YALE GDP40VX Transmission

Maintenance
POWERSHIFT
TRANSMISSION
REPAIR
GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX [C809];
GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/
GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) [C810];
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) [A910];
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) [B875]; GLC40,
45, 55VX; GLC55SVX (GC/GLC080, 100, 120VX; GC/GLC080,
100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) [E818];
GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6;
GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) [G813]
This manual contains information that is confidential and/or proprietary to Yale Materials Handling Corpora-
tion, its subsidiaries and/or vendors. Copying or distribution of any sections of this manual marked "Confi-
dential/Proprietary" is prohibited.
PART NO. 550043436 1300 YRM 1529

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product.
Updated technical service information may be available from your local authorized Yale® dealer. Service Manuals
provide general guidelines for maintenance and service and are intended for use by trained and experienced techni-
cians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in
damage to the products, personal injury, property damage or death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being
lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Discon-
nect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS
in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications
of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to
follow the necessary safety precautions when handling these fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure
the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange background.
The CAUTION symbol and word are on yellow background.
Powershift Transmission Table of Contents
TABLE OF CONTENTS
General................................................................................................................................................................ 1
Serial Number ................................................................................................................................................. 1
Charge Pump Repair........................................................................................................................................... 2
Lift Trucks Manufactured Before July, 2013..................................................................................................... 2
Remove....................................................................................................................................................... 2
Inspect ........................................................................................................................................................ 2
Install .......................................................................................................................................................... 2
Lift Trucks Manufactured After July, 2013........................................................................................................ 2
Remove....................................................................................................................................................... 2
Inspect ........................................................................................................................................................ 2
Install .......................................................................................................................................................... 2
Torque Converter Replace................................................................................................................................... 4
Remove ........................................................................................................................................................... 4
Install............................................................................................................................................................... 11
Housings and Chain Drive Repair ....................................................................................................................... 17
Remove ........................................................................................................................................................... 17
Clean............................................................................................................................................................... 24
Inspect............................................................................................................................................................. 24
Install............................................................................................................................................................... 24
Clutch Packs Repair ............................................................................................................................................ 32
Remove and Disassemble .............................................................................................................................. 32
Transmission, Remove and Disassemble ................................................................................................... 32
Clutch Assemblies, Remove and Disassemble........................................................................................... 40
Clean............................................................................................................................................................... 46
Inspect............................................................................................................................................................. 46
Assemble and Install ....................................................................................................................................... 47
Clutch Assemblies, Assemble and Install ................................................................................................... 47
Transmission, Assemble and Install............................................................................................................ 56
Control Valve Repair............................................................................................................................................ 60
Clean............................................................................................................................................................... 63
Inspect............................................................................................................................................................. 63
Foot Directional Control Pedal Repair ................................................................................................................. 64
Direction Control Lever ........................................................................................................................................ 70
Remove ........................................................................................................................................................... 70
Install............................................................................................................................................................... 70
This section is for the following models:
GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX [C809];

GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) [C810];
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) [A910];
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) [B875];
GLC40, 45, 55VX; GLC55SVX (GC/GLC080, 100, 120VX; GC/GLC080,
100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) [E818];
GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX) [G813]
©2013 Yale Materials Handling Corp. i

1300 YRM 1529 General
General
This section has the repair procedures for the transmission.
SERIAL NUMBER
The transmission serial number is located on the right
side of the transmission control valve directly below the
floor plate. See Figure 1.
1. TRANSMISSION SERIAL NUMBER
Figure 1. Transmission Serial Number Location
Confidential/Proprietary - Do Not Copy or Duplicate 1

Charge Pump Repair 1300 YRM 1529
Charge Pump Repair

LIFT TRUCKS MANUFACTURED BEFORE Legend for Figure 2
JULY, 2013
NOTE: THE TRANSMISSION IS SHOWN REMOVED
Remove FROM LIFT TRUCK FOR CLARITY.
1. CAPSCREW
NOTE: The charge pump can be removed from the 2. CHARGE PUMP
transmission while it is still in the lift truck but, for the 3. GASKET
sake of clarity, the following procedures are shown with 4. TORQUE CONVERTER HOUSING
the transmission removed from the lift truck.
LIFT TRUCKS MANUFACTURED AFTER
Remove four mounting capscrews, washers, transmis- JULY, 2013
sion charge pump, and gasket from torque converter
housing. Discard gasket. See Figure 2. Remove
Inspect NOTE: The charge pump can be removed from the
transmission while it is still in the lift truck but, for the
Inspect the splines on shaft of transmission charge sake of clarity, the following procedures are shown with
pump for damage or worn areas that could affect oper- the transmission removed from the lift truck.
ation of the pump. If the splines are damaged, replace
the transmission charge pump. Remove four mounting capscrews, washers, transmis-
sion charge pump, and gasket from torque converter
Install housing. Discard gasket. See Figure 3.
Install new gasket, transmission charge pump, four Inspect
washers, and mounting capscrews on torque converter
housing. Tighten capscrews to 19 N•m (168 lbf in). Inspect the splines on shaft of transmission charge
pump for damage or worn areas that could affect oper-
ation of the pump. If the splines are damaged, replace
the transmission charge pump.
Install
Install new gasket, transmission charge pump, four
washers, and mounting capscrews on torque converter
housing. Tighten capscrews in star pattern to 6 N•m
(53 lbf in) on first pass. On second pass, tighten
capscrews in star pattern to 19 N•m (168 lbf in). See
Figure 3.
Figure 2. Transmission Charge Pump
2 Confidential/Proprietary - Do Not Copy or Duplicate

1300 YRM 1529 Charge Pump Repair
NOTE: THE TRANSMISSION IS SHOWN REMOVED FROM LIFT TRUCK FOR CLARITY.
1. CAPSCREW 4. GASKET
2. WASHER 5. TORQUE CONVERTER HOUSING
3. CHARGE PUMP
Figure 3. Transmission Charge Pump

Torque Converter Replace 1300 YRM 1529
Torque Converter Replace

REMOVE NOTE: When disconnecting wiring harness connectors
during disassembly, tag each connector to aid in con-
WARNING necting the wiring harness during reassembly.
Make sure the engine and transmission are held in 2. Put engine and transmission on solid blocks on a
position so that they will not fall and cause an injury work surface.
and damage to the equipment.
Disconnect transmission wiring harness connec-
tors from control valve and transmission.
CAUTION
Be careful that you DO NOT damage parts of the Remove transmission wiring harness from trans-
torque converter or transmission when the transmission. See Figure 4.
mission is separated from the engine. Keep the
transmission and engine in alignment until they are
completely separated so parts of the transmission
WARNING
are not damaged. Use a crane or lifting device to Make sure that the engine/transmission assembly
separate the transmission from the engine. is stable before attempting to rotate the engine.
1. Remove engine and transmission as a unit from lift Use a flashlight to see the bolts as they are rotated
truck as described in one of the following sections: into view through the access hole. DO NOT use
your fingers to check for alignment of the bolts with
See Frame 100 YRM 1243 for lift truck models: the access hole.
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
100, 120VX; GC/GLC080, 100VXBCS; 3. Move each bolt into view through access hole of fly-
GC/GLC120SVX; GC/GLC120VXPRS) (E818) wheel housing by rotating crankshaft. Remove four
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, capscrews that attach flywheel to torque converter.
GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ See Figure 5.
GDP080, 090, 100, 110, 120VX ) (F813, G813)
4. Remove access cover from torque converter hous-
See Frame 100 YRM 1120 for lift truck models: ing. Install a lifting eye bolt into rear access cover
• GC/GLC030VX, GC/GLC035VX, bolt hole, and connect a lifting device to eye bolt.
GC/GLC040SVX (C809) Remove ten capscrews that hold torque converter
• GLP/GDP16VX, GLP/GDP18VX, housing to flywheel housing on engine. Carefully
GLP/GDP20SVX (GP/GLP/GDP030VX, separate transmission from engine.
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
NOTE: The torque converter cannot be repaired and
(C810)
must be replaced as a unit, if damaged.
• GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910) 5. Carefully remove torque converter from stator sup-
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) port.
(B875)
See Figure 6 for lift trucks manufactured before July,
2013
CAUTION
Use care when disconnecting the wiring harness See Figure 7 for lift trucks manufactured after July,
connectors from electrical connectors on the trans- 2013
mission and control valve. The connectors on the
transmission and control valve are easily damaged.

1300 YRM 1529 Torque Converter Replace
1. GM 2.4L ENGINE 4. TRANSMISSION

2. CAPSCREW 5. ACCESS COVER
3. TRANSMISSION WIRING HARNESS 6. CONTROL VALVE
Figure 4. Engine-Transmission Combination

Figure 5. Torque Converter Bolt Access

Legend for Figure 5

A. GM 2.4L ENGINE D. GM 4.3L ENGINE
B. MAZDA ENGINE E. CUMMINS 3.3L DIESEL ENGINE
C. YANMAR ENGINE
1. ACCESS HOLE 2. FLYWHEEL HOUSING
6. Remove plug, suction screen spring, and suction 11. Remove transmission oil temperature sensor from
screen from torque converter housing, and drain oil torque converter housing.
from transmission.
See Figure 6 for lift trucks manufactured before July, 2013
2013
See Figure 7 for lift trucks manufactured after July,
See Figure 7 for lift trucks manufactured after July, 2013
2013
NOTE: Perform Step 12 through Step 16 only if repair
7. Remove transmission charge pump. See Charge of the of the transmission chain drive is required. If the
Pump Repair. transmission clutch packs are in need of further repair,
see Clutch Packs Repair.
8. Remove transmission oil filter from torque converter
housing. 12. Remove two long capscrews and washers from in-
ner face of torque converter housing. See Figure 9.
2013 13. Remove 15 capscrews from transmission housing.
See Figure 8.
2013 14. Remove two mounting capscrews and harness
bracket from front of torque converter housing.
9. If damaged, remove two cap screws and small ac- See Figure 8.
cess cover from the torque converter housing.
15. Using a small pry bar in the designated pry points,
10. Remove dipstick and dipstick tube from torque con- remove the torque converter housing from the
verter housing. transmission housing. See Figure 8.
See Figure 6 for lift trucks manufactured before July, 16. Remove and discard O-rings and gasket. See Fig-
2013 ure 9.
2013

1. TRANSMISSION OIL FILTER 9. PLUG

2. DIPSTICK 10. CAPSCREW
3. DIPSTICK TUBE 11. WASHER
4. TRANSMISSION HOUSING 12. SMALL ACCESS COVER
5. TORQUE CONVERTER HOUSING 13. TORQUE CONVERTER
6. TRANSMISSION OIL TEMPERATURE SENSOR 14. TRANSMISSION CHARGE PUMP
7. SUCTION SCREEN 15. STATOR SUPPORT
8. SUCTION SCREEN SPRING 16. PILOT HUB
Figure 6. Torque Converter Removal, Lift Trucks Manufactured Before July, 2013


Figure 7. Torque Converter Removal, Lift Trucks Manufactured After July, 2013

Legend for Figure 8

1. PRY POINTS
2. TORQUE CONVERTER HOUSING
3. TRANSMISSION HOUSING
4. HARNESS BRACKET
5. CAPSCREW
Figure 8. Pry Point Location
1. LONG CAPSCREW 5. TRANSMISSION HOUSING

2. WASHER 6. O-RING
3. TORQUE CONVERTER HOUSING 7. CAPSCREW
4. GASKET
Figure 9. Torque Converter Housing

INSTALL 10. Lubricate the pilot hub on the torque converter with
antiseize compound.
NOTE: Perform Step 1 through Step 4 only if repair of
the transmission chain drive was performed. See Figure 10 for lift trucks manufactured before
July, 2013
1. Install new O-rings and gasket to torque converter
housing and transmission housing. See Figure 9. See Figure 11 for lift trucks manufactured after July,
2013
2. Install harness bracket and two mounting cap-
screws to front of torque converter housing. See 11. Install transmission oil temperature sensor on
Figure 8. torque converter housing.
3. Using fifteen capscrews, install transmission hous- See Figure 10 for lift trucks manufactured before
ing to torque converter housing. Tighten capscrews July, 2013
to 38 N•m (28 lbf ft).
4. Install two washers and long capscrews into face 2013
of torque converter housing. Tighten capscrews to
38 N•m (28 lbf ft). See Figure 9. NOTE: Apply adhesive to entire surface of hole,
20.0 mm (0.79 in.) deep. Also apply adhesive to lower
5. If removed, install small access cover and two cap- 20.0 mm (0.79 in.) of dipstick tube.
screws on torque converter housing. Tighten cap-
screws to 7.9 N•m (69 lbf in). 12. Install dipstick tube and dipstick into torque con-
verter housing.
See Figure 10 for lift trucks manufactured before
July, 2013 See Figure 10 for lift trucks manufactured before
July, 2013
2013 See Figure 11 for lift trucks manufactured after July,
2013
6. Install a new transmission oil filter on torque con-
verter housing. 13. If removed, install a lifting eye bolt into rear access
cover bolt hole, and connect a lifting device to eye
7. Install the transmission charge pump. See Charge bolt.
Pump Repair.
Align torque converter housing with flywheel hous-
8. Install suction screen, suction screen spring, and ing. Make sure pilot hub on torque converter en-
plug into torque converter housing. gages flywheel.

July, 2013 CAUTION
Be careful that you DO NOT damage parts of the
See Figure 11 for lift trucks manufactured after July, torque converter or transmission when the trans-
2013 mission is joined to the engine. Keep the transmis-
sion and engine in alignment until they are com-
9. Install torque converter onto stator support. Make
pletely joined so parts of the transmission are not
sure splines are aligned and converter engages
damaged. Use a crane or lifting device to join the
fully.
transmission to the engine.
14. Install transmission on engine. Install ten cap-
July, 2013
screws that connect torque converter housing to
See Figure 11 for lift trucks manufactured after July, flywheel housing. Tighten capscrews to 38 N•m
2013 (28 lbf ft). See Figure 12.


Figure 10. Torque Converter Installation, Lift Trucks Manufactured Before July, 2013


Figure 11. Torque Converter Installation, Lift Trucks Manufactured After July, 2013



See Frame 100 YRM 1120 for lift truck models:

CAUTION • GC/GLC030VX, GC/GLC035VX,
Use care when connecting the wiring harness GC/GLC040SVX (C809)
connectors to electrical connectors on the trans- • GLP/GDP16VX, GLP/GDP18VX,
mission and control valve. The connectors on the GLP/GDP20SVX (GP/GLP/GDP030VX,
transmission and control valve are easily damaged. GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810)
15. Install transmission wiring harness on trans- • GLC20-35VX (GC/GLC040-070VX,
mission. Connect transmission wiring harness GC/GLC055SVX) (A910)
connectors to control valve and transmission. See • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
Figure 12. (B875)
NOTE: Coat the bolt threads that hold the torque con- 18. Fill transmission to correct level using transmission
verter to flywheel with Loctite™ 242. fluid and procedure indicated in following sections:
16. Rotate engine crankshaft to position the flywheel See Periodic Maintenance 8000 YRM 1150 for lift
mounting holes in line with torque converter mount- truck models:
ing holes. Install capscrews that hold torque con- • GLC20-35VX (GC/GLC040-070VX,
verter to flywheel through access hole of flywheel GC/GLC055SVX) (A910)
housing. See Figure 13. Tighten capscrews to • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
56 N•m (41 lbf ft). (B875)
Remove lifting eye bolt, and install access cover on See Periodic Maintenance 8000 YRM 1207 for lift
torque converter housing. truck models:
• GC/GLC030VX, GC/GLC035VX,
WARNING GC/GLC040SVX (C809)
Make sure the engine and transmission are held in • GLP/GDP16VX, GLP/GDP18VX,
position so that they will not fall and cause an injury GLP/GDP20SVX (GP/GLP/GDP030VX,
and damage to the equipment. GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810)
17. Install engine and transmission as a unit into lift
truck as described in one of the following sections: See Periodic Maintenance 8000 YRM 1248 for lift
truck models:
See Frame 100 YRM 1243 for lift truck models: • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS;
100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818)
GC/GLC120SVX; GC/GLC120VXPRS) (E818) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX ) (G813)
GDP080, 090, 100, 110, 120VX ) (F813, G813)


1300 YRM 1529 Housings and Chain Drive Repair
Legend for Figure 13

C. YANMAR ENGINE
Housings and Chain Drive Repair

REMOVE CAUTION
To prevent possible damage to the transmission as-
WARNING sembly when placing the assembly on a work sur-
Make sure the engine and transmission are held in face, place blocks under the back side of the trans-
position so that they will not fall and cause an injury mission housing for additional support.
and damage to the equipment.
CAUTION
CAUTION Use care when disconnecting the wiring harness
Keep the transmission and engine in alignment un- connectors from electrical connectors on the trans-
til they are completely separated so parts of the mission and control valve. The connectors on the
transmission are not damaged. Use a crane or lift- transmission and control valve are easily damaged.
ing device to separate the transmission from the en-
gine. NOTE: When disconnecting wiring harness connectors
during disassembly, tag each connector to aid in con-
1. Remove engine and transmission as a unit from lift necting the wiring harness during reassembly.
truck as described in one of the following sections:
2. Put engine and transmission on solid blocks on a
See Frame 100 YRM 1243 for lift truck models: work surface. Disconnect transmission wiring con-
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, nectors from control valve and transmission. Re-
100, 120VX; GC/GLC080, 100VXBCS; move transmission wiring harness from transmis-
GC/GLC120SVX; GC/GLC120VXPRS) (E818) sion. See Figure 14.
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX ) (F813, G813)
WARNING
Make sure that the engine/transmission assembly
See Frame 100 YRM 1120 for lift truck models: is stable before attempting to rotate the engine.
GC/GLC040SVX (C809) Use a flashlight to see the bolts as they are rotated
• GLP/GDP16VX, GLP/GDP18VX, into view through the access hole. DO NOT use
GLP/GDP20SVX (GP/GLP/GDP030VX, your fingers to check for alignment of the bolts with
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) the access hole.
(C810)
3. Move each bolt into view through access hole of fly-
wheel housing by rotating crankshaft. Remove four
GC/GLC055SVX) (A910)
capscrews that attach flywheel to torque converter.
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
See Figure 15.
(B875)

Housings and Chain Drive Repair 1300 YRM 1529


C. YANMAR ENGINE


4. Remove access cover from torque converter hous- 7. Remove transmission charge pump. See Charge
ing. Install a lifting eye bolt into rear access cover Pump Repair.
bolt hole, and connect a lifting device to eye bolt.
Remove ten capscrews that hold torque converter 8. Remove two long capscrews and washers from in-
housing to flywheel housing. Carefully separate ner face of torque converter housing. See Fig-
transmission from the engine. ure 18.
5. Carefully remove torque converter from stator sup- 9. Remove 15 capscrews from transmission housing.
port. See Figure 19.
See Figure 16 for lift trucks manufactured before 10. Remove two mounting capscrews and harness
July, 2013 bracket from front of torque converter housing.
See Figure 19.
2013 11. Using a small pry bar in the designated pry points,
remove the torque converter housing from the
6. Remove plug, suction screen spring, and suction transmission housing. See Figure 19.
screen from torque converter housing and drain oil
from the transmission. 12. Remove and discard O-rings and gasket. See Fig-
ure 18.
July, 2013

2013


Figure 16. Torque Converter Housing Removal, Lift Trucks Manufactured Before July, 2013


Figure 17. Torque Converter Housing Removal, Lift Trucks Manufactured After July, 2013


2. WASHER 6. O-RING
4. GASKET

1. PRY POINTS
3. TRANSMISSION HOUSING
4. HARNESS BRACKET
5. CAPSCREW
Figure 19. Pry Point Location

NOTE: While performing Step 13, note position of oil INSPECT

seal to aid in installation of new oil seal.
1. Inspect snubbers for cracks or wear. If damaged or
13. Remove and discard oil seal from rear of torque worn, replace both snubbers.
converter housing. See Figure 20.
2. Inspect chain, sprockets, and stator support for
14. Remove two snubbers from transmission housing. damage. If damage is present, replace damaged
See Figure 20. component.
15. Carefully remove pump drive chain, driven 3. Inspect driving and driven gears for damage or
sprocket, driving sprocket, and bearings from wear to gear teeth. If gear teeth are worn or dam-
transmission housing. See Figure 20. aged, replace gear.
16. Remove bearing from driven sprocket. See Fig- 4. Inspect splines on the input shaft for damage. If
ure 20. damaged, replace input clutch pack. See Clutch
Packs Repair.
17. Remove angular contact bearing, bushing, and
O-ring from driving sprocket. Discard O-ring. See INSTALL
Figure 20.
1. Install new O-rings on transmission housing. See
18. Remove four capscrews, lockwashers, and stator Figure 20.
support from transmission housing. Remove and
discard sealing ring and O-ring from stator support. 2. Install the baffle in transmission housing. See Fig-
See Figure 20. ure 20.
19. Remove baffle from transmission housing. See Fig- 3. Install new sealing ring and O-ring on the stator
ure 20. support. See Figure 20.
20. Remove O-rings from transmission housing and 4. Install stator support, lockwashers, and capscrews
discard. See Figure 20. on transmission housing. Tighten capscrews to
38 N•m (28 lbf ft). See Figure 20.
CLEAN
5. On a lint-free cloth, place driving sprocket on right
side, driven sprocket on left side, and place chain
WARNING around both sprockets (see Figure 20). Install bear-
Cleaning solvents can be flammable and toxic and ings on sprockets. The angular bearing should be
can cause skin irritation. When using cleaning installed onto driving sprocket with thinner shoulder
solvents, always follow the solvent manufacturer’s of outer race towards the sprocket and wider shoul-
recommended safety procedures. der of outer race (side marked with part number)
towards torque converter housing. Carefully place
Compressed air can move particles so they cause
driving and driven sprockets, chain, and bearings
injury to the user or to other personnel. Make sure
assembly on transmission. Install two snubbers on
the path of the compressed air is away from all per-
transmission housing. See Figure 20.
sonnel. Wear protective goggles or a face shield to
prevent injury to the eyes. 6. Install new oil seal into rear of torque converter
housing as noted during removal.
1. Clean snubbers with warm, soapy water and dry
with compressed air. 7. Install new O-rings and gasket on torque converter
housing. See Figure 21.
2. Clean bearings, chain, stator support, and gears
with solvent and dry with compressed air.

1. SNUBBER 9. DRIVING SPROCKET

2. PUMP DRIVE CHAIN 10. CAPSCREW
3. BEARING 11. LOCKWASHER
4. DRIVEN SPROCKET 12. STATOR SUPPORT
5. OIL SEAL 13. SEALING RING
6. ANGULAR CONTACT BEARING 14. TRANSMISSION HOUSING
7. BUSHING 15. BAFFLE
8. O-RING
Figure 20. Chain Drive

8. Using fifteen capscrews, install transmission hous- See Figure 22 for lift trucks manufactured before
ing to torque converter housing. Tighten capscrews July, 2013
to 38 N•m (28 lbf ft). See Figure 21.
9. Install two washers and long capscrews into face 2013
of torque converter housing. Tighten capscrews to
38 N•m (28 lbf ft). See Figure 21. 13. Lubricate the pilot hub on the torque converter with
antiseize compound.
10. Install harness bracket and two mounting cap-
screws to front of torque converter housing. See See Figure 22 for lift trucks manufactured before
Figure 19. July, 2013
11. Install suction screen, suction screen spring, and See Figure 23 for lift trucks manufactured after July,
plug into torque converter housing. 2013
See Figure 22 for lift trucks manufactured before 14. Install the transmission charge pump. See Charge
July, 2013 Pump Repair.
See Figure 23 for lift trucks manufactured after July, 15. If removed, install a lifting eye bolt into rear access
2013 cover bolt hole, and connect a lifting device to eye
bolt. Align torque converter housing with flywheel
12. Install torque converter onto input shaft and stator housing. Make sure pilot hub on torque converter
support of the transmission. Make sure splines are engages flywheel.
aligned and converter engages fully.

2. WASHER 6. O-RING
4. GASKET


Figure 22. Torque Converter Housing Installation, Lift Trucks Manufactured Before July, 2013

16. Install transmission to engine. Install ten capscrews NOTE: Coat the bolt threads that hold the torque con-
that connect torque converter housing to flywheel verter to flywheel with Loctite™ 242.
housing. Tighten capscrews to 38 N•m (28 lbf ft).
See Figure 24. 18. Rotate engine crankshaft to position the flywheel
mounting holes in line with torque converter mount-
ing holes. Install capscrews that hold torque con-
CAUTION verter to flywheel through access hole of flywheel
Use care when connecting the wiring harness housing. See Figure 25. Tighten capscrews to
connectors to electrical connectors on the trans- 56 N•m (41 lbf ft).
transmission and control valve are easily damaged. Remove lifting eye bolt, and install access cover on
torque converter housing.
17. Install transmission wiring harness on trans-
mission. Connect transmission wiring harness
connectors to control valve and transmission. See
Figure 24.

Figure 23. Torque Converter Housing Installation, Lift Trucks Manufactured After July, 2013





C. YANMAR ENGINE
19. Install engine and transmission as a unit into lift See Periodic Maintenance 8000 YRM 1150 for lift
truck as described in one of the following sections: truck models:
See Frame 100 YRM 1243 for lift truck models: GC/GLC055SVX) (A910)
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
100, 120VX; GC/GLC080, 100VXBCS; (B875)
GC/GLC120SVX; GC/GLC120VXPRS) (E818)
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, See Periodic Maintenance 8000 YRM 1207 for lift
GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ truck models:
GDP080, 090, 100, 110, 120VX ) (F813, G813) • GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809)
See Frame 100 YRM 1120 for lift truck models: • GLP/GDP16VX, GLP/GDP18VX,
• GC/GLC030VX, GC/GLC035VX, GLP/GDP20SVX (GP/GLP/GDP030VX,
GC/GLC040SVX (C809) GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
• GLP/GDP16VX, GLP/GDP18VX, (C810)
GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) See Periodic Maintenance 8000 YRM 1248 for lift
(C810) truck models:
• GLC20-35VX (GC/GLC040-070VX, • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
GC/GLC055SVX) (A910) 100, 120VX; GC/GLC080, 100VXBCS;
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) GC/GLC120SVX; GC/GLC120VXPRS) (E818)
(B875) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
20. Fill transmission to the correct level using transmis- GDP080, 090, 100, 110, 120VX ) (G813)
sion fluid and procedure indicated in the following
sections:

Clutch Packs Repair 1300 YRM 1529
Clutch Packs Repair

REMOVE AND DISASSEMBLE CAUTION
Transmission, Remove and Disassemble Use care when disconnecting the wiring harness
connectors from electrical connectors on the trans-
WARNING transmission and control valve are easily damaged.
Make sure the engine and transmission are held in
position so that they will not fall and cause an injury NOTE: When disconnecting wiring harness connectors
and damage to the equipment. during disassembly, tag each connector to aid in con-
necting the wiring harness during reassembly.
CAUTION 2. Put engine and transmission on solid blocks on a

Be careful that you do not damage parts of the work surface.
torque converter or transmission when the trans-
Disconnect two connectors of chassis wiring har-
mission is separated from the engine. Keep the
ness from transmission wiring harness.
transmission and engine in alignment until they are
completely separated so parts of the transmission Disconnect transmission wiring harness connec-
are not damaged. Use a crane or lifting device to tors from control valve and transmission. Remove
separate the transmission from the engine. transmission wiring harness from transmission.
See Figure 26.
1. Remove engine and transmission as a unit from lift
truck as described in one of the following sections:
WARNING
Make sure that the engine/transmission assembly
is stable before attempting to rotate the engine.
100, 120VX; GC/GLC080, 100VXBCS;
GC/GLC120SVX; GC/GLC120VXPRS) (E818) Use a flashlight to see the bolts as they are rotated
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, into view through the access hole. DO NOT use
GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ your fingers to check for alignment of the bolts with
GDP080, 090, 100, 110, 120VX ) (F813, G813) the access hole.
See Frame 100 YRM 1120 for lift truck models: 3. Move each bolt into view through access hole of fly-
• GC/GLC030VX, GC/GLC035VX, wheel housing by rotating crankshaft. Remove four
GC/GLC040SVX (C809) capscrews that attach flywheel to torque converter.
• GLP/GDP16VX, GLP/GDP18VX, See Figure 27.
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) 4. Remove access cover from torque converter hous-
(C810) ing. Install a lifting eye bolt into rear access cover
• GLC20-35VX (GC/GLC040-070VX, bolt hole, and connect a lifting device to eye bolt.
GC/GLC055SVX) (A910) Remove ten capscrews that hold torque converter
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) housing to flywheel housing. Carefully separate
(B875) transmission from engine.
5. Remove torque converter housing from transmis-

CAUTION sion housing. See Housings and Chain Drive Re-
To prevent possible damage to the transmission as- pair, Remove.
sembly when placing the assembly on a work sur-
face, place blocks under the back side of the trans- 6. Remove idler gear and two bearings. See Fig-
mission housing for additional support. ure 28.

1300 YRM 1529 Clutch Packs Repair
7. Remove bolt, stato seal, and yoke from back of 9. Remove oil seal from back of transmission housing.
transmission housing. See Figure 28. See Figure 28.
8. Remove spacer from yoke. See Figure 28. 10. Remove bearing, snap ring, special nut, output
gear, and bearing from transmission housing. See
NOTE: Note the position of the oil seal during removal Figure 28.
to aid in installation.




C. YANMAR ENGINE
1. BEARING 8. OIL SEAL

2. IDLER GEAR 9. YOKE
3. SNAP RING 10. STATO SEAL
4. SPECIAL NUT 11. BOLT
5. OUTPUT GEAR 12. REVERSE GEAR
6. TRANSMISSION HOUSING 13. FORWARD CLUTCH PACK
7. SPACER 14. HIGH FORWARD CLUTCH PACK
Figure 28. Output Gear Removal

11. Removal and disassembly of clutch assemblies fol- See Figure 30 for reverse clutch pack
lows. The procedures are the same for forward, re-
verse, and high clutch pack assemblies. See Figure 31 for high clutch pack
See Figure 29 for forward clutch pack
Figure 29. Forward Clutch Pack


1. SEAL 8. SNAP RING
2. BEARING 9. CONICAL PLATE
3. GEAR ASSEMBLY DRUM 10. FRICTION DISK
4. PISTON SEAL 11. SEPARATOR PLATE
5. PISTON 12. PRESSURE PLATE
6. SPRING 13. BACK PLATE
7. SPRING GUIDE 14. OUTPUT GEAR


6. SPRING 13. OUTPUT GEAR
7. SPRING GUIDE 14. BACK PLATE
Figure 30. Reverse Clutch Pack


6. SPRING 13. BACK PLATE
7. SPRING GUIDE 14. OUTPUT GEAR
Figure 31. High Clutch Pack

Clutch Assemblies, Remove and Disassemble

STEP 1.
Pull forward clutch (low gear), reverse clutch and for-
ward clutch (high gear) assemblies straight out from
transmission housing.
1. FORWARD CLUTCH (LOW GEAR)

2. REVERSE CLUTCH
3. FORWARD CLUTCH (HIGH GEAR)
4. TRANSMISSION INPUT SPEED SENSOR (TISS)
5. TRANSMISSION OUTPUT SPEED SENSOR
(TOSS)
STEP 2.
Remove shaft seal and bearing from forward (low)
clutch pack input shaft. Discard shaft seal. Remove
bearing from forward (high) and reverse gear packs.

3. REVERSE CLUTCH
4. BEARING
5. SHAFT SEAL

STEP 3.
Remove snap ring from output gear. Remove output
gear from input shaft

3. REVERSE CLUTCH
4. OUTPUT GEAR
5. SNAP RING
NOTE: Before removing seal bearing, note position of seal on bearing.
STEP 4.
Remove seal from output gear. Remove seal bearing,
snap ring, and bearing from output gear.
1. SEAL BEARING 4. OUTPUT GEAR

2. SNAP RING 5. BEARING
3. SEAL

STEP 5.
Remove snap ring, back plate and pressure plate from

gear assembly drum.
1. SNAP RING
2. BACK PLATE
3. PRESSURE PLATE
4. GEAR ASSEMBLY DRUM

STEP 6.
Remove friction disks and separator plates alternately until all have been removed from gear assembly drum
1. FRICTION DISK 3. GEAR ASSEMBLY DRUM

2. SEPARATOR PLATE
STEP 7.
Remove conical plate from gear assembly drum.
1. CONICAL PLATE

WARNING
The springs for the piston are compressed. Make sure the springs and spring retainer cannot cause injury
when the snap ring is removed.
NOTE: Remove piston only if there is a problem with piston or piston seals.
STEP 8.
Using spring compression tool, Yale P/N 150121831,
and a press, place spring compression tool on spring
guide with opening of the tool above opening of snap
ring, and compress large and small springs just enough
to allow removal of snap ring from spring guide. Slowly
release press to decompress springs.
1. SPRING COMPRESSION TOOL

2. SPRING GUIDE

STEP 9.
Remove snap ring, spring guide, large spring, and small
spring from input shaft.
1. SNAP RING 4. SMALL SPRING

2. SPRING GUIDE 5. INPUT SHAFT
3. LARGE SPRING
STEP 10.
Remove piston from gear assembly drum and piston
seal from piston. Discard piston seal.
1. PISTON
2. PISTON SEAL
4. SHAFT SEAL

STEP 11.
Remove shaft seals and bearing from input shaft. Dis-
card shaft seals.
1. SHAFT SEALS 3. INPUT SHAFT

2. BEARING
CLEAN 4. The conical plate and separator plates must not be

bent, have damaged surfaces, or have large blue
WARNING areas from too much heat. If any of the above con-
ditions exist, replace damaged component.
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning 5. Check "H" dimension of conical plate as shown
solvents, always follow the solvent manufacturer’s in Figure 32. If dimension is less than 3.2 mm
recommended safety procedures. (0.126 in.), replace conical plate.
Clean all metal parts with cleaning solvent and place 6. Check "t" dimension of conical plate as shown
on a lint-free cloth to dry. Ensure that the cleaning and in Figure 32. If dimension is less than 2.4 mm
assembly environment is free of dust, dirt, and any other (0.094 in.), replace conical plate.
foreign matter that would affect the performance of the
parts. 7. Inspect bearings for wear or damage. If bearings
are damaged, replace them.
INSPECT
8. Inspect piston for damage. Make sure that sealing
1. Inspect gear teeth on clutch assemblies and all surfaces are good. Make sure orifice is clean.
other gears for wear or damage. If the gear teeth
are worn or damaged, replace damaged compo-
nent.
2. Check all parts that have splines for damage to

splines. Check for notches worn in splines. Re-
place clutch pack or gears that have spline damage.
3. Inspect friction discs for burned lining or bent sur-

faces. Check for small holes in the lining. Replace
friction discs if one-half depth of oil grooves is worn
away or discs are damaged. Discard a friction disc
that has a thickness less than 2.2 mm (0.087 in.). Figure 32. Conical Plate Inspection

9. Check for grooves or other damage on machined

surfaces of clutch pack shafts and transmission CAUTION
housing. Check mounting and sealing surfaces in The dowel pins are used to properly align the hous-
housing for damage. If there is evidence of any ings for proper mating to each other. If the align-
damage, replace housing or transmission. If clutch ment is not correct, damage to the transmission as-
pack shaft is damaged, replace clutch pack. sembly could occur.
10. Inspect all hardware and mounting surfaces for 11. Inspect dowel pins and dowel pin holes. If any
presence of rust, sealing compounds, and usable dowel pin is damaged at all, replace the dowel pin.
condition. If hardware is to be reused, clean all If a dowel pin hole is damaged, replace housing.
rust and sealing compounds from threaded areas.
If hardware is not in usable condition, replace 12. Check fit of bearings in transmission housings. If
hardware. bearings fit too loosely into the housings, this could
mean that bores are oversized. Replace housings
as necessary.
ASSEMBLE AND INSTALL
Clutch Assemblies, Assemble and Install

STEP 1.
Install bearing and new shaft seals on input shaft.
1. SHAFT SEALS 3. INPUT SHAFT

2. BEARING

NOTE: Perform STEP 2 through STEP 5 only if piston was removed.
STEP 2.
Lubricate all parts with clean transmission oil. Install
shaft seal on shaft and piston seal on piston.
1. PISTON SEAL 2. PISTON
STEP 3.
Install piston into gear assembly drum.
1. PISTON
2. PISTON SEAL
4. SHAFT SEAL

STEP 4.
Install small spring, large spring, spring guide, and snap
ring on the input shaft.
1. SNAP RING 4. SMALL SPRING

2. SPRING GUIDE 5. INPUT SHAFT
3. LARGE SPRING

STEP 5.
Using spring compression tool, Yale P/N 150121831,
and a press, place spring compression tool on spring
guide with opening of tool above opening of the snap
ring, and compress large and small springs just enough
to allow installation of snap ring in spring guide. Slowly
release press.
1. SPRING COMPRESSION TOOL

2. SPRING GUIDE

NOTE: The conical plate is properly installed when inner diameter is touching piston, and outer diameter of conical
plate is touching outer diameter of friction disk.
STEP 6.
Install conical plate into gear assembly drum.
1. CONICAL PLATE

STEP 7.
Install separator plates and friction disks alternately until all have been installed in gear assembly drum.
1. FRICTION DISK 3. GEAR ASSEMBLY DRUM

2. SEPARATOR PLATE

STEP 8.
Install pressure plate, back plate and snap ring in gear

assembly drum. Using a dial indicator or feeler gauge,
check clearance between snap ring and pressure plate.
There must be 2.7±0.2 mm (0.106±0.008 in.) of clear-
ance. If clearance is not correct, see Parts Manual for
correct pressure plate.
1. SNAP RING
2. BACK PLATE
3. PRESSURE PLATE
NOTE: Make sure seal on seal bearing is in correct position as noted during removal.
STEP 9.
Install seal onto output gear. Install bearing, snap ring,
and seal bearing into output gear.
1. SEAL BEARING 4. OUTPUT GEAR

2. SNAP RING 5. BEARING
3. SEAL

STEP 10.
Install output gear on input shaft. Install bearing and
snap ring in output gear.

3. REVERSE CLUTCH
4. OUTPUT GEAR
5. SNAP RING
STEP 11.
Install bearing and shaft seal on input shaft for Forward
(low) gear pack. Install bearing to Forward (high) and
Reverse gear packs.

3. REVERSE CLUTCH
4. BEARING
5. SHAFT SEAL

STEP 12.
Install reverse clutch assembly in transmission housing.
DO NOT damage seal rings on end of clutch shaft.
Check gap between TOSS and TISS sensors and re-

verse gear. The allowable gap for TOSS sensor is 0.8
to 1.8 mm (0.031 to 0.071 in.). The allowable gap for
TISS sensor is 0.8 to 2.0 mm
(0.031 to 0.080 in.).
1. REVERSE CLUTCH 3. TISS SENSOR

2. FORWARD 4. TOSS SENSOR
CLUTCH
STEP 13.
Install forward clutch assemblies (high and low) in trans-
mission housing. DO NOT damage seal rings on end of
clutch shaft.
1. REVERSE CLUTCH 3. TISS SENSOR

2. FORWARD 4. TOSS SENSOR
CLUTCH

Transmission, Assemble and Install

CAUTION
1. Install bearing, output gear, special nut, snap ring, Use care when connecting the wiring harness
and bearing on transmission. See Figure 33. connectors to electrical connectors on the trans-
2. Install oil seal into back of transmission as noted
transmission and control valve are easily damaged.
during removal.
7. Install transmission wiring harness on transmis-
3. Install spacer in yoke.
sion. Connect transmission wiring harness con-
4. Install yoke, stato seal, and bolt in back of trans- nectors to control valve and transmission. Connect
mission. Tighten bolt to 38 N•m (28 lbf ft). See two chassis wiring harness connectors to trans-
Figure 33. mission wiring harness. See Figure 34.
5. Install two bearings and idler gear. See Figure 33.
6. Install torque converter housing on transmission.

See Housings and Chain Drive Repair, Install.
1. BEARING 8. SPACER
2. IDLER GEAR 9. YOKE
3. SNAP RING 10. STATO SEAL
4. SPECIAL NUT 11. BOLT
5. OUTPUT GEAR 12. REVERSE GEAR
6. TRANSMISSION HOUSING 13. FORWARD CLUTCH PACK (LOW)
7. OIL SEAL 14. FORWARD CLUTCH PACK (HIGH)
Figure 33. Output Gear Installation



NOTE: Coat the bolt threads that hold the torque con- • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
verter to flywheel with Loctite™ 242. (B875)
8. Rotate engine crankshaft to position the flywheel 10. Fill transmission to the correct level using transmis-
mounting holes in line with torque converter mount- sion fluid and procedure indicated in the following
ing holes. Install capscrews that hold torque con- sections:
verter to flywheel through access hole of flywheel
housing. See Figure 35. Tighten capscrews to See Periodic Maintenance 8000 YRM 1150 for lift
56 N•m (41 lbf ft). truck models:
Remove lifting eye bolt, and install access cover on GC/GLC055SVX) (A910)
torque converter housing. • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875)
9. Install engine and transmission as a unit into lift
truck as described in one of the following sections: See Periodic Maintenance 8000 YRM 1207 for lift
truck models:
See Frame 100 YRM 1243 for lift truck models: • GC/GLC030VX, GC/GLC035VX,
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, GC/GLC040SVX (C809)
100, 120VX; GC/GLC080, 100VXBCS; • GLP/GDP16VX, GLP/GDP18VX,
GC/GLC120SVX; GC/GLC120VXPRS) (E818) GLP/GDP20SVX (GP/GLP/GDP030VX,
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ (C810)
GDP080, 090, 100, 110, 120VX ) (F813, G813)
See Periodic Maintenance 8000 YRM 1248 for lift
See Frame 100 YRM 1120 for lift truck models: truck models:
• GC/GLC030VX, GC/GLC035VX, • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
GC/GLC040SVX (C809) 100, 120VX; GC/GLC080, 100VXBCS;
• GLP/GDP16VX, GLP/GDP18VX, GC/GLC120SVX; GC/GLC120VXPRS) (E818)
GLP/GDP20SVX (GP/GLP/GDP030VX, • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
(C810) GDP080, 090, 100, 110, 120VX ) (G813)

C. YANMAR ENGINE


Control Valve Repair 1300 YRM 1529
Control Valve Repair

REMOVE AND DISASSEMBLE 4. Remove capscrew, lock washer and the transmis-
sion input speed sensor (TISS) from transmission.
CAUTION See Figure 38.
Use care when disconnecting the wiring harnesses
from the connectors. The connectors are easily
damaged.
1. Clean area around control valve. Put identification

tags on wire harness connectors and connectors on
transmission and control valve. Disconnect wiring
harness connectors from transmission and control
valve connectors. Remove cable connector from
standoff located on torque converter housing. See
Figure 36.
2. Remove capscrews and lockwashers from control

valve and transmission. See Figure 37.
3. Remove control valve assembly and gasket from

transmission. Discard gasket. Put a cover on top
of the transmission to keep dirt out of the transmis-
sion. See Figure 37.
1. TRANSMISSION ASSEMBLY
2. GASKET
3. CONTROL VALVE ASSEMBLY
4. LOCKWASHER
5. CAPSCREW
(TOSS)
Figure 37. Control Valve Removal

2. HARNESS STANDOFF
3. TRANSMISSION WIRING HARNESS
Figure 36. Transmission Assembly

1300 YRM 1529 Control Valve Repair
NOTE: Disassemble the control valve in a clean, con-

tamination-free area.
6. Remove two pressure transducers and two fittings

from control valve body. See Figure 39.
WARNING
There are compressed springs under the plugs in
the control valve. Carefully remove the plugs so
that the compressed springs do not cause injury.
7. Remove plug for proportional supply regulator

spool. Discard O-ring. See Figure 39.
8. Remove spring and proportional supply regulator

spool from control valve body. See Figure 39.
9. Remove plug for torque converter regulator spool.

Discard O-ring. See Figure 39.
10. Remove the spring and torque converter regulator

spool from control valve body. See Figure 39.
1. TRANSMISSION ASSEMBLY 11. Remove plug for supply spool. Discard O-ring. See
(TOSS) Figure 39.
4. LOCK WASHER 12. Remove the spring and supply spool from the con-
5. CAPSCREW trol valve body. See Figure 39.
Figure 38. Transmission Speed Sensor 13. Remove socket head screws and forward propor-
tional valve from control valve body. Repeat for re-
5. Remove capscrew, lock washer and the transmis- verse proportional valve. See Figure 39.
sion output speed sensor (TOSS) from transmis-
sion. See Figure 38. 14. Remove socket head screws and transmission en-
able valve from control valve body. See Figure 39.
NOTE: Disassemble control valve only to extent re-
quired for repairs.

Control Valve Repair 1300 YRM 1529
1. CONTROL VALVE BODY 7. FORWARD PROPORTIONAL VALVE

2. PRESSURE TRANSDUCER 8. SOCKET HEAD SCREW
3. FITTING 9. TORQUE CONVERTER REGULATOR SPOOL
4. PROPORTIONAL SUPPLY REGULATOR SPOOL 10. REVERSE PROPORTIONAL VALVE
5. SPRING 11. TRANSMISSION ENABLE VALVE
6. PLUG 12. SUPPLY SPOOL
Figure 39. Control Valve Arrangement

1300 YRM 1529 Control Valve Repair
CLEAN 2. Install reverse proportional valve, forward propor-

tional valve, and socket head screws onto control
WARNING valve body. Tighten socket head screws to 3 to
4 N•m (27 to 35 lbf in). See Figure 39.
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning 3. Install supply spool and spring into control valve
solvents, always follow the solvent manufacturer’s body. Install new O-ring on plug. Install plug into
recommended safety procedures. control valve body. See Figure 39.
Compressed air can move particles so they cause 4. Install torque converter regulator spool and spring
injury to the user or to other personnel. Make sure into control valve body. Install new O-ring on plug.
the path of the compressed air is away from all per- Install plug into control valve body. See Figure 39.
sonnel. Wear protective goggles or a face shield to
prevent injury to the eyes. 5. Install proportional supply regulator spool and
spring into control valve body. Install new O-ring
on plug. Install plug into control valve body. See
CAUTION
Figure 39.
DO NOT allow cleaning solvent to come in contact
with rubber or plastic components as it can damage 6. Install two fittings and two pressure transducers into
those components. control valve body. See Figure 39.
Clean all metal components in solvent and dry with 7. Install transmission input speed sensor (tiss) and
compressed air. capscrew in transmission. Tighten capscrews to
6.9 N•m (61 lbf in). See Figure 39.
INSPECT
8. Install the transmission output speed sensor (toss)
1. Make sure there are no scratches or damage on the and capscrew in the transmission. Tighten cap-
spools or in the bores of the control valve body. If screws to 6.9 N•m (61 lbf in). See Figure 39.
the control valve body bores are damaged, replace
the control valve. 9. Install a new control valve gasket on transmis-
sion. Install control valve on transmission. See
2. Inspect the control valve body for the presence of Figure 37. Install capscrews that hold control valve
burrs. Burrs may be removed using a fine file, on transmission. DO NOT tighten at this time. See
emery cloth, or crocus cloth. Figure 39.
3. Check that the springs are not bent or damaged. 10. Tighten capscrews to 13.3 N•m (118 lbf in) in the se-
Make sure the spools move freely in their bores. quence shown in Figure 40. Retighten capscrews
to 19 N•m (168 lbf in) in sequence shown in Fig-
4. Inspect the connectors on the proportional and so-
ure 40.
lenoid valves and, if they are damaged, replace the
damaged proportional or solenoid valves.
CAUTION
ASSEMBLE AND INSTALL Use care when connecting the wiring harnesses to
the connectors. The connectors are easily dam-
NOTE: Lubricate the parts of the control valve with aged.
clean transmission oil during assembly.
11. Install cable connector in standoff and connect
1. Install transmission enable valve and socket head wiring harness connectors to transmission and
screws onto control valve body. Tighten socket control valve as tagged during removal. See Fig-
head screws to 3 to 4 N•m (27 to 35 lbf in). See ure 36.
Figure 39.

Foot Directional Control Pedal Repair 1300 YRM 1529
Figure 40. Control Valve Mounting Screw

Tightening Sequence
Foot Directional Control Pedal Repair

REMOVE AND DISASSEMBLE
1. Remove five screws, dash panel, and kick plate
from lift truck.

100, 120VX; GC/GLC080, 100VXBCS;
GC/GLC120SVX; GC/GLC120VXPRS) (E818)
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GDP080, 090, 100, 110, 120VX ) (G813)

GC/GLC040SVX (C809)
• GLP/GDP16VX, GLP/GDP18VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810)
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875)
Remove three capscrews and swing hydraulic lever

assembly toward operator’s seat. Disconnect two
cable assemblies from the pedal assembly. See 1. CAPSCREW
Figure 41. 2. HYDRAULIC LEVER ASSEMBLY
Figure 41. Hydraulic Lever Relocation

1300 YRM 1529 Foot Directional Control Pedal Repair
2. Remove three capscrews that hold throttle base to

cowl, and remove pedal assembly from lift truck. CAUTION
See Figure 42. Use care when removing the connector from its
holder as the connector can be easily damaged.
NOTE: Remove only those components necessary

to complete the repair of the Foot Directional Control
pedal.
4. Remove connector from connector holder on throt-

tle base. Remove outer and inner springs from
throttle base and Foot Directional Control pedal as-
sembly.
5. Remove e-clip and throttle base from throttle pedal

shaft. Remove roll pin and throttle pedal shaft from
Foot Directional Control pedal assembly. Discard
roll pin.
NOTE: Tag wires prior to removing from microswitches

to aid in connecting.
6. Remove u-clip, foam lock seal, and wiring harness

from pedal frame. Remove four pan head screws,
lockwashers, washers, pedal pad, and springs from
pedal frame. If any metal inserts in pedal pad are
damaged, replace as necessary. See Figure 44.
7. Remove two hex head screws, lockwashers, nuts,

and microswitch from pedal pad. Repeat for re-
maining microswitch and remove wiring harness
from pedal frame.
1. CAPSCREWS 3. COWL
2. PEDAL ASSEMBLY 8. If damaged, remove stop screw and nut from pedal
frame.
Figure 42. Foot Directional Control Pedal Removal
3. Remove two pan head screws, lockwashers, and

accelerator position sensor from throttle base. See
Figure 43.

1. PAN HEAD SCREW 6. THROTTLE PEDAL SHAFT

2. LOCKWASHER 7. E-CLIP
3. ACCELERATOR POSITION SENSOR (APS) 8. ROLL PIN
4. PEDAL FRAME 9. INNER AND OUTER SPRINGS
5. CONNECTOR 10. FOOT DIRECTIONAL CONTROL ASSEMBLY
Figure 43. Foot Directional Control Pedal Bracket Disassembly

1. WIRING HARNESS 9. METAL INSERT

2. FOAM LOCK SEAL 10. NUT
3. U-CLIP 11. LOCKWASHER
4. PAN HEAD SCREW 12. MICROSWITCH
5. LOCKWASHER 13. HEX HEAD SCREW
6. WASHER 14. SPRING
7. STOP SCREW 15. PEDAL PAD
8. NUT 16. PEDAL FRAME
Figure 44. Foot Directional Control Pedal Disassembly

ASSEMBLE AND INSTALL 7. Install inner and outer springs on throttle base and
Foot Directional Control pedal assembly. Install
1. If removed, install stop screw and nut on pedal connector in connector holder on throttle base.
frame. See Figure 44.
8. Install actuator and magnet in the throttle base. In-
2. Install microswitch and two hex head screws in stall accelerator position sensor, lockwashers, and
pedal pad. Coat exposed threads of hex head two pan head screws in the throttle base. Tighten
screws with Loctite™ 222. Install two lockwashers screws to 2.25 N•m (19 lbf in).
and nuts on hex head screws. DO NOT tighten
nuts at this time. Repeat for the other microswitch. 9. Apply adhesive compound to three mounting bolts.
Using three capscrews that hold the throttle base
3. Put wires through hole in pedal frame. The white to the cowl, install the pedal assembly on lift truck.
banded wire is for reverse microswitch, and the blue Tighten the bolts to 19 to 25 N•m (168 to 221 lbf in).
banded wire is for forward microswitch. Adjust each See Figure 42.
microswitch in its mount so that the measurement
between the edge of the mount and the base of the 10. Connect two cable assemblies to pedal assembly.
microswitch equals 0.0 to 0.5 mm (0.0 to 0.02 in.). Swing hydraulic lever assembly toward cowl and in-
Tighten the mounting nuts of each microswitch as stall three capscrews. See Figure 41. Install dash-
adjustment is completed. See Figure 45. board on the lift truck.
4. Install wiring harness in the pedal frame. Install See Frame 100 YRM 1243 for lift truck models:
foam lock seal and u-clip. Install pedal pad and • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
springs in the pedal frame. Coat threads of four 100, 120VX; GC/GLC080, 100VXBCS;
pan head screws with Loctite 222. Install pan head GC/GLC120SVX; GC/GLC120VXPRS) (E818)
screws, lockwashers, and washers in the pedal • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
pad. Tighten pan head screws to 2.25 to 2.50 N•m GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
(19 to 32 lbf in). GDP080, 090, 100, 110, 120VX ) (G813)
5. Using an ohmmeter, check for continuity between See Frame 100 YRM 1120 for lift truck models:
pins 3 and 4 of the Foot Directional Control wiring • GC/GLC030VX, GC/GLC035VX,
harness connector with the Foot Directional Control GC/GLC040SVX (C809)
pedal in the reverse position, and between pins 1 • GLP/GDP16VX, GLP/GDP18VX,
and 2 with the pedal in the forward position. See GLP/GDP20SVX (GP/GLP/GDP030VX,
Figure 46. GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810)
6. Install throttle pedal shaft and new roll pin in the • GLC20-35VX (GC/GLC040-070VX,
Foot Directional Control pedal assembly. Install GC/GLC055SVX) (A910)
throttle base and e-clip on throttle pedal shaft. See • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
Figure 43. (B875)
11. Depress the Foot Directional Control pedal until it

CAUTION stops. Unscrew stop screw until it contacts metal
Use care when installing the connector in its holder floor plate. Tighten nut to 10 N•m (89 lbf in).
as the connector can be easily damaged.

1. WIRING HARNESS CONNECTOR

2. WIRING HARNESS
Figure 46. Microswitch Continuity Check
1. MICROSWITCH MOUNT
2. MICROSWITCH BASE
Figure 45. Microswitch Adjustment

Direction Control Lever 1300 YRM 1529
Direction Control Lever

REMOVE enough to free tab of interior lock of the display
panel. See B, Figure 47.
NOTE: There is no repair of the direction control lever.
3. Repeat above steps on the opposite side of direc-
1. Insert a small, flat-blade screwdriver with a tion control lever. Remove direction control lever
3.175 mm (0.125 in.) or less, wide blade into from display panel.
opening on display panel on an outward angle
enough to compress spring tab on direction control INSTALL
lever. See A, Figure 47.
Slide the direction control lever into opening on left side
2. Pry spring tab toward body of direction control lever of display panel until locking tabs are engaged in display
and, at the same time, pull on the handle of lever panel.
NOTE: DISPLAY PANEL SHOWN OUTSIDE OF LIFT TRUCK FOR CLARITY.

A. STEP 1 B. STEP 2
1. DIRECTION CONTROL LEVER 3. DISPLAY PANEL
2. FLAT-BLADE SCREWDRIVER
Figure 47. Direction Control Lever Removal

Yale Europe Materials Handling Limited
Flagship House, Reading Road North, Fleet, Hampshire GU138 HR United Kingdom
1300 YRM 1529 8/13 (10/11) Printed in the United Kingdom

YALE GDP40VX Transmission

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Maintenance

PART NO. 550043436 1300 YRM 1529

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

This section is for the following models:

GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX [C809];

©2013 Yale Materials Handling Corp. i

1. TRANSMISSION SERIAL NUMBER

Figure 1. Transmission Serial Number Location

Confidential/Proprietary - Do Not Copy or Duplicate 1

Charge Pump Repair

Figure 2. Transmission Charge Pump

2 Confidential/Proprietary - Do Not Copy or Duplicate

Figure 3. Transmission Charge Pump

Confidential/Proprietary - Do Not Copy or Duplicate 3

Torque Converter Replace

4 Confidential/Proprietary - Do Not Copy or Duplicate

1. GM 2.4L ENGINE 4. TRANSMISSION

Figure 4. Engine-Transmission Combination

Confidential/Proprietary - Do Not Copy or Duplicate 5

Figure 5. Torque Converter Bolt Access

6 Confidential/Proprietary - Do Not Copy or Duplicate

Legend for Figure 5

Confidential/Proprietary - Do Not Copy or Duplicate 7

1. TRANSMISSION OIL FILTER 9. PLUG

8 Confidential/Proprietary - Do Not Copy or Duplicate

1. TRANSMISSION OIL FILTER 9. PLUG

Confidential/Proprietary - Do Not Copy or Duplicate 9

Legend for Figure 8

Figure 8. Pry Point Location

1. LONG CAPSCREW 5. TRANSMISSION HOUSING

Figure 9. Torque Converter Housing

10 Confidential/Proprietary - Do Not Copy or Duplicate

See Figure 10 for lift trucks manufactured before

Confidential/Proprietary - Do Not Copy or Duplicate 11

1. TRANSMISSION OIL FILTER 9. PLUG

12 Confidential/Proprietary - Do Not Copy or Duplicate

1. TRANSMISSION OIL FILTER 9. PLUG

Confidential/Proprietary - Do Not Copy or Duplicate 13

1. GM 2.4L ENGINE 4. TRANSMISSION

Figure 12. Engine-Transmission Combination

14 Confidential/Proprietary - Do Not Copy or Duplicate

See Frame 100 YRM 1120 for lift truck models:

Confidential/Proprietary - Do Not Copy or Duplicate 15

Figure 13. Torque Converter Bolt Access

16 Confidential/Proprietary - Do Not Copy or Duplicate

Legend for Figure 13

Housings and Chain Drive Repair

Confidential/Proprietary - Do Not Copy or Duplicate 17

1. GM 2.4L ENGINE 4. TRANSMISSION

Figure 14. Engine-Transmission Combination

Legend for Figure 15

18 Confidential/Proprietary - Do Not Copy or Duplicate

Figure 15. Torque Converter Bolt Access

Confidential/Proprietary - Do Not Copy or Duplicate 19

See Figure 17 for lift trucks manufactured after July,

20 Confidential/Proprietary - Do Not Copy or Duplicate

1. TRANSMISSION OIL FILTER 9. PLUG

Confidential/Proprietary - Do Not Copy or Duplicate 21

1. TRANSMISSION OIL FILTER 9. PLUG