................................................. 28
Tie Rods.......................................................................................................................................................... 28
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), and GLC40, 45, 55VX; GLC55SVX;
(GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS)
(E818, F818)............................................................................................................................................... 28
Remove .................................................................................................................................................. 28
Install ...................................................................................................................................................... 29
Tie Rods.......................................................................................................................................................... 30
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).................................................................................................................. 30
Remove .................................................................................................................................................. 30
Install ...................................................................................................................................................... 36
Steering Cylinder Repair ..................................................................................................................................... 36
Remove and Disassemble .............................................................................................................................. 36
Clean and Inspect ........................................................................................................................................... 37
Assemble and Install ....................................................................................................................................... 37
©2013 Yale Materials Handling Corp. i

Table of Contents Steering Axle
TABLE OF CONTENTS (Continued)
Torque Specifications .......................................................................................................................................... 38
This section is for the following models:
GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX [C809];
GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) [C810];
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) [A910];
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) [B875];
GLC40, 45, 55VX; GLC55SVX (GC/GLC080, 100, 120VX; GC/GLC080,
100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) [E818, F818];
GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX) [F813, G813, H813, J813];
GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
[C879, D879, E879, F879];
GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX)
[C878, D878, E878];
GLP/GDP80VX, GLP/GDP80VX9,GLP/GDP90VX (GLP/GDP170VX,
GLP/GDP175VX36, GLP/GDP190VX) [A909, B909]
ii

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. AXLE FRAME
2. MOUNT
3. BRACKET
4. STEERING CYLINDER
5. TIE ROD
6. SPINDLE
7. MOUNT
8. HUB ASSEMBLIES
Figure 1. Steering Axle
2

1600 YRM 1133 Steering Axle Assembly Repair
When the piston reaches the end of the stroke, a re-
lief valve in the steering circuit controls the oil pressure.
The tie rods that connect the spindle arms to the cylin-
der 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 ad-
ditional 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. In-
stall plug fittings in cylinder and put caps on hy-
draulic 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/GDP040-
070VX) (B875)
• GLC40, 45, 55VX; GLC55SVX;
(GC/GLC080, 100, 120VX; GC/GLC080,
100VXBCS; GC/GLC120SVX;
GC/GLC120VXPRS) (E818, F818)
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813)
b. To remove plate type mounts, remove four cap-
screws and washers from two plates.
• GC/GLC030-035VX, GC/GLC040SVX
(C809)
• GLP/GDP16-18VX, GLP/GDP20SVX
(GP/GLP/GDP030-035VX, GP/GLP/
GDP040SVX) (C810)
3

Steering Axle Assembly Repair 1600 YRM 1133
• 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)
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.
GDP135VX, GP/GLP/GDP155VX) (C878, D878,
E878)
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 cot-
ter pin.
NOTE: Identify and tag the outer and inner bearing
cones so they can be reassembled in their original
locations.
NOTE: The wear ring may not be present on all steering
axles.
3. Slide wheel from spindle. Remove inner bearing
cone, wear ring, and oil seal from spindle.
• 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)
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
100, 120VX; GC/GLC080, 100VXBCS;
GC/GLC120SVX; GC/GLC120VXPRS) (E818,
F818)
GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
GDC135VX, GC/GLC/GDC155VX) (C879, D879,
E879, F879)
E878)
B909)
NOTE: If the bearing is replaced, then the associated
bearing cup must be replaced also.
4. If the bearings must be replaced, use a brass drift
pin to remove the bearing cups and wear ring.
5. Repeat Step 1 through Step 4 for the other wheel.
4

1. MOUNT
2. STEER AXLE ASSEMBLY
3. MOUNT
4. PLATE
5. WASHER
6. LOCK NUT
7. CAPSCREW
8. STEERING CYLINDER ROD
9. LUBRICATION FITTING
10. COTTER PIN
11. OIL SEAL
12. WEAR RING
13. BEARING CONE
14. BEARING CUP
15. WASHER
16. CASTLE NUT
17. HUB CAP
Figure 2. Spindle to Tie Rod Assembly for Lift Truck Models GLC20-35VX (GC/GLC040-070VX,
5

1. MOUNT
2. STEERING AXLE ASSEMBLY
3. MOUNT
4. BRACKET
5. NUT
6. WASHER
7. WASHER
8. CAPSCREW
11. OIL SEAL
12. WEAR RING
13. BEARING CONE
14. BEARING CUP
15. HUB
16. BEARING CUP
17. BEARING CONE
18. CASTLE NUT
19. HUB CAP
20. COTTER PIN
Figure 3. Spindle to Tie Rod Assembly for Lift Truck Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875)
6

A. PNEUMATIC TRUCKS ONLY
1. MOUNT
3. MOUNT
4. PLATE
5. CAPSCREW
8. OIL SEAL
9. BEARING
10. HUB
11. BEARING
12. WASHER
13. CASTLE NUT
14. HUB CAP
15. COTTER PIN
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

1. HUB CAP
2. CASTLE NUT
3. COTTER PIN
4. WASHER
5. BEARING CONE (OUTER)
6. BEARING CUP (OUTER)
7. BEARING CUP (INNER)
8. BEARING CONE (INNER)
9. WEAR RING
10. OIL SEAL
13. PADS
14. MOUNT
15. CAPSCREW
16. WASHER
17. PLATE
18. 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

1. HUB CAP
2. CASTLE NUT
3. COTTER PIN
4. WASHER
5. BEARING CONE
6. BEARING CUP
7. HUB
8. WEAR RING
9. OIL SEAL
10. LUBE FITTING
11. MOUNT
12. STEERING AXLE ASSEMBLY
13. MOUNT
14. CAPSCREW
15. WASHER
16. NUT
18. SPINDLE (LEFT SIDE SHOWN)
19. TIE ROD
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

1. HUB CAP
2. COTTER PIN
3. CASTLE NUT
4. WASHER
9. SEAL
10. WEAR RING
11. PAD
12. MOUNT
13. PLATE
14. CAPSCREW
15. LUBE FITTING
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

2. TIE ROD
3. PLATE
4. WASHER
5. CAPSCREW
6. RING SEAL
7. SHIM
8. FLANGE
9. SHIM
10. BUSHING
11. STUB SHAFT
14. GREASE FITTING
15. COTTER PIN
16. HUB CAP
17. CASTLE NUT
18. WASHER
19. HUB
24. WEAR RING
25. OIL SEAL
26. SPINDLE
27. 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

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 pur-
poses, or for clearing restrictions. Wear protective
clothing (goggles/shield, gloves, etc.) to avoid in-
jury to personnel.
1. Clean bearings by placing them in a wire basket
and immersing in a container of fresh solvent. Agi-
tate 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 pro-
tect them from dust and other foreign matter.
INSPECT
1. Inspect for loose, burned, missing, cracked or dam-
aged 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 re-
paired, 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
GC/GLC055SVX) (A910
(B875)
models
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)
models
090, 100, 110, 120VX) (H813)
models
090, 100, 110, 120VX) (J813)
models
GDC135VX, GC/GLC/GDC155VX) (C879, D879)
models
• GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
GDC135VX, GC/GLC/GDC155VX) (E879)
models
GDC135VX, GC/GLC/GDC155VX) (F879)
models
GDP135VX, GP/GLP/GDP155VX) (C878, D878)
model
• GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX
(GLP/GDP170VX, GLP/GDP170VX36, GLP/
GDP190VX) (A909)
model
(B909)
model
GDP135VX, GP/GLP/GDP155VX) (E878)
12

model
GC/GLC120VXPRS) (F818)
1. If necessary, use a press to install new bearing cups
in wheel or hub.
(B875)
100, 120VX; GC/GLC080, 100VXBCS;
F818)
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
E879, F879)
E878)
B909)
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.
CAUTION
DO NOT damage the seals during installation.
2. Carefully slide wheel onto spindle. Install outer
bearing cone and install washer.
1. WASHER
2. COTTER PIN
3. HUB CAP
4. CASTLE NUT
5. OUTER BEARING CUP AND CONE
6. INNER BEARING CUP AND CONE
7. WEAR RING
8. OIL SEAL
Figure 9. Bearing Arrangement for Lift Truck
Models GLC20-35VX (GC/GLC040-070VX,
13

1. SPINDLE
2. HUB CAP
3. COTTER PIN
4. CASTLE NUT
5. BEARING CONE
6. BEARING CUP
7. BEARING CONE
8. BEARING CUP
9. OIL SEAL
10. WEAR RING
Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875)
1. HUB
2. OIL SEAL
3. BEARING
4. BEARING
5. WASHER
6. CASTLE NUT
7. COTTER PIN
8. HUB CAP
Models GC/GLC030-035VX, GC/GLC040SVX (C809)
14

1. BEARING
2. BEARING
3. CASTLE NUT
4. COTTER PIN
5. WASHER
6. HUB CAP
7. OIL SEAL
Models GLP/GDP16-18VX, GLP/GDP20SVX
(GP/GLP/GDP030-035VX, GP/GLP/GDP040SVX)
(C810)
1. WEAR RING
6. HUB CAP
7. COTTER PIN
8. CASTLE NUT
9. WASHER
10. 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

NOTE: RIGHT SIDE IS SHOWN
1. OIL SLEEVE
3. HUB
5. CASTLE NUT
6. COTTER PIN
7. HUB CAP
8. WASHER
Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GDP080, 090, 100, 110, 120VX) (F813, G813, H813,
J813)
3. WASHER
4. HUB CAP
5. COTTER PIN
6. CASTLE NUT
9. WEAR RING
10. OIL SEAL
Truck Models GLC/GDC60VX, GLC/GDC70VX,
(GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879,
D879, E879, F879)
16

NOTE: RIGHT SIDE IS SHOWN
1. HUB ASSEMBLY
2. HUB CAP
3. COTTER PIN
4. CASTLE NUT
5. WASHER
8. SEAL
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)
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.
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 di-
rections 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 di-
end play. Tighten nut to 12 N•m (106 lbf in).
17

e. GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
100, 120VX; GC/GLC080, 100VXBCS;
F818) - Tighten the castle nut to 203 N•m
(150 lbf ft) while rotating the wheel in both di-
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/
D878, E878) - Tighten castle nut to 203 N•m
(150 lbf ft) while rotating the wheel in both di-
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,
(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/
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 can-
not be installed, tighten castle nut to the first align-
ment position where the cotter pin can be installed.
5. Install hub cap.
6. Repeat Step 1 through Step 5 for other wheel.
NOTE: Apply multipurpose grease to stub shaft prior to
installing.
7. Install stub shaft, bushing, shims, flange, and rig
seal to steering axle assembly.
E878)
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.
(B875)
100, 120VX; GC/GLC080, 100VXBCS;
F818)
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
E879, F879)
2. Apply lubricant that is approved for use with rubber
to rubber mount. The lubricant is used to ease as-
sembly of the mount into frame and brackets.
18

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.
NOTE: Steering axle assembly may be attached to
frame with brackets or plates.
a. Install bottom brackets.
• GLP/GDP20-35VX (GP/GLP/GDP040-
070VX) (B875)
• GLC40, 45, 55VX; GLC55SVX;
(GC/GLC080, 100, 120VX; GC/GLC080,
100VXBCS; GC/GLC120SVX;
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813)
b. Install mount plates.
• GC/GLC030-035VX, GC/GLC040SVX
(C809)
• GLP/GDP16-18VX, GLP/GDP20SVX
(GP/GLP/GDP030-035VX, GP/GLP/
GDP040SVX) (C810)
D879, E879, F879)
D878, E878)
(A909, B909)
4. Proceed as follows for your lift truck:
GC/GLC055SVX) (A910) - tighten four
bracket bolts and nuts to 90 N•m (66.4 lbf ft).
b. GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875) - tighten four bracket bolts and nuts to
88 N•m (65 lbf ft).
c. GC/GLC030-035VX, GC/GLC040SVX (C809)
- tighten four flange bolts to 41 to 49 N•m (30
to 36 lbf ft).
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).
e. GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
100, 120VX; GC/GLC080, 100VXBCS;
F818) - tighten four flange bolts to 215 N•m
(159 lbf ft).
f. GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
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/
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/
D878, E878) - apply thread lock and wash-
ers and tighten four capscrews to 270 N•m
(199 lbf ft).
i. GLP/GDP80VX, GLP/GDP80VX9,
(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 sys-
tem. 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,
(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
(C878, D878, E878), GLP/GDP80VX,
GLP/GDP80VX9, GLP/GDP90VX
(GLP/GDP170VX, GLP/GDP170VX36,
GLP/GDP190VX) (A909, B909)
Remove
WARNING
fall backward.
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.
100, 120VX; GC/GLC080, 100VXBCS;
F818)
20

1600 YRM 1133 Spindles, Bearings, and Tie Rods Repair
1. CLAMP
2. DUST COVER
3. CLAMP
4. SNAP RING
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;
21

4. Remove two snap rings from the pin holding the tie
rod to steering cylinder rod and remove pin.
100, 120VX; GC/GLC080, 100VXBCS;
F818)
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
E879, F879)
E878)
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 cot-
ter pin. Use a puller to remove the tie rod end from
the spindle arm.
100, 120VX; GC/GLC080, 100VXBCS;
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
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
See Figure 22 or Figure 27 for lift truck models
E879, F879)
E878)
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 Fig-
ure 18, for the following lift truck models:
100, 120VX; GC/GLC080, 100VXBCS;
F818)
E879, F879)
D878, E878) and GLP/GDP80VX, GLP/
GDP80VX9, GLP/GDP90VX (GLP/GDP170VX,
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.
22

Clean
WARNING
WARNING
Compressed air is used for cleaning or drying pur-
poses, or for clearing restrictions. Wear protective
clothing (goggles/shield, gloves, etc.) to avoid in-
jury to personnel.
1. Clean bearings by placing them in a wire basket
and immersing in a container of fresh solvent. Agi-
tate 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 pro-
tect them from dust and other foreign matter.
Inspect
1. Inspect for loose, missing, cracked, burned or dam-
aged 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 neces-
sary, 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.
100, 120VX; GC/GLC080, 100VXBCS;
F818)
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
E879, F879)
E878)
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 Loc-
tite® 242 to threads of capscrews. Install the bear-
ing cap and capscrews.
GC/GLC055SVX) (A910) - tighten cap-
screws to 44 N•m (32 lbf ft).
b. GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
100, 120VX; GC/GLC080, 100VXBCS;
F818) - tighten the capscrews to 52 N•m
(38 lbf ft).
c. GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/
D879, E879, F879) - tighten the capscrews to
52 N•m (38 lbf ft).
23

1. PRY BAR
2. BEARING CUP
3. BEARING CAP
4. O-RING
Figure 18. Bearing Cup Removal
d. GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
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/
D878, E878) - tighten capscrews to 47 N•m
(35 lbf ft).
f. GLP/GDP80VX, GLP/GDP80VX9,
(A909, B909) - tighten capscrews to 47 N•m
(35 lbf ft).
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
If removed, tighten the castle nut to 175 N•m
(129 lbf ft) for lift truck models
100, 120VX; GC/GLC080, 100VXBCS;
F818)
2. Tighten the castle nut until the new cotter pin can
be installed.
3. Install tie rod end to spindle arm and steering cylin-
der with pins, seals and snap rings.
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
E879, F879)
E878)
B909)
4. Install the grease cap on the top of the steering axle.
5. Install the bearings and wheel. See section Steer-
ing Axle Assembly Repair, Assemble.
7. Remove the lift truck from blocks.
24

NOTE: THE LUBRICATION FITTING NEEDS TO BE
ORIENTED TOWARDS THE CENTERLINE OF THE
LIFT TRUCK.
1. GREASE CAP
2. BEARING ASSEMBLY
3. WEAR SLEEVE
4. SEAL
5. SPINDLE
6. OIL SEAL
7. BEARING CONE
8. BEARING CUP
9. WASHER
10. CASTLE NUT
11. COTTER PIN
12. HUB CAP
13. O-RING
14. SHIMS (AS REQUIRED)
15. CAPSCREW AND LOCKWASHER ASSEMBLY
17. BEARING CAP
18. TIE ROD
19. CASTLE NUT
20. COTTER PIN
Figure 19. Spindle Assembly for Lift Truck Models
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX)
(A910)
ORIENTED 45° TO CENTERLINE AND REAR OF LIFT
TRUCK.
1. HUB CAP
2. WASHER
7. WEAR SLEEVE
8. OIL SEAL
9. CAPSCREW
10. LUBE FITTING
11. CAP ASSEMBLY
12. SHIM
13. BEARING CUP
14. BEARING CONE
15. SEAL
16. O-RING
17. CAP
18. CASTLE NUT
19. COTTER PIN
20. TIE ROD
GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100,
25

NOTE: LEFT SIDE SPINDLE ASSEMBLY SHOWN
1. HUB CAP
2. CASTLE NUT
3. COTTER PIN
4. WASHER
5. BEARING CONE
6. BEARING CUP
7. HUB
8. WEAR SLEEVE
9. OIL SEAL
10. SPINDLE
11. LUBE FITTING
12. CAP
13. TIE ROD
14. SEAL
15. O-RING
16. SHIM
17. CAP ASSEMBLY
18. LOCKWASHER
19. CAPSCREW
GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
090, 100, 110, 120VX) (F813, G813, H813, J813)
TRUCK.
1. PLUG
2. BEARING CONE (UPPER)
3. BEARING CUP (UPPER)
4. WEAR SLEEVE
5. OIL SEAL
6. PIN
7. SNAP RING
8. SPHERICAL BEARING
9. TIE ROD
10. BEARING CONE (LOWER)
11. O-RING
12. BEARING CUP (LOWER)
13. SHIM
14. BEARING CAP
15. CAPSCREW
16. LUBE FITTING
17. HUB CAP
18. CASTLE NUT
19. COTTER PIN
20. WASHER
22. BEARING CUP (OUTER
Figure 22. Spindle Assembly for Lift Truck
Models GLC/GDC60VX, GLC/GDC70VX,
(GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879,
D879, E879, F879)
26

TRUCK.
1. SNAP RING
2. PIN
3. SEAL
4. TIE ROD
5. SEAL
6. BEARING CONE (LOWER)
7. O-RING
8. BEARING CUP (LOWER)
9. SEAL
10. SHIM
11. BEARING CAP
12. CAPSCREW
13. LUBE FITTING
14. OIL SEAL
15. WEAR SLEEVE
20. HUB
21. COTTER PIN
22. WASHER
23. CASTLE NUT
24. HUB CAP
25. SEAL
26. WEAR SLEEVE
27. BEARING CUP (UPPER)
28. BEARING CONE (UPPER)
29. PLUG
Figure 23. Spindle Assembly for Lift Truck
Models GLP/GDP60VX, GLP/GDP70VX
(C878, D878, E878) and GLP/GDP80VX,
GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX,
GLP/GDP170VX36, GLP/GDP190VX) (A909, B909)
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
fall backward.
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 fol-
lows:
a. Remove and discard cotter pin from castle nut
and remove castle nut from kingpin. See Fig-
ure 24.
b. Remove the oil seal, sleeve, and bearing cone.
27

NOTE: If the bearing cone is being replaced, the bear-
ing cup must be replaced.
c. If necessary, remove the bearing cup.
5. Disassemble the top half of the spindle as follows:
a. Remove pin and O-ring from kingpin.
b. Remove spacer, seal, and bearing cone.
NOTE: If the bearing cone is being replaced, the bear-
ing 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 Fig-
ure 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. In-
stall 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 Re-
pair, Assemble.
6. Repeat the procedure for the other spindle and tie
rod.
TIE RODS
GC/GLC055SVX) (A910), and GLC40,
45, 55VX; GLC55SVX; (GC/GLC080,
100, 120VX; GC/GLC080, 100VXBCS;
GC/GLC120SVX; GC/GLC120VXPRS)
(E818, F818)
Remove
WARNING
fall backward.
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 cot-
ter 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.
100, 120VX; GC/GLC080, 100VXBCS;
F818)
28

1. PIN
2. O-RING
3. SPACER
4. SEAL
5. BEARING CONE
6. BEARING CUP
7. SLEEVE
8. OIL SEAL
9. CASTLE NUT
10. COTTER PIN
11. HUB CAP
12. WASHER
13. BEARING (OUTER)
14. BEARING (INNER)
15. OIL SEAL
16. SPINDLE
17. KINGPIN
18. SNAP RING
19. WASHER
20. TIE ROD
21. PIN
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)
4. Loosen the clamps on the dust cover and slide the
dust cover off the steering cylinder rod. See Fig-
ure 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.
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;
F818) - tighten castle nut to 175 N•m (129 lbf ft)
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 Steer-
ing Axle Assembly Repair, Assemble.
29

10. Repeat the procedure for the other tie rod.
TIE RODS
GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875),
GC/GLC030-035VX, GC/GLC040SVX
(C809), GLP/GDP16-18VX,
GLP/GDP20SVX (GP/GLP/GDP030-035VX,
GP/GLP/GDP040SVX) (C810),
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813), GLC/GDC60VX,
GC/GLC/GDC155VX) (C879, D879, E879,
F879), GLP/GDP60VX, GLP/GDP70VX
(C878, D878, E878), and GLP/GDP80VX,
GLP/GDP80VX9, GLP/GDP90VX
GLP/GDP190VX) (A909, B909)
Remove
WARNING
fall backward.
30

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.
• GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809)
• GLP/GDP16VX, GLP/GDP18VX,
GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810)
(B875)
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
E879, F879)
E878)
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 hous-
ing and steering cylinder rod.
31

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
3. WASHERS
4. TIE ROD
5. PIN
6. SPINDLE
32

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

2. SNAP RING
3. SEAL
4. TIE ROD ASSEMBLY
5. PIN
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

1. SNAP RING
2. PIN
4. SEAL
5. TIE ROD ASSEMBLY
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 spin-
dle and steering cylinder rod.
• GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809)
• GLP/GDP16VX, GLP/GDP18VX,
GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810)
(B875)
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
E879, F879)
E878)
B909)
2. Align holes and place lubricated pin into the spindle
and tie rod. Install the two snap rings on top and
bottom of pin.
3. Align holes and place lubricated pin into the steer-
ing cylinder rod and tie rod. Install the two snap
rings on top and bottom of pin.
4. If removed, install the bearings and install the
wheel. See Steering Axle Assembly Repair, As-
semble.
5. Repeat the procedure for the other tie rod.
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 cylin-
der. See Figure 28. Install caps in fittings on cylin-
der and put fittings on hydraulic lines.
2. Remove the tie rods. See Spindles, Bearings, and
Tie Rods Repair, Tie Rods.
3. Remove capscrews that fasten cylinder to axle
frame. Hold end caps on shell and remove steer-
ing cylinder.
4. Hold end of steering cylinder over a container. Re-
move 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.
36

1600 YRM 1133 Steering Cylinder Repair
6. Remove piston seal. If present, remove two guide
rings.
CLEAN AND INSPECT
WARNING
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
4. Inspect mounts for cracks.
ASSEMBLE AND INSTALL
CAUTION
Do not damage the O-rings, seals, or wipers during
installation.
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.
2. Lubricate O-rings, seals, and wipers with O-ring lu-
bricant 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 dam-
aged. 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.
6. Remove plugs and caps and connect hydraulic
lines as tagged during removal, to steering cylin-
der. 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.
1. ROD
2. WIPER
3. END CAP
4. O-RING
5. BACKUP RING
6. SHELL
7. PISTON SEAL
8. ROD SEAL
9. O-RING
10. HYDRAULIC LINE PORT
11. GUIDE RING
Figure 28. Steering Cylinder
37

Torque Specifications 1600 YRM 1133
Torque Specifications
Axle Mounting Bolts and Nuts
90 N•m (66.4 lbf ft)
GLP/GDP20-35VX (GP/GLP/GDP040-
070VX) (B875)
88 N•m (65 lbf ft)
GC/GLC030-035VX, GC/GLC040SVX (C809) and
GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/
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)
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813) 90 N•m (66.4 lbf ft)
GLP/GDP40VX5/VX6; GLC/GDC60VX,
GC/GLC/GDC155VX) (C879, D879, E879, F879)
250 to 275 N•m (184 to 203 lbf ft)
GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
E878) 270 N•m (199 lbf ft)
GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX
GLP/GDP190VX) (A909, B909) 270 N•m (199 lbf ft)
Hub Nut (Initial)
68 N•m (50 lbf ft)
(C809), and GLP/GDP16-18VX, GLP/
GDP20SVX (GP/GLP/GDP030-035VX,
200 N•m (147.5 lbf ft)
100, 120VX; GC/GLC080, 100VXBCS;
F818) 203 N•m (150 lbf ft)
(GP/GLP/GDP080, 090, 100, 110, 120VX) (F813,
G813, H813, J813) 200 to 220 N•m (148 to 162 lbf ft)
GC/GLC/GDC155VX) (C879, D879, E879,
F879) 203 N•m (150 lbf ft)
E878) 203 N•m (150 lbf ft)
Hub Nut (Final)
3 N•m (27 lbf in)
GLP/GDP20-35VX (GP/GLP/GDP040-
070VX) (B875)
15 N•m (133 lbf ft)
GC/GLC030-035VX, GC/GLC040SVX (C809) and
GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/
12 N•m (106 lbf in)
38

1600 YRM 1133 Torque Specifications
GC/GLC120VXPRS) (E818, F818) 34 N•m (25 lbf ft)
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813) 35 N•m (26 lbf ft)
GC/GLC/GDC155VX) (C879, D879, E879,
F879) 35 N•m (26 lbf ft)
D878, E878) 34 N•m (25 lbf ft)
GLP/GDP190VX) (A909, b909) 34 N•m (25 lbf ft)
King Pin Lock Nut (Initial)
90 N•m (66.4 lbf ft)
King Pin Lock Nut (Final)
34 N•m (25 lbf ft)
Spindle Bearing Cap Capscrews
44 N•m (32 lbf ft)
GC/GLC120VXPRS) (E818, F818) 52 N•m (38 lbf ft)
(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/
E879, F879) 52 N•m (38 lbf ft)
D878, E878) 47 N•m (35 lbf ft)
Tie Rod Nut
163 N•m (120 lbf ft)
100, 120VX; GC/GLC080, 100VXBCS;
F818) 175 N•m (129 lbf ft)
Steer Cylinder Mounting Bolts
GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/
D879, E879, F879)
225 N•m (166 lbf ft)
E878) 225 N•m (166 lbf ft)
39

NOTES
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
40

General
DRY BRAKE SYSTEM
NOTE: The dry brake system is used only on lift truck
models
GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080,
090, 100, 110, 120VX) (F813, G813, H813)
This section has service procedures for the dry brake
system. The dry brake system includes the following
parts: master cylinder and parking brake system (see
Figure 1) and brake shoes and wheel cylinders (see
Figure 6).
WET BRAKE SYSTEM
NOTE: The wet brake system is used on all lift truck
models covered in this YRM.
The wet brake system in this section includes the follow-
ing parts: master cylinder and parking brake system.
E879, F879)
E878)
GDP190VX) (A909, B909)
090, 100, 110, 120VX ) (F813, G813, H813)
The wet disc brakes are a component of the wet brake
drive axle. The brake discs are located inside the plan-
etary carrier housing at each end of the drive axle. For
the removal, assembly and installation procedures see:
1. PARK BRAKE HANDLE ASSEMBLY
2. ADJUSTMENT KNOB
3. PARK BRAKE CABLES
4. INCHING/BRAKE PEDAL
5. MASTER CYLINDER AND BOOSTER
6. BRAKE ASSEMBLY
7. BRAKE POSITION SENSOR (RIGHT-HAND
SIDE)
Figure 1. Dry Brake System
Drive Axle and Differential Assembly Repair, (Wet
Brake) 1400 YRM 1246 for lift truck models
090, 100, 110, 120VX) (F813, G813, H813)
1

General 1800 YRM 1247
2. INCH/BRAKE PEDAL
3. BOOSTER ASSEMBLY
4. PARK BRAKE LEVERS
5. PLANETARY CARRIER HOUSING (LEFT-HAND
SIDE SHOWN)
6. WET DISC BRAKE HOUSING
8. ADJUSTMENT KNOB
9. BRAKE POSITION SENSOR (LEFT-HAND SIDE
SHOWN)
10. MASTER CYLINDER
11. CYLINDER BLOCK
Figure 2. Wet Brake System for Lift Truck Models
E879, F879)
E878)
GDP190VX) (A909, B909)
NOTE: LIFT TRUCK MODEL GLC/GDC60VX,
GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/
GDC155VX) (C879, D879, E879, F879) SHOWN.
2. INCH/BRAKE PEDAL
3. BOOSTER ASSEMBLY
4. ADJUSTMENT KNOB
SIDE SHOWN)
8. BRAKE POSITION SENSOR
9. MASTER CYLINDER
10. CYLINDER BLOCK
Figure 3. Wet Brake System for Lift Truck
Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
E879, F879) and GLP/GDP60VX, GLP/GDP70VX
(GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878,
D878, E878)
2

2. INCH/BRAKE PEDAL
3. ADJUSTMENT KNOB
5. PARK BRAKE CABLE
6. PARK BRAKE LEVER
7. CHARGE VALVE
8. ACCUMULATOR
9. MODULATING BRAKE VALVE
10. DRIVE AXLE ASSEMBLY
Figure 4. Wet Brake System for Lift Truck Model
GLP/GDP190VX) (A909. B909)
2. INCH/BRAKE PEDAL
3. BOOSTER ASSEMBLY
SIDE SHOWN)
8. ADJUSTMENT KNOB
9. BRAKE POSITION SENSOR (LEFT-HAND SIDE
SHOWN)
10. MASTER CYLINDER
Figure 5. Wet Brake System for Lift Truck Model
090, 100, 110, 120VX) (F813, G813, H813)
3

Service Brakes Repair (Dry Brake) 1800 YRM 1247
Service Brakes Repair (Dry Brake)
NOTE: The procedures in this section apply only to lift
truck models
090, 100, 110, 120VX) (F813, G813, H813)
equipped with the dry brake system.
WARNING
Brake linings can contain dangerous fibers.
Breathing the dust from these brake linings is
a cancer or lung disease hazard. DO NOT create
dust! DO NOT clean brake parts with compressed
air or by brushing. Use vacuum equipment ap-
proved for brake dust or follow the cleaning pro-
cedure in this section. When the brake drums are
removed, DO NOT create dust.
DO NOT sand, grind, chisel, hammer, or change lin-
ings in any way that will create dust. Any changes
to brake linings must be done in a restricted area
with special ventilation. Protective clothing and a
respirator must be used.
1. See the procedure How to Put Lift Truck on
Blocks in the Operating Manual or Periodic
Maintenance section for your lift truck. Start the
engine and tilt the mast fully backward. Put blocks
under the mast. Tilt the mast forward until the
wheels just touch the floor. Stop the engine. Put
blocks under the frame of the lift truck.
2. Remove the capscrews that hold the axle shaft to
the hub. Remove the axle shaft.
3. Bend the lock plate tab and remove the nut, lock-
plate, washer and bearing cone.
4. Pull the wheel assembly from the lift truck. If the
wheel assembly cannot be removed easily, use
a small screwdriver to push the adjuster actuator
away from the adjuster wheel. Use a brake ad-
justment tool or a screwdriver to turn the adjuster
wheel to loosen the brake shoes. Remove the hub
and drum assembly. Do not damage the grease
seal when removing the hub.
NOTE: During disassembly, note the arrangement of
parts to aid in re-assemble of the brake system.
5. Remove the primary, secondary return springs and
tension spring with spring pliers and remove the an-
chor pin from the primary brake shoe. See Figure 6.
6. Remove the pressure springs that hold the brake
shoes to the backing plate.
7. Disconnect the parking brake cable from park brake
lever. See Figure 6.
WARNING
When the brake shoes are removed, DO NOT create
dust in the air. See the Clean procedure in this sec-
tion.
8. Remove brake shoes.
9. Remove the auto adjuster assembly from the back-
ing plate. See Figure 7.
10. Disconnect the brake line from the wheel cylinder.
Remove wheel cylinder from backing plate. See
Figure 7.
11. If damaged, remove the backing plate from the axle
housing. Discard the eight mounting lock bolts.
4

1800 YRM 1247 Service Brakes Repair (Dry Brake)
1. RETAINER
2. SECONDARY RETURN SPRING
3. SECONDARY BRAKE SHOE
4. PRESSURE SPRING
5. AUTO ADJUSTER LINK
6. ADJUSTER WHEEL
7. AUTO ADJUSTMENT ASSEMBLY
8. PARKING BRAKE CABLE
9. TENSION SPRING
10. PRIMARY BRAKE SHOE
11. PARK BRAKE LEVER
12. STRUT
13. PRIMARY RETURN SPRING
14. ANCHOR PIN
15. BACKING PLATE
16. WHEEL CYLINDER
Figure 6. Brake Assembly (Left-Hand Shown)
5

1. WHEEL CYLINDER CAPSCREWS
2. AUTO ADJUSTER CAPSCREW
3. ADJUSTER WHEEL ACCESS PLUGS
4. BRAKE LINE
Figure 7. Auto Adjuster and Wheel Cylinder Mount
Location
CLEAN
WARNING
DO NOT use an oil solvent to clean the brake lin-
ings, use a solvent approved for cleaning of brake
parts. Do not permit oil or grease on the brake
linings, the brakes will not operate correctly if oil,
grease, or brake cleaning fluid is on the brake lin-
ings. Oil and grease will cause damage and leaks
in the seals of a brake system.
Small amounts of water in the brake system can
cause reduced braking if the water reaches the
wheel cylinders and is subject to high tempera-
tures. DO NOT allow water entry into the brake
system. If water is present, remove all water and
refill the system with Dexron III from a sealed con-
tainer. Unfiltered shop air can contain substantial
amounts of water. DO NOT use unfiltered shop air
to blow out brake components.
can cause skin irritation. When using cleaning sol-
vents, always follow the safety instructions of the
solvent manufacturer.
CAUTION
DO NOT permit brake cleaning fluid to contact the
master cylinder or wheel cylinder. Brake cleaning
fluid will cause damage and leaks in seals of the
brake system.
1. DO NOT release brake lining dust from the brake
linings into the air when the brake drum is removed.
CAUTION
DO NOT permit oil or grease on the brake linings.
Use a brake cleaning fluid as necessary to clean
linings that will not be replaced.
2. Use a solvent approved for cleaning of brake parts
to wet the brake lining dust. Follow the instructions
and cautions of the manufacturer for the use of the
solvent. If a solvent spray is used, spray at a dis-
tance so that the dust is not released into the air.
3. When the brake lining dust is wet, clean the parts.
Put any cloth or towels in a plastic bag or an airtight
container while they are still wet. Put a DANGER-
OUS FIBERS warning label on the plastic bag or
airtight container.
4. Any cleaning cloths that will be washed must be
cleaned so that fibers are not released into the air.
6

INSPECT
WARNING
Small amounts of water in the brake system can
cause reduced braking if the water reaches the
wheel cylinders and is subject to high tempera-
tures. DO NOT allow water entry into the brake
system. If water is present, remove all water and
refill the system with Dexron III from a sealed con-
tainer. Unfiltered shop air can contain substantial
amounts of water. DO NOT use unfiltered shop air
to blow out brake components.
can cause skin irritation. When using cleaning sol-
vents, always follow the safety instructions of the
solvent manufacturer.
CAUTION
DO NOT permit brake cleaning fluid to contact the
master cylinder or wheel cylinder. Brake cleaning
fluid will cause damage and leaks in seals of the
brake system.
1. Inspect the bore of the wheel cylinder for holes or
scratches. Replace the wheel cylinder assembly if
there is any damage.
2. Inspect wheel cylinder parts for dirt or water. Clean
any dirt or water present in the wheel cylinder parts
using a lint free cloth.
3. Inspect the primary, secondary and tension springs
for wear and damage. Inspect the back plate for
wear where the brake shoes touch the back plate.
Remove any grooves or replace a worn or damaged
back plate.
4. Inspect the park brake lever and strut. If damaged,
replace primary and secondary brake shoe assem-
bly.
WARNING
The brake shoes on both wheels must be replaced
if any shoe is damaged. The brake performance on
both ends of an axle must be equal, or the lift truck
can be difficult to steer when the brakes are applied.
5. Inspect the brake shoes for cracks or damage. If
the linings or shoes are worn or damaged, replace
the brake shoes. Maximum wear is to within 1 mm
(0.039 in.) of contact with the rivets, or the metal
shoe on bonded linings. Brake shoes must be re-
placed in complete sets. Inspect the brake drums
for cracks or damage. Replace any damaged parts.
6. Inspect the brake drum for deep grooves or other
damage.
NOTE: If grooves must be removed from the brake
drums, do not grind more than 1.5 mm (0.060 in.) from
the internal diameter of the brake drum. The maxi-
mum limit of the internal diameter of the brake drum is
319.5 mm (12.6 in.). If the internal diameter is larger
than the limit, replace the brake drum.
7. The teeth of the adjuster wheels must not be worn.
The adjuster wheel must turn freely. Check the ad-
juster links for damage. Replace the auto adjuster
assembly if there is any damage. See Figure 6 and
Figure 7.
8. Make sure the parking brake cables are in good
condition. Replace parking brake cables if worn or
damaged.
9. Check the grease seals and the surfaces of the
seals for wear or damage. Replace damaged seals.
ASSEMBLE AND INSTALL
1. If removed, install backing plate using eight new
lock bolts to the axle housing using tightening se-
quence. Tighten bolts to 340 to 375 N•m (251 to
277 lbf ft). See Figure 8.
7

Figure 8. Backing Plate to Axle Housing Tightening
sequence
NOTE: Replace wheel cylinder if there is any damage
or it is not working properly.
2. Install the wheel cylinder on the backing plate and
tighten capscrews to 20 to 25 N•m (15 to 19 lbf ft).
Connect the brake line to the wheel cylinder. See
Figure 7.
NOTE: Replace auto adjuster assembly if there is any
damage or it is not working properly.
3. Install the auto adjuster assembly on the backing
plate between the two brake shoes and tighten cap-
screw to 120 to 140 N•m (89 to 103 lbf ft). See Fig-
ure 6 and Figure 7.
4. Lubricate the backing plate with small amount of
lithium grease where the brake shoes touch.
NOTE: The park brake lever and strut are a component
of the primary brake shoe. If damaged, replace primary
and secondary brake shoe assembly.
5. Install the primary and secondary brake shoes on
the push rod of wheel cylinder and auto adjuster
link. See Figure 6.
6. Connect the parking brake cable to park brake
lever.
7. Install pressure springs to hold the brake shoes to
the backing plate.
8. Install the primary and secondary return springs,
and tension spring to the brake shoe. See Figure 6.
9. Coat threads of the adjuster wheels with antiseize
compound. Turn the adjuster wheels so that the
adjuster assembly is in its shortest position. This
action permits the brake drum to be easily installed
over the brake shoes.
NOTE: Seal and bearings are to be installed flush with
the hub. Seal is to be installed with no grease or oil on
outside surface.
10. Clean the bearings and lubricate them with wheel
bearing grease. Install the bearings and seals in
the wheel hub. Install the assembly on the axle
housing. See Figure 9 and Figure 10.
NOTE: To prevent damage to the inner oil seal when
installing the hub, the hub and drum assembly can be
temporarily fastened to the wheel.
11. Align the height of the axle housing with hub bear-
ings. Install the outer bearing and nut.
12. Install the washer, lock plate and wheel adjustment
nut. See Figure 11.
a. To align the bearing rollers, tighten the wheel
adjustment nut to 28 to 32 N•m (21 to 24 lbf ft)
and rotate the hub 2 revolutions in both direc-
tions.
b. To seat the wheel bearings, tighten the wheel
adjustment nut to 400 to 480 N•m (295 to
354 lbf ft). Back off the wheel adjustment nut
to zero end play.
c. Preload the wheel bearings by tightening the
wheel adjustment nut to 28 to 32 N•m (21 to
24 lbf ft).
8

1. INNER SEAL
2. OUTER SEAL
3. BRAKE DRUM
4. INNER BEARING
5. OUTER BEARING
Figure 9. Grease Seals and Bearing Locations
9

Figure 10. Inner Grease Seal Installation
1. AXLE SHAFT
2. WHEEL ADJUSTMENT NUT
3. LOCK PLATE
4. WASHER
5. HUB
Figure 11. Wheel Adjustment
d. Rotate the hub 3 complete revolutions in both
directions. Verify the wheel adjustment nut
torque is 28 to 32 N•m (21 to 24 lbf ft) and that
the torque stabilizes at that specification.
CAUTION
If there is too much clearance, the automatic ad-
justers will not operate. If the clearance is too
small, the automatic adjuster cannot turn the ad-
juster wheel to increase the clearance, and the
adjuster wheel will not turn until the brake shoes
wear. If the adjuster wheel does not move for a
long operating period, the adjuster link can wear a
spot on the adjuster wheel so that it will not turn
correctly.
1. ADJUSTER LEVER
2. ADJUSTER WHEEL
3. ADJUSTER LINK
Figure 12. Auto Adjuster Assembly
NOTE: If the brake shoes were not replaced, loosen the
two adjuster wheels equally, approximately 20 teeth.
13. To manually adjust the brakes, it is necessary to
turn the adjuster wheels. See Figure 6.
a. Remove the two access plugs in the adjustment
slots located on the back side of the backing
plate. Place an adjuster tool and screwdriver
through the slot in the backing plate. See Fig-
ure 7.
b. Push the adjuster lever away from the adjuster
wheel, in the direction indicated in Figure 12
and turn the adjuster wheel until the brake shoe
just touches the brake drum.
c. Use the adjuster tool to loosen the adjuster
wheel approximately 20 teeth. Adjust the brake
shoe for the other adjuster wheel using the
same method. See Figure 12.
d. Install the access plugs after the adjustment is
complete. See Figure 7.
14. Install the drive wheels. Remove the lift truck from
the blocks.
15. Operate the lift truck in the FORWARD and RE-
VERSE directions. Stop the lift truck 10 times in
each direction. This procedure causes the brake
shoes to wear a small amount and fit the brake
drum better.
10

1800 YRM 1247 Parking Brake Repair
Figure 13. Axle Shaft Tightening Sequence
16. Coat the flange of the axle shaft with liquid sealant,
Yale Part Number 520042831. Install the axle shaft
and capscrews. Tighten the capscrews in the se-
quence shown in Figure 13 to 90 to 99 N•m (66 to
73 lbf ft).
ADJUST
1. Remove the air from the brake hydraulic system.
See Brake System Air Removal.
2. Install the wheel on the hub. Tighten the wheel nuts
to 610 to 680 N•m (450 to 502 lbf ft).
3. Start the engine and tilt the mast backward to re-
move the blocks. Push on the brake pedal. The
pedal must not touch the floor plate. Move the lift
truck in REVERSE and push on the brake pedal
to permit adjusting mechanism to operate. Repeat
this operation several times.
4. The service brakes must be adjusted before the
parking brake can be adjusted. See Figure 15 and
the following paragraphs in this section for the cor-
rect adjustment of the parking brake.
Parking Brake Repair
NOTE: For removal and disassembly procedures for a
dry brake system use Step 1 through Step 5. For the
wet brake system use Step 1 through Step 4 and Step 6.
If the handle assembly for the parking brake must be
removed from the cowl, use the following procedures.
For dry brake system, see Figure 15.
For wet brake system, see
Figure 16 for lift truck models
090, 100, 110, 120VX ) (F813, G813, H813)
E879, F879)
E878)
GDP190VX) (A909, B909)
1. Block the front and rear side of the wheels to make
sure the lift truck cannot move. Release the parking
brake handle assembly.
2. Remove the four capscrews that fasten the bracket
for the parking brake to the cowl. Remove the
bracket and parking brake handle assembly.
11

Parking Brake Repair 1800 YRM 1247
3. Loosen the jam nuts that fasten the threaded ends
of the parking brake cables to the parking brake
handle assembly.
4. Turn the adjustment knob counterclockwise until
the parking brake cables are loosened. Disconnect
the cables from the equalizer links.
5. The service brake assembly must be removed be-
fore the parking brake cable can be removed from
the back plate of the service brake. A snap ring
holds the sheath of the parking brake cable in the
back plate of the service brake. Remove the snap
ring and remove the parking brake cable from the
back plate. See Figure 14.
6. The cotter pin, clevis pin, and cable clamps must
be removed from the parking brake levers before
the parking brake cables can be removed.
100, 120VX; GC/GLC080, 100VXBCS;
GC/GLC120SVX; GC/GLC120VXPRS) (E818)
GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX ) (F813, G813,
H813)
E879, F879)
E878)
B909)
1. PARKING BRAKE CABLE
2. SHEATH
3. SNAP RING
4. SERVICE BRAKE ASSEMBLY
5. BACK PLATE
Figure 14. Parking Brake Cable Removal for
Lift Truck Models GLC40, 45, 55VX; GLC55SVX;
(GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS;
GC/GLC120SVX; GC/GLC120VXPRS) (E818) and
090, 100, 110, 120VX) (F813, G813, H813) With Dry
Brake System
A. RIGHT HAND SIDE B. LEFT HAND SIDE
1. PARKING BRAKE HANDLE ASSEMBLY
2. ADJUSTMENT KNOB
3. PARKING BRAKE CABLES
6. BRAKE ASSEMBLY
8. ADJUSTMENT SLOT (UNDERNEATH SPRING)
9. EQUALIZER LINK
10. NUT
11. CAPSCREW
12. PARKING BRAKE BRACKET
13. JAM NUTS
14. PARKING BRAKE CABLE BRACKET
12

Figure 15. Parking Brake Lever Adjustment for Lift Truck Models GLC40, 45, 55VX; GLC55SVX;
(GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) and
GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100,
110, 120VX) (F813, G813, H813) With Dry Brake System
13

Figure 16. Parking Brake Lever Adjustment for Lift Truck Models GLC40, 45, 55VX; GLC55SVX;
(GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) and
GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100,
110, 120VX) (F813, G813, H813) With Wet Brake System
14

A. GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
(GP/GLP/GDP080, 090, 100, 110, 120VX) (F813,
G813, H813)
B. GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
100, 120VX; GC/GLC080, 100VXBCS;
GC/GLC120SVX; GC/GLC120VXPRS) (E818)
2. ADJUSTMENT KNOB
3. EQUALIZER LINKS
5. NUT
6. CAPSCREW
7. BRAKE POSITION SENSOR (RIGHT SIDE
SHOWN)
11. CLEVIS PIN
12. COTTER PIN
13. PARKING BRAKE LEVER
14. CABLE CLAMPS
15. PARKING BRAKE BRACKET
16. JAM NUTS
17. PARKING BRAKE CABLE BRACKET
15

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

A. GLP/GDP60VX, GLP/GDP70VX
(C878, D878, E878)
B. GLC/GDC60VX, GLC/GDC70VX,
(GC/GLC/GDC135VX, GC/GLC/GDC155VX)
(C879, D879, E879, F879)
2. ADJUSTMENT KNOB
3. EQUALIZER LINKS
5. NUT
6. CAPSCREW
11. CLEVIS PIN
12. COTTER PIN
13. PARKING BRAKE LEVER
14. CABLE CLAMPS/MOUNTING BRACKET
15. JAM NUTS
17

YALE E878 GLP60VX LIFT TRUCK Service Repair Manual

YALE E878 GLP60VX LIFT TRUCK Service Repair Manual

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YALE E878 GLP60VX LIFT TRUCK Service Repair Manual