YALE (E879) GC155VX LIFT TRUCK Service Repair Manual

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) [E879]

PART NO. 550048609

8000 YRM 1572

8000 YRM 1572

Tire Sizes

Lift Truck Lifting Capacity Model

Weight

GLC/GDC60VX (GC/GLC/GDC0135VX)

6123 kg (13,500 lb)

GLC/GDC70VX (GC/GLC/GDC155VX)

7030 kg (15,500 lb)

NOTE: Load center at 600 mm (24 in.).

Counterweight Weights Model

Weight

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX)

2955 kg (6515 lb)

Tire Sizes Truck

Drive Tires

Steer Tires

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX GC/GLC/GDC155VX)

28 × 12 × 22

22 × 8 × 16

1

Capacities

8000 YRM 1572

Capacities Table 1. GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (E879) Lift Truck Models Item

Quantity

Specifications

Fuel Capacity Gas

65.8 liter (17.4 gal)

87 Octane

LPG

38.6 liter (10.2 gal) Empty 19.0 kg (41 lb) Full 38.2 kg (84.51 lb)

LPG-HD 5, HD 10

Diesel

65.8 liter (17.4 gal)

Diesel No. 2

Engine Oil GM 4.3L

4.7 liter (5.0 qt)

7°C ( 20°F) and below SAE 5W-20 16°C (60 °F) and below SAE 5W-30 18°C (0°F) and above SAE 10W-30 API SM ILSAC GF4 SAE J2362

Kubota 3.8L Diesel

13.2 liter (13.9 qt)

-15°C (5°F) and above SAE 15W-40 API CF or CI-4 25°C ( 13°F) and above SAE 10W-30 Below 25°C ( 13°F) SAE 5W-20

2

8000 YRM 1572

Capacities

Table 1. GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (E879) Lift Truck Models (Continued) Item

Quantity

Specifications

Cooling System GM 4.3L

15.1 liter (15.9 qt)

CAUTION Additives may damage the cooling system. Before using additives, contact your local Yale dealer.

Use Ethylene Glycol Boron-free Antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concentrate with 50% distilled water or deionized water.

Kubota 3.8L Diesel

10.6 liter (11.2 qt)

CAUTION Additives may damage the cooling system. Before using additives, contact your local Yale dealer.

Use Ethylene Glycol Boron-free Antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concentrate with 50% distilled water or deionized water.

Hydraulic Tank Oil Capacity All Trucks

64.7 liter (68.4 qt)

CAUTION Additives may damage the hydraulic system. Before using additives, contact your local Yale dealer.

ISO VG-46 Hydraulic Oil 15°C (5°F) and above Transmission Oil Capacity Standard Powershift Transmission (2-Speed)

24 liter (25.4 qt)

John Deere JDM J20C

Techtronix 332 (3-Speed)

24 liter (25.2 qt)

John Deere JDM J20C

3

Electrical System

8000 YRM 1572

Table 1. GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (E879) Lift Truck Models (Continued) Item

Quantity

Specifications

Drive Axle Housing Arm Oil Right Chamber

8.8 liter (9.3 qt)

John Deere JDM J20C

Drive Axle Housing Arm Oil Left Chamber

8.8 liter (9.3 qt)

John Deere JDM J20C

Right Wheel Hub Oil

1.6 liter (1.7 qt)

John Deere JDM J20C

Left Wheel Hub Oil

1.6 liter (1.7 qt)

John Deere JDM J20C

Wet Brake Drive Axle Oil Capacities

Brake Oil (Master Cylinder) All Lift Truck Models

0.35 liter (0.74 pt)

WARNING DO NOT use DOT fluid; only use Dexron III oil from sealed container to prevent possible damage to the brake system.

Failure to observe the above Warning could result in death or serious injury.

Dexron III From Sealed Container Wet Brake Center Section Oil All Lift Truck Models

4.2 liter (4.4 qt)

SAE 80W-90

Electrical System Table 2. GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (E879) Lift Truck Models Item

GM 4.3L

Kubota 3.8L

Battery

12-volt, negative ground

12-volt, negative ground

Spark Plugs

AC 41-993

N/A

Spark Plug Gap

1.5 mm (0.059 in.)

N/A

Gas

Not Adjustable

N/A

LPG

Not Adjustable

N/A

Diesel

N/A

Not Adjustable

Ignition Timing

4

8000 YRM 1572

Transmission Oil Pressures

GM 4.3L Alternator Output (14 Volts)

G and LPG

GS and LPS

Idle

50 amps @ 750 rpm

38 amps @ 750 rpm

Governed Speed

65 amps @ 2400 rpm

45 amps @ 2400 rpm

Kubota Diesel Alternator Output (13.5 Volts)

D

DS

Low Idle

30 amps @ 825 rpm

Not Offered

Governed Speed

80 amps @ 2325 rpm

Not Offered

Transmission Oil Pressures Table 3. 3-Speed Transmission All Pressures at 2000 rpm and Oil at 50 to 65°C (120 to 150°F) Port 1 Transmission Pump

Port 2

Port 3

Port 4

Port 5

Low and High Pressure

Reverse Clutch (R1 and R2)

Forward Low Clutch (F1 and F2)

Forward High Clutch (F3)

1793 to 2068 kPa (260 to 300 psi)

1793 to 2068 kPa (260 to 300 psi)

1793 to 2068 kPa (260 to 300 psi)

1793 to 2068* kPa (260 to 300 psi)

Port 6

Port 7

Port 8

Torque Converter

Lubrication

First Test Port (F1 and R1)

Second Test Port (F2, F3 and R2)

758 kPa (110 psi)

69 to 276 kPa (10 to 40 psi)

1793 to 2068 kPa (260 to 300 psi)

1793 to 2068 kPa (260 to 300 psi)

*Relief Pressure

5

Hydraulic System Relief Pressures

8000 YRM 1572

Table 4. 2-Speed Transmission All Pressures at 2000 rpm and Oil at 50 to 65°C (120 to 150°F) Port 1 Transmission Pump

Port 2

Port 3

Port 4

Port 5

Low and High Pressure

Reverse Clutch (R1 and R2)

Forward Low Clutch (F1 and F2)

Forward High Clutch (F3)

1793 to 2068 kPa (260 to 300 psi)

1793 to 2068 kPa (260 to 300 psi)

1793 to 2068 kPa (260 to 300 psi)

1793 to 2068* kPa (260 to 300 psi)

Port 6

Port 7

Port 8

Torque Converter

Lubrication

First Test Port (F1 and R1)

Second Test Port (F2, F3 and R2)

758 kPa (110 psi)

69 to 276 kPa (10 to 40 psi)

1793 to 2068 kPa (260 to 300 psi)

1793 to 2068 kPa (260 to 300 psi)

*Relief Pressure

Hydraulic System Relief Pressures

6

Item

Specification

Oil Temperature for Setting Relief Pressure

50 to 65°C (122 to 149°F)

Primary Relief Valve Pressure (High Idle)

21.4 ±0.48 MPa (3104 ± 70 psi)

Secondary Relief Valve Pressure (High Idle)

15.51 ±0.48 MPa (2250 ±70 psi)

8000 YRM 1572

Stall Speeds (in RPM ±100 rpm)

Steering System Table 5. GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (E879) Lift Truck Models Item

Quantity

Oil Temperature for Setting Relief Pressure

50 to 65°C (122 to 149°F)

Steering Relief Pressure at 800 rpms

12.4 ±0.3 MPa (1798 ±43.5 psi)

Steering Cylinder Stroke (Each Side)

210.8 mm (8.3 in.)

Inside Steering Tire Angle

80.3°

Number of Turns to Lock

4.07

Turning Radius (±76 mm NO LOAD)

Outside

Inside

All Trucks

2585

107

Stall Speeds (in RPM ±100 rpm) GM 4.3L GAS Transmission

New Engine

Broken-In Engine (30 hrs)

Standard Powershift

2160

2210

Techtronix 332

N/A*

N/A*

*Techtronix 332 transmission has torque limiting feature.

GM 4.3L LPG Transmission

New Engine

Broken-In Engine (30 hrs)

Standard Powershift

2070

2170

Techtronix 332

N/A*

N/A*

*Techtronix 332 transmission has torque limiting feature.

KUBOTA DIESEL Transmission

New Engine

Broken-In Engine (30 hrs)

Standard Powershift

1900

2050

Techtronix 332

N/A*

N/A*

*Techtronix 332 transmission has torque limiting feature.

7

Engine Specifications

8000 YRM 1572

Tilt Angles Lift truck should be on level ground and in unloaded condition.

Table 6. GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (E879) Lift Truck Models Mast Type

Forward

Tolerance

Back

Tolerance

2-Stage FFL, 3-Stage FFL, 3-Stage LFL

6°

+1°,

0.5°

6°

+0°,

0.5°

2-Stage LFL

6°

+1°,

0.5°

10°

+0°,

0.5°

Front End Equipment - Mast Creep MAST CREEP

NOTE: Mast should be 90° vertical prior to test.

Measure with rated load at 2.5 m (8.0 ft) high and with the lift, tilt, and auxiliary control levers in neutral position.

Table 7. GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (E879) Lift Truck Models Hydraulic Oil Temperature

Maximum Vertical Creep at Carriage

Maximum Tilt Creep Mast Angle

Cylinder Stroke

°C

°F

mm/Min

in./Min

°/Min

mm/Min

in./Min

20

68

2.2

0.086

0.11

1.24

0.054

25

77

3.0

0.118

0.15

1.69

0.067

30

86

3.3

0.130

0.16

1.80

0.071

35

95

5.1

0.201

0.25

2.83

0.111

40

104

6.3

0.247

0.31

3.50

0.137

45

113

8.1

0.319

0.40

4.52

0.178

50

122

10.0

0.394

0.50

5.62

0.221

55

131

12.1

0.476

0.61

6.89

0.271

60

140

14.6

0.575

0.73

8.20

0.323

Engine Specifications

8

Item

GM 4.3L

No. of Cylinders

6

Firing Order

1-6-5-4-3-2

Bore

101.6 mm (3.9 in.)

Stroke

88.4 mm (3.48 in.)

8000 YRM 1572

Engine Specifications

Item

GM 4.3L

Displacement

4.3 liter (262.4 in. 3 )

Horsepower (Gasoline)

100 @ 2400 rpm

Horsepower (LPG)

93 @ 2400 rpm

Engine Timing

Timing is controlled by the Electronic Control Module (ECM) Compression Ratio

Gas

9.4:1

LPG

9.4:1

Oil Pressure With PSI Installed

124 kPa (18 psi) @ 2000 80°C (176°F) Valve Clearance

Intake

Not Adjustable

Exhaust

Not Adjustable

Idle Speed - Gas

750 ±25 rpm

Idle Speed - LPG

750 ±25 rpm

Governed Speed High Idle (No Load)

2400 ±25 rpm

Thermostat Range STARTS TO OPEN

82 ±1.5°C (180 ±35°F)

FULL OPEN

128 ±1.5°C (260 ±35°F)

Cooling System Pressure

103 kPa (15 psi)

Item

Kubota 3.8L

No. of Cylinders

4

Firing Order

1-3-4-2

Bore and Stroke

100 mm × 120 mm (3.94 in. × 4.72 in.)

Displacement

3769 cc

Compression Ratio

17.5:1

Horsepower/rpm

73 @ 2325 rpm

Oil Pressure

50 kPa (7 psi) Valve Clearance

Intake

0.23 to 0.27 mm (0.009 to 0.011 in.)

(COLD)

Exhaust

0.23 to 0.27 mm (0.009 to 0.011 in.)

(COLD)

Idle Speed (Operating Temperature > 15°C (89°F))

800 ±50 rpm

9

Torque Specifications

8000 YRM 1572

Item

Kubota 3.8L

Governed Speed High Idle (No Load)

2230 ±50 rpm

Thermostat Range STARTS TO OPEN

75°C (167°F)

FULL OPEN

90°C (194°F)

Cooling System Pressure

103 kPa (15 psi)

Torque Specifications FRAME Overhead Guard Mount Capscrews 66 N•m (49 lbf ft) Cowl-to-Overhead Guard Legs 66 N•m (49 lbf ft) Steering Column Nut 40 to 54 N•m (30 to 40 lbf ft) Counterweight Capscrews 1020 N•m (750 lbf ft)

MAST Mast Mounting Capscrews Mast to Drive Axle 320 N•m (236 lbf ft) Tilt/Cylinder Adjust 90 N•m (66 lbf ft) Pivot Pin Retainer 68 N•m (50 lbf ft) Chain Anchor Nut 370 N•m (273 lbf ft) Integral Sideshift Carriage Lower Hooks Capscrews 78 N•m (58 lbf ft) Hang On Sideshift Assembly Lower Hook Capscrews 155 to 170 N•m (115 to 125 lbf ft) Fork Positioner Installation Capscrews 155 to 170 N•m (115 to 125 lbf ft)

(E879) MANUFACTURED AFTER AUGUST, 2012 Fork Carrier Block Capscrews 80 N•m (60 lbf ft) Retainer Capscrew 100 N•m (75 lbf ft) Cylinder Retainer 65 N•m (120 lbf ft) Hang On Sideshift Assembly Lower Hook Capscrews 320 N•m (236 lbf ft) Fork Positioner Frame to Hang On Sideshift Frame Capscrews 145 N•m (110 lbf ft) Fork Positioner to Sideshift Frame Capscrews 225 N•m (166 lbf ft) Side Retainer to Fork Carrier Capscrews 80 N•m (60 lbf ft) Lift Chain Anchor Nuts 210 N•m (155 lbf ft) Load Backrest to Carriage Assembly Capscrews 225 N•m (166 lbf ft)

STEERING SYSTEM

Load Backrest to Carriage Assembly Nuts (Without Fork Positioner) 70 to 80 N•m (56 to 60 lbf ft)

Hub Nut (Slotted Nut) 203 N•m (150 lbf ft) initial 35 N•m (26 lbf in) final

HANG ON SIDESHIFT CARRIAGE WITH FORK POSITIONER, LIFT TRUCK MODELS GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX)

Steering Axle Mounting Bolts and Nuts 250 to 275 N•m (184 to 203 lbf ft)

10

Spindle Bearing Cap Capscrew 52 N•m (38 lbf ft)

8000 YRM 1572

Torque Specifications

Steering Cylinder Mounting Bolts 225 N•m (166 lbf ft)

Coolant Temperature Sensor 16 to 23 N•m (12 to 17 lbf ft)

TRANSMISSION

Cooling Fan to Pulley 24 N•m (212 lbf in)

Transmission Mounting Bracket to Differential Housing Capscrew 225 to 255 N•m (166 to 188 lbf ft)

Cylinder Head See the section for torque value and tightening sequence to use.

Torque Converter Housing to Transmission Case Capscrews 38 N•m (28 lbf ft)

Distributor Mount Capscrew 25 N•m (18 lbf ft)

Torque Converter Access Bolts 55 N•m (41 lbf ft)

Exhaust Manifold 15 N•m (133 lbf in) - first step 30 N•m (22 lbf ft) - second step

Drive Shaft to Output Yoke Capscrews 55 to 63 N•m (41 to 47 lbf ft) Control Valve Mounting Capscrews 20 to 25 N•m (15 to 18 lbf ft) Engine Mounting Bracket to Frame Bolts 320 N•m (236 lbf ft)

ENGINE - GM 4.3L Alternator Pulley 58 to 79 N•m (43 to 58 lbf ft) Balance Shaft Gear Capscrew 20 N•m (177 lbf in) Plus 35 Degrees Balance Shaft Retainer Capscrews 12 N•m (106 lbf in) Camshaft Position Sensor 4 to 5 N•m (35 to 44 lbf in) Camshaft Retainer Screws 12 N•m (106 lbf in) Camshaft Sprocket Capscrews 28 N•m (21 lbf ft) Camshaft Sprocket Nut 25 N•m (18 lbf ft) Chain Control Block for Hydraulic Pump Drive 19 N•m (168 lbf in) with Adhesive Sealant Connecting Rod Cap 27 N•m (240 lbf in) After this step, tighten nuts an additional 70 degrees.

Coolant Pump to Engine Block 41 N•m (30 lbf ft)

Flywheel 100 N•m (74 lbf ft) Flywheel Housing 48 N•m (35 lbf ft) Inlet Manifold to Cylinder Head 3 N•m (27 lbf in) - first step 12 N•m (106 lbf ft) - second step 15 N•m (133 lbf in) - third step (final) Main Bearing Cap 105 N•m (77 lbf ft) Motor Mount to Engine 31 N•m (23 lbf ft) Oil Pump Cover 12 N•m (106 lbf in) Oil Pump to Crankcase 90 N•m (66 lbf ft) Oil Pressure Switch 15 to 19 N•m (11 to 14 lbf ft) Oil Screen Support to Crankcase 50 N•m (37 lbf ft) Oil Pan to Crankcase Capscrews 25 N•m (18 lbf ft) Nuts 25 N•m (18 lbf ft) Rear Oil Seal Retainer Screws and Nut 15 N•m (133 lbf in) Rocker Arm Cover 12 N•m (106 lbf in) Rocker Arm Nuts 25 N•m (18 lbf ft)

11

Torque Specifications

8000 YRM 1572

Rocker Arm Studs 47 N•m (35 lbf ft)

Cylinder Head Mounting Screw 98 to 107 N•m (72.4 to 79.5 lbf ft)

Rocker Arm Bolts 30 N•m (22 lbf ft)

Cylinder Head Valve Cover, Upper 6.9 to 11.2 N•m (61 to 99 lbf in)

Thermostat Housing 25 N•m (18 lbf ft)

Cylinder Head Cover, Lower 9.8 to 11.2 N•m (87 to 99 lbf ft)

Timing Cover 12 N•m (106 lbf in)

Engine Oil Pressure Switch Mounting Screw 15 to 19 N•m (11 to 14 lbf ft)

Valve Lifter Retainer Capscrews 16 N•m (142 lbf in)

Flywheel Housing Mounting Screw 78 to 90 N•m (58 to 66 lbf ft)

Vibration Damper 95 N•m (70 lbf ft)

Flywheel Mounting Screw 98 to 107 N•m (72.4 to 79.5 lbf ft)

ENGINE - KUBOTA 3.8L DIESEL

Fuel Injection Pump Gear Cover Mounting Screw 24 to 27 N•m (18 to 20 lbf ft)

Alternator Pulley 58.4 to 78.9 N•m (43.1 to 58.2 lbf ft) B Terminal Starter Nut 9.8 to 11 N•m (86.7 to 97.4 lbf in) Camshaft Position Sensor Mounting Screw 4 to 5 N•m (35 to 44 lbf in) Camshaft Pulsar Gear Mounting Screw 4.7 to 5.6 N•m (41.6 to 49.6 lbf in) Camshaft to Cylinder Head Setscrew 24 to 27 N•m (18 to 20 lbf ft) Common Fuel Rail Mounting Bracket Screw 24 to 27 N•m (18 to 20 lbf ft)

Fuel Injection Pump Gear Mounting Nut 24 to 27 N•m (18 to 20 lbf ft) Fuel Injection Harness Terminal Nut 1.6 to 2.2 N•m (14 to 19.5 lbf in) Fuel Injection Line Clamp Nut 24 to 27 N•m (18 to 20 lbf ft) Fuel Injection Pipe to Cylinder Head Retainer Nut 23 to 36 N•m (17 to 26 lbf ft) Fuel Injection Overflow Pipe to Cylinder Head Joint Screw 7.9 to 12 N•m (69.9 to 106 lbf in)

Connecting Rod Cap Screw 79 to 83 N•m (58 to 61 lbf ft)

Fuel Injection Overflow Pipe To Injection Pump Joint Screw 16 to 19 N•m (12 to 14 lbf ft)

Coolant Temperature Sensor Mounting Screw 16 to 23 N•m (12 to 17 lbf ft)

Fuel Injection Pump Mounting Nut 27 to 27 N•m (18 to 20 lbf ft)

Crankshaft Position Sensor Mounting Screw 4 to 5 N•m (35 to 44 lbf in)

Intake Air Temperature Sensor 30 to 39 N•m (22 to 28 lbf ft)

Crankshaft Pulley Mounting Screw 255 to 274 N•m (188 to 202 lbf ft)

Main Bearing Cap Mounting Screw 138 to 147 N•m (102 to 108 lbf ft)

Crankcase Housing to Engine Block Mounting Screw 49 to 55 N•m (37 to 41 lbf ft)

12

1600 YRM 1133

General

General This section has the description and repair procedures for the steering axle.

The steering axle assembly includes an axle frame, steering cylinder, and two spindle and hub assemblies.

See Figure 1. The steering axle is articulated and is connected to the frame by center pivot mounts. The center pivot mounts permit the steering axle to move in the frame mount when the lift truck travels over rough surfaces.

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

1

General

1600 YRM 1133

A. CUSHION TRUCKS ONLY

B. PNEUMATIC TRUCKS ONLY

1.

2.

3.

4.

5.

6.

7.

8.

AXLE FRAME MOUNT BRACKET STEERING CYLINDER

TIE ROD SPINDLE MOUNT HUB ASSEMBLIES

Figure 1. Steering Axle

2

1600 YRM 1133

Steering Axle Assembly Repair

When the piston reaches the end of the stroke, a relief valve in the steering circuit controls the oil pressure.

The tie rods that connect the spindle arms to the cylinder are not adjustable.

Each spindle turns on two tapered roller bearings in mounts in the axle frame. The preload on the bearings is controlled by shims at the lower bearing cap.

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

Wear sleeves protect the hub from wear by the seals.

Steering Axle Assembly Repair REMOVE WARNING PUTTING THE LIFT TRUCK ON BLOCKS The lift truck must be put on blocks for some types of maintenance and repair. The removal of the mast, drive axle, battery, or counterweight assemblies will cause large changes in the center of gravity. When the lift truck is put on blocks, put additional blocks in the following positions: • If the mast and drive axle are removed, put blocks under the counterweight so the lift truck cannot fall backward.

• If the counterweight is removed, put blocks under the mast so that the lift truck cannot fall forward.

Put the lift truck on blocks on a solid, even, and level surface. Verify the blocks or stands have enough capacity to hold the lift truck. Use additional blocks next to the tires as necessary to prevent movement of the lift truck. Verify the lifting devices used during repairs can lift the weight of the parts and assemblies.

See the Operating Manual or Periodic Maintenance section for your lift truck model, for the procedures to put the lift truck on blocks.

The steering axle can be removed without removing the counterweight.

1. Verify wheels are set for straight travel. Put lift truck on blocks so the steering axle will have enough clearance to be removed. The top of the axle frame must have clearance under the bottom of the frame at the rear of the lift truck.

2. Disconnect hydraulic lines at steering cylinder. Install plug fittings in cylinder and put caps on hydraulic lines. Plug fittings will prevent spindles from turning as axle is removed from under the lift truck.

NOTE: Steering Axle Assembly may be mounted to the frame with brackets or plates.

3. Slide floor jack or forks of another lift truck under steering axle. Raise lifting device until it holds the weight of the axle assembly. a. To remove bracket type mounts, remove four capscrews and nuts that fasten two brackets under rubber mounts.

See Figure 2 for lift truck model • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) See Figure 3 for lift truck models • GLP/GDP20-35VX (GP/GLP/GDP040070VX) (B875) See Figure 5 for lift truck model • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) See Figure 6 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) b. To remove plate type mounts, remove four capscrews and washers from two plates.

See Figure 4 for lift truck models • GC/GLC030-035VX, GC/GLC040SVX (C809) • GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/GDP030-035VX, GP/GLP/ GDP040SVX) (C810)

3

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

DISASSEMBLE 1. Remove ring seal, shims, flange, stub shaft and bushing from steering axle assembly for lift truck models below.

See Figure 8 for lift truck models • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP170VX36, GLP/GDP190VX) (A909, B909) 2. Put axle on blocks so the wheels just touch the floor.

Remove hub cap. Remove cotter pin, washer, and castle nut. Remove bearing cone and discard cotter pin.

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

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

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

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

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

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

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

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1600 YRM 1133

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

Steering Axle Assembly Repair

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

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

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Steering Axle Assembly Repair

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

1600 YRM 1133

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

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

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