Service Manual for GC/GLC080VX, 100VX & 120VX Lift Trucks

GC/GLC080VX & 080VX-BCS, GC/GLC100VX & 100VX-BCS, GC/GLC120VX
& SVX & PRS (F818)
SERVICE MANUAL CONTENTS
SECTION
PART
NUMBER
YRM
NUMBER
REV
DATE
FRAME............................................................................................................................ 524262274 0100 YRM 1243 05/14
GM 4.3L V-6 ENGINES................................................................................................... 524265337 0600 YRM 1251 05/14
COOLING SYSTEM........................................................................................................ 524223757 0700 YRM 1123 03/13
LPG FUEL SYSTEM GM 4.3L ENGINE WITH PSI........................................................ 550043871 0900 YRM 1556 04/14
GASOLINE FUEL SYSTEM............................................................................................ 550048401 0900 YRM 1570 09/13
1 AND 2 SP PS TRANSMISSION REPAIR.................................................................... 550048681 1300 YRM 1569 08/13
DRIVE AXLE AND DIFFERENTIAL ASSEMBLY REPAIR............................................ 524262278 1400 YRM 1246 12/13
DRIVE AXLE AND DIFFERENTIAL ASSEMBLY REPAIR............................................ 550055280 1400 YRM 1582 12/13
STEERING AXLE............................................................................................................ 524223764 1600 YRM 1133 07/13
WET BRAKES - NMHG.................................................................................................. 550064329 1800 YRM 1597 12/13
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 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).......................................................................................................................... 524223768 2100 YRM 1139 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
DIAGRAMS AND SCHEMATICS.................................................................................... 550055283 8000 YRM 1585 04/14
PERIODIC MAINTENANCE............................................................................................ 550064334 8000 YRM 1598 04/14
CAPACITIES AND SPECIFICATIONS........................................................................... 550064342 8000 YRM 1599 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. 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 con-
tained 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 re-
move 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 man-
ual:
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 back-
ground. The CAUTION symbol and word are on yellow background.

©2014 Yale Materials Handling Corp.
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
Table of Contents
i

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]
Table of Contents
ii

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)
the 24 cc/rev gear pump
• GLC050LX (A967)
• GLP20-25LX (GLP050LX) (A974)
the 25.7 cc/rev gear pump
• 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)
one of two different gear pumps: 41.3 cc/rev, or 51.6
cc/rev
100, 120VX; GC/GLC080, 100VXBCS; GC/
F818)
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
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
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)
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).
1900 YRM 1136 General
1

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.
Variable Displacement Pump Assembly
one of three different variable displacement pumps:
24 cc/rev, 26 cc/rev, or 28 cc/rev
• GLP/GDP20-35VX (B875)
one of two different variable displacement pumps: 42
cc/rev or 45 cc/rev
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 1600YRM1133 for lift truck
models
GLC040SVX (C809)
GLC055SVX) (A910)
(B875)
100, 120VX; GC/GLC080, 100VXBCS; GC/
F818)
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
D879, E879, F879)
D878, E878)
B909).
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
GLC040SVX (C809)
GDP20SVX, (G{/GLP/GDP030VX, GP/GLP/
GLC055SVX) (A910)
(B875)
• GLC050LX (A967)
100, 120VX; GC/GLC080, 100VXBCS; GC/
F818)
General 1900 YRM 1136
2

GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
D879, E879, F879)
D878, E878)
B909).
See Main Control Valve 2000YRM1457 for lift truck
models
• GLP/GDP20-35VX (B875)
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
GLC040SVX (C809)
GLC055SVX) (A910)
(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
100, 120VX; GC/GLC080, 100VXBCS; GC/
F818)
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
D879, E879, F879)
D878, E878)
See Mast Repair (S/N A513, A514, A613, A614,
A643, A644, A683, A684) 4000YRM1406 for lift truck
models
GDP175VX36, GLP/GDP190VX) (A909, B909)
See Mast Repair (S/N A698, A699, B551)
4000YRM1431 for lift truck models
• GLC050LX (A967)
3

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 com-
mon 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.
2. Place a drain pan under the hydraulic tank, re-
move drain plug at the bottom of hydraulic oil
tank, and drain oil from tank.
a. Drain pan capacity approximately 30 li-
ter (8 gal) for lift truck models
GLC040SVX (C809)
GDP20SVX, (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/
GDP040SVX) (C810)
GLC055SVX) (A910)
• GLC050LX (A967)
• GLP/GDP20-35VX (GP/GLP/
GDP040-070VX) (B875)
• GLP/GDP20-25LX (GLP/GDP050LX)
(A974)
NOTE: For lift trucks equipped with dual hudraulic
tanks, place a second drain pan with same capacity
under opposite hydraulic tank.
Single Gear Pump Assembly Repair 1900 YRM 1136
4

b. Drain pan capacity approximately 40 li-
ter (11 gal) for lift truck model
• GLC40, 45, 55VX; GLC55SVX; (GC/
GLC080, 100, 120VX; GC/GLC080,
100VXBCS; GC/GLC120SVX; GC/
GLC120VXPRS) (E818, F818)
c. Drain pan capacity approximately 51 li-
ter (13.5 gal) for lift truck model
• 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. Dis-
connect 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
GLC040SVX (C809)
• GLP/GDP16VX, GLP/GDP18VX, (GLP/
GDP040SVX) (C810)
GLC055SVX) (A910)
GDP040-070VX) (B875)
• GLC40, 45, 55VX; GLC55SVX; (GC/
GLC080, 100, 120VX; GC/GLC080,
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,
GLC120VXPRS) (F818) equipped with dual
hydraulic tanks.
1900 YRM 1136 Single Gear Pump Assembly Repair
5

A. EARLY LIFT TRUCK MODELS B. NEWER LIFT TRUCK MODELS
1. SUCTION HOSE
2. HYDRAULIC INLET HOSE
3. SUCTION ADAPTER
4. SOCKET HEAD SCREW (2)
5. HYDRAULIC PUMP
6. TRANSMISSION
7. PUMP OUTLET FITTING
Figure 1. Hydraulic Pump for 1.5 to 3.5 Ton Lift Truck Models Equipped With an Iron Transmission
Housing
6

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. TRANSMISSION
2. SOCKET HEAD SCREW
3. HYDRAULIC PUMP
4. SUCTION HOSE
5. SUCTION ADAPTER
Figure 2. Hydraulic Pump for 4 to 5.5 Ton Lift Truck Models
7

1. TRANSMISSION
3. HYDRAULIC PUMP
4. SUCTION HOSE
5. SUCTION ADAPTER
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

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 transmis-
sion housing. Remove the pump assembly.
NOTE: Perform Step 5 through Step 8 for lift trucks
equipped with an aluminum transmission housing.
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.
6. On lift truck models not equipped with a Quick-
Lok™ hydraulic hose, disconnect all hydraulic
lines connected to the pump assembly. Remove
pump outlet fitting and suction adapter from hy-
draulic gear pump. Put caps on all hose fittings
and hydraulic gear pump ports.
GLC040SVX (C809)
GDP040SVX) (C810)
GLC055SVX) (A910)
GDP040-070VX) (B875)
GLC040SVX (C809)
GDP040SVX) (C810)
GLC055SVX) (A910)
GDP040-070VX) (B875)
• GLC050LX (A967)
7. On lift truck models GLP/GDP20-35VX (GP/GLP/
GDP040-070VX) (B875) equipped with a Quick-
Lok™ hydraulic hose and single speed transmis-
sion, remove the adapter and hydraulic hose from
gear pump assembly. Disconnect all other hy-
draulic 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.
GDP040-070VX) (B875)
GDP040-070VX) (B875)
9

8. Hold the pump assembly to keep it from falling.
Remove the two flange head capscrews that fas-
ten the pump to the transmission housing. Re-
move the pump assembly.
GLC040SVX (C809)
GDP040SVX) (C810)
GLC055SVX) (A910)
GDP040-070VX) (B875)
GLC040SVX (C809)
GDP040SVX) (C810)
GLC055SVX) (A910)
GDP040-070VX) (B875)
• GLC050LX (A967)
1. SUCTION HOSE
3. SUCTION ADAPTER
5. FLANGE HEAD CAPSCREW (2)
6. HYDRAULIC PUMP
7. TRANSMISSION
Figure 4. Hydraulic Pump for 1.5 to 3.5 Ton Lift
Truck Models, Equipped With Aluminum
Transmission Housing, Prior to January, 2011
10

NOTE: QUICK-LOK™ 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. SUCTION HOSE
3. FLANGE HEAD CAPSCREW (2)
5. SUCTION ADAPTER
6. HYDRAULIC PUMP
7. TRANSMISSION
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

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 to-
gether. Remove the flange end housing. Remove
the rear valve housing. DO NOT let the seals and
gears fall. See Figure 7.
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.
12

1. SNAP RING
2. SHAFT SEAL
3. FLANGE END HOUSING
4. PLATE SEAL
5. PRESSURE PLATE
6. GEAR HOUSING
7. DRIVEN GEAR
8. DRIVE GEAR
9. REAR VALVE HOUSING
10. CAPSCREW
11. BACKUP SEAL
Figure 7. Hydraulic Pump Assembly
13

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.
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 hy-
draulic 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 disassem-
bly. See the notes made during disassembly.
Make sure all seals are complete and in the cor-
rect 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 lock-
washers. Make sure the pressure plates do not
move and that the seals stay in the correct posi-
tion. Make sure the marks made during disassem-
bly 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 mod-
els below
GLC040SVX (C809)
GDP040SVX) (C810)
GLC055SVX) (A910)
• GLC050LX (A967)
GDP040-070VX) (B875)
• GLP/GDP20-25LX (GLP/GDP050LX)
(A974)
• GLP/GDP60VX, GLP/GDP70VX
(GP/GLP/GDP135VX, GP/GLP/
GDP155VX) (C878, D878, E878)
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,
• GLP/GDP40VX5/VX6; GLP/
GDP50-55VX (GP/GLP/GDP080, 090,
100, 110, 120VX) (F813, G813, H813,
J813)
14

Lok™ 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 Quick-
Lok™ hydraulic hose:
a. Disconnect standard hydraulic hose from steer-
ing 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 perma-
nently installed on the hose. To remove the Quick-
Lok™ hydraulic hose again, remove the adapters
from the SCU and gear pump ports. When replacing
the Quick-Lok™ hydraulic hose, replace both adapt-
ers and the hose at the same time. See Parts Man-
ual.
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.
NOTE: Perform Step 4 and Step 5 for lift trucks
equipped with an iron transmission housing.
4. Clean the pump flange and transmission mount-
ing 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).
GLC040SVX (C809)
GDP040SVX) (C810)
GLC055SVX) (A910)
GDP040-070VX) (B875)
• GLC40, 45, 55VX; GLC55SVX; (GC/
GLC080, 100, 120VX; GC/GLC080,
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813)
• GLC40, 45, 55VX; GLC55SVX; (GC/
GLC080, 100, 120VX; GC/GLC080,
GLC120VXPRS) (F818) equipped with dual
hydraulic tanks.
15

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
GLC040SVX (C809)
GDP040SVX) (C810)
GLC055SVX) (A910)
GDP040-070VX) (B875)
• GLC40, 45, 55VX; GLC55SVX; (GC/
GLC080, 100, 120VX; GC/GLC080,
(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 hous-
ing.
6. Make sure pump flange and transmission mount-
ing 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 transmis-
sion 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/
GDP035VX, GP/GLP/GDP040SVX) (C810);
GLC20-35VX (GC/GLC040-070VX, GC/
GLC055SVX) (A910) GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875)
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/
GDP035VX, GP/GLP/GDP040SVX) (C810),
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX)
(A910), and GLP/GDP20-35VX (GP/GLP/
GDP040-070VX) (B875)
16

A. X = 32° ±5° FOR ALL LIFT TRUCK MODELS EX-
CEPT GLC40, 45, 55VX; GLC55SVX; (GC/
GLC080, 100, 120VX; GC/GLC080, 100VXBCS;
GC/GLC120SVX; GC/GLC120VXPRS) (E818,
F818) AND GLP/GDP40VX5/VX6; 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,
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
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)
GLC040SVX (C809)
GDP040SVX) (C810)
GLC055SVX) (A910)
GDP040-070VX) (B875)
GLC040SVX (C809)
GDP040SVX) (C810)
GLC055SVX) (A910)
GDP040-070VX) (B875)
• GLC050LX (A967)
Lok™ 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 Op-
erating 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
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 nec-
essary.
17

NOTE: QUICK-LOK™ 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

NOTE: ELECTRO-HYDRAULIC CONTROL VALVE SHOWN. ORIENTATION IS THE SAME ON MANUAL CON-
TROL 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
REMOVE
WARNING
one-piece units.
NOTE: Worn or damaged seals are the most com-
mon 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.
your lift truck for the procedures to put the lift
truck on blocks. The following lift trucks are equip-
ped with the tandem gear pump assembly:
• GLC/GDC60VX, GLC/GDC70VX,
(GC/GLC/GDC135VX, GC/GLC/
GDC155VX) (C879, D879, E879, F879)
D878, E878)
B909)
move the drain plug at the bottom of hydraulic oil
tank, and drain oil from tank.
ter (16.9 gal) 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)
B909)
3. Put a drain pan under the tandem gear pump as-
sembly. Remove hydraulic outlet hoses at the fit-
tings on the tandem gear pump assembly. Re-
move 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.
Tandem Gear Pump Assembly 1900 YRM 1136
20

1. OUTLET HOSES
2. OUTLET HOSE FITTINGS
3. INLET HOSE CLAMPS
4. INLET HOSES
5. HEX SOCKET CAPSCREW
6. LOCK WASHER
7. TRANSMISSION CHARGE PUMP
8. 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)
1900 YRM 1136 Tandem Gear Pump Assembly
21

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.
1. FITTING
2. DRIVEN PUMP
3. ADAPTER
4. DRIVE PUMP
Figure 13. Tandem Gear Pump Fittings
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 O-
rings, 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.
back up seals, pressure plates, gear plate, cover
plate, oil seal and gears from the housings. Dis-
card plate seals and backup seals.
22

Figure 14. Tandem Gear Pump Assembly
23

Legend for Figure 14
1. SOCKET HEAD FLANGE SCREW
2. MOUNTING FLANGE COVER
3. PLATE SEAL
4. BACKUP SEAL
5. PRESSURE PLATE
6. GEAR PLATE
7. DOWEL PIN
8. GEARS
9. CAPSCREW
10. WASHER
11. FLANGE END HOUSING
12. SNAP RING
13. O-RING
14. COUPLING
16. ADAPTER PLATE
17. COVER PLATE
18. HOUSING
19. OIL SEAL
20. DRIVE PUMP FLANGE END HOUSING
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.
pressure plates, gear plate and gears from the
housings. Discard plate seals and backup seals.
Remove the snap ring from the flange end hous-
ing. Discard snap ring.
CLEAN
WARNING
Cleaning solvents can be flammable and toxic and
solvents, always follow the solvent manufacturers
recommended safety precautions.
WARNING
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 hy-
draulic 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 disassem-
bly. 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.
24

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 posi-
tion. Make sure the marks made during disassem-
bly are aligned. Tighten the capscrews to 88 to
98 N•m (65 to 72 lbf ft). Install new snap ring in
flange end housing.
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.
6. Install a new shaft seal in the drive pump flange
end housing. Carefully install the flange end hous-
ing. DO NOT move the pressure plates. Make
sure the seals do not move out of the correct po-
sition.
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 disas-
sembly 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 O-
ring 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).
9. Reposition tandem gear pump in the vise and in-
stall two outlet hose fittings. See Figure 13.
Tighten the fittings to 78 to 88 N•m (58 to
65 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.
INSTALL
1. Clean the tandem gear pump flange and trans-
mission 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 trans-
mission. Install the socket head screws and lock-
washers 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. In-
stall outlet hoses to outlet hose fittings.
erating 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
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 nec-
essary.
25

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)
Gear Pump Specifications 1900 YRM 1136
26

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 Main Relief
Valve
Pressure -
Mpa (PSI)
Pump Flow
Rate - LPM
(GPM)
GLC050LX
(A967)
Mazda 2.0L 24.0 cc/rev 2400 rpm
21.4 MPa
(3104 psi)
57.6 liter/min
(15.2 gal/min)
GLP20-25L
(A974)
Mazda 2.0L 24.0 cc/rev 2400 rpm
23.4 MPa
(3394 psi) 57.6 liter/min
(15.2 gal/min)GLP050LX
(A974)
21.4 MPa
(3104 psi)
GDP20-25LX
(A974)
Yanmar 2.6L 25.7 cc/rev 2400 rpm
23.4 MPa
(3394 psi) 61.7 liter/min
(16.3 gal/min)GDP050LX
(A974)
21.4 MPa
(3104 psi)
GLC20-30VX
(GC/
GLC040-060VX,
GC/
GLC055SVX)
(A910) GLP/
GDP20-30VX
(GP/GLP/
GDP040-060VX
) (B875)
Mazda 2.0L/2.2L 24.0 cc/rev
2700 rpm
21.37 MPa
(3100 psi)
63.1 liter/min
(16.7 gal/min)
GM 2.4L 25.7 cc/rev 67.5 liter/min
(17.8 gal/min)
Yanmar 2.6L
29.4 cc/rev
77.3 liter/min
(20.4 gal/min)
Yanmar 3.3L 2600 rpm 74.4 liter/min
(19.7 gal/min)
GLC35VX (GC/
GLC070VX)
(A910) GLP/
GDP35VX
(GP/GLP/
GDP070VX)
(B875)
Mazda 2.0L/2.2L 24.0 cc/rev
2700 rpm
23.44 MPa
(3400 psi)
63.1 liter/min
(16.7 gal/min)
GM 2.4L 25.7 cc/rev 67.5 liter/min
(17.8 gal/min)
Yanmar 2.6L
29.4 cc/rev
77.3 liter/min
(20.4 gal/min)
Yanmar 3.3L 2600 rpm 74.4 liter/min
(19.7 gal/min)
1900 YRM 1136 Gear Pump Specifications
27

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 Displacement Governed
Speed
Main Relief
Valve Pressure -
Mpa (PSI)
Pump Flow Rate
- LPM (GPM)
GLC40VX (GC/
GLC080VX, GC/
GLC080VXBCS)
(E818, F818)
GM 4.3L
32.5 cc/rev
2400 rpm
22.06 MPa
(3200 psi)
75.9 liter/min
(20.1 gal/min)
41.3 cc/rev
96.5 liter/min
(25.5 gal/min)
GLC45, 55VX;
GLC55SVX; (GC/
GLC100, 120VX;
GC/
GLC100VXBCS;
GC/GLC120SVX;
GC/
GLC120VXPRS)
(E818, F818)
96.5 liter/min
(25.5 gal/min)
51.6 cc/rev 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)
Speed
Main Relief
Valve Pressure -
Mpa (PSI)
Pump Flow Rate
- LPM (GPM)
GLP/
GDP40VX5/VX6
(GP/GLP/
GDP080, 090VX)
(F813, G813,
H813, J813)
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)
GLP/
GDP45SVX5,
GLP/GDP45VX6;
GLP/
GDP50-55VX
(GP/GLP/
GDP100, 110,
120VX) (F813,
GM 4.3L (Paper
Kit Industry)
41.3 cc/rev 2400 rpm 22.06 MPa
(3200 psi)
96.5 liter/min
(25.5 gal/min)
(3200 psi)
96.5 liter/min
(25.5 gal/min)
28

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)
Speed
Main Relief
Valve Pressure -
Mpa (PSI)
Pump Flow Rate
- LPM (GPM)
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)
Speed
Main Relief
Valve Pressure -
Mpa (PSI)
Pump Flow Rate
- LPM (GPM)
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)
(3200 psi)
96.5 liter/min
(25.5 gal/min)
GLC/GDC70VX,
(GC/GLC/
GDC155VX)
(C879, D879,
E879, F879);
GLP/GDP70VX
(GP/GLP/
GDP155VX)
GM 4.3L 63.3 cc/rev 2400 rpm 22.06 MPa
(3200 psi)
144.3 liter/min
(38.1 gal/min)
1900 YRM 1136 Gear Pump Specifications
29

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)
Speed
Main Relief
Valve Pressure -
Mpa (PSI)
Pump Flow Rate
- LPM (GPM)
(C878, D878,
E878)
(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)
Speed
Main Relief
Valve Pressure -
Mpa (PSI)
Pump Flow Rate
- LPM (GPM)
GDP80VX
(GDP170VX)
(A909, B909)
Cummins 3.3L
Turbo
46.5cc/rev 2500 rpm
22.06 MPa
(3200 psi)
177.2 liter/min
(46.8 gal/min)
GDP80VX9
(GDP175VX36)
(A909, B909)
GDP90VX
(GDP190VX)
(A909, B909)
GLP80VX
(GLP170VX)
(A909, B909)
GM 5.7L 46.5 cc/rev 2500 rpm
22.06 MPa
(3200 psi)
177.2 liter/min
(46.8 gal/min)
GLP80VX9
(GLP175VX36)
(A909, B909)
GLP90VX
(GLP190VX)
(A909, B909)
30

Variable Displacement Pump Repair
REMOVE
WARNING
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 re-
pairs to the parts. To prevent more failures, always re-
place parts that are worn or damaged. If several main
parts need replacing, replace the with a new pump.
Manual or one of the following service manuals
for the procedures to put the lift truck on blocks:
Periodic Maintenance 8000YRM1150 for lift truck
models
• GLP/GDP20-35VX (B875)
models
• GLP/GDP40VX5/VX6, GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX (G813)
model
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(H813)
Capacities and Specifications 8000YRM1605 for
lift truck model
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(J813)
move drain plug at bottom of hydraulic oil tank,
and drain oil from tank. See Figure 15.
• GLP/GDP20-35VX (B875)
b. Drain pan capacity approximately 62 li-
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.
1900 YRM 1136 Variable Displacement Pump Repair
31

c. Drain pan capacity approximately 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 hy-
draulic tank, install drain plug.
4. Place drain pan under variable displacement
pump (VDP).
5. Disconnect all hydraulic lines connected to varia-
ble displacement pump and steering control unit.
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)
6. Remove the suction adapter from the VDP.
H813, J813)
• GP/GLP/GDP080, 090, 100, 110, 120VX
(J813)
• GLP/GDP20-35VX (B875)
7. Allow hydraulic oil to drain from VDP. Put caps on
all hose fittings and VDP ports.
8. Support the VDP assembly to prevent it from fall-
ing. Remove two flange head capscrews and
VDP from transmission housing.
H813, J813)
• GP/GLP/GDP080, 090, 100, 110, 120VX
(J813)
• GLP/GDP20-35VX (B875)
Variable Displacement Pump Repair 1900 YRM 1136
32

1. HYDRAULIC TANK 2. DRAIN PLUG
Figure 15. Drain Hydraulic Oil
33

Figure 16. Variable Displacement Pump Arrangement, Lift Truck Models GLP/GDP40VX5/VX6, GLP/
GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (G813, H813, J813)
34

A. FRONT VIEW B. TOP VIEW
2. LOAD SENSE LINE
3. DRAIN CASE LINE
4. DRAIN CASE FILL PLUG
5. VARIABLE DISPLACEMENT PUMP
6. FLANGE HEAD CAPSCREWS
7. SUCTION HOSE
8. MAIN CONTROL VALVE
10. ACCUMULATOR
11. DRAIN CASE DRAIN PLUG
12. TRANSMISSION
13. SUCTION HOSE ADAPTER
35

Figure 17. Variable Displacement Pump Arrangement, Lift Truck Models GP/GLP/GDP080, 090, 100, 110,
120VX (J813)
36

2. LOAD SENSE LINE
3. DRAIN CASE LINE
7. SUCTION HOSE
10. ACCUMULATOR
12. TRANSMISSION
37

Figure 18. Variable Displacement Pump Arrangement, Lift Truck Models GLP/GDP20-35VX (B875) With 1-
Speed Transmission
38

2. LOAD SENSE LINE
3. DRAIN CASE LINE
6. SUCTION HOSE
8. ACCUMULATOR
11. TRANSMISSION
39

Figure 19. Variable Displacement Pump Arrangement, Lift Truck Models GLP/GDP20-35VX (B875) With 2-
Speed Transmission
40

2. LOAD SENSE LINE
3. DRAIN CASE LINE
7. SUCTION HOSE
9. ACCUMULATOR
12. TRANSMISSION
13. SUCTION ADAPTER
DISASSEMBLE
1. Put the variable displacement pump in a vise.
CAUTION
Protect the drive shaft from damage before re-
moving 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 pro-
tective material to protect drive shaft before re-
moving retaining ring and shaft seal. See Fig-
ure 20.
b. Remove the retaining ring. See Figure 20.
1. RETAINING RING
2. SHAFT SEAL
3. DRIVE SHAFT
Figure 20. Retaining Ring Removal
41

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.
1. SCREWS
2. SHAFT SEAL
3. DRIVE SHAFT
Figure 21. Shaft Seal Removal
d. Inspect and clean shaft and internal shaft seal-
ing 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 Fig-
ure 22.
e. Install new shaft seal onto drive shaft. Use spe-
cial VDP shaft seal installation tool, Yale Part
Number 582016143, and seat shaft seal down
onto pump stop ring.
f. Use rubber hammer and tap on VDP shaft seal
tool until VDP shaft seal tool shoulder stops
against the face of VDP housing. See Fig-
ure 22.
g. Install the retaining ring. Be sure retaining ring
correctly rests in the groove. See Figure 20.
42

Figure 22. Shaft Seal Installation
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. VDP SHAFT SEAL TOOL
2. TWO RINGS
3. ONE RING
4. VDP SHAFT SEAL TOOL SHOULDER
5. STOP RING
6. BEARING
7. RETAINING RING
8. DRIVE SHAFT
3. Remove four socket head screws from control
valve and VDP. Remove seal from control valve.
H813, J813)
• GP/GLP/GDP080, 090, 100, 110, 120VX
(J813)
• GLP/GDP20-35VX (B875)
43

2. CONTROL VALVE
3. SEAL
5. DRIVE SHAFT
6. 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)
2. CONTROL VALVE
3. SEAL
5. DRIVE SHAFT
Dissembly, Lift Truck Models GP/GLP/GDP080,
090, 100, 110, 120VX (J813)
44

2. CONTROL VALVE
3. SEAL
5. DRIVE SHAFT
Dissembly, Lift Truck Models GLP/GDP20-35VX
(B875)
CLEAN
WARNING
Cleaning solvents can be flammable and toxic,
solvents, always follow the recommendations of
the manufacturer.
WARNING
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
Check the control valve seal, drive shaft seal, and re-
taining ring for wear or damage and replace if neces-
sary. 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 dis-
placement pump.
45

ASSEMBLE
1. Coat seal with clean hydraulic oil. Install seal,
control valve, and four socket head screws on
VDP.
H813, J813)
• GP/GLP/GDP080, 090, 100, 110, 120VX
(J813)
• GLP/GDP20-35VX (B875)
2. Apply clean hydraulic oil to shaft seal and retain-
ing ring. Install shaft seal and retaining ring onto
drive shaft.
H813, J813)
• 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
H813, J813)
• 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 trans-
mission. 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 steer-
ing control unit. Tighten the flange head cap-
screws at the VDP, using sequence shown in Fig-
ure 26, to 70 to 77 N•m (52 to 57 lbf ft).
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
• GLP/GDP20-35VX (B875)
46

Figure 29 and Figure 31 for lift truck models
H813, J813)
Figure 30 and Figure 31for lift truck model
• GP/GLP/GDP080, 090, 100, 110, 120VX
(J813)
A. X = 45° ±5° B. Y = 54° ±5°
2. SUCTION HOSE
3. LOAD SENSE LINE
4. DRAIN CASE LINE
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°
D. FRONT VIEW
E. SIDE VIEW
1. LOAD SENSE LINE
2. SUCTION HOSE
3. DRAIN CASE LINE
GLP/GDP20-35VX (B875) Equipped With 2-Speed
Transmission
47

A. X = 30° ±5° B. Y = 12° ±5°
1. LOAD SENSE LINE
2. SUCTION HOSE
4. DRAIN CASE LINE
GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/
GDP45VX6, GLP/GDP50-55VX (G813, H813, J813)
A. X = 30° ±5° B. Y = 12° ±5°
1. LOAD SENSE LINE
2. SUCTION HOSE
4. DRAIN CASE LINE
GP/GLP/GDP080, 090, 100, 110, 120VX (J813)
48

Steering Control Unit
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/
D. Y = 55° ±5° FOR LIFT TRUCK MODELS GLP/
E. 1-SPEED TRANSMISSION
F. 2-SPEED TRANSMISSION
4. LOAD SENSE LINE
49

erating Manual or one of the following service
manuals for the procedures:
models
• GLP/GDP20-35VX (B875)
models
model
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(H813)
lift truck model
(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:
models
• GLP/GDP20-35VX (B875)
models
model
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(H813)
lift truck model
(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 neces-
sary.
50

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 pres-
sure 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)
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.
1. P-PORT 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.
1900 YRM 1136 Variable Displacement Pump Checks and Adjustments
51

4. If the margin pressure is not within range speci-
fied in Table 7, go to Flow Compensator Adjust-
ment section.
FLOW COMPENSATOR ADJUSTMENT
WARNING
DO NOT operate the hydraulic functions while ad-
justing 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 ad-
justment screw. Hold allen wrench in flow com-
pensator screw and turn jam nut counter clock-
wise 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 Mar-
gin Pressure Check. If margin pressure is not cor-
rect, perform Step 1 and Step 2 until correct mar-
gin pressure is reached.
4. Tighten the jam nut to 21 N•m (186 lbf in). See
Figure 33.
PRESSURE COMPENSATOR
ADJUSTMENT
WARNING
justing the pressure compensator. Serious injury
to personnel and damage to the lift truck can re-
sult if hydraulic functions are operated.
1. FLOW COMPENSATOR
2. JAM NUT
3. FLOW COMPENSATOR ADJUSTMENT SCREW
4. PRESSURE COMPENSATOR
5. 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.
A. MEASURE AND NOTE THIS DISTANCE
1. PRESSURE COMPENSATOR
2. FLOW COMPENSATOR
Figure 34. Screw Location
Variable Displacement Pump Checks and Adjustments 1900 YRM 1136
52

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 counter-
clockwise all the way.
3. Turn the flow compensator adjustment screw
clockwise until it stops.
WARNING
justing the pressure compensator. Serious injury
to personnel and damage to the lift truck can re-
sult if hydraulic functions are operated.
4. Start lift truck engine and let it idle. DO NOT oper-
ate the hydraulic functions. Measure the pressure
at the P-port of the SCU. See Figure 32. If pres-
sure does not match what is shown in Table 8,
adjust the pressure compensator as follows:
a. Turn pressure compensator adjustment screw
clockwise to increase pressure by
50 bar (725 psi) per turn.
b. Turn pressure compensator adjustment screw
counter clockwise to decrease pressure by
50 bar (725 psi) per turn.
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 adjust-
ment screw counter clockwise by the number of
turns noted earlier.
6. Tighten jam nut on pressure compensator adjust-
ment screw to 21 N•m (186 lbf in).
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.
8. Check the margin pressures as described in Mar-
gin Pressure Check.
9. If margin pressure is correct, tighten the flow com-
pensator jam nut to 21 N•m (186 lbf in). If margin
pressure is not correct, adjust margin pressure as
outlined in Margin Pressure Check.
1900 YRM 1136 Variable Displacement Pump Checks and Adjustments
53

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
Margin Setting -
Bar (PSI)
Pump Flow Rate @
≤ 30 Bar LPM (GPM)
Pump Flow Rate @
210 Bar LPM (GPM)
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)
(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)
(19.0 ±0.82 gal/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)
(20.4 ±0.82 gal/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)
Load Sense
Margin Setting -
Bar (PSI)
Pump Flow Rate @
≤ 30 Bar LPM (GPM)
Pump Flow Rate @
210 Bar LPM (GPM)
42.0 cc/rev 2900 rpm 2458 ±5 rpm 226 ±3 bar
(3278 ±44 psi)
14.0 ±1 bar
(203 ±15 psi)
(27.3 ±1.20 gal/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)
(29.2 ±1.20 gal/min)
(28.3 ±1.10 gal/min)
Variable Displacement Pump Specifications 1900 YRM 1136
54

Torque Specifications
HYDRAULIC GEAR PUMP
Rear Valve End Housing to Gear Pump Body Cap-
screws - Lift Truck Models GC/GLC030-035VX,
GC/GLC040SVX (C809); GLP/GDP16-18VX, 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/
GP/GLP/GDP155VX) (C878, D878, E878), GLC/
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/
88 to 98 N•m (65 to 72 lbf ft)
1900 YRM 1136 Torque Specifications
55

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);
(A910); GLC050LX (A967); GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875); GLP/
GDP20-25LX (GLP/GDP050LX) (A974); GLP/
GP/GLP/GDP155VX) (C878, D878, E878); GLC/
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 Equip-
ped 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 Hous-
ing, GC/GLC030-035VX, GC/GLC040SVX (C809);
GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/
GDP030-035VX, GP/GLP/GDP040SVX) (C810);
(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)
Gear Pump to Transmission Flange Head Cap-
screws - Lift Truck Models With Aluminum Trans-
mission Housing, GC/GLC030-035VX, GC/
GLC040SVX (C809); GLP/GDP16-18VX, 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/
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)
Torque Specifications 1900 YRM 1136
56

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
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.
• 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)
(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
D879, E879, F879)
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.
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.
• GLC20-35VX (GC/GLC040-070VX,
(B875)
• GC/GLC030-035VX, GC/GLC040SVX (C809)
• GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/
GDP030-035VX, GP/GLP/GDP040SVX) (C810)
100, 120VX; GC/GLC080, 100VXBCS;
GC/GLC120SVX; GC/GLC120VXPRS) (E818,
F818)
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
GDC135VX, GC/GLC/GDC155VX) (C879, D879,
E879, F879)
E878)
GLP/GDP170VX36, GLP/GDP190VX) (A909,
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

Service Manual for GC/GLC080VX, 100VX & 120VX Lift Trucks

Service Manual for GC/GLC080VX, 100VX & 120VX Lift Trucks

Recommended

Recommended

More Related Content

Similar to Service Manual for GC/GLC080VX, 100VX & 120VX Lift Trucks

Similar to Service Manual for GC/GLC080VX, 100VX & 120VX Lift Trucks (20)

More from uksjemm

More from uksjemm (17)

Recently uploaded

Recently uploaded (20)

Service Manual for GC/GLC080VX, 100VX & 120VX Lift Trucks