Powershift Transmission: Maintenance

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) [F813, 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. 524223762 1300 YRM 1129

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed
the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and when
working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange background.
The CAUTION symbol and word are on yellow background.
Powershift Transmission Table of Contents
TABLE OF CONTENTS
General................................................................................................................................................................ 1
Serial Number ................................................................................................................................................. 1
Charge Pump Repair........................................................................................................................................... 2
Remove ........................................................................................................................................................... 2
Inspect............................................................................................................................................................. 2
Install............................................................................................................................................................... 2
Torque Converter Replace................................................................................................................................... 3
Remove ........................................................................................................................................................... 3
Install............................................................................................................................................................... 10
Front Cover Housing and Chain Drive Repair ..................................................................................................... 15
Remove ........................................................................................................................................................... 15
Clean............................................................................................................................................................... 22
Inspect............................................................................................................................................................. 22
Install............................................................................................................................................................... 22
Clutch Packs Repair ............................................................................................................................................ 29
Remove and Disassemble .............................................................................................................................. 29
Transmission, Remove and Disassemble ................................................................................................... 29
Clutch Assemblies, Remove and Disassemble........................................................................................... 40
Clean............................................................................................................................................................... 45
Inspect............................................................................................................................................................. 45
Assemble and Install ....................................................................................................................................... 46
Clutch Assemblies, Assemble and Install ................................................................................................... 46
Transmission, Assemble and Install............................................................................................................ 53
Control Valve Repair............................................................................................................................................ 59
Clean............................................................................................................................................................... 62
Inspect............................................................................................................................................................. 62
Foot Directional Control Pedal Repair ................................................................................................................. 63
Direction Control Lever ........................................................................................................................................ 68
Remove ........................................................................................................................................................... 68
Install............................................................................................................................................................... 68
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) [F813, G813]
©2009 Yale Materials Handling Corp. i

1300 YRM 1129 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.
A. EARLY LIFT TRUCK MODELS EXCEPT

GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX) (F813,
G813) MODELS
B. NEWER LIFT TRUCK MODELS
Figure 1. Transmission Serial Number Location
Confidential/Proprietary - Do Not Copy or Duplicate 1

Charge Pump Repair 1300 YRM 1129
Charge Pump Repair

REMOVE
NOTE: The charge pump can be removed from the
transmission while it is still in the lift truck but, for the
sake of clarity, the following procedures are shown with
the transmission removed from the lift truck.
Remove four mounting capscrews, washers, transmis-

sion charge pump, and gasket from the torque con-
verter housing. Discard the gasket. See Figure 2.
INSPECT
Inspect the splines on the shaft of the transmission
charge pump for damage or worn areas that could
affect the operation of the pump. If the splines are
damaged, replace the transmission charge pump.
INSTALL NOTE: THE TRANSMISSION IS SHOWN REMOVED

FROM THE LIFT TRUCK FOR CLARITY.
Install new gasket, transmission charge pump, four
mounting capscrews, and washers in the torque A. EARLY LIFT TRUCK MODELS EXCEPT
converter housing. Tighten capscrews to 19 N•m GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
(168 lbf in). (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813,
G813) MODELS
1. CAPSCREW
2. CHARGE PUMP
3. GASKET
4. TORQUE CONVERTER HOUSING
Figure 2. Transmission Charge Pump
2 Confidential/Proprietary - Do Not Copy or Duplicate

1300 YRM 1129 Torque Converter Replace
Torque Converter Replace

REMOVE G813) lift trucks, and Frame 100 YRM 1120 for
GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX
WARNING (C809); GLP/GDP16VX, GLP/GDP18VX, GLP/
GDP20SVX, GLP/GDP030VX, GP/GLP/GDPVX,
Make sure the engine and transmission are held in
GP/GLP/GDP040SVX (C810); GLC20-35VX
position so that they will not fall and cause an injury
(GC/GLC040-070VX, GC/GLC055SVX (A910)
and damage to the equipment.
GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875) lift trucks.
CAUTION
Be careful that you do not damage parts of the CAUTION
torque converter or transmission when the trans-
Use care when disconnecting the wiring harness
mission is separated from the engine. Keep the
connectors from electrical connectors on the trans-
transmission and engine in alignment until they are
mission and control valve. The connectors on the
completely separated so parts of the transmission
transmission and control valve are easily damaged.
are not damaged. Use a crane or lifting device to
separate the transmission from the engine. NOTE: When disconnecting wiring harness connectors
during disassembly, tag each connector to aid in con-
1. Remove the engine and transmission as a unit
necting the wiring harness during reassembly.
from the lift truck. See the section Frame 100 YRM
1243 for GLC40, 45, 55VX; GLC55SVX; (GC/ 2. Put the engine and transmission on solid blocks on
GLC080, 100, 120VX; GC/GLC080, 100VXBCS; a work surface. Disconnect the connectors of the
GC/GLC120SVX; GC/GLC120VXPRS) (E818) transmission wiring harness from the control valve
and GLP/GDP40VX5/VX6; GLP/GDP45SVX5, and transmission. Remove the transmission wiring
GLP/GDP45VX6; GLP/GDP50-55VX (GP/ harness from the transmission. See Figure 3.
GLP/GDP080, 090, 100, 110, 120VX) (F813,

Torque Converter Replace 1300 YRM 1129
A. EARLY LIFT TRUCK MODELS EXCEPT (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813,
GLP/GDP40VX5/VX6; GLP/GDP45SVX5, G813) MODELS
GLP/GDP45VX6; GLP/GDP50-55VX B. NEWER LIFT TRUCK MODELS
1. GM 2.4L ENGINE 5. CAPSCREW
2. CAPSCREW 6. ACCESS COVER
3. TRANSMISSION WIRING HARNESS 7. CONTROL VALVE
4. TRANSMISSION
Figure 3. Engine-Transmission Combination

4. Remove the access cover from the torque converter

WARNING housing. Install a lifting eye bolt into the rear access
Make sure that the engine/transmission assembly cover bolt hole, and connect a lifting device to the
is stable before attempting to rotate the engine. eye bolt. Remove the 10 capscrews that hold the
torque converter housing to the flywheel housing
Use a flashlight to see the bolts as they are rotated on the engine. Carefully separate the transmission
into view through the access hole. Do not use your from the engine.
fingers to check for alignment of the bolts with the
access hole. NOTE: The torque converter cannot be repaired and
must be replaced as a unit, if damaged.
3. Move each bolt into view through the access hole
of the flywheel housing by rotating the crankshaft. 5. Carefully remove the torque converter from the sta-
Remove the four capscrews that attach the flywheel tor support. See Figure 5.
to the torque converter. See Figure 4.

Figure 4. Torque Converter Bolt Access

Legend for Figure 4

A. GM 2.4L ENGINE USED ON ENGINE AND GLP/GDP50-55VX
B. MAZDA ENGINE TRANSMISSIONS SHOWN IN (GP/GLP/GDP080, 090,
C. YANMAR ENGINE ILLUSTRATIONS A THROUGH 100, 110, 120VX) (F813, G813)
D. GM 4.3L ENGINE D, EXCEPT WHEN D IS USED LIFT TRUCK MODELS
E. ILLUSTRATES NEW DIPSTICK ON GLP/GDP40VX5/VX6; F. CUMMINS 4.5L DIESEL
AND BREATHER LOCATION GLP/GDP45SVX5, ENGINE
AND NEW FITTING DESIGN GLP/GDP45VX6;
1. ACCESS HOLE 2. FLYWHEEL HOUSING
1. TRANSMISSION OIL FILTER 10. PLUG
2. DIPSTICK 11. CAPSCREW
3. DIPSTICK TUBE 12. WASHER
4. TRANSMISSION HOUSING 13. SMALL ACCESS COVER
5. VENT TUBE ASSEMBLY 14. TORQUE CONVERTER
6. TORQUE CONVERTER HOUSING 15. TRANSMISSION CHARGE PUMP
7. TRANSMISSION OIL TEMPERATURE SENSOR 16. STATOR SUPPORT
8. SUCTION SCREEN 17. PILOT HUB
9. SUCTION SCREEN SPRING
Figure 5. Torque Converter Removal

6. Remove the plug, suction screen spring, and suc-

tion screen from the torque converter housing, and
drain the oil from the transmission.
7. Remove the transmission charge pump and trans-

mission oil filter from the torque converter housing.
NOTE: Step 8, Step 9, and the NOTE below apply to

early lift truck models except GLP/GDP40VX5/VX6;
GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-
55VX (GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813) models.
8. Remove the dipstick from the dipstick tube, and dis-

connect the vent tube assembly from the transmis-
sion housing.
NOTE: The dipstick tube must be removed before the

torque converter housing can be removed from the front
cover housing.
9. Remove the dipstick tube from the torque converter

housing.
10. If damaged, remove the small access cover from

the torque converter housing. A. EARLY LIFT TRUCK MODELS EXCEPT
NOTE: Perform Step 11 only if repair of the of the GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX) (F813,
transmission chain drive is required. If the transmission G813) MODELS
clutch packs are in need of further repair, see Clutch B. NEWER LIFT TRUCK MODELS
Packs Repair.
1. PRY POINTS
11. Remove 12 capscrews from the transmission hous- 2. TORQUE CONVERTER HOUSING
ing and four mounting capscrews from the front 3. FRONT COVER HOUSING
4. TRANSMISSION HOUSING
of the torque converter housing. Using a small
pry bar in the designated pry points, remove the Figure 6. Pry Point Location
torque converter housing from the front cover hous-
ing. Discard the O-rings and gasket. See Figure 6
and Figure 7.

1. CAPSCREW
2. WASHER
4. GASKET
5. FRONT COVER HOUSING
Figure 7. Torque Converter Housing

INSTALL 2. If removed, install the small access cover on the

torque converter housing. Tighten capscrews to
1. Install new O-rings and gasket and using four cap- 7.9 N•m (69 lbf in). See Figure 8.
screws, install the torque converter housing on the
front cover housing and 12 capscrews on the trans-
mission housing. Tighten capscrews to 38 N•m
(28 lbf ft). See Figure 7.
1. TRANSMISSION OIL FILTER 10. PLUG
2. DIPSTICK 11. CAPSCREW
3. DIPSTICK TUBE 12. WASHER
4. TRANSMISSION HOUSING 13. SMALL ACCESS COVER
5. VENT TUBE ASSEMBLY 14. TORQUE CONVERTER
6. TORQUE CONVERTER HOUSING 15. TRANSMISSION CHARGE PUMP
7. TRANSMISSION OIL TEMPERATURE SENSOR 16. STATOR SUPPORT
8. SUCTION SCREEN 17. PILOT HUB
9. SUCTION SCREEN SPRING
Figure 8. Torque Converter Installation

NOTE: The information in Step 3 and Step 4 ap- 10. If removed, install a lifting eye bolt into the rear ac-
plies only to early lift truck models except for cess cover bolt hole, and connect a lifting device
GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ to the eye bolt. Align the torque converter housing
GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, with the flywheel housing. Make sure the pilot hub
090, 100, 110, 120VX) (F813, G813) models. on the torque converter engages the flywheel.
3. Clean the surface of the dipstick tube and dipstick

hole in the torque converter housing. Apply adhe- CAUTION
sive (Yale P/N 520042831) to the entire surface of Be careful that you do not damage parts of the
the hole in the housing. Insert the dipstick tube un- torque converter or transmission when the trans-
til the collar bottoms on the housing and orient the mission is joined to the engine. Keep the trans-
tab against the housing flange. mission and engine in alignment until they are
completely joined so parts of the transmission are
4. Install the dipstick into the dipstick tube, and con- not damaged. Use a crane or lifting device to join
nect the vent tube assembly to the transmission the transmission to the engine.
housing.
11. Install the transmission to the engine. Install the
5. Install a new transmission oil filter on the torque capscrews that connect the torque converter hous-
converter housing. ing to the flywheel housing. Tighten the capscrews
to 38 N•m (28 lbf ft). See Figure 9.
6. Install the transmission charge pump on the torque
converter housing. Tighten capscrews to 19 N•m
(168 lbf in). CAUTION
Use care when connecting the wiring harness
7. Install the suction screen, suction screen spring, connectors to electrical connectors on the trans-
and plug into the torque converter housing. mission and control valve. The connectors on the
8. Install the torque converter onto the input shaft and transmission and control valve are easily damaged.
stator support of the transmission. Make sure the 12. Install the transmission wiring harness on the trans-
splines are aligned and the converter engages fully. mission. Connect the connectors of the transmis-
9. Lubricate the pilot hub on the torque converter with sion wiring harness to the control valve and trans-
antiseize compound. See Figure 8. mission. See Figure 9.

4. TRANSMISSION

13. Rotate the engine crankshaft to position the fly- (C809); GLP/GDP16VX, GLP/GDP18VX, GLP/
wheel mounting holes in line with the torque con- GDP20SVX, GLP/GDP030VX, GP/GLP/GDPVX,
verter mounting holes. Install the capscrews that GP/GLP/GDP040SVX (C810); GLC20-35VX
hold the torque converter to the flywheel, after coat- (GC/GLC040-070VX, GC/GLC055SVX (A910)
ing the threads with Loctite™ 242, through the ac- GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
cess hole of the flywheel housing. See Figure 10. (B875) lift trucks.
Tighten the capscrews to 56 N•m (41 lbf ft). Re-
move the lifting eye bolt, and install the access 15. Fill the transmission to the correct level using the
cover on the torque converter housing. correct transmission fluid and procedure given in
the section Periodic Maintenance 8000 YRM
1150 for GLC20-35VX (GC/GLC040-070VX,
WARNING GC/GLC055SVX (A910) GLP/GDP20-35VX
Make sure the engine and transmission are held in (GP/GLP/GDP040-070VX) (B875) lift trucks,
position so that they will not fall and cause an injury Periodic Maintenance 8000 YRM 1207 for
and damage to the equipment. GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX
(C809); GLP/GDP16VX, GLP/GDP18VX, GLP/
14. Install the engine and transmission as a unit into GDP20SVX, GLP/GDP030VX, GP/GLP/GDPVX,
the lift truck. See the section Frame 100 YRM GP/GLP/GDP040SVX (C810) lift trucks, and Pe-
1243 for GLC40, 45, 55VX; GLC55SVX; (GC/ riodic Maintenance 8000 YRM 1248 for GLC40,
GLC080, 100, 120VX; GC/GLC080, 100VXBCS; 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX;
GC/GLC120SVX; GC/GLC120VXPRS) (E818) GC/GLC080, 100VXBCS; GC/GLC120SVX;
and GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GC/GLC120VXPRS) (E818) and GLP/GDP40VX5/
GLP/GDP45VX6; GLP/GDP50-55VX (GP/ VX6; GLP/GDP45SVX5, GLP/GDP45VX6;
GLP/GDP080, 090, 100, 110, 120VX) (F813, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100,
G813) lift trucks, and Frame 100 YRM 1120 for 110, 120VX) (F813, G813) lift trucks.


1300 YRM 1129 Front Cover Housing and Chain Drive Repair
Legend for Figure 10

Front Cover Housing and Chain Drive Repair

REMOVE GP/GLP/GDP040SVX (C810); GLC20-35VX
WARNING GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875) lift trucks.
position so that they will not fall and cause an injury
and damage to the equipment. CAUTION
To prevent possible damage to the transmission as-
CAUTION sembly when placing the assembly on a work sur-
face, place blocks under the back side of the trans-
Keep the transmission and engine in alignment un-
mission housing for additional support.
til they are completely separated so parts of the
transmission are not damaged. Use a crane or lift-
ing device to separate the transmission from the en- CAUTION
gine. Use care when disconnecting the wiring harness
connectors from electrical connectors on the trans-
1. Remove the engine and transmission as a unit
transmission and control valve are easily damaged.
1243 for GLC40, 45, 55VX; GLC55SVX; (GC/
GLC080, 100, 120VX; GC/GLC080, 100VXBCS; NOTE: When disconnecting wiring harness connectors
GC/GLC120SVX; GC/GLC120VXPRS) (E818) during disassembly, tag each connector to aid in con-
and GLP/GDP40VX5/VX6; GLP/GDP45SVX5, necting the wiring harness during reassembly.
GLP/GDP45VX6; GLP/GDP50-55VX (GP/
GLP/GDP080, 090, 100, 110, 120VX) (F813, 2. Put the engine and transmission on solid blocks on
G813) lift trucks, and Frame 100 YRM 1120 for a work surface. Disconnect the connectors of the
GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX transmission wiring harness from the control valve
(C809); GLP/GDP16VX, GLP/GDP18VX, GLP/ and transmission. Remove the transmission wiring
GDP20SVX, GLP/GDP030VX, GP/GLP/GDPVX, harness from the transmission. See Figure 11.

Front Cover Housing and Chain Drive Repair 1300 YRM 1129
4. TRANSMISSION

the eye bolt. Remove the 10 capscrews that hold

WARNING the torque converter housing to the flywheel hous-
Make sure that the engine/transmission assembly ing. Carefully separate the transmission from the
is stable before attempting to rotate the engine. engine.
Use a flashlight to see the bolts as they are rotated 5. Carefully remove the torque converter from the sta-
into view through the access hole. Do not use your tor support. See Figure 13.
access hole. NOTE: The information in Step 6, Step 7, and the
NOTE below applies only to early lift truck models ex-
3. Move each bolt into view through the access hole cept GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
of the flywheel housing by rotating the crankshaft. GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080,
Remove the four capscrews that attach the flywheel 090, 100, 110, 120VX) (F813, G813) models.
to the torque converter. See Figure 12.
6. Remove the dipstick from the dipstick tube, and dis-
4. Remove the access cover from the torque converter connect the tube assembly from the transmission
housing. Install a lifting eye bolt into the rear ac- housing.
cess cover bolt hole, and connect a lifting device to



1. TORQUE CONVERTER 5. SUCTION SCREEN SPRING
2. CAPSCREW 6. SUCTION SCREEN
3. WASHER 7. TORQUE CONVERTER HOUSING
4. PLUG 8. FRONT COVER HOUSING
Figure 13. Torque Converter Housing Removal

NOTE: The dipstick tube must be removed before the

torque converter housing can be removed from the front
cover housing.
7. Remove the dipstick tube from the torque converter

housing.
8. Remove the plug, suction screen spring, and suc-

tion screen from the torque converter housing and
drain the oil from the transmission.
9. Remove the transmission charge pump from the

torque converter housing.
10. Remove the four mounting capscrews from the front

of the torque converter housing. Loosen the re-
maining 12 capscrews on the transmission housing
and using a small pry bar, remove the torque con-
verter housing from the front cover housing. See
Figure 14. Discard the O-rings on the front cover
housing and the gasket.
NOTE: While performing Step 11, note the position of

the oil seal to aid in the proper installation of new oil
seal.
11. Remove and discard the oil seal from the rear of the GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
torque converter housing. See Figure 15. (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813,
G813) MODELS
1. PRY POINTS
3. FRONT COVER HOUSING
4. TRANSMISSION HOUSING
Figure 14. Pry Point Location

1. SNUBBER 8. O-RING 16. BAFFLE
2. PUMP DRIVE CHAIN 9. DRIVING SPROCKET 17. PLUG
3. BEARING 10. CAPSCREW 18. REGULATOR COMPRESSION
4. DRIVEN SPROCKET 11. LOCKWASHER SPRING
5. OIL SEAL 12. STATOR SUPPORT 19. REGULATOR SPOOL
6. ANGULAR CONTACT 13. SEALING RING 20. FRONT COVER HOUSING
BEARING 14. FRONT COVER HOUSING MOUNTING CAPSCREWS
7. BUSHING 15. TRANSMISSION HOUSING

Figure 15. Chain Drive

12. Remove the two snubbers from the front cover 1. Clean the snubbers with warm, soapy water and dry
housing. Carefully pull the driving and driven with compressed air.
sprockets, chain, and bearings from the front cover
housing as an assembly. Remove and discard the 2. Clean bearings, chain, stator support, and gears
O-ring from the driving sprocket. with solvent and dry with compressed air
13. Remove the stator support from the front cover INSPECT
housing. Remove and discard the sealing ring and
O-ring from the stator support. 1. Inspect the snubbers for cracks or wear. If dam-
aged or worn, replace both snubbers.
14. Remove the plug, regulator compression spring,
and regulator spool from the front cover housing. 2. Inspect the chain, gears, and stator support for
damage. If damage is present, replace the dam-
15. Remove the baffle from the front cover housing. aged component. Inspect the driving and driven
gears for damage or wear to the gear teeth. If the
16. The front cover housing is held in alignment with gear teeth are worn or damaged, replace the gear.
the transmission housing with dowel pins. Remove Inspect the splines on the input shaft for damage,
three mounting capscrews from the front of the and if damaged, replace the input clutch pack. See
front cover housing. Remove the remaining 12 Clutch Packs Repair.
capscrews from the transmission housing. To sep-
arate the front cover housing from the transmission INSTALL
housing, use a small pry bar to loosen the front
cover housing. See Figure 14. Remove the front 1. Install new O-rings and gasket on the transmission
cover housing from the transmission housing. Dis- housing. The front cover housing is held in align-
card the O-rings on the transmission housing and ment with the transmission housing with dowel pins.
the gasket. Install the front cover housing on the transmission
housing. Install 12 capscrews through the trans-
CLEAN mission housing and front cover housing. Install the
three front cover housing capscrews and tighten to
WARNING 38 N•m (28 lbf ft) See Figure 16.
Cleaning solvents can be flammable and toxic and 2. Install the baffle in the front cover housing. See
can cause skin irritation. When using cleaning Figure 16.
solvents, always follow the solvent manufacturer’s
recommended safety procedures. 3. Install the regulator spool, regulator compression
spring, and plug into the front cover housing.
Compressed air can move particles so they cause
injury to the user or to other personnel. Make sure 4. Install the new sealing ring and O-ring on the stator
the path of the compressed air is away from all per- support. Install the stator support on the front cover
sonnel. Wear protective goggles or a face shield to housing. See Figure 16. Tighten the capscrews to
prevent injury to the eyes. 38 N•m (28 lbf ft).

1. SNUBBER 8. O-RING 16. BAFFLE
2. PUMP DRIVE CHAIN 9. DRIVING SPROCKET 17. PLUG
3. BEARING 10. CAPSCREW 18. REGULATOR COMPRESSION
4. DRIVEN SPROCKET 11. LOCKWASHER SPRING
5. OIL SEAL 12. STATOR SUPPORT 19. REGULATOR SPOOL
6. ANGULAR CONTACT 13. SEALING RING 20. FRONT COVER HOUSING
BEARING 14. FRONT COVER HOUSING MOUNTING CAPSCREWS
7. BUSHING 15. TRANSMISSION HOUSING

Figure 16. Chain Drive

5. On a lint-free cloth, place the driving sprocket on the 6. Install the new oil seal into rear of the torque con-
right side and the driven sprocket on the left side, verter housing as noted during removal.
and place the chain around both sprockets (see Fig-
ure 16). Install the bearings on the sprockets. The 7. Install the new O-rings and gasket on the front
angular bearing should be installed onto the driving cover housing. Using the front four mounting cap-
sprocket with the thinner shoulder of the outer race screws, install the torque converter housing to the
towards the sprocket and the wider shoulder of the front cover housing. Install 12 capscrews from the
outer race (side marked with part number) towards back of the transmission housing. See Figure 17.
the torque converter housing. Carefully place the Tighten 16 capscrews on the transmission housing
driving and driven sprockets, chain, and bearings and front cover housing to 38 N•m (28 lbf ft).
assembly on the front cover. Install two snubbers
on the front cover housing.
1. TORQUE CONVERTER 5. SUCTION SCREEN SPRING
2. CAPSCREW 6. SUCTION SCREEN
3. WASHER 7. TORQUE CONVERTER HOUSING
4. PLUG 8. FRONT COVER HOUSING
Figure 17. Torque Converter Housing Installation

8. Install the suction screen, suction screen spring, 13. Install the transmission charge pump on the torque
and plug into the torque converter housing. converter housing. Tighten the capscrews to
19 N•m (168 lbf in).
NOTE: The information in Step 9 and Step 10
applies only to early lift truck models except 14. If removed, install a lifting eye bolt into the rear ac-
GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ cess cover bolt hole, and connect a lifting device
GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, to the eye bolt. Align the torque converter housing
090, 100, 110, 120VX) (F813, G813) models. with the flywheel housing. Make sure the pilot hub
on the torque converter engages the flywheel.
9. Clean the surface of the dipstick tube and dipstick
hole in the torque converter housing. Apply adhe- 15. Install the transmission to the engine. Install the
sive (Yale P/N 520042831) to the entire surface of capscrews that connect the torque converter hous-
the hole in the housing. Insert the dipstick tube un- ing to the flywheel housing. Tighten the capscrews
til the collar bottoms on the housing and orient the to 38 N•m (28 lbf ft). See Figure 18.
tab against the housing flange.
10. Install the dipstick into the dipstick tube, and con- CAUTION
nect the tube assembly to the transmission hous- Use care when connecting the wiring harness
ing. connectors to electrical connectors on the trans-
11. Install the torque converter onto the input shaft and transmission and control valve are easily damaged.
stator support of the transmission. Make sure the
splines are aligned and the converter engages fully. 16. Install the transmission wiring harness on the trans-
mission. Connect the connectors of the transmis-
12. Lubricate the pilot hub on the torque converter with sion wiring harness to the control valve and trans-
antiseize compound. See Figure 17. mission. See Figure 18.

4. TRANSMISSION

17. Rotate the engine crankshaft to position the fly- (GC/GLC040-070VX, GC/GLC055SVX (A910)
wheel mounting holes in line with the torque con- GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
verter mounting holes. Install the capscrews that (B875) lift trucks.
hold the torque converter to the flywheel, after coat-
ing the threads with Loctite™ 242, through the ac- 19. Fill the transmission to the correct level using the
cess hole of the flywheel housing. See Figure 19. correct transmission fluid and procedure given in
Tighten the capscrews to 56 N•m (41 lbf ft). Re- the section Periodic Maintenance 8000 YRM
move the lifting eye bolt, and install the access 1150 for GLC20-35VX (GC/GLC040-070VX,
cover on the torque converter housing. GC/GLC055SVX (A910) GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875) lift trucks,
18. Install the engine and transmission as a unit into Periodic Maintenance 8000 YRM 1207 for
the lift truck. See the section Frame 100 YRM GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX
1243 for GGLC40, 45, 55VX; GLC55SVX; (GC/ (C809); GLP/GDP16VX, GLP/GDP18VX, GLP/
GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GDP20SVX, GLP/GDP030VX, GP/GLP/GDPVX,
GC/GLC120SVX; GC/GLC120VXPRS) (E818) GP/GLP/GDP040SVX (C810) lift trucks, and Pe-
and GLP/GDP40VX5/VX6; GLP/GDP45SVX5, riodic Maintenance 8000 YRM 1248 for GLC40,
GLP/GDP45VX6; GLP/GDP50-55VX (GP/ 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX;
GLP/GDP080, 090, 100, 110, 120VX) (F813, GC/GLC080, 100VXBCS; GC/GLC120SVX;
G813) lift trucks, and Frame 100 YRM 1120 for GC/GLC120VXPRS) (E818) and GLP/GDP40VX5/
GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX VX6; GLP/GDP45SVX5, GLP/GDP45VX6;
(C809); GLP/GDP16VX, GLP/GDP18VX, GLP/ GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100,
GDP20SVX, GLP/GDP030VX, GP/GLP/GDPVX, 110, 120VX) (F813, G813) lift trucks.


1300 YRM 1129 Clutch Packs Repair

Clutch Packs Repair

REMOVE AND DISASSEMBLE GDP20SVX, GLP/GDP030VX, GP/GLP/GDPVX,
Transmission, Remove and Disassemble (GC/GLC040-070VX, GC/GLC055SVX (A910);
and GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
WARNING (B875) lift trucks.
position so that they will not fall and cause an injury CAUTION
and damage to the equipment. To prevent possible damage to the transmission as-
sembly when placing the assembly on a work sur-
CAUTION face, place blocks under the back side of the trans-
mission housing for additional support.
Be careful that you do not damage parts of the
torque converter or transmission when the trans-
mission is separated from the engine. Keep the CAUTION
transmission and engine in alignment until they are Use care when disconnecting the wiring harness
completely separated so parts of the transmission connectors from electrical connectors on the trans-
are not damaged. Use a crane or lifting device to mission and control valve. The connectors on the
separate the transmission from the engine. transmission and control valve are easily damaged.
1. Remove the engine and transmission as a unit NOTE: When disconnecting wiring harness connectors
from the lift truck. See the section Frame 100 YRM during disassembly, tag each connector to aid in con-
1243 for GLC40, 45, 55VX; GLC55SVX; (GC/ necting the wiring harness during reassembly.
GLC080, 100, 120VX; GC/GLC080, 100VXBCS;
GC/GLC120SVX; GC/GLC120VXPRS) (E818) 2. Put the engine and transmission on solid blocks on
and GLP/GDP40VX5/VX6; GLP/GDP45SVX5, a work surface. Disconnect the two connectors of
GLP/GDP45VX6; GLP/GDP50-55VX (GP/ the chassis wiring harness from the transmission
GLP/GDP080, 090, 100, 110, 120VX) (F813, wiring harness. Disconnect the connectors of the
G813) lift trucks, and Frame 100 YRM 1120 for transmission wiring harness from the control valve
GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX and transmission. Remove the transmission wiring
(C809); GLP/GDP16VX, GLP/GDP18VX, GLP/ harness from the transmission. See Figure 20.

Clutch Packs Repair 1300 YRM 1129
4. TRANSMISSION


WARNING access hole.
Make sure that the engine/transmission assembly
is stable before attempting to rotate the engine. 3. Move each bolt into view through the access hole
of the flywheel housing by rotating the crankshaft.
Use a flashlight to see the bolts as they are rotated Remove the four capscrews that attach the flywheel
into view through the access hole. Do not use your to the torque converter. See Figure 21.



4. Remove the access cover from the torque converter 5. Remove the torque converter housing and the front
housing. Install a lifting eye bolt into the rear ac- cover housing from the transmission housing. See
cess cover bolt hole, and connect a lifting device to Front Cover Housing and Chain Drive Repair, Re-
the eye bolt. Remove the 10 capscrews that hold move, Step 4 through Step 16.
the torque converter housing to the flywheel hous-
ing. Carefully separate the transmission from the 6. On the two-speed transmission, remove the idler
engine. gear and two bearings. See Figure 22.

Figure 22. Output Gear Removal


A. 1-SPEED TRANSMISSION B. 2-SPEED TRANSMISSION
1. BEARING 9. YOKE
2. IDLER GEAR 10. WASHER
3. SNAP RING 11. LOCKWASHER
4. SPECIAL NUT 12. BOLT
5. OUTPUT GEAR 13. REVERSE GEAR
6. TRANSMISSION HOUSING 14. FORWARD CLUTCH PACK
7. OIL SEAL 15. 2 SPEED HIGH FORWARD
8. SPACER CLUTCH PACK
NOTE: The procedure for removal of the output gear is 9. Remove the oil seal from the back of the transmis-
the same for both transmissions. sion.
7. Remove the bolt, three washers, and yoke from the 10. Remove the bearings, snap ring, special nut, and
back of the transmission. See Figure 22. output gear from the transmission.
8. Remove the spacer from the yoke. 11. Disassembly of the clutch assemblies follows. The
procedures are the same for removal and disas-
NOTE: Note the position of the oil seal during removal sembly of the clutch pack assemblies for both the
to aid in installation. 1- and 2-speed transmissions. See Figure 23, Fig-
ure 24, and Figure 25.

Figure 23. 1- and 2-Speed Forward Clutch Packs


A. 1-SPEED TRANSMISSION FORWARD CLUTCH B. 2-SPEED TRANSMISSION FORWARD CLUTCH
1. SEAL 9. CONICAL PLATE
2. BEARING 10. FRICTION DISK
3. GEAR ASSEMBLY DRUM 11. SEPARATOR PLATE
4. PISTON SEAL 12. PRESSURE PLATE
5. PISTON 13. SPACER
6. SPRING 14. OUTPUT GEAR
7. SPRING GUIDE 15. BACK PLATE
8. SNAP RING

Figure 24. 1- and 2-Speed Reverse Clutch Packs


A. 1-SPEED TRANSMISSION REVERSE CLUTCH B. 2-SPEED TRANSMISSION REVERSE CLUTCH
1. SEAL 9. CONICAL PLATE
2. BEARING 10. FRICTION DISK
3. GEAR ASSEMBLY DRUM 11. SEPARATOR PLATE
4. PISTON SEAL 12. PRESSURE PLATE
5. PISTON 13. SPACER
6. SPRING 14. OUTPUT GEAR
7. SPRING GUIDE 15. BACK PLATE
8. SNAP RING
1. SEAL 6. SPRING 11. SEPARATOR PLATE

2. BEARING 7. SPRING GUIDE 12. PRESSURE PLATE
3. GEAR ASSEMBLY DRUM 8. SNAP RING 13. BACK PLATE
4. PISTON SEAL 9. CONICAL PLATE 14. SPACER
5. PISTON 10. FRICTION DISK 15. OUTPUT GEAR
Figure 25. 2-Speed High Clutch Pack

Clutch Assemblies, Remove and Disassemble

NOTE: The 1-speed forward clutch assembly is shown in the illustrations for the disassembly procedures.
STEP 1.
Pull the forward clutch assembly straight from the trans-
mission housing.
1. REVERSE CLUTCH
2. FORWARD CLUTCH
3. TRANSMISSION INPUT SPEED SENSOR (TISS)
4. TRANSMISSION OUTPUT SPEED SENSOR
(TOSS)
STEP 2.
Remove the shaft seal and bearing from the input shaft.
Discard the shaft seal.
1. SHAFT SEAL
2. BEARING
3. INPUT SHAFT

STEP 3.
Remove the snap ring from the output gear. Remove
the output gear from the input shaft
1. SNAP RING
2. BEARING
3. OUTPUT GEAR
NOTE: Before removing the seal bearing, note the position of the seal on the bearing.
STEP 4.
Remove seal from the output gear. Remove seal bear-
ing, snap ring, spacer, snap ring, and bearing from the
output gear.
1. SEAL BEARING
2. SNAP RING
3. SPACER
4. SEAL
5. OUTPUT GEAR
6. BEARING
NOTE: On 2-speed transmissions, there will be a back plate in front of the pressure plate.

STEP 5.
Remove the snap ring and pressure plate from the gear
assembly drum.
1. SNAP RING
2. PRESSURE PLATE
3. GEAR ASSEMBLY DRUM
STEP 6.
Remove the friction disks and separator plates al-
ternately until all have been removed from the gear
assembly drum
1. FRICTION DISK
2. SEPARATOR PLATE
STEP 7.
Remove the conical plate from the 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 the piston only if there is a problem with the piston or piston seals.
STEP 8.
Using the spring compression tool Yale P/N 150121831
and a press, place the spring compression tool on the
spring guide with the opening of the tool above the
opening of the snap ring, and compress the large and
small springs just enough to allow removal of the snap
ring from the spring guide. Slowly release the press to
decompress the springs.
1. SPRING COMPRESSION TOOL

2. SPRING GUIDE

STEP 9.
Remove the snap ring, spring guide, large spring, and
small spring from the input shaft.
1. SNAP RING
2. SPRING GUIDE
3. LARGE SPRING
4. SMALL SPRING
5. INPUT SHAFT
STEP 10.
Remove the piston from the gear assembly drum and
the piston seal from the piston. Discard the piston seal.
1. PISTON
2. PISTON SEAL
4. SHAFT SEAL

STEP 11.
Remove the shaft seals and bearing from the input
shaft. Discard shaft seals.
1. SHAFT SEALS
2. BEARING
3. INPUT SHAFT
CLEAN areas from too much heat. If any of the above con-
ditions exist, replace the damaged component.
WARNING 5. Check the "H" dimension of the conical plate as
Cleaning solvents can be flammable and toxic and shown in Figure 26. If the dimension is less than
can cause skin irritation. When using cleaning 3.2 mm (0.126 in.), replace the conical plate.
solvents, always follow the solvent manufacturer’s
recommended safety procedures. 6. Check the "t" dimension of the conical plate as
shown in Figure 26. If the dimension is less than
Clean all metal parts with cleaning solvent and place 2.4 mm (0.094 in.), replace the conical plate.
on a lint-free cloth to dry. Ensure that the cleaning and
assembly environment is free of dust, dirt, and any other
foreign matter that would affect the performance of the
parts.
INSPECT
1. Inspect the gear teeth on clutch assemblies and all
other gears for wear or damage. If the gear teeth
are worn or damaged, replace the damaged com-
ponent.
2. Check all parts that have splines for damage to the

Figure 26. Conical Plate Inspection
splines. Check for notches worn in the splines. Re-
place the clutch pack or gears that have spline dam- 7. Inspect the bearings for wear or damage. If the
age. bearings are damaged, replace them.
3. Inspect the friction discs for burned lining or bent 8. Inspect the piston for damage. Make sure that the
surfaces. Check for small holes in the lining. Re- sealing surfaces are good. Make sure the orifice is
place the friction discs if one-half the depth of the clean.
oil grooves is worn away or the discs are damaged.
Discard a friction disc that has a thickness less than 9. Check for grooves or other damage on the ma-
2.2 mm (0.087 in.). chined surfaces of the clutch pack shafts and trans-
mission housing. Check the mounting and sealing
4. The conical plate and separator plates must not be
bent, have damaged surfaces, or have large blue

surfaces in the housing for damage. If there is evi-

dence of any damage, replace the housing or trans- CAUTION
mission. If the clutch pack shaft is damaged, re- The dowel pins are used to properly align the hous-
place the clutch pack. ings for proper mating to each other. If the align-
ment is not correct, damage to the transmission as-
10. Inspect all hardware and mounting surfaces for the sembly could occur.
presence of rust, sealing compounds, and usable
condition. If the hardware is to be reused, clean 11. Inspect dowel pins and dowel pin holes. If any
all rust and sealing compounds from the threaded dowel pin is damaged at all, replace the dowel pin.
areas. If the hardware is not in usable condition, If a dowel pin hole is damaged, replace the hous-
replace the hardware. ing.
12. Check the fit of bearings in the transmission hous-

ings. If the bearings fit too loosely into the housings,
this could mean that the bores are oversized. Re-
place housings as necessary.
ASSEMBLE AND INSTALL
Clutch Assemblies, Assemble and Install

NOTE: The 1-speed forward clutch assembly is shown in the illustrations for the assembly procedures.
STEP 1.
Install the bearing and new shaft seals on the input
shaft.
1. SHAFT SEALS
2. BEARING
3. INPUT SHAFT
NOTE: Perform STEP 2 through STEP 5 only if the piston was removed.

STEP 2.
Lubricate all parts with clean transmission oil. Install the
shaft seal on the shaft and the piston seal on the piston.
1. PISTON SEAL
2. PISTON
STEP 3.
Install the piston into the gear assembly drum.
1. PISTON
2. PISTON SEAL
4. SHAFT SEAL
STEP 4.
Install the small spring, large spring, spring guide, and
snap ring on the input shaft.
1. SNAP RING
2. SPRING GUIDE
3. LARGE SPRING
4. SMALL SPRING
5. INPUT SHAFT

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

2. SPRING GUIDE
NOTE: The conical plate is properly installed when the inner diameter is touching the piston, and the outer diameter
of the conical plate is touching the outer diameter of the friction disk.

STEP 6.
Install the conical plate into the gear assembly drum.
1. CONICAL PLATE
STEP 7.
Install the separator plates and friction disks alternately
until all have been installed in the gear assembly drum.
1. FRICTION DISK
2. SEPARATOR PLATE
NOTE: On 2-speed transmissions, install the back plate in front of the pressure plate.

STEP 8.
Install the pressure plate and snap ring in the gear

assembly drum. Using a dial indicator or feeler
gauge, check the clearance between the snap ring
and pressure plate. There must be 1.8±0.2 mm
(0.071±0.008 in.) of clearance for a single speed
transmission, and 2.7±0.2 mm (0.106±0.008 in.)of
clearance for a 2 speed trnasmission. If the clearance
is not correct, see the Parts Manual for the correct
pressure plate.
1. SNAP RING
2. PRESSURE PLATE
NOTE: Make sure the seal on seal bearing is in correct position as noted during removal.
STEP 9.
Install seal onto output gear. Install the bearing, snap
ring, spacer, snap ring, and seal bearing into output
gear.
1. SEAL BEARING
2. SNAP RING
3. SPACER
4. SEAL
5. OUTPUT GEAR
6. BEARING

STEP 10.
Install the output gear on the input shaft. Install bearing
and snap ring in the output gear.
1. SNAP RING
2. BEARING
3. OUTPUT GEAR
STEP 11.
Install the bearing and shaft seal on the input shaft.
1. SHAFT SEAL
2. BEARING
3. INPUT SHAFT

STEP 12.
Install the reverse clutch assembly in the transmission
housing. Do not damage the seal rings on the end of
the clutch shaft.
Check the gap between the TOSS and TISS sensors

and reverse gear. The allowable gap for the TOSS sen-
sor is 0.8 to 1.8 mm (0.031 to 0.071 in.). The allowable
gap for the TISS sensor is 0.8 to 2.0 mm
(0.031 to 0.080 in.).
1. REVERSE CLUTCH
2. FORWARD CLUTCH
3. TISS SENSOR
4. TOSS SENSOR
STEP 13.
Install the forward clutch assembly in the transmission
housing. Do not damage the seal rings on the end of
the clutch shaft.
1. REVERSE CLUTCH
2. FORWARD CLUTCH
3. TISS SENSOR
4. TOSS SENSOR

Transmission, Assemble and Install 1. Install the bearing, output gear, special nut, snap
ring, and bearing on the transmission. See Fig-
NOTE: The procedure for installation of the output gear ure 27.
is the same for both transmissions.

Figure 27. Output Gear Installation


A. 1 SPEED TRANSMISSION B. 2 SPEED TRANSMISSION
1. BEARING 7. OIL SEAL
2. IDLER GEAR 8. SPACER
3. SNAP RING 9. YOKE
4. SPECIAL NUT 10. WASHER
5. OUTPUT GEAR 11. LOCKWASHER
6. TRANSMISSION HOUSING 12. CAPSCREW
2. Install the oil seal into the back of the transmission

as noted during removal.
CAUTION
Use care when connecting the wiring harness
3. Install the spacer in the yoke. connectors to electrical connectors on the trans-
4. Install the yoke, three washers, and bolt in the back transmission and control valve are easily damaged.
of the transmission. Tighten the bolt to 38 N•m
(28 lbf ft). See Figure 27. 7. Install the transmission wiring harness on the trans-
mission. Connect the connectors of the transmis-
5. On the 2-speed transmission, install the two bear- sion wiring harness to the control valve and trans-
ings and idler gear. See Figure 27. mission. Connect the two connectors of the chassis
wiring harness to the transmission wiring harness.
6. Install the front cover housing and the torque con-
See Figure 28.
verter housing on the transmission. See Front
Cover Housing and Chain Drive Repair, Install,
Step 1 through Step 15.

A. EARLY LIFT TRUCK MODELS EXCEPT GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6;

GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813) MODELS
4. TRANSMISSION

8. Rotate the engine crankshaft to position the fly- (GC/GLC040-070VX, GC/GLC055SVX (A910)
wheel mounting holes in line with the torque con- GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
verter mounting holes. Install the capscrews that (B875) lift trucks.
hold the torque converter to the flywheel through
the access hole of the flywheel housing. See Fig- 10. Fill the transmission to the correct level using the
ure 29. Tighten the capscrews to 56 N•m (41 lbf ft). correct transmission fluid and procedure given
Remove the lifting eye bolt, and install the access in section Periodic Maintenance 8000 YRM
cover on the torque converter housing. 1150 for GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX (A910) GLP/GDP20-35VX
9. Install the engine and transmission as a unit into (GP/GLP/GDP040-070VX) (B875) lift trucks,
the lift truck. See the section Frame 100 YRM Periodic Maintenance 8000 YRM 1207 for
1243 for GLC40, 45, 55VX; GLC55SVX; (GC/ GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX
GLC080, 100, 120VX; GC/GLC080, 100VXBCS; (C809); GLP/GDP16VX, GLP/GDP18VX, GLP/
GC/GLC120SVX; GC/GLC120VXPRS) (E818) GDP20SVX, GLP/GDP030VX, GP/GLP/GDPVX,
and GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GP/GLP/GDP040SVX (C810) lift trucks, and Pe-
GLP/GDP45VX6; GLP/GDP50-55VX (GP/ riodic Maintenance 8000 YRM 1248 for GLC40,
GLP/GDP080, 090, 100, 110, 120VX) (F813, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX;
G813) lift trucks, and Frame 100 YRM 1120 for GC/GLC080, 100VXBCS; GC/GLC120SVX;
GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX GC/GLC120VXPRS) (E818) and GLP/GDP40VX5/
(C809); GLP/GDP16VX, GLP/GDP18VX, GLP/ VX6; GLP/GDP45SVX5, GLP/GDP45VX6;
GDP20SVX, GLP/GDP030VX, GP/GLP/GDPVX, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100,
GP/GLP/GDP040SVX (C810); GLC20-35VX 110, 120VX) (F813, G813) lift trucks.


1300 YRM 1129 Control Valve Repair

Control Valve Repair

REMOVE AND DISASSEMBLE
CAUTION
Use care when disconnecting the wiring harnesses
from the connectors. The connectors are easily
damaged.
1. Clean the area around the control valve. Put iden-

tification tags on the wire harness connectors and
the connectors on the transmission and control
valve. Disconnect the wiring harness connectors
from transmission and control valve connectors,
and remove the cable connector from the standoff
located on the torque converter housing. See
Figure 30.
2. Remove the capscrews that attach the control valve

to the transmission. Remove the control valve as-
sembly and discard the gasket. Put a cover on top
of the transmission to keep dirt out of the transmis- GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
sion. See Figure 31. GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX) (F813,
G813) MODELS
2. HARNESS STANDOFF
3. TRANSMISSION WIRING HARNESS
Figure 30. Transmission Assembly

Control Valve Repair 1300 YRM 1129

(GP/GLP/GDP080, 090, 100, 110, 120VX) (F813,
G813) MODELS
1. TRANSMISSION ASSEMBLY
2. GASKET
3. CONTROL VALVE ASSEMBLY
4. LOCKWASHER
5. CAPSCREW
6. TRANSMISSION INPUT SPEED SENSOR (TISS)
7. TRANSMISSION OUTPUT SPEED SENSOR
(TOSS)
3. Remove two capscrews and the transmission input

speed sensor (TISS). Remove two capscrews and
the transmission output speed sensor (TOSS) from
the transmission.
NOTE: Disassemble the control valve only to the extent

to complete any repairs that are required.
NOTE: Disassemble the control valve in a clean, con-

tamination-free area.
4. Remove two pressure transducers, two fittings,

capscrew, lockwasher, and clip from the control
valve body. See Figure 32.
Figure 31. Control Valve Removal

1. CONTROL VALVE BODY 9. PLUG
2. PRESSURE TRANSDUCER 10. FORWARD PROPORTIONAL VALVE
3. FITTING 11. SOCKET HEAD CAPSCREW
4. CLIP 12. TORQUE CONVERTER REGULATOR SPOOL
5. LOCKWASHER 13. REVERSE PROPORTIONAL VALVE
6. CAPSCREW 14. TRANSMISSION ENABLE VALVE
7. PROPORTIONAL SUPPLY REGULATOR SPOOL 15. SUPPLY SPOOL
8. SPRING

1300 YRM 1129 Control Valve Repair
Figure 32. Control Valve Arrangement

Control Valve Repair 1300 YRM 1129
2. Inspect the control valve body for the presence of

WARNING burrs. Burrs may be removed using a fine file,
There are compressed springs under the plugs in emery cloth, or crocus cloth.
the control valve. Carefully remove the plugs so
that the compressed springs do not cause injury. 3. Check that the springs are not bent or damaged.
Make sure the spools move freely in their bores.
5. Remove the plug for the proportional supply regu-
lator spool. Discard the O-ring. Remove the spring 4. Inspect the connectors on the proportional and so-
and proportional supply regulator spool from the lenoid valves and, if they are damaged, replace the
control valve body. damaged proportional or solenoid valves.
6. Remove the plug for the torque converter regulator ASSEMBLE AND INSTALL
spool. Discard the O-ring. Remove the spring and
torque converter regulator spool from the control NOTE: Lubricate the parts of the control valve with
valve body. clean transmission oil during assembly.
7. Remove the plug for the supply spool. Discard the 1. Install the transmission enable valve and socket
O-ring. Remove the spring and supply spool from head screws into the control valve body. Tighten
the control valve body. socket head screws to 3 to 4 N•m (27 to 35 lbf in).
See Figure 32.
8. Remove the socket head screws and forward pro-
portional valve from the control valve body. Repeat 2. Install the reverse proportional valve, forward pro-
for the reverse proportional valve. portional valve, and socket head capscrews into the
control valve body. Tighten socket head screws to
9. Remove the socket head screws and transmission 3 to 4 N•m (27 to 35 lbf in).
enable valve from the control valve body.
3. Install the supply spool and spring into the control
CLEAN valve body. Install the plug with a new O-ring.
4. Install the torque converter regulator spool and

WARNING spring into the control valve body. Install the plug
Cleaning solvents can be flammable and toxic and and new O-ring.
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufacturer’s 5. Install the proportional supply regulator spool and
recommended safety procedures. spring into the control valve body. Install the plug
and new O-ring.
Compressed air can move particles so they cause
injury to the user or to other personnel. Make sure 6. Install the clip, lockwasher, capscrew, two fittings,
the path of the compressed air is away from all per- and two pressure transducers into the control valve
sonnel. Wear protective goggles or a face shield to body.
prevent injury to the eyes.
7. Install the transmission input speed sensor (tiss)
and two capscrews in the transmission. Install the
CAUTION transmission output speed sensor (toss) and two
Do not allow cleaning solvent to come in contact capscrews in the transmission. Tighten all cap-
with rubber or plastic components as it can damage screws to 6.9 N•m (61 lbf in).
those components.
8. Install a new control valve gasket on the transmis-
Clean all metal components in solvent and dry with sion. Install the control valve on the transmission.
compressed air. See Figure 31. Install the capscrews that hold the
control valve on the transmission. Do not tighten at
INSPECT this time.
1. Make sure there are no scratches or damage on the 9. Tighten capscrews to 13.3 N•m (118 lbf in) in the se-
spools or in the bores of the control valve body. If quence shown in Figure 33. Retighten capscrews
the control valve body bores are damaged, replace to 19 N•m (168 lbf in) in the sequence shown in Fig-
the control valve. ure 33.

1300 YRM 1129 Foot Directional Control Pedal Repair
CAUTION
Use care when connecting the wiring harnesses to
the connectors. The connectors are easily dam-
aged.
10. Install the cable connector in the standoff and con-

nect the wiring harness connectors to the transmis-
sion and control valve as tagged during removal.
See Figure 30.
Figure 33. Control Valve Mounting Screw

Tightening Sequence
Foot Directional Control Pedal Repair

REMOVE AND DISASSEMBLE
1. Remove five screws, dash panel, and kick plate
1243 for GLC40, 45, 55VX; GLC55SVX; (GC/
GLC080, 100, 120VX; GC/GLC080, 100VXBCS;
GC/GLC120SVX; GC/GLC120VXPRS) (E818)
and GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX (GP/
GLP/GDP080, 090, 100, 110, 120VX) (F813,
G813) lift trucks, and Frame 100 YRM 1120 for
(C809); GLP/GDP16VX, GLP/GDP18VX, GLP/
GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875) lift trucks. Remove three capscrews and
swing the hydraulic lever assembly toward the
operator’s seat. Disconnect two cable assemblies
from the pedal assembly. See Figure 34.
1. CAPSCREW
2. HYDRAULIC LEVER ASSEMBLY
Figure 34. Hydraulic Lever Relocation

Foot Directional Control Pedal Repair 1300 YRM 1129
2. Remove three capscrews that hold the throttle base 3. Remove two pan head screws, lockwashers, and
to the cowl, and remove the pedal assembly from accelerator position sensor from throttle base. See
the lift truck. See Figure 35. Figure 36.
CAUTION
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 the connector from the connector holder

on the throttle base. Remove the outer and inner
springs from the throttle base and Foot Directional
Control pedal assembly.
5. Remove the e-clip and throttle base from the throttle

pedal shaft. Remove the roll pin and the throttle
pedal shaft from the Foot Directional Control pedal
assembly. Discard the roll pin.
1. CAPSCREWS
2. PEDAL ASSEMBLY
3. COWL
Figure 35. Foot Directional Control Pedal Removal

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 36. Foot Directional Control Pedal Bracket Disassembly
NOTE: Tag wires prior to removing from microswitches 7. Remove two hex head screws, lockwashers, nuts,
to aid in connecting. and microswitch from the pedal pad. Repeat for
remaining microswitch and remove the wiring har-
6. Remove u-clip, foam lock seal, and wiring harness ness from the pedal frame.
from the pedal frame. Remove four pan head
screws, lockwashers, washers, pedal pad, and 8. If damaged, remove the stop screw and nut from
springs from the pedal frame. If any metal inserts the pedal frame.
in the pedal pad are damaged, replace as neces-
sary. See Figure 37.

Foot Directional Control Pedal Repair 1300 YRM 1129
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 37. Foot Directional Control Pedal Disassembly

ASSEMBLE AND INSTALL 4. Install the wiring harness in the pedal frame. In-
stall the foam lock seal and u-clip. Install pedal pad
1. If removed, install the stop screw and nut on the and springs in the pedal frame. Coat the threads
pedal frame. See Figure 37. of four pan head screws with Loctite 222. Install
pan head screws, lockwashers, and washers in the
2. Install the microswitch and two hex head screws in
pedal pad. Tighten pan head screws to 2.25 to
the pedal pad. Coat the exposed threads of the
2.50 N•m (19 to 32 lbf in).
hex head screws with Loctite™ 222. Install the two
lockwashers and nuts on the hex head screws. Do 5. Using an ohmmeter, check for continuity between
not tighten the nuts at this time. Repeat for the other pins 3 and 4 of the Foot Directional Control wiring
microswitch. harness connector with the Foot Directional Control
pedal in the reverse position, and between pins 1
3. Put the wires through the hole in the pedal frame.
and 2 with the pedal in the forward position. See
The white banded wire is for the reverse mi-
Figure 39.
croswitch, and the blue banded wire is for the
forward microswitch. Adjust each microswitch in
its mount so that the measurement between the
edge of the mount and the base of the microswitch
equals 0.0 to 0.5 mm (0.0 to 0.02 in.). Tighten the
mounting nuts of each microswitch as adjustment
is completed. See Figure 38.
1. WIRING HARNESS CONNECTOR

2. WIRING HARNESS
Figure 39. Microswitch Continuity Check
6. Install the throttle pedal shaft and new roll pin in the
Foot Directional Control pedal assembly. Install the
throttle base and e-clip on the throttle pedal shaft.
See Figure 36.
CAUTION
Use care when installing the connector in its holder
as the connector can be easily damaged.
7. Install the inner and outer springs on the throttle

base and Foot Directional Control pedal assembly.
Install the connector in the connector holder on the
throttle base.
1. MICROSWITCH MOUNT 8. Install the actuator and magnet in the throttle base.
2. MICROSWITCH BASE Install the accelerator position sensor, lockwash-
ers, and two pan head screws in the throttle base.
Figure 38. Microswitch Adjustment
Tighten screws to 2.25 N•m (19 lbf in).

Direction Control Lever 1300 YRM 1129
9. Apply adhesive compound to the three mounting GLP/GDP45VX6; GLP/GDP50-55VX (GP/

bolts. Using the three capscrews that hold the throt- GLP/GDP080, 090, 100, 110, 120VX) (F813,
tle base to the cowl, install the pedal assembly on G813) lift trucks, and Frame 100 YRM 1120 for
the lift truck. Tighten the bolts to 19 to 25 N•m (168 GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX
to 221 lbf in). See Figure 35. (C809); GLP/GDP16VX, GLP/GDP18VX, GLP/
10. Connect two cable assemblies to the pedal as- GP/GLP/GDP040SVX (C810); GLC20-35VX
sembly. Swing the hydraulic lever assembly (GC/GLC040-070VX, GC/GLC055SVX (A910)
toward the cowl and install three capscrews. GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
See Figure 34. Install the dashboard on the (B875) lift trucks.
lift truck. See the section Frame 100 YRM
1243 for GLC40, 45, 55VX; GLC55SVX; (GC/ 11. Depress the Foot Directional Control pedal un-
GLC080, 100, 120VX; GC/GLC080, 100VXBCS; til it stops. Unscrew stop screw until it contacts
GC/GLC120SVX; GC/GLC120VXPRS) (E818) the metal floor plate. Tighten the nut to 10 N•m
and GLP/GDP40VX5/VX6; GLP/GDP45SVX5, (89 lbf in).
Direction Control Lever

REMOVE 3. Repeat the above steps on the opposite side of the
direction control lever. Remove the direction control
NOTE: There is no repair of the direction control lever. lever from the display panel.
1. Insert a small, flat-blade screwdriver with a
INSTALL
3.175 mm (0.125 in.) or less, wide blade into
the opening on the display panel on an outward Slide the direction control lever into the opening on the
angle enough to compress the spring tab on the left side of the display panel until the locking tabs are
direction control lever. See A, Figure 40. engaged in the display panel.
2. Pry the spring tab toward the body of the direction
control lever and, at the same time, pull on the han-
dle of the lever enough to free the tab of the interior
lock of the display panel. See B, Figure 40.

1300 YRM 1129 Direction Control Lever
NOTE: DISPLAY PANEL SHOWN OUTSIDE OF THE LIFT TRUCK FOR CLARITY.
A. STEP 1 B. STEP 2
1. DIRECTION CONTROL LEVER 3. DISPLAY PANEL
2. FLAT-BLADE SCREWDRIVER
Figure 40. Direction Control Lever Removal

NOTES
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70
Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011
1300 YRM 1129 9/09 (7/08)(3/07)(10/06)(6/06)(3/06)(10/05)(6/05)(5/05)(12/04) Printed in U.S.A.

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Maintenance

PART NO. 524223762 1300 YRM 1129

• 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];

©2009 Yale Materials Handling Corp. i

A. EARLY LIFT TRUCK MODELS EXCEPT

Figure 1. Transmission Serial Number Location

Confidential/Proprietary - Do Not Copy or Duplicate 1

Charge Pump Repair

Remove four mounting capscrews, washers, transmis-

INSTALL NOTE: THE TRANSMISSION IS SHOWN REMOVED

Figure 2. Transmission Charge Pump

2 Confidential/Proprietary - Do Not Copy or Duplicate

Torque Converter Replace

Confidential/Proprietary - Do Not Copy or Duplicate 3

Figure 3. Engine-Transmission Combination

4 Confidential/Proprietary - Do Not Copy or Duplicate

4. Remove the access cover from the torque converter

Confidential/Proprietary - Do Not Copy or Duplicate 5

Figure 4. Torque Converter Bolt Access

6 Confidential/Proprietary - Do Not Copy or Duplicate

Legend for Figure 4

Figure 5. Torque Converter Removal

Confidential/Proprietary - Do Not Copy or Duplicate 7

6. Remove the plug, suction screen spring, and suc-

7. Remove the transmission charge pump and trans-

NOTE: Step 8, Step 9, and the NOTE below apply to

8. Remove the dipstick from the dipstick tube, and dis-

NOTE: The dipstick tube must be removed before the

9. Remove the dipstick tube from the torque converter

10. If damaged, remove the small access cover from

8 Confidential/Proprietary - Do Not Copy or Duplicate

Figure 7. Torque Converter Housing

Confidential/Proprietary - Do Not Copy or Duplicate 9

INSTALL 2. If removed, install the small access cover on the

Figure 8. Torque Converter Installation

10 Confidential/Proprietary - Do Not Copy or Duplicate

3. Clean the surface of the dipstick tube and dipstick

Confidential/Proprietary - Do Not Copy or Duplicate 11

Figure 9. Engine-Transmission Combination

12 Confidential/Proprietary - Do Not Copy or Duplicate

Confidential/Proprietary - Do Not Copy or Duplicate 13

Figure 10. Torque Converter Bolt Access

14 Confidential/Proprietary - Do Not Copy or Duplicate

Legend for Figure 10

Front Cover Housing and Chain Drive Repair

Confidential/Proprietary - Do Not Copy or Duplicate 15

Figure 11. Engine-Transmission Combination

16 Confidential/Proprietary - Do Not Copy or Duplicate

the eye bolt. Remove the 10 capscrews that hold

Confidential/Proprietary - Do Not Copy or Duplicate 17

Figure 12. Torque Converter Bolt Access

18 Confidential/Proprietary - Do Not Copy or Duplicate

Legend for Figure 12

Figure 13. Torque Converter Housing Removal

Confidential/Proprietary - Do Not Copy or Duplicate 19

NOTE: The dipstick tube must be removed before the

7. Remove the dipstick tube from the torque converter