Main Control Valve: Maintenance

Maintenance
MAIN CONTROL VALVE

GLC050LX [A967]; GLP050LX [A974]; 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]; GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX,
GC/GLC/GDC155VX) [C879, D879]; GLP/GDP60VX,
GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) [C878,
D878]; GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX,
GDP175VX36, GDP190VX) [A909]
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. 524223767 2000 YRM 1137

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.
Main Control Valve Table of Contents
TABLE OF CONTENTS
General.................................................................................................................................................................. 1
Electro-Hydraulic Main Control Valve .................................................................................................................... 2
Description ........................................................................................................................................................ 2
Remove ............................................................................................................................................................. 8
Electro-Hydraulic Control Valve Sections........................................................................................................ 14
General ....................................................................................................................................................... 14
Outlet Control Valve Section ....................................................................................................................... 14
Remove .................................................................................................................................................. 14
Disassemble ........................................................................................................................................... 14
Clean ...................................................................................................................................................... 16
Inspect .................................................................................................................................................... 16
Assemble................................................................................................................................................ 16
Install ...................................................................................................................................................... 17
Auxiliary Control Valve Sections ................................................................................................................. 17
Remove .................................................................................................................................................. 17
Disassemble ........................................................................................................................................... 23
Clean ...................................................................................................................................................... 24
Inspect .................................................................................................................................................... 25
Assemble................................................................................................................................................ 25
Install ...................................................................................................................................................... 26
Tilt Control Valve Section............................................................................................................................ 27
Remove .................................................................................................................................................. 27
Disassemble ........................................................................................................................................... 28
Clean ...................................................................................................................................................... 32
Inspect .................................................................................................................................................... 33
Assemble................................................................................................................................................ 33
Install ...................................................................................................................................................... 34
Lift/Lower Control Valve Section ................................................................................................................. 34
Remove .................................................................................................................................................. 34
Disassemble ........................................................................................................................................... 34
Clean ...................................................................................................................................................... 43
Inspect .................................................................................................................................................... 43
Assemble................................................................................................................................................ 43
Install ...................................................................................................................................................... 44
Mid-Inlet Section ......................................................................................................................................... 45
Remove .................................................................................................................................................. 45
Clean ...................................................................................................................................................... 45
Inspect .................................................................................................................................................... 45
Install ...................................................................................................................................................... 45
Install............................................................................................................................................................... 46
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment......................................................................... 50
Lift Pilot Pin ................................................................................................................................................. 50
Lower Pilot Pin ............................................................................................................................................ 52
Abnormal/Erroneous EHPV Adjustment ..................................................................................................... 54
Manual Main Control Valve.................................................................................................................................. 55
Description ...................................................................................................................................................... 55
Remove ........................................................................................................................................................... 59
OPS Solenoid Assembly ................................................................................................................................. 66
General ....................................................................................................................................................... 66
Remove....................................................................................................................................................... 66
Clean and Inspect ....................................................................................................................................... 68
©2011 Yale Materials Handling Corp. i

Table of Contents Main Control Valve
TABLE OF CONTENTS (Continued)

Install .......................................................................................................................................................... 68
Manual Control Valve Sections ....................................................................................................................... 69
General ....................................................................................................................................................... 69
Outlet Control Valve Section ....................................................................................................................... 69
Remove .................................................................................................................................................. 69
Disassemble ........................................................................................................................................... 69
Clean ...................................................................................................................................................... 72
Inspect .................................................................................................................................................... 72
Assemble................................................................................................................................................ 72
Install ...................................................................................................................................................... 73
Auxiliary Control Valve Sections ................................................................................................................. 73
Remove .................................................................................................................................................. 73
Disassemble ........................................................................................................................................... 73
Clean ...................................................................................................................................................... 76
Inspect .................................................................................................................................................... 76
Assemble................................................................................................................................................ 76
Install ...................................................................................................................................................... 76
Lift/Tilt Control Valve Section ...................................................................................................................... 77
Remove .................................................................................................................................................. 77
Disassemble ........................................................................................................................................... 77
Clean ...................................................................................................................................................... 83
Inspect .................................................................................................................................................... 83
Assemble................................................................................................................................................ 83
Install ...................................................................................................................................................... 85
Mid-Inlet Section ......................................................................................................................................... 85
Remove .................................................................................................................................................. 85
Clean ...................................................................................................................................................... 85
Inspect .................................................................................................................................................... 86
Install ...................................................................................................................................................... 86
Install............................................................................................................................................................... 86
Pressure Relief Valve Check and Adjustment ..................................................................................................... 92
Primary Relief Valve........................................................................................................................................ 92
Secondary Relief Valve ................................................................................................................................... 95
Steering Control Unit Repair ............................................................................................................................. 100
Steering Control Unit, Remove ..................................................................................................................... 100
Steering Control Unit, Disassemble .............................................................................................................. 103
Steering Control Unit, Clean ......................................................................................................................... 104
Steering Control Unit, Inspect ....................................................................................................................... 104
Steering Control Unit, Assemble ................................................................................................................... 105
Relief Valve, Disassemble............................................................................................................................. 105
Relief Valve, Clean ........................................................................................................................................ 106
Relief Valve, Inspect...................................................................................................................................... 106
Relief Valve, Assemble.................................................................................................................................. 106
Steering Control Unit, Install ......................................................................................................................... 106
ii
Main Control Valve Table of Contents
TABLE OF CONTENTS (Continued)

This section is for the following models:
GLC050LX [A967];
GLP050LX [A974];
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];
GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/
GDC155VX) [C879, D879];
GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/
GDP155VX) [C878, D878];
GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX,
GDP175VX36, GDP190VX) [A909]
iii
2000 YRM 1137 General
General
This section contains a description and repair pro-
cedures for both manual and electronic main control
valves used in the hydraulic system for this series of lift
trucks.
NOTE: Lift truck models GLC050LX (A967) and

GLP050LX (A974) are equipped only with a manual
main control valve.
There are two main control valves available for this se-
ries of lift trucks. One is controlled manually (manual
main control valve) and the other is controlled elec-
tronically (electro-hydraulic main control valve). The
main control valves are mounted to the cowl using three
mounting bolts. See Figure 1.
NOTE: MAJOR COMPONENTS NOT SHOWN FOR

CLARITY. VIEW IS FROM THE FRONT OF LIFT
TRUCK.
1. COWL
2. INSERT
3. WASHER
4. MOUNTING CAPSCREW
5. MAIN CONTROL VALVE
6. FRAME
Figure 1. Main Control Valve Mounting, Typical
Confidential/Proprietary - Do Not Copy or Duplicate 1

Electro-Hydraulic Main Control Valve 2000 YRM 1137
Electro-Hydraulic Main Control Valve

DESCRIPTION • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
GDC135VX, GC/GLC/GDC155VX) (D879)
The E-Valve is an electronically-controlled, closed-cen- • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
ter, load-sensing stack valve. It uses an unloader valve GDP135VX, GP/GLP/GDP155VX) (D878)
(single functions only) and has parallel hydraulic cir-
cuitry. Operating multiple functions simultaneously will See Figure 5 for the following lift truck models equipped
result in a non-proportionate increase in pump flow to with an E-Valve with an anti-stall plug:
functions which receive the lowest amount of pressur- • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX
ized fluid. A fixed displacement pump is used in con- (GDP170VX, GDP175VX36, GDP190VX) (A909)
junction with the inlet compensator to achieve the re-
quired load-sense logic. Lift function is on main re- See Figure 6 for the following lift truck models equipped
lief pressure setting. Tilt and auxiliary functions are on with an E-Valve with an anti-stall plug:
secondary relief pressure setting. Lift pressure is unaf- • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX
fected by secondary relief operation. (C809)
• GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX
The electronic main control valve incorporate an emer- (GP/GLP/GDP030VX, GP/GLP/GDP035VX,
gency (manual) lowering valve. This valve allows the GP/GLP/GDP040SVX) (C810), GLC20-35VX
operator or service technician to lower the lift truck’s (GC/GLC040-070VX, GC/GLC055SVX) (A910)
mast assembly if the electrical signal to the electronic • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
main control valve is disrupted. (B875)
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100,
See Figure 2 for the following lift truck models equipped 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX;
with an E-Valve without an anti-stall port: GC/GLC120VXPRS) (E818)
• GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
(C809) GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080,
• GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX 090, 100, 110, 120VX) (F813, G813)
(GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GP/GLP/GDP040SVX) (C810) See Figure 7 for the following lift truck models equipped
• GLC20-35VX (GC/GLC040-070VX, with an E-Valve with an anti-stall solenoid:
GC/GLC055SVX) (A910) • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100,
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX;
(B875) GC/GLC120VXPRS) (E818)
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080,
GC/GLC120VXPRS) (E818) 090, 100, 110, 120VX) (F813, G813)
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, The electronic main control valve assembly with fixed
090, 100, 110, 120VX) (F813, G813) displacement pump is divided into the following sec-
tions:
See Figure 3 for the following lift truck models with an • Steering Control Unit (SCU)
E-Valve without an anti-stall port: • Lift/Lower
• GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ • Tilt
GDC135VX, GC/GLC/GDC155VX) (C879, D879) • Auxiliary
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ • Outlet
GDP135VX, GP/GLP/GDP155VX) (C878, D878) • Mid-Inlet* (Primary Pump Inlet)
See Figure 4 for lift truck models below, equipped with

anti-stall solenoid:
2 Confidential/Proprietary - Do Not Copy or Duplicate

2000 YRM 1137 Electro-Hydraulic Main Control Valve
1. STEERING CONTROL UNIT (SCU) 7. AUXILIARY I SECTION

2. SCU MOUNTING CAPSCREW 8. AUXILIARY II SECTION
3. LIFT/LOWER SECTION 9. SECONDARY RELIEF VALVE (ADJUSTABLE)
4. EMERGENCY LOWERING VALVE 10. OUTLET SECTION
5. ELECTRO-HYDRAULIC POPPET VALVE (EHPV) 11. TILT SECTION
6. PROPORTIONAL PRESSURE REDUCING 12. PRIMARY RELIEF VALVE (ADJUSTABLE)
VALVE (PPRV) 13. EF PORT
Figure 2. Electronic Control Valve Without Anti-Stall Port, Lift Truck Models GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809), GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX)
(A910), 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)
See Figure 2 and Figure 6 for lift truck models: • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
• GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080,
(C809) 090, 100, 110, 120VX) (F813, G813)
(GP/GLP/GDP030VX, GP/GLP/GDP035VX, See Figure 3 for lift truck models:
GP/GLP/GDP040SVX) (C810) • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/
• GLC20-35VX (GC/GLC040-070VX, GDC135VX, GC/GLC/GDC155VX) (C879, D879)
GC/GLC055SVX) (A910) • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) GDP135VX, GP/GLP/GDP155VX) (C878, D878)
(B875)
See Figure 4 for lift truck models:
• GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX;
GC/GLC120VXPRS) (E818)
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
GDP135VX, GP/GLP/GDP155VX) (D878)


3. MID-INLET SECTION (PRIMARY PUMP INLET) 9. SECONDARY RELIEF VALVE (ADJUSTABLE)
4. ELECTRO-HYDRAULIC POPPET VALVE (EHPV) 10. OUTLET SECTION
(LIFT) 11. TILT SECTION
5. ELECTRO-HYDRAULIC POPPET VALVE (EHPV) 12. PRIMARY RELIEF VALVE (ADJUSTABLE)
(LOWER) 13. EMERGENCY LOWERING VALVE
6. PROPORTIONAL PRESSURE REDUCING 14. EF PORT
VALVE (PPRV) 15. LIFT/LOWER SECTION
Figure 3. Electronic Control Valve Without Anti-Stall Port, Lift Truck Models GLC/GDC60VX,
GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) and GLP/GDP60VX, GLP/GDP70VX
(GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878)

1. STEERING CONTROL UNIT (SCU) 7. TILT SECTION

2. SCU MOUNTING CAPSCREW 8. AUXILIARY I SECTION
(LIFT) 11. EF PORT
6. PROPORTIONAL PRESSURE REDUCING 14. ANTI-STALL SOLENOID
VALVE (PPRV)
Figure 4. Electronic Control Valve With Anti-Stall Solenoid, Lift Truck Models GLC/GDC60VX,
GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (D879), and GLP/GDP60VX, GLP/GDP70VX
(GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878)
See Figure 5 for lift truck models: *Mid-inlet (primary pump inlet) section is used only on
• GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX the main control valve of lift truck models
(GDP170VX, GDP175VX36, GDP190VX) (A909) • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/
GDC135VX, GC/GLC/GDC155VX) (C879, D879)
See Figure 7 for lift truck models: • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, GDP135VX, GP/GLP/GDP155VX) (C878, D878)
120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX
GC/GLC120VXPRS) (E818) (GDP170VX, GDP175VX36, GDP190VX) (A909)
GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080,
090, 100, 110, 120VX) (F813, G813)


(LIFT) 12. EF PORT
6. PROPORTIONAL PRESSURE REDUCING 15. ANTI-STALL SOLENOID PORT
VALVE (PPRV) 16. ANTI-STALL PLUG
7. TILT SECTION 17. LIFT/LOWER SECTION
Figure 5. Electronic Control Valve With Anti-Stall Plug, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9,
GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909)
See Figure 4 for lift truck models: See Figure 5 for lift truck models:
• GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX
GDC135VX, GC/GLC/GDC155VX) (C879, D879) (GDP170VX, GDP175VX36, GDP190VX) (A909)
GDP135VX, GP/GLP/GDP155VX) (C878, D878)


3. ELECTRO-HYDRAULIC POPPET VALVE (EHPV) 9. SECONDARY RELIEF VALVE (ADJUSTABLE)
(LIFT) 10. OUTLET SECTION
4. ELECTRO-HYDRAULIC POPPET VALVE (EHPV) 11. EF PORT
(LOWER) 12. PRIMARY RELIEF VALVE (ADJUSTABLE)
5. PROPORTIONAL PRESSURE REDUCING 13. EMERGENCY LOWERING VALVE
VALVE (PPRV) 14. ANTI-STALL PLUG
6. TILT SECTION 15. ANTI-STALL SOLENOID PORT
Figure 6. Electronic Control Valve With Anti-Stall Plug, Lift Truck Models GC/GLC030VX, GC/GLC035VX,


3. ELECTRO-HYDRAULIC POPPET VALVE (EHPV) 9. SECONDARY RELIEF VALVE (ADJUSTABLE)
(LIFT) 10. OUTLET SECTION
4. ELECTRO-HYDRAULIC POPPET VALVE (EHPV) 11. EF PORT
(LOWER) 12. PRIMARY RELIEF VALVE (ADJUSTABLE)
5. PROPORTIONAL PRESSURE REDUCING 13. EMERGENCY LOWERING VALVE
VALVE (PPRV) 14. ANTI-STALL SOLENOID
6. TILT SECTION
Figure 7. Electronic Control Valve With Anti-Stall Solenoid, Lift Truck Models GLC40, 45, 55VX; GLC55SVX;
(GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) and
GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100,
110, 120VX) (F813, G813)
REMOVE NOTE: Most of the individual valve components can

be removed and replaced while the control valve is in-
WARNING stalled in the truck. Removal of the control valve for
repairs is normally only required to replace a valve sec-
Lower carriage completely before working on con-
tion, or to replace the O-rings between the sections.
trol valve or hydraulic system. Do not work under
a raised carriage. Put mast in a vertical position, 1. Power wash the interior of the operator compart-
with no forward or back tilt, and lower carriage com- ment to remove any dirt or debris.
pletely before disconnecting any parts of hydraulic
system. The mast can lower suddenly and cause 2. Move truck to disassembly area and shut off engine.
injury if the carriage is not lowered.

• GLP/GDP80VX, GLP/GDP80VX9,
WARNING GLP/GDP90VX (GDP170VX, GDP175VX36,
Cleaning solvents can be flammable and toxic and GDP190VX) (A909)
cause skin irritation. When cleaning solvents are
used, always follow the solvent manufacturer’s 4. Before disconnecting any hydraulic hoses or re-
recommended safety procedures. Wear protective moving any parts from the control valve, clean the
goggles or a face shield to prevent eye injuries. outside of the valve either by steam cleaning or with
cleaning solvent.
WARNING 5. To remove the accelerator pedal or Foot Directional
Be careful when cleaning with steam. Steam can Control pedal assembly, disconnect the cowl wiring
cause serious burns. Wear protective clothing, harness from the pedal assembly wiring harness
gloves, and eye protection. Never expose your skin and remove three mounting capscrews. See Fig-
to steam. ure 8.
NOTE: Take all necessary steps to prevent debris, dust,

or other contaminants from entering the valve cavities,
hydraulic lines, or replacement parts.
3. Remove the floor plate, kick panel, seal plate, and

dashboard. See one of the following service man-
ual sections for your lift truck’s procedures:
See Frame 100 YRM 1120 for lift truck models

• GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809)
• GLP/GDP16VX, GLP/GDP18VX,
GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810)
• GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910)
• 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)
See Frame 100 YRM 1316 for lift truck models NOTE: ACCELERATOR PEDAL NOT SHOWN, HOW-
• GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ EVER, REMOVAL IS THE SAME.
GDC135VX, GC/GLC/GDC155VX) (C879,
D879) 1. MOUNTING CAPSCREW
2. FOOT DIRECTIONAL CONTROL PEDAL
See Frame 100 YRM 1321 for lift truck models ASSEMBLY
3. PEDAL ASSEMBLY WIRING HARNESS
GDP135VX, GP/GLP/GDP155VX) (C878, D878) Figure 8. Foot Directional Control Pedal Removal

NOTE: To aid in installation, tag all connectors prior to • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
disconnecting from the solenoids. 100, 120VX; GC/GLC080, 100VXBCS;
6. Disconnect the cowl wiring harness connectors • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
from the lift and lower Electro-Hydraulic Poppet GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
Valve (EHPV) solenoids. Disconnect the cowl GDP080, 090, 100, 110, 120VX) (F813, G813)
wiring harness from the top auxiliary function
Proportional Pressure Reducing Valve (PPRV) 8. Remove the two SCU mounting capscrews and
solenoids. See Figure 9. move the SCU approximately 1.3 cm (0.5 in.) to
the left, and lower the SCU until the steering shaft
is disengaged. Remove the SCU from the lift truck.
CAUTION
To prevent any foreign matter from getting into See Figure 2 and Figure 6 for lift truck models:
either the hydraulic hoses or the hydraulic control • GC/GLC030VX, GC/GLC035VX,
valve sections, all openings must have plugs or GC/GLC040SVX (C809)
covers installed immediately after hoses are dis- • GLP/GDP16VX, GLP/GDP18VX,
connected from the control valve. This also applies GLP/GDP20SVX (GP/GLP/GDP030VX,
if any other items are removed from the control GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
valve. (C810)
NOTE: Lift truck models GLP/GDP20-35VX (GP/GLP/ GC/GLC055SVX) (A910)
GDP040-070VX) (B875) may be equipped with an op- • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
tional Quick-Lok™ hydraulic inlet hose and adapter be- (B875)
tween the steering control unit and hydraulic gear pump. • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
100, 120VX; GC/GLC080, 100VXBCS;
NOTE: To aid in correctly connecting hydraulic hoses
during installation, tag each hose prior to disconnecting
from the control valve.
GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
7. Disconnect hydraulic hoses from the control valve. GDP080, 090, 100, 110, 120VX) (F813, G813)
Install plugs or caps on all open hose ends and
control valve ports to prevent contamination.
• GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/
See Figure 9 for lift truck models: GDC135VX, GC/GLC/GDC155VX) (C879,
• GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ D879)
GDC135VX, GC/GLC/GDC155VX) (C879, • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
D879) GDP135VX, GP/GLP/GDP155VX) (C878, D878)
GLP/GDP90VX (GDP170VX, GDP175VX36,
GDP190VX) (A909)
See Figure 5 for the following lift truck models:
GC/GLC040SVX (C809)
GDP190VX) (A909)
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) See Figure 7 for the following lift truck models:
(C810) • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
• GLC20-35VX (GC/GLC040-070VX, 100, 120VX; GC/GLC080, 100VXBCS;
GC/GLC055SVX) (A910) GC/GLC120SVX; GC/GLC120VXPRS) (E818)
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
(B875) GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (F813, G813)

NOTE: HARNESS CONNECTORS FOR GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/

GDC155VX) (C879, D879), GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878,
D878), AND GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909)
LIFT TRUCKS SHOWN. HARNESS CONNECTORS FOR ALL OTHER LIFT TRUCK MODELS COVERED IN
THIS YRM ARE SIMILAR.
1. LIFT ELECTRO-HYDRAULIC POPPET VALVE 6. MID INLET HOSE (MAIN PUMP HOSE)
(EHPV) HARNESS CONNECTOR 7. LIFT/LOWER HOSE
2. LOWER ELECTRO-HYDRAULIC POPPET VALVE 8. TILT HOSE
(EHPV) HARNESS CONNECTOR 9. AUXILIARY I HOSE
3. AUXILIARY FUNCTION PROPORTIONAL 10. AUXILIARY II HOSE
PRESSURE REDUCING VALVE (PPRV) 11. RETURN HOSE
HARNESS CONNECTOR 12. STEERING COLUMN
4. STEERING SYSTEM HOSES 13. STEERING CONTROL UNIT (SCU)
5. SECONDARY HYDRAULIC PUMP HOSE 14. SCU MOUNTING CAPSCREWS
Figure 9. Hydraulic Hose Removal and Harness Disconnection, Lift Truck Models GLC/GDC60VX,
GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879), GLP/GDP60VX, GLP/GDP70VX
(GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878), and GLP/GDP80VX, GLP/GDP80VX9,

NOTE: QUICK-LOK™ HYDRAULIC INLET HOSE AND ADAPTER NOT SHOWN.

1. STEERING SYSTEM HOSES 6. LIFT/LOWER HOSE
2. HYDRAULIC INLET HOSE 7. TILT HOSE
3. STEERING CONTROL UNIT (SCU) 8. AUXILIARY I HOSE
4. STEERING COLUMN 9. AUXILIARY II HOSE
5. SCU MOUNTING CAPSCREWS 10. RETURN HOSE
Figure 10. Hydraulic Hose Removal, Lift Truck Models GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX
(C809), GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GP/GLP/GDP040SVX) (C810), GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), 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)

9. Remove and discard two O-rings located between See Figure 2 and Figure 6 for lift truck models:
the control valve and the SCU. • GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809)
WARNING • GLP/GDP16VX, GLP/GDP18VX,
The main control valve weighs approximately
30.5 kg (67 lb). Use a lifting device capable of lifting
(C810)
the main control valve to avoid the possibility of
injury to personnel.
10. Support the main control valve. Remove three • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
mounting capscrews, washers, inserts, and the (B875)
main control valve from the lift truck. See Fig- • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
ure 11. 100, 120VX; GC/GLC080, 100VXBCS;
GDP080, 090, 100, 110, 120VX) (F813, G813)

D879)

See Figure 5 for the following lift truck models:

1. COWL 5. MAIN CONTROL GLP/GDP90VX (GDP170VX, GDP175VX36,
2. INSERT VALVE GDP190VX) (A909)
3. WASHER 6. FRAME
4. MOUNTING See Figure 7 for the following lift truck models:
CAPSCREW • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
100, 120VX; GC/GLC080, 100VXBCS;
Figure 11. Main Control Valve Removal GC/GLC120SVX; GC/GLC120VXPRS) (E818)
NOTE: To aid in installation, tag all connectors prior to
disconnecting from the solenoids.
GDP080, 090, 100, 110, 120VX) (F813, G813)
11. Raise the main control valve approximately 25.4 cm
12. Remove the main control valve from the lift truck.
(10 in.) to gain access to the lower tilt and auxil-
iary function Proportional Pressure Reducing Valve
(PPRV) solenoids. Disconnect the cowl harness
from the lower tilt and auxiliary function (PPRV)
solenoids.

ELECTRO-HYDRAULIC CONTROL VALVE

SECTIONS
General
CAUTION
While working on the electro-hydraulic control
valve sections, place a cover over the remaining
sections of the control valve to prevent the possi-
bility of contaminants getting into the control valve
openings which could cause damage to the control
valve.
CAUTION
If O-rings are to be replaced between two sections
that have a hydraulic oil leak, replace all O-rings be-
tween all sections. This eliminates the possibility
of a subsequent oil leak or possible damage to an-
other O-ring.
Disassemble the electro-hydraulic control valve only as

necessary for repairs. Most repairs to the control valve
will be for the replacement of O-rings to stop leaks be-
tween sections.
1. OUTLET CONTROL VALVE SECTION
Outlet Control Valve Section 2. SOLENOID
3. ORIFICE DISK
Remove 4. CONNECTOR
1. Remove four nuts from the control valve tie rods. Figure 12. Outlet Control Valve Section With
See Figure 13. Anti-Stall Solenoid
2. Remove the outlet control valve section from the NOTE: Note placement of backup rings and O-ring prior
four tie rods and discard 10 O-rings (item 13 in Fig- to disassembly to aid in assembly.
ure 15) from the auxiliary control valve section.
2. Remove and discard two backup rings and one
Disassemble O-ring from solenoid.
NOTE: Perform Step 1 and Step 2 for lift truck models 3. Remove the plug from the outlet control valve sec-
listed below, equipped with anti-stall solenoid. tion and discard the O-ring. See Figure 13.
4. If the secondary relief valve has been leaking,
remove it from the outlet control valve section.
See Step 5 through Step 9 to disassemble the
secondary relief valve. See Figure 13.
090, 100, 110, 120VX) (F813, G813) 5. Remove the plug from the adjusting nut. Remove
• GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ and discard the O-ring from the plug. Remove and
GDC135VX, GC/GLC/GDC155VX) (D879) discard the backup rings and O-ring from the ad-
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ justing nut. See Figure 13.
6. While holding the adjustment nut, loosen the jam
1. Remove solenoid and orifice disk from outlet control nut.
valve section. See Figure 12.

Figure 13. Outlet Control Valve Section

Legend for Figure 13
NOTE: SECONDARY RELIEF VALVE ASSEMBLY IS THE SAME FOR BOTH OUTLET SECTIONS COVERED IN
FIGURE 13.
A. OUTLET SECTION USED ON LIFT TRUCK MODEL COVERED IN THIS SERVICE MANUAL THAT ARE
EQUIPPED WITH AN ANTI-STALL PORT ON OUTLET SECTION.
B. OUTLET SECTION USED ON LIFT TRUCK MODELS, EXCEPT GLP/GDP80VX, GLP/GDP80VX9,
GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909), COVERED IN THIS SERVICE MANUAL
THAT ARE NOT EQUIPPED WITH AN ANTI-STALL PORT ON OUTLET SECTION.
1. O-RING 8. SPRING
2. PLUG 9. JAM NUT
3. OUTLET VALVE SECTION 10. ADJUSTING NUT
4. BACKUP RING 11. CONTROL VALVE TIE ROD
5. SECONDARY RELIEF VALVE PLUG 12. NUT
6. POPPET 13. ANTI-STALL PORT
7. WASHER 14. SECONDARY RELIEF VALVE ASSEMBLY
NOTE: While performing Step 7, count and note the Inspect

number of turns used to remove the adjusting nut.
Inspect the outlet control valve section mating surfaces
7. Remove the adjusting nut and jam nut assembly and the bore of the secondary relief valve, if removed,
from the secondary relief valve plug and discard the for damage. If either the mating surface or the sec-
O-ring on the adjusting nut. ondary relief valve bore are damaged, replace the outlet
control valve section.
8. Remove the spring, washer, and poppet from the
secondary relief valve plug. If disassembled, inspect the components of the sec-
ondary relief valve. If any components other than
9. Remove and discard the backup ring from the sec- O-rings, backup rings, and the spring are damaged,
ondary relief valve plug. replace the secondary relief valve.
Clean NOTE: If the outlet control valve section is not to be
reassembled immediately, coat surfaces with clean hy-
WARNING draulic oil to prevent the possibility of rust. Cover the
Cleaning solvents can be flammable and toxic and outlet control valve section with a clean, dry, lint-free
can cause skin irritation. When using cleaning cloth to prevent the possibility of contaminants entering
solvents, always follow the solvent manufacturer’s the outlet control valve section.
recommended safety procedures.
Assemble
WARNING NOTE: Coat all backup rings and O-rings with a light
Compressed air can move particles so they cause coat of clean hydraulic oil to make installation easier.
injury to the user or to other personnel. Make sure
NOTE: Perform Step 1 through Step 7 only if the sec-
the path of the compressed air is away from all per-
ondary relief valve was repaired.
sonnel. Wear protective goggles or a face shield to
prevent injury to the eyes. 1. Install a new backup ring on the secondary relief
valve plug. See Figure 13.
1. If all components of the outlet control valve section
have been removed, clean the outlet control valve 2. Install the poppet, washer, and spring into the sec-
section using cleaning solvent and dry using com- ondary relief valve plug.
pressed air.
3. Install a new O-ring on the adjusting nut, and install
2. If all components have not been removed, clean the the adjusting nut and jam nut assembly into the sec-
outlet control valve section using a lint-free cloth. ondary relief valve plug using the same number of
turns noted during disassembly.

4. While holding the adjusting nut in place, tighten the NOTE: Make sure solenoid connector is oriented as
jam nut to 24 ±3 N•m (18 ±2 lbf ft). shown in Figure 12.
5. Install a backup ring, O-ring, and backup ring into 10. Install new backup rings and O-ring onto solenoid
the adjusting nut. as noted during disassembly. Install solenoid into
outlet control valve section. See Figure 12. Tighten
6. Install a new O-ring onto the plug. Install the plug solenoid to 25.8 to 28.6 N•m (19 to 21 lbf ft).
into the adjusting nut.
Install
7. If removed, install secondary relief valve into out-
let control valve section. Tighten relief valve plug NOTE: Coat all O-rings with light coat of clean hydraulic
to 45 N•m (33 lbf ft). See the section Pressure Re- oil to make installation easier.
lief Valve Check and Adjustment to adjust the sec-
ondary relief valve and check the pressure. 1. Install new O-rings (13, Figure 15) into the auxiliary
valve section. Install the outlet control valve section
8. Install new O-ring on plug and install in the outlet on the four tie rods.
valve section. See Figure 13.
2. Install the four nuts on the tie rods and tighten to 19
NOTE: Perform Step 9 and Step 10 for lift truck models ±2 N•m (168 ±18 lbf in).
listed below, equipped with an anti-stall solenoid.
Auxiliary Control Valve Sections
GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, NOTE: There is the possibility of having two or three
090, 100, 110, 120VX) (F813, G813) auxiliary control valve sections depending upon how
• GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ many functions are on the lift truck. If the main con-
GDC135VX, GC/GLC/GDC155VX) (D879) trol valve is a four-function control valve, there will be
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ two auxiliary control valve sections. If the main control
GDP135VX, GP/GLP/GDP155VX) (D878) valve is a five-function control valve, there will be three
auxiliary control valve sections.
9. Install orifice disk into outlet control section as
shown in Figure 14. These sections are repaired the same way with one ex-
ception. The auxiliary control valve section next to the
tilt control valve will always have the anti-stall valve in-
stalled as a part of that control valve section.
Remove
1. Remove the outlet control valve section. See Outlet

Control Valve Section, Remove.
NOTE: Step 2 and Step 3 are for a three-function control

valve. If a four or five-function control valve is being
disassembled, go to Step 4.
NOTE: If lift truck is equipped with either an anti-stall

solenoid or plug in the anti-stall port on the outlet sec-
tion, there will not be an anti-stall valve in the auxiliary
control valve section that is next to the tilt control valve
NOTE: CUTAWAY VIEW OF SOLENOID PORT section.
SHOWN WITH ORIFICE DISK INSTALLED.
1. ORIFICE DISK
Figure 14. Orifice Disk Placement • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/

See Figure 5 for the following lift truck models equipped • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
with an E-Valve with an anti-stall plug: (B875)
• GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
(GDP170VX, GDP175VX36, GDP190VX) (A909) 100, 120VX; GC/GLC080, 100VXBCS;
See Figure 6 for the following lift truck models equipped • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
with an E-Valve with an anti-stall plug: GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
• GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX GDP080, 090, 100, 110, 120VX) (F813, G813)
(C809)
• GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX 4. Remove the auxiliary III control valve section from
(GP/GLP/GDP030VX, GP/GLP/GDP035VX, the four tie rods. Remove and discard O-rings (13,
GP/GLP/GDP040SVX) (C810), GLC20-35VX Figure 15, illustration B) from side of the auxiliary II
(GC/GLC040-070VX, GC/GLC055SVX) (A910) control valve section. Remove the auxiliary II con-
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) trol valve section from the four tie rods. Remove
(B875) and discard O-rings (13, Figure 15, illustration B)
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, from side of the auxiliary I control valve section.
GC/GLC120VXPRS) (E818) NOTE: If working on lift truck model GLP/GDP80VX,
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GLP/GDP80VX9, GLP/GDP90VX (GDP170VX,
GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, GDP175VX36, GDP190VX) (A909) go to Step 6.
090, 100, 110, 120VX) (F813, G813)
NOTE: If lift truck is equipped with either an anti-stall
See Figure 7 for the following lift truck models equipped solenoid or plug in the anti-stall port on the outlet sec-
with an E-Valve with an anti-stall solenoid: tion, there will not be an anti-stall valve in the auxiliary
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, control valve section that is next to the tilt control valve
120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; section.
090, 100, 110, 120VX) (F813, G813)
2. Remove the anti-stall valve from the auxiliary con- • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
trol valve section. See Figure 15. If the anti-stall GDP135VX, GP/GLP/GDP155VX) (D878)
valve is to be repaired, go to Step 5 of the Dis-
See Figure 5 for the following lift truck models equipped
assemble procedure for the auxiliary control valve
with an E-Valve with an anti-stall plug:
section.
• GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX
3. Remove the auxiliary control valve section from the (GDP170VX, GDP175VX36, GDP190VX) (A909)
four tie rods. Remove and discard O-rings from the
side of tilt control valve section.
See Figure 16 for lift truck models: • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX
• GLP/GDP80VX, GLP/GDP80VX9, (C809)
GLP/GDP90VX (GDP170VX, GDP175VX36, • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX
GDP190VX) (A909) (GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GP/GLP/GDP040SVX) (C810), GLC20-35VX
See Figure 18 for lift truck models: (GC/GLC040-070VX, GC/GLC055SVX) (A910)
• GC/GLC030VX, GC/GLC035VX, • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
GC/GLC040SVX (C809) (B875)
• GLP/GDP16VX, GLP/GDP18VX, • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100,
GLP/GDP20SVX (GP/GLP/GDP030VX, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX;
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) GC/GLC120VXPRS) (E818)
(C810) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
• GLC20-35VX (GC/GLC040-070VX, GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080,
GC/GLC055SVX) (A910) 090, 100, 110, 120VX) (F813, G813)

See Figure 7 for the following lift truck models equipped GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
with an E-Valve with an anti-stall solenoid: (C810)
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, • GLC20-35VX (GC/GLC040-070VX,
120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC055SVX) (A910)
GC/GLC120VXPRS) (E818) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ (B875)
GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
090, 100, 110, 120VX) (F813, G813) 100, 120VX; GC/GLC080, 100VXBCS;
5. Remove the anti-stall valve from the auxiliary I con- • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
trol valve section. If the anti-stall valve is to be re- GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
paired, go to Step 5 of the Disassemble procedure GDP080, 090, 100, 110, 120VX) (F813, G813)
for the auxiliary control valve section. • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/
6. Remove the auxiliary I control valve section from
D879)
the four tie rods. Remove and discard O-rings from
side of the tilt control valve section.
GC/GLC040SVX (C809)
GDP190VX) (A909)

Figure 15. Auxiliary I, II, and III Control Valve Sections, for All Lift Truck Models Except GLP/GDP80VX,
GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909)

NOTE: IF LIFT TRUCK HAS AN E-HYDRAULIC CONTROL VALVE THAT IS NOT EQUIPPED WITH AN ANTI-STALL
PORT IN THE OUTLET SECTION, THEN THE AUXILIARY I CONTROL VALVE SECTION IS SHOWN IN ILLUS-
TRATION A AND THE OTHER AUXILIARY CONTROL VALVE SECTIONS SHOWN IN ILLUSTRATION B. IF LIFT
TRUCK IS EQUIPPED WITH AN E-HYDRAULIC CONTROL VALVE THAT DOES HAVE AN ANTI-STALL PORT IN
THE OUTLET SECTION, THEN THE AUXILIARY CONTROL VALVE SECTIONS ARE SHOWN IN ILLUSTRATION
B.
A. AUXILIARY I CONTROL VALVE SECTION (WITH ANTI-STALL VALVE)
B. AUXILIARY I, II, AND III CONTROL VALVE SECTION (ANTI-STALL SOLENOID IN OUTLET SECTION)
1. PLUG 7. SPOOL
2. O-RING 8. POPPET
3. SPRING 9. AUXILIARY I CONTROL VALVE BODY
4. WASHER 10. BACKUP RING
5. SOCKET HEAD CAPSCREW 11. ANTI-STALL VALVE SLEEVE
6. PROPORTIONAL PRESSURE REDUCING 12. AUXILIARY II CONTROL VALVE BODY
VALVE (PPRV) 13. O-RING

Figure 16. Auxiliary Control Valve Sections, for Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9,
GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909) With an E-Hydraulic Control Valve That is
Equipped With an Anti-Stall Port in the Outlet Section


A. AUXILIARY I CONTROL VALVE SECTION B. AUXILIARY II CONTROL VALVE SECTION
1. AUXILIARY I VALVE BODY 8. WASHER
2. AUXILIARY II VALVE BODY 9. CAPSCREW
3. PLUG 10. SOLENOID
4. POPPET - C.V. 11. SEALS
5. SPRING 12. O-RING
6. PLUG 13. SPOOL
7. SPRING
Disassemble 4. Remove two plugs, two springs, and two poppets

from the auxiliary control valve. Discard one O-ring
NOTE: Disassemble the auxiliary control valve section from each plug. See Figure 15.
only as needed to accomplish the repairs required. The
disassemble procedures for the auxiliary I, II, and III NOTE: If lift truck is equipped with either an anti-stall
sections are the same. The auxiliary I section is used solenoid or plug in the anti-stall port on the outlet sec-
in the procedures described below because it contains tion, there will not be an anti-stall valve in the auxiliary
the anti-stall valve. control valve section that is next to the tilt control valve
section.
NOTE: Perform Step 1 through Step 7 for lift truck mod-
els See Figure 4 for lift truck models below, equipped with
• GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX anti-stall solenoid:
(C809) • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
• GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX GDC135VX, GC/GLC/GDC155VX) (D879)
(GP/GLP/GDP030VX, GP/GLP/GDP035VX, • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
GP/GLP/GDP040SVX) (C810) GDP135VX, GP/GLP/GDP155VX) (D878)
GC/GLC055SVX) (A910) See Figure 5 for the following lift truck models equipped
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) with an E-Valve with an anti-stall plug:
(B875) • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, (GDP170VX, GDP175VX36, GDP190VX) (A909)
• GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX
GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080,
(C809)
090, 100, 110, 120VX) (F813, G813)
(GC/GLC040-070VX, GC/GLC055SVX) (A910)
1. Remove four capscrews and two proportional pres- (B875)
sure reducing valves (PPRV) from the auxiliary con- • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100,
trol valve section. Remove and discard the backup 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX;
ring, two O-rings, backup ring, and O-ring from GC/GLC120VXPRS) (E818)
each PPRV. See Figure 15. • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
2. Remove the plug, spring, washer, and spool from 090, 100, 110, 120VX) (F813, G813)
the auxiliary control valve section. Discard the
O-ring on the plug. See Figure 15.
3. Remove the plug, spring, and washer from the aux-

iliary control valve section. Discard the O-ring on
the plug. See Figure 15.

See Figure 7 for the following lift truck models equipped 10. Remove plug from top of auxiliary II control valve
with an E-Valve with an anti-stall solenoid: section. Remove and discard O-ring from plug.
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, See Figure 16.
GC/GLC120VXPRS) (E818) 11. Remove plug, spring, and poppet-c.v. from bottom
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ of auxiliary II control valve section. Remove and
GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, discard O-ring from plug. See Figure 16.
090, 100, 110, 120VX) (F813, G813)
12. Remove four capscrews and two solenoids from
5. Remove spring from the large end of the anti-stall auxiliary I control valve section. See Figure 16.
valve sleeve. See Figure 17.
NOTE: Note placement of seals during disassembly to
aid in assembly.
13. Remove and discard seals from solenoids, if

present. See Figure 16.
14. Remove plug, spring, washer, and spool from aux-

iliary I control valve section. Remove and discard
O-ring from plug. See Figure 16.
15. Remove plug from top of auxiliary I control valve

section. Remove and discard O-ring from plug.
See Figure 16.
16. Remove plug, spring, and poppet-c.v. from bottom

of auxiliary I control valve section. Remove and
discard O-ring from plug. See Figure 16.
1. SPOOL 4. ANTI-STALL VALVE Clean
2. BACKUP RING SLEEVE
3. O-RING 5. SPRING
WARNING
Figure 17. Anti-Stall Valve Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
6. Remove the spool from the small end of the anti- solvents, always follow the solvent manufacturer’s
stall valve sleeve. See Figure 17. recommended safety procedures.
NOTE: Note the orientation of the O-rings and backup
rings for correct installation. WARNING
Compressed air can move particles so they cause
7. Remove and discard two backup rings and two
O-rings from the anti-stall valve sleeve. See Fig-
ure 17. To reassemble the anti-stall sleeve valve,
see Step 5 of the assembly procedure.
prevent injury to the eyes.
NOTE: Perform Step 8 through Step 16 for lift
1. If all components of the auxiliary control valve sec-
truck model GLP/GDP80VX, GLP/GDP80VX9, GLP/
tion have been removed, clean the auxiliary con-
GDP90VX (GDP170VX, GDP175VX36, GDP190VX)
trol valve section and components, except the two
(A909).
PPRVs, using cleaning solvent and dry using com-
8. Remove four capscrews and two solenoids from pressed air.
auxiliary II control valve section. See Figure 16.
2. If all components have not been removed, clean the
9. Remove plug, spring, washer, and spool from aux- auxiliary control valve section using a lint-free cloth.
iliary II control valve section. Remove and discard
3. If the anti-stall valve was disassembled, clean the
O-ring from plug. See Figure 16.
spool, anti-stall valve sleeve, and spring with clean-
ing solvent. Dry with a lint-free cloth.

Inspect NOTE: If lift truck is equipped with either an anti-stall

solenoid or plug in the anti-stall port on the outlet sec-
Inspect the auxiliary control valve section mating sur- tion, there will not be an anti-stall valve in the auxiliary
faces and any open bores for damage. If damage is control valve section that is next to the tilt control valve
found, replace the auxiliary control valve section. If the section.
spool has been removed, inspect the spool and the bore
for damage. If damage to either the spool or the bore is See Figure 4 for lift truck models below, equipped with
found, replace the auxiliary control valve section. anti-stall solenoid:
If the anti-stall valve was disassembled, inspect the GDC135VX, GC/GLC/GDC155VX) (D879)
spool, anti-stall valve sleeve, and spring for damage. • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
If the spring is damaged, replace the spring. If the GDP135VX, GP/GLP/GDP155VX) (D878)
spool or anti-stall valve sleeve is damaged, replace the
anti-stall valve assembly. See Figure 5 for the following lift truck models equipped
NOTE: If the auxiliary control valve section is not to be • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX
reassembled immediately, coat surfaces with clean hy- (GDP170VX, GDP175VX36, GDP190VX) (A909)
draulic oil to prevent the possibility of rust. Cover the
auxiliary control valve section with a clean, dry, lint-free See Figure 6 for the following lift truck models equipped
cloth to prevent the possibility of contaminants entering with an E-Valve with an anti-stall plug:
the auxiliary control valve section. • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX
(C809)
Assemble • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX
NOTE: Perform Step 1 through Step 7 for lift truck mod-
els
(C809)
(B875)
GP/GLP/GDP040SVX) (C810)
090, 100, 110, 120VX) (F813, G813)
(B875)
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, See Figure 7 for the following lift truck models equipped
120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; with an E-Valve with an anti-stall solenoid:
GC/GLC120VXPRS) (E818) • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100,
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX;
GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, GC/GLC120VXPRS) (E818)
090, 100, 110, 120VX) (F813, G813) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
• GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080,
GDC135VX, GC/GLC/GDC155VX) (C879, D879) 090, 100, 110, 120VX) (F813, G813)
GDP135VX, GP/GLP/GDP155VX) (C878, D878) 1. Install the spool, washer, spring, and plug, with
new O-ring, into the bore of the auxiliary control
NOTE: Coat all backup rings and O-rings with a light valve section. Tighten the plug to 14 ±1 N•m (120
coat of clean hydraulic oil to make installation easier. ±12 lbf in). See Figure 15.
NOTE: The assembly procedures for the auxiliary I, II, 2. Install the washer, spring, and plug, with new
and III sections are the same. The auxiliary I section O-ring, into the auxiliary control valve section. See
is used in the procedures described below because it Figure 15. Tighten the plug to 14 ±1 N•m (120
contains the anti-stall valve. ±12 lbf in).

3. Install two poppets, two springs, and two plugs, 5. Install two backup rings and two O-rings on the anti-
with new O-rings installed, into the auxiliary control stall valve sleeve as noted during disassembly. See
valve section. See Figure 15. Tighten the plugs to Figure 17.
81 ±8 N•m (60 ±6 lbf ft).
6. Install the spool in the small end of the anti-stall
4. Install the new O-ring, backup ring, two O-rings, valve sleeve. See Figure 17.
and backup ring on each PPRV. Install two PPRVs
and four capscrews into the auxiliary control valve 7. Install the spring in the large end of the anti-stall
section. See Figure 15. Tighten the capscrews to valve sleeve. See Figure 17.
3 ±0.3 N•m (24 ±2 lbf in).
NOTE: Perform Step 8 through Step 12 for lift
NOTE: If lift truck is equipped with either an anti-stall truck model GLP/GDP80VX, GLP/GDP80VX9, GLP/
solenoid or plug in the anti-stall port on the outlet sec- GDP90VX (GDP170VX, GDP175VX36, GDP190VX)
tion, there will not be an anti-stall valve in the auxiliary (A909).
control valve section that is next to the tilt control valve
8. Install new O-ring onto plug. Install poppet-c.v.
section.
spring, and plug into bottom of auxiliary control
See Figure 4 for lift truck models below, equipped with valve section. See Figure 16.
9. Install new O-ring onto plug. Install plug into top of
auxiliary control valve section. See Figure 16.
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ 10. Install new O-ring onto plug. Install spool, washer,
GDP135VX, GP/GLP/GDP155VX) (D878) spring, and plug into auxiliary control valve section.
See Figure 16.
with an E-Valve with an anti-stall plug: 11. Install new seals onto solenoids as noted during
• GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX disassembly. See Figure 16.
(GDP170VX, GDP175VX36, GDP190VX) (A909)
12. Install two solenoids and four capscrews onto aux-
See Figure 6 for the following lift truck models equipped iliary control valve section. See Figure 16.
• GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX Install
(C809)
• GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX NOTE: Step 1 through Step 3 are for a three-function
(GP/GLP/GDP030VX, GP/GLP/GDP035VX, control valve. Step 4 through Step 7 are for a four and
GP/GLP/GDP040SVX) (C810), GLC20-35VX five-function control valves.
1. Install new O-rings into the side of tilt control valve
section. Install the auxiliary I control valve section
(B875)
on the four tie rods. See Figure 18.
120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; NOTE: If lift truck is equipped with either an anti-stall
GC/GLC120VXPRS) (E818) solenoid or plug in the anti-stall port on the outlet sec-
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ tion, there will not be an anti-stall valve in the auxiliary
GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, control valve section that is next to the tilt control valve
090, 100, 110, 120VX) (F813, G813) section.
See Figure 7 for the following lift truck models equipped See Figure 4 for lift truck models below, equipped with
with an E-Valve with an anti-stall solenoid: anti-stall solenoid:
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GDC135VX, GC/GLC/GDC155VX) (D879)
GC/GLC120VXPRS) (E818) • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP135VX, GP/GLP/GDP155VX) (D878)
090, 100, 110, 120VX) (F813, G813)

See Figure 5 for the following lift truck models equipped 7. Install the outlet control valve section. See Outlet
with an E-Valve with an anti-stall plug: Control Valve Section, Install.
• GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX
(GDP170VX, GDP175VX36, GDP190VX) (A909) Tilt Control Valve Section
See Figure 6 for the following lift truck models equipped Remove
• GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX 1. Remove the outlet control valve section. See Outlet
(C809) Control Valve Section, Remove.
2. Remove the auxiliary control valve section. See
Auxiliary Control Valve Sections, Remove.
(GC/GLC040-070VX, GC/GLC055SVX) (A910) 3. Remove the tilt control valve section from the lift/
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) lower control valve section.
(B875)
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 4. Remove and discard O-rings from the side of lift/
120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; lower control valve section.
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ See Figure 21 for lift truck models:
GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, • GC/GLC030VX, GC/GLC035VX,
090, 100, 110, 120VX) (F813, G813) GC/GLC040SVX (C809)
See Figure 7 for the following lift truck models equipped GLP/GDP20SVX (GP/GLP/GDP030VX,
with an E-Valve with an anti-stall solenoid: GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, (C810)
120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; • GLC20-35VX (GC/GLC040-070VX,
GC/GLC120VXPRS) (E818) GC/GLC055SVX) (A910)
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, (B875)
090, 100, 110, 120VX) (F813, G813) • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
100, 120VX; GC/GLC080, 100VXBCS;
2. Install the anti-stall valve into the auxiliary I control GC/GLC120SVX; GC/GLC120VXPRS) (E818)
valve section. See Figure 15. • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
3. Install the outlet control valve section. See Outlet
GDP080, 090, 100, 110, 120VX) (F813, G813)
Control Valve Section, Install.
4. Install new O-rings into the side of tilt control valve
section. Install the auxiliary I control valve section
on the four tie rods. See Figure 18.
D879)
5. Install the anti-stall valve into the auxiliary I control • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
valve section. Install new O-rings into the side of GDP135VX, GP/GLP/GDP155VX) (C878, D878)
auxiliary I control valve section. See Figure 15.
6. Install the auxiliary II control valve section on the

four tie rods. Install new O-rings into the side of
auxiliary II control valve section.

Disassemble See Figure 19 for lift truck models:

NOTE: Disassemble the tilt control valve section only GDC135VX, GC/GLC/GDC155VX) (C879,
as needed to accomplish the repairs required. D879)
NOTE: Perform Step 1 for lift truck models
(C809) 2. Remove and discard the backup ring, two O-rings,
• GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX backup ring, and O-ring from each PPRV.
GP/GLP/GDP040SVX) (C810) NOTE: Perform Step 3 for lift truck model
• GLC20-35VX (GC/GLC040-070VX, • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX
GC/GLC055SVX) (A910) (GDP170VX, GDP175VX36, GDP190VX) (A909)
(B875) 3. Remove four capscrews and two solenoids from tilt
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, control valve section. See Figure 20.
4. Remove the plug, spring, washer, and spool from
the tilt control valve section. Discard the O-ring on
the plug.
090, 100, 110, 120VX) (F813, G813) See Figure 18 for lift truck models:
• GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ • GC/GLC030VX, GC/GLC035VX,
GDC135VX, GC/GLC/GDC155VX) (C879, D879) GC/GLC040SVX (C809)
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ • GLP/GDP16VX, GLP/GDP18VX,
GDP135VX, GP/GLP/GDP155VX) (C878, D878) GLP/GDP20SVX (GP/GLP/GDP030VX,
1. Remove four socket head capscrews and two pro-
(C810)
portional pressure-reducing valves (PPRV) from
the tilt control valve section.
See Figure 18 for lift truck models: • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
• GC/GLC030VX, GC/GLC035VX, (B875)
GC/GLC040SVX (C809) • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
• GLP/GDP16VX, GLP/GDP18VX, 100, 120VX; GC/GLC080, 100VXBCS;
GLP/GDP20SVX (GP/GLP/GDP030VX, GC/GLC120SVX; GC/GLC120VXPRS) (E818)
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
(C810) GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
• GLC20-35VX (GC/GLC040-070VX, GDP080, 090, 100, 110, 120VX) (F813, G813)
(B875)
D879)
100, 120VX; GC/GLC080, 100VXBCS;
GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ See Figure 20 for lift truck models:
GDP080, 090, 100, 110, 120VX) (F813, G813) • GLP/GDP80VX, GLP/GDP80VX9,
GDP190VX) (A909)

5. Remove the socket head capscrew, spring and pis- • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
ton from the spool for lift truck models GDP135VX, GP/GLP/GDP155VX) (C878, D878)
GC/GLC040SVX (C809) See Figure 20 for lift truck models:
• GLP/GDP16VX, GLP/GDP18VX, • GLP/GDP80VX, GLP/GDP80VX9,
GLP/GDP20SVX (GP/GLP/GDP030VX, GLP/GDP90VX (GDP170VX, GDP175VX36,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) GDP190VX) (A909)
(C810)
7. Remove two plugs, two springs, and two poppets
from the tilt control valve section. Discard one
O-ring from each plug.
(B875) See Figure 18 for lift truck models:
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, • GC/GLC030VX, GC/GLC035VX,
100, 120VX; GC/GLC080, 100VXBCS; GC/GLC040SVX (C809)
GC/GLC120SVX; GC/GLC120VXPRS) (E818) • GLP/GDP16VX, GLP/GDP18VX,
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP20SVX (GP/GLP/GDP030VX,
GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
GDP080, 090, 100, 110, 120VX) (F813, G813) (C810)
6. Remove the plug, spring, and washer from the tilt
control valve section. Discard the O-ring on the
plug.
(B875)
See Figure 18 for lift truck models: • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
• GC/GLC030VX, GC/GLC035VX, 100, 120VX; GC/GLC080, 100VXBCS;
GC/GLC040SVX (C809) GC/GLC120SVX; GC/GLC120VXPRS) (E818)
• GLP/GDP16VX, GLP/GDP18VX, • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP20SVX (GP/GLP/GDP030VX, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) GDP080, 090, 100, 110, 120VX) (F813, G813)
(C810)
D879)
(B875)
100, 120VX; GC/GLC080, 100VXBCS;
GC/GLC120SVX; GC/GLC120VXPRS) (E818) See Figure 20 for lift truck models:
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, • GLP/GDP80VX, GLP/GDP80VX9,
GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GLP/GDP90VX (GDP170VX, GDP175VX36,
GDP080, 090, 100, 110, 120VX) (F813, G813) GDP190VX) (A909)
D879)

1. PLUG 8. TILT CONTROL VALVE BODY

2. O-RING 9. SETSCREW
3. SPRING 10. POPPET
5. SOCKET HEAD CAPSCREW 12. SPOOL
6. PISTON
7. PROPORTIONAL PRESSURE-REDUCING
VALVE (PPRV)
Figure 18. Tilt Control Valve Section, Lift Truck Models GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX

1. PLUG 7. TILT CONTROL VALVE BODY

2. O-RING 8. SETSCREW
3. SPRING 9. POPPET
5. SOCKET HEAD CAPSCREW 11. SPOOL
6. PROPORTIONAL PRESSURE-REDUCING
VALVE (PPRV)
Figure 19. Tilt Control Valve Section, Lift Truck Models GLC/GDC60VX, GLC/GDC70VX
(GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) and GLP/GDP60VX, GLP/GDP70VX

1. TILT CONTROL VALVE SECTION 7. SPRING

2. PLUG 8. WASHER
3. SPRING 9. CAPSCREW
4. POPPET-C.V. 10. SOLENOID
5. O-RING 11. SEAL
6. PLUG 12. SPOOL
Figure 20. Tilt Control Valve Section, Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX
Clean the path of the compressed air is away from all per-
WARNING prevent injury to the eyes.
Cleaning solvents can be flammable and toxic and 1. If all components of the tilt control valve section
can cause skin irritation. When using cleaning have been removed, clean the tilt control valve sec-
solvents, always follow the solvent manufacturer’s tion and components, except the two PPRVs, using
recommended safety procedures. cleaning solvent and dry using compressed air.
WARNING 2. If not all components have been removed, clean the

tilt control valve section using a lint-free cloth.

Inspect 4. Install two poppets, two springs, and two plugs, with
new O-rings installed, into the tilt control valve sec-
Inspect the tilt control valve section mating surfaces and tion. Tighten the plugs to 81 ±8 N•m (60 ±6 lbf ft).
any open bores for damage. If damage is found, replace
the tilt control valve section. If the spool has been re- See Figure 18 for lift truck models:
moved, inspect the spool and the bore for the spool for • GC/GLC030VX, GC/GLC035VX,
damage. If damage to either the spool or the bore is GC/GLC040SVX (C809)
found, replace the tilt control valve section. • GLP/GDP16VX, GLP/GDP18VX,
NOTE: If the tilt control valve section is not to be re- GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
assembled immediately, coat surfaces with clean hy- (C810)
draulic oil to prevent the possibility of rust. Cover the • GLC20-35VX (GC/GLC040-070VX,
tilt control valve section with a clean, dry, lint-free cloth GC/GLC055SVX) (A910)
to prevent the possibility of contaminants entering the • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
tilt control valve section. (B875)
Assemble
100, 120VX; GC/GLC080, 100VXBCS;
NOTE: Coat all backup rings and O-rings with a light GC/GLC120SVX; GC/GLC120VXPRS) (E818)
coat of clean hydraulic oil to make installation easier. • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
1. Install the piston, spring, and socket head capscrew GDP080, 090, 100, 110, 120VX) (F813, G813)
in the spool for lift truck models listed below. See
Figure 18. See Figure 19 for lift truck models:
• GC/GLC030VX, GC/GLC035VX, • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/
GC/GLC040SVX (C809) GDC135VX, GC/GLC/GDC155VX) (C879,
• GLP/GDP16VX, GLP/GDP18VX, D879)
GLP/GDP20SVX (GP/GLP/GDP030VX, • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) GDP135VX, GP/GLP/GDP155VX) (C878, D878)
(C810)
GDP190VX) (A909)
(B875)
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, NOTE: Perform Step 5 for lift truck models.
100, 120VX; GC/GLC080, 100VXBCS; • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX
GC/GLC120SVX; GC/GLC120VXPRS) (E818) (C809)
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX
GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ (GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GDP080, 090, 100, 110, 120VX) (F813, G813) GP/GLP/GDP040SVX) (C810)
2. Install the spool, washer, spring, and plug, with new
O-ring, into the bore of the tilt control valve section.
Tighten the plug to 14 ±1 N•m (120 ±12 lbf in).
(B875)
3. Install the washer, spring, and plug, with new • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100,
O-ring, into the tilt control valve section. Tighten 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX;
the plug to 14 ±1 N•m (120 ±12 lbf in). GC/GLC120VXPRS) (E818)
090, 100, 110, 120VX) (F813, G813)

5. Install the new O-ring, backup ring, two O-rings, Lift/Lower Control Valve Section
and backup ring on each PPRV. Install two PPRVs
and four capscrews into the tilt control valve section. Remove
Tighten the capscrews to 3 ±0.3 N•m (24 ±2 lbf in).
1. Remove the outlet control valve. See Outlet Control
NOTE: Perform Step 6 for lift truck model Valve Section, Remove.
GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX
2. Remove the auxiliary control valve section(s). See
(GDP170VX, GDP175VX36, GDP190VX) (A909).
Auxiliary Control Valve Sections Remove.
6. Install two solenoids and four capscrews onto tilt
3. Remove the tilt control valve section. See Tilt Con-
control valve section. See Figure 20.
trol Valve Section, Remove.
Install
Disassemble
1. Install new O-rings on the side of lift/lower control
NOTE: Disassemble the lift/lower control valve section
valve section.
only as needed to accomplish the repairs required.
1. Remove four tie rods from the lift/lower control valve
section.
GC/GLC040SVX (C809)
• GLP/GDP16VX, GLP/GDP18VX, 2. Remove coil nut and coil from the lift electro-hy-
GLP/GDP20SVX (GP/GLP/GDP030VX, draulic poppet valve (EHPV).
(C810) See Figure 21 for lift truck models:
• GLC20-35VX (GC/GLC040-070VX, • GC/GLC030VX, GC/GLC035VX,
GC/GLC055SVX) (A910) GC/GLC040SVX (C809)
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) • GLP/GDP16VX, GLP/GDP18VX,
(B875) GLP/GDP20SVX (GP/GLP/GDP030VX,
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
100, 120VX; GC/GLC080, 100VXBCS; (C810)
GC/GLC120SVX; GC/GLC120VXPRS) (E818) • GLC20-35VX (GC/GLC040-070VX,
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GC/GLC055SVX) (A910)
GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
GDP080, 090, 100, 110, 120VX) (F813, G813) (B875)
See Figure 22 for lift truck models: 100, 120VX; GC/GLC080, 100VXBCS;
• GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ GC/GLC120SVX; GC/GLC120VXPRS) (E818)
GDC135VX, GC/GLC/GDC155VX) (C879, • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
D879) GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813)
2. Install the tilt control valve section on the lift/lower • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/
control valve section. GDC135VX, GC/GLC/GDC155VX) (C879,
D879)
3. Install the auxiliary control valve section. See Aux-
iliary Control Valve Sections, Install.
4. Install the outlet control valve section. See Outlet
Control Valve Section, Install.

1. LOCK NUT 13. SETSCREW

2. ADJUSTING SCREW 14. SHUTTLE
3. O-RING 15. POPPET
4. SPRING 16. LIFT POPPET
5. PISTON 17. SOLENOID TUBE
6. PRIMARY RELIEF VALVE CARTRIDGE 18. COIL
7. BACKUP RING 19. COIL NUT
8. SPOOL 20. LOWER POPPET
9. LIFT/LOWER CONTROL VALVE SECTION 21. SLEEVE ASSEMBLY
10. SOCKET HEAD PLUG 22. LIFT POPPET VALVE ASSEMBLY
11. EMERGENCY LOWERING VALVE 23. LOWER POPPET VALVE ASSEMBLY
12. PLUG 24. PILOT PIN
Figure 21. Lift/Lower Control Valve Section, Lift Truck Models GC/GLC030VX, GC/GLC035VX,


2. ADJUSTING SCREW 14. SHUTTLE
Figure 22. Lift/Lower Control Valve Section, For Lift Truck Models GLC/GDC60VX, GLC/GDC70VX

Figure 23. Lift/Lower Control Valve Section, For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9,


2. ADJUSTING NUT 14. SHUTTLE
3. Using special socket (Yale P/N 580057794), re- 4. Remove the spring from the poppet assembly un-
move the lift solenoid tube assembly from lift/lower less it came out with the solenoid tube assembly
control valve section. Take care to pull the tube in which case remove it from the solenoid tube as-
assembly straight out so that the pilot pin does not sembly.
get damaged.
See Figure 21 for lift truck models: • GC/GLC030VX, GC/GLC035VX,
• GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809)
GC/GLC040SVX (C809) • GLP/GDP16VX, GLP/GDP18VX,
• GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX,
GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810)
(C810) • GLC20-35VX (GC/GLC040-070VX,
• GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910)
GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)
(B875) • 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) (F813, G813)
GDP080, 090, 100, 110, 120VX) (F813, G813)
See Figure 22 for lift truck models: • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/
• GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879,
D879) • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878)
See Figure 23 for lift truck models: • GLP/GDP80VX, GLP/GDP80VX9,
• GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36,
GDP190VX) (A909)

NOTE: The lower poppet valve assembly is approxi- • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,

mately 7 mm (0.28 in.) longer than the lift poppet valve GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
assembly. GDP080, 090, 100, 110, 120VX) (F813, G813)
5. Remove the lift poppet assembly from the lift/lower See Figure 22 for lift truck models:
control valve section. • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/
See Figure 21 for lift truck models: D879)
• GC/GLC030VX, GC/GLC035VX, • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
GC/GLC040SVX (C809) GDP135VX, GP/GLP/GDP155VX) (C878, D878)
GLP/GDP20SVX (GP/GLP/GDP030VX, See Figure 23 for lift truck models:
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) • GLP/GDP80VX, GLP/GDP80VX9,
(C810) GLP/GDP90VX (GDP170VX, GDP175VX36,
• GLC20-35VX (GC/GLC040-070VX, GDP190VX) (A909)
(B875)
CAUTION
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, Use care, when removing the emergency lowering
100, 120VX; GC/GLC080, 100VXBCS; valve, not to damage the tip of the emergency low-
GC/GLC120SVX; GC/GLC120VXPRS) (E818) ering valve.
7. Remove the emergency lowering valve from the lift/
lower control valve section. Remove and discard
GDP080, 090, 100, 110, 120VX) (F813, G813)
the O-ring.
GC/GLC040SVX (C809)
D879)
See Figure 23 for lift truck models: (C810)
• GLP/GDP80VX, GLP/GDP80VX9, • GLC20-35VX (GC/GLC040-070VX,
GLP/GDP90VX (GDP170VX, GDP175VX36, GC/GLC055SVX) (A910)
GDP190VX) (A909) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875)
6. Repeat Step 2 through Step 5 for the lower EHPV. • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
After completing Step 5, remove the sleeve assem- 100, 120VX; GC/GLC080, 100VXBCS;
bly from lower control valve section. GC/GLC120SVX; GC/GLC120VXPRS) (E818)
See Figure 21 for lift truck models: GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
• GC/GLC030VX, GC/GLC035VX, GDP080, 090, 100, 110, 120VX) (F813, G813)
GC/GLC040SVX (C809)
• GLP/GDP16VX, GLP/GDP18VX, See Figure 22 for lift truck models:
GLP/GDP20SVX (GP/GLP/GDP030VX, • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) GDC135VX, GC/GLC/GDC155VX) (C879,
(C810) D879)
• GLC20-35VX (GC/GLC040-070VX, • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
GC/GLC055SVX) (A910) GDP135VX, GP/GLP/GDP155VX) (C878, D878)
(B875) See Figure 23 for lift truck models:
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, • GLP/GDP80VX, GLP/GDP80VX9,
100, 120VX; GC/GLC080, 100VXBCS; GLP/GDP90VX (GDP170VX, GDP175VX36,
GC/GLC120SVX; GC/GLC120VXPRS) (E818) GDP190VX) (A909)

8. Remove the plug from the lift/lower control valve • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
section. Remove and discard the O-ring. GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (F813, G813)
• GC/GLC030VX, GC/GLC035VX, See Figure 22 for lift truck models:
GC/GLC040SVX (C809) • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/
• GLP/GDP16VX, GLP/GDP18VX, GDC135VX, GC/GLC/GDC155VX) (C879,
GLP/GDP20SVX (GP/GLP/GDP030VX, D879)
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
(C810) GDP135VX, GP/GLP/GDP155VX) (C878, D878)
GC/GLC055SVX) (A910) See Figure 23 for lift truck models:
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) • GLP/GDP80VX, GLP/GDP80VX9,
(B875) GLP/GDP90VX (GDP170VX, GDP175VX36,
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, GDP190VX) (A909)
100, 120VX; GC/GLC080, 100VXBCS;
10. Remove the socket head plug, spring, and poppet
from the lift/lower control valve section. Remove
and discard the O-ring.
GDP080, 090, 100, 110, 120VX) (F813, G813) See Figure 21 for lift truck models:
GC/GLC040SVX (C809)
D879)
(C810)
See Figure 23 for lift truck models: GC/GLC055SVX) (A910)
• GLP/GDP80VX, GLP/GDP80VX9, • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
GLP/GDP90VX (GDP170VX, GDP175VX36, (B875)
GDP190VX) (A909) • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
100, 120VX; GC/GLC080, 100VXBCS;
9. Remove the socket head plug from the lift/lower GC/GLC120SVX; GC/GLC120VXPRS) (E818)
control valve section. Remove and discard the • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
O-ring. GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (F813, G813)
100, 120VX; GC/GLC080, 100VXBCS;

11. Remove the shuttle and setscrew from the lift/lower • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
control valve section. GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (F813, G813)
100, 120VX; GC/GLC080, 100VXBCS;
NOTE: Step 13 through Step 16 are for the disassembly
of the primary relief valve.
GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ 13. While holding the adjustment screw in place, loosen
GDP080, 090, 100, 110, 120VX) (F813, G813) the lock nut.
• GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ • GC/GLC030VX, GC/GLC035VX,
GDC135VX, GC/GLC/GDC155VX) (C879, GC/GLC040SVX (C809)
D879) • GLP/GDP16VX, GLP/GDP18VX,
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GLP/GDP20SVX (GP/GLP/GDP030VX,
GDP135VX, GP/GLP/GDP155VX) (C878, D878) GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810)
GDP190VX) (A909)
(B875)
12. Remove the primary relief valve, spring, and spool • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
from the lift/lower control valve section. 100, 120VX; GC/GLC080, 100VXBCS;
See Figure 21 for lift truck models: • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
• GC/GLC030VX, GC/GLC035VX, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
GC/GLC040SVX (C809) GDP080, 090, 100, 110, 120VX) (F813, G813)
GLP/GDP20SVX (GP/GLP/GDP030VX, See Figure 22 for lift truck models:
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/
(C810) GDC135VX, GC/GLC/GDC155VX) (C879,
• GLC20-35VX (GC/GLC040-070VX, D879)
GC/GLC055SVX) (A910) • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) GDP135VX, GP/GLP/GDP155VX) (C878, D878)
(B875)
100, 120VX; GC/GLC080, 100VXBCS;
GDP190VX) (A909)

NOTE: While performing Step 14, count and note the • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
number of turns used to remove the adjusting screw. 100, 120VX; GC/GLC080, 100VXBCS;
14. Remove the adjusting screw from the primary relief • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
valve. Remove and discard the O-ring on the ad- GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
justing screw. GDP080, 090, 100, 110, 120VX) (F813, G813)
(C810)
• GLC20-35VX (GC/GLC040-070VX, See Figure 23 for lift truck models:
GC/GLC055SVX) (A910) • GLP/GDP80VX, GLP/GDP80VX9,
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) GLP/GDP90VX (GDP170VX, GDP175VX36,
(B875) GDP190VX) (A909)
100, 120VX; GC/GLC080, 100VXBCS; 16. Remove and discard the small O-ring, backup ring,
GC/GLC120SVX; GC/GLC120VXPRS) (E818) and large O-ring from the primary relief valve.
GDP080, 090, 100, 110, 120VX) (F813, G813)
GC/GLC040SVX (C809)
See Figure 22 for lift truck models: • GLP/GDP16VX, GLP/GDP18VX,
• GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ GLP/GDP20SVX (GP/GLP/GDP030VX,
GDC135VX, GC/GLC/GDC155VX) (C879, GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
D879) (C810)
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ • GLC20-35VX (GC/GLC040-070VX,
GDP135VX, GP/GLP/GDP155VX) (C878, D878) GC/GLC055SVX) (A910)
See Figure 23 for lift truck models: (B875)
• GLP/GDP80VX, GLP/GDP80VX9, • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
GLP/GDP90VX (GDP170VX, GDP175VX36, 100, 120VX; GC/GLC080, 100VXBCS;
GDP190VX) (A909) GC/GLC120SVX; GC/GLC120VXPRS) (E818)
15. Remove the spring and piston from the primary re- GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
lief valve. GDP080, 090, 100, 110, 120VX) (F813, G813)
(C810)
• GLC20-35VX (GC/GLC040-070VX, See Figure 23 for lift truck models:
GC/GLC055SVX) (A910) • GLP/GDP80VX, GLP/GDP80VX9,
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) GLP/GDP90VX (GDP170VX, GDP175VX36,
(B875) GDP190VX) (A909)

Clean 1. Install the new large O-ring on the primary relief

valve. Install the new backup ring and small O-ring
WARNING on the primary relief valve.
Cleaning solvents can be flammable and toxic and See Figure 21 for lift truck models:
can cause skin irritation. When using cleaning • GC/GLC030VX, GC/GLC035VX,
solvents, always follow the solvent manufacturer’s GC/GLC040SVX (C809)
recommended safety procedures. • GLP/GDP16VX, GLP/GDP18VX,
WARNING GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
Compressed air can move particles so they cause (C810)
injury to the user or to other personnel. Make sure • GLC20-35VX (GC/GLC040-070VX,
the path of the compressed air is away from all per- GC/GLC055SVX) (A910)
sonnel. Wear protective goggles or a face shield to • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
prevent injury to the eyes. (B875)
1. If all components of the lift/lower control valve sec- 100, 120VX; GC/GLC080, 100VXBCS;
tion have been removed, clean the lift/lower con- GC/GLC120SVX; GC/GLC120VXPRS) (E818)
trol valve section and components, except the two • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
PPRVs, using cleaning solvent and dry using com- GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
pressed air. GDP080, 090, 100, 110, 120VX) (F813, G813)
2. If not all components have been removed, clean the See Figure 22 for lift truck models:
lift/lower control valve section using a lint-free cloth. • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/
Inspect D879)
Inspect the lift/lower control valve section mating sur-
faces and any open bores for damage. If damage is
found, replace the lift/lower control valve section. If the See Figure 23 for lift truck models:
spool has been removed, inspect the spool and the bore • GLP/GDP80VX, GLP/GDP80VX9,
for the spool for damage. If damage to either the spool GLP/GDP90VX (GDP170VX, GDP175VX36,
or the bore is found, replace the lift/lower control valve GDP190VX) (A909)
section.
2. Install the piston and spring into the primary relief
If disassembled, inspect the components of the pri- valve.
mary relief valve. If any components other than O-rings,
backup rings, and the spring are damaged, replace the See Figure 21 for lift truck models:
primary relief valve. • GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809)
NOTE: If the lift/lower control valve section is not to be • GLP/GDP16VX, GLP/GDP18VX,
reassembled immediately, coat surfaces with clean hy- GLP/GDP20SVX (GP/GLP/GDP030VX,
draulic oil to prevent the possibility of rust. Cover the GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
lift/lower control valve section with a clean, dry, lint-free (C810)
cloth to prevent the possibility of contaminants entering • GLC20-35VX (GC/GLC040-070VX,
the lift/lower control valve section. GC/GLC055SVX) (A910)
Assemble
(B875)
NOTE: Step 1 through Step 6 are for the assembly of • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
the primary relief valve, if disassembled. If the primary 100, 120VX; GC/GLC080, 100VXBCS;
relief valve has not been disassembled, go to Step 6. GC/GLC120SVX; GC/GLC120VXPRS) (E818)
NOTE: Coat all backup rings and O-rings with a light GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
coat of clean hydraulic oil to make installation easier. GDP080, 090, 100, 110, 120VX) (F813, G813)

See Figure 22 for lift truck models: 6. Install the shuttle and setscrew into the body of the
• GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ lift/lower control valve section. Tighten the setscrew
GDC135VX, GC/GLC/GDC155VX) (C879, to 4 ±0.6 N•m (36 ±6 lbf in). See the section Pres-
D879) sure Relief Valve Check and Adjustment to adjust
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ the primary relief valve and check the pressure.
7. Install plug with new O-ring installed into the lift/
See Figure 23 for lift truck models: lower control valve section. Tighten the plug to 45
• GLP/GDP80VX, GLP/GDP80VX9, ±5 N•m (33 ±4 lbf ft).
GDP190VX) (A909) 8. Install poppet, spring, and socket head plug with
new O-ring installed, into the lift/lower control valve
3. Install a new O-ring on the adjusting screw, and in- section. Tighten the plug to 65 ±7 N•m (48 ±5 lbf ft).
stall the adjusting screw into the primary relief valve
the number of turns noted during disassembly. 9. Install the emergency lowering valve, with a new
O-ring installed, into the lift/lower control valve sec-
See Figure 21 for lift truck models: tion. Tighten to 14 ±1 N•m (120 ±12 lbf in).
GC/GLC040SVX (C809) NOTE: Ensure that the correct poppet is being installed
• GLP/GDP16VX, GLP/GDP18VX, in the proper position. The lower poppet valve assembly
GLP/GDP20SVX (GP/GLP/GDP030VX, is approximately 7 mm (0.28 in.) longer than the lift
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) poppet valve assembly.
(C810)
10. Install the lift poppet into the lift/lower control valve
section until the poppet "bottoms out."
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) 11. Install the spring onto the solenoid tube.
(B875)
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 12. Install the solenoid tube into the lift/lower control
100, 120VX; GC/GLC080, 100VXBCS; valve section. Tighten to 100 ±11 N•m (74 ±8 lbf ft).
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, 13. Install the coil and coil nut on the solenoid tube.
GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ Tighten the coil nut to 2.3 N•m (20 lbf in).
GDP080, 090, 100, 110, 120VX) (F813, G813)
14. Repeat Step 10 through Step 13 for the lower
See Figure 22 for lift truck models: EHPV. Before installing the lower poppet into the
• GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ lower control valve section in Step 10, install sleeve
GDC135VX, GC/GLC/GDC155VX) (C879, assembly into the lift/lower control valve section
D879) first. Tighten sleeve assembly to 122 ±12 N•m (90
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ ±9 lbf ft).
Install
1. Install four tie rods into the lift/lower control valve
section.
GDP190VX) (A909) 2. Install the tilt control valve section. See Tilt Control
Valve Section, Install.
4. Install the lock nut onto the adjusting screw while
holding the adjustment screw so that it will not turn. 3. Install the auxiliary control valve section. See Aux-
Tighten the lock nut to 9 ±1 N•m (84 ±12 lbf in). iliary Control Valve Sections, Install.
5. Install the spool, spring, and primary relief valve 4. Install the outlet control valve section. See Outlet
into the lift/lower control valve section. Tighten the Control Valve Section, Install.
primary relief valve to 65 ±7 N•m (48 ±5 lbf ft).

Mid-Inlet Section Install
Remove NOTE: If the mid-inlet control valve section is not to be

installed immediately, coat surfaces with clean hydraulic
NOTE: The mid-inlet section is used only on lift truck oil to prevent the possibility of rust. Cover the mid-inlet
models control valve section with a clean, dry, lint-free cloth to
• GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ prevent the possibility of contaminants entering the mid-
GDC135VX, GC/GLC/GDC155VX) (C879, D879) inlet control valve section.
GDP135VX, GP/GLP/GDP155VX) (C878, D878) NOTE: Coat all O-rings with a light coat of clean hy-
• GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX draulic oil to make installation easier.
1. Install new O-ring on socket head plug. Install
Remove the mid-inlet section only as necessary for re- socket head plug into mid-inlet section. See Fig-
pair. Most repairs to the mid-inlet section will be for the ure 24.
replacement of O-rings to stop leaks. There are no dis-
assembly or assembly procedures for the mid-inlet sec- 2. Install new O-rings on mating surfaces of mid-inlet
tion. section.
1. Remove three socket head capscrews and wash- 3. Install mid-inlet section to lift/lower section using
ers that secure the mid-inlet section to the lift/lower three socket head capscrews and washers. Tighten
section. See Figure 24. capscrews to 45 to 55 N•m (33 to 41 lbf ft).
2. Remove mid-inlet section from the lift/lower section.

Discard O-rings.
3. Remove socket head plug and discard O-ring.
Clean
WARNING
Cleaning solvents can be flammable and toxic and
solvents, always follow the solvent manufacturer’s
WARNING
injury to the user or to other personnel. Make sure 1. MID-INLET SECTION
2. SOCKET HEAD PLUG
the path of the compressed air is away from all per- 3. O-RING
sonnel. Wear protective goggles or a face shield to 4. SOCKET HEAD CAPSCREW
prevent injury to the eyes. 5. WASHER
Clean the mid-inlet control valve section using cleaning Figure 24. Mid-Inlet Section
solvent and dry using compressed air.
Inspect
Inspect the mid-inlet control valve section and mating

surfaces. If either the mating surfaces or mid-inlet con-
trol valve section are damaged, replace the mid-inlet

INSTALL 3. Coat new O-rings with clean hydraulic oil. Install

O-rings between control valve section and SCU.
WARNING 4. Position the SCU under the steering shaft and raise
The main control valve weighs approximately the SCU to engage the steering shaft. When the
30.5 kg (67 lb). Use a lifting device capable of lifting steering shaft is completely engaged, position the
the main control valve, to avoid the possibility of SCU against the main control valve, and install two
injury to personnel. mounting capscrews and washers. Tighten to 45 to
55 N•m (33 to 41 lbf ft).
1. Lower the control valve enough to allow the cowl
wiring harness to be connected to the lower PPRV See Figure 26 for lift truck models:
solenoid connectors as noted during removal. See • GC/GLC030VX, GC/GLC035VX,
Figure 27. GC/GLC040SVX (C809)
2. Install three inserts into holes on cowl where the
control valve will be mounted. While supporting the
main control valve in place on the cowl, install three
(C810)
mounting capscrews and washers through the front
of the cowl into the control valve. Tighten the cap-
screws to 19 N•m (14 lbf ft). See Figure 25.
(B875)
100, 120VX; GC/GLC080, 100VXBCS;
GDP080, 090, 100, 110, 120VX) (F813, G813)

D879)
GDP190VX) (A909)
1. COWL
2. INSERT
3. WASHER
5. MAIN CONTROL VALVE
6. FRAME
Figure 25. Main Control Valve Installation


2. HYDRAULIC INLET HOSE 7. TILT HOSE
5. SCU MOUNTING CAPSCREWS 10. RETURN HOSE
Figure 26. Hydraulic Hose Installation, Lift Truck Models GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX

NOTE: HARNESS CONNECTORS FOR GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/

GDC155VX) (C879, D879), GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878,
D878), AND GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909)
LIFT TRUCKS SHOWN. HARNESS CONNECTORS FOR ALL OTHER LIFT TRUCK MODELS COVERED IN
THIS YRM ARE SIMILAR.
1. LIFT ELECTRO-HYDRAULIC POPPET VALVE 6. MID INLET HOSE (MAIN PUMP HOSE)
(EHPV) HARNESS CONNECTOR 7. LIFT/LOWER HOSE
2. LOWER ELECTRO-HYDRAULIC POPPET VALVE 8. TILT HOSE
(EHPV) HARNESS CONNECTOR 9. AUXILIARY I HOSE
3. AUXILIARY FUNCTION PROPORTIONAL 10. AUXILIARY II HOSE
PRESSURE REDUCING VALVE (PPRV) 11. RETURN HOSE
HARNESS CONNECTOR 12. STEERING COLUMN
4. STEERING SYSTEM HOSES 13. STEERING CONTROL UNIT (SCU)
5. SECONDARY HYDRAULIC PUMP HOSE 14. SCU MOUNTING CAPSCREWS
Figure 27. Hydraulic Hose Installation and Harness Connection, Lift Truck Models GLC/GDC60VX,
GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879), GLP/GDP60VX, GLP/GDP70VX
(GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878), and GLP/GDP80VX, GLP/GDP80VX9,

NOTE: Lift truck models GLP/GDP20-35VX (GP/GLP/ Using the three capscrews that hold the throttle
GDP040-070VX) (B875) may be equipped with an op- base to the cowl, install the pedal assembly on the
tional Quick-Lok™ hydraulic inlet hose and adapter be- lift truck. Connect the cowl wiring harness to the
tween the steering control unit and hydraulic gear pump. pedal assembly wiring harness. Tighten the bolts
to 19 to 25 N•m (168 to 221 lbf in). See Figure 28.
5. Remove all caps and plugs from the control valve
and hose fittings. Connect hydraulic hoses to the
control valve as noted during removal.

GC/GLC040SVX (C809)
(C810)
(B875)
100, 120VX; GC/GLC080, 100VXBCS;
GDP080, 090, 100, 110, 120VX) (F813, G813)

D879)
GLP/GDP90VX (GDP170VX, GDP175VX36, NOTE: ACCELERATOR PEDAL NOT SHOWN, HOW-
GDP190VX) (A909) EVER, INSTALLATION IS THE SAME.
6. Connect the cowl wiring harness to the top PPRV 1. MOUNTING CAPSCREW
2. FOOT DIRECTIONAL CONTROL PEDAL
solenoids and the lift/lower EHPV solenoids as ASSEMBLY
noted during removal. 3. PEDAL ASSEMBLY WIRING HARNESS
7. Apply adhesive compound, (Yale Part No. Figure 28. Foot Directional Control Pedal
501702904), to the three mounting capscrews. Installation

8. Install the dashboard, seal plate, kick panel, and Lift Pilot Pin
floor plate.

WARNING
• GC/GLC030VX, GC/GLC035VX, Hot hydraulic oil can cause serious burns to skin.
GC/GLC040SVX (C809) Do not touch hydraulic components or oil during
• GLP/GDP16VX, GLP/GDP18VX, test. Make sure hydraulic oil has cooled to safe tem-
GLP/GDP20SVX (GP/GLP/GDP030VX, perature before installing or removing test equip-
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) ment.
(C810)
• GLC20-35VX (GC/GLC040-070VX, WARNING
GC/GLC055SVX) (A910) Hydraulic oil under pressure can be injected into
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) skin. Lower forks to ground and relieve all circuit
(B875) pressure before removing or installing test equip-
ment.
100, 120VX; GC/GLC080, 100VXBCS; CAUTION
GC/GLC120SVX; GC/GLC120VXPRS) (E818) Do not permit dirt or other contaminants to enter
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, the hydraulic system. Disconnected hoses, tubes,
GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ open valves, cylinder fittings, and ports should be
GDP080, 090, 100, 110, 120VX) (F813, G813) protected with clean caps or plugs.
See Frame 100 YRM 1316 for lift truck models NOTE: Always attempt to re-calibrate the threshold set-
• GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ ting through the display switch cluster (DSC) to elimi-
GDC135VX, GC/GLC/GDC155VX) (C879, nate the symptoms below before adjusting the pilot pin.
D879)
NOTE: The lift poppet should be bled prior to perform-
See Frame 100 YRM 1321 for lift truck models ing this adjustment if the control valve has been disas-
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ sembled or hose has been disconnected by following
GDP135VX, GP/GLP/GDP155VX) (C878, D878) the procedure in Calibration Procedures 8000 YRM
• GLP/GDP80VX, GLP/GDP80VX9, 1134.
GDP190VX) (A909) 1. Remove side covers, floor plates, seal plate and
dash.
9. Perform the calibration procedures in the section
Calibration Procedures 8000 YRM 1134. See Frame 100 YRM 1120 for lift truck models
ELECTRO HYDRAULIC POPPET VALVE GC/GLC040SVX (C809)
(EHPV) PILOT PIN ADJUSTMENT GLP/GDP20SVX (GP/GLP/GDP030VX,
This section outlines the procedures for adjusting the GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
lift and lower EHPV pilot pin. This adjustment is preset (C810)
at the valve supplier and should not need to be altered. • GLC20-35VX (GC/GLC040-070VX,
However, minor adjustments may be required if a new GC/GLC055SVX) (A910)
poppet assembly is installed. • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875)
These procedures assume the poppet assembly, tube
assembly, and coil have been replaced and installed See Frame 100 YRM 1243 for lift truck models
correctly. These procedures also assume the forks are • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
initially on the ground. 100, 120VX; GC/GLC080, 100VXBCS;
The coil nut should be removed to access the adjust- • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
ment screw and re-installed for proper operation. See GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/
Figure 29. GDP080, 090, 100, 110, 120VX) (F813, G813)

See Frame 100 YRM 1316 for lift truck models b. Method 2: Monitor the current using the display
• GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ switch cluster (DSC). See Diagnostic Trou-
GDC135VX, GC/GLC/GDC155VX) (C879, bleshooting Manual 9000 YRM 1112 for the
D879) procedure.
See Frame 100 YRM 1321 for lift truck models 5. Remove coil nut. See Figure 29.
GDP135VX, GP/GLP/GDP155VX) (C878, D878) 6. Loosen pilot pin adjustment screw lock nut. See
• GLP/GDP80VX, GLP/GDP80VX9, Figure 29.
7. Start vehicle.
GDP190VX) (A909)
8. Slowly increase current to the lift function by pulling
2. To prevent truck from moving, block front and rear
back on the lever or joystick.
wheels while the engine is operating.
NOTE: A 1/4 turn will change the value approximately
3. Ensure hydraulic oil is at operating temperature,
130 mA. Turn clockwise or IN to increase value and
which is 122° to 150°.
counterclockwise or OUT to decrease value.
4. Monitor the EHPV coil current.
9. If the forks move before the current reaches 550 mA
a. Method 1: Connect a current probe to either of or appear to jump, turn pilot pin adjustment screw
the lift EHPV coil leads. approximately 15° clockwise to increase the value.
1. POPPET ASSEMBLY 5. COIL NUT

2. SOLENOID TUBE ASSEMBLY 6. PILOT PIN ADJUSTMENT SCREW LOCK NUT
3. COIL 7. O-RING
4. PILOT PIN ADJUSTMENT SCREW 8. BIAS SPRING
Figure 29. Hoist Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment

10. Repeat the adjustment until the forks begin to move Lower Pilot Pin
between 550 mA and 650 mA.
11. If the forks have not started to move prior to reach-

WARNING
ing 650 mA, turn the pilot adjustment screw approx- Hot hydraulic oil can cause serious burns to skin.
imately 15° counterclockwise to reduce the value. Do not touch hydraulic components or oil during
test. Make sure hydraulic oil has cooled to safe tem-
12. Repeat the adjustment until the forks begin to move perature before installing or removing test equip-
between 550 mA and 650 mA. ment.
13. Tighten pilot pin adjustment screw lock nut while

WARNING
holding the pilot pin adjustment screw to prevent
slipping. Slipping of the adjustment screw will Hydraulic oil under pressure can be injected into
cause threshold to increase. See Figure 29. skin. Lower forks to ground and relieve all circuit
pressure before removing or installing test equip-
14. Replace coil nut. ment.
15. Repeat test to verify that fork movement occurs be-

CAUTION
tween 550 mA and 650 mA.
Do not permit dirt or other contaminants to enter
16. Install side covers, floor plates, seal plate and dash. the hydraulic system. Disconnected hoses, tubes,
open valves, cylinder fittings, and ports should be
See Frame 100 YRM 1120 for lift truck models protected with clean caps or plugs.
GC/GLC040SVX (C809) 1. Remove side covers, floor plates, seal plate and
• GLP/GDP16VX, GLP/GDP18VX, dash.
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) See Frame 100 YRM 1120 for lift truck models
(C810) • GC/GLC030VX, GC/GLC035VX,
• GLC20-35VX (GC/GLC040-070VX, GC/GLC040SVX (C809)
GC/GLC055SVX) (A910) • GLP/GDP16VX, GLP/GDP18VX,
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) GLP/GDP20SVX (GP/GLP/GDP030VX,
(B875) GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810)
See Frame 100 YRM 1243 for lift 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/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ See Frame 100 YRM 1243 for lift truck models
GDP080, 090, 100, 110, 120VX) (F813, G813) • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
100, 120VX; GC/GLC080, 100VXBCS;
See Frame 100 YRM 1316 for lift truck models GC/GLC120SVX; GC/GLC120VXPRS) (E818)
• GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GDC135VX, GC/GLC/GDC155VX) (C879, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/
D879) GDP080, 090, 100, 110, 120VX) (F813, G813)
See Frame 100 YRM 1321 for lift truck models See Frame 100 YRM 1316 for lift truck models
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/
GDP135VX, GP/GLP/GDP155VX) (C878, D878) GDC135VX, GC/GLC/GDC155VX) (C879,
• GLP/GDP80VX, GLP/GDP80VX9, D879)
GDP190VX) (A909)

See Frame 100 YRM 1321 for lift truck models 6. Turn the engine off, and turn the display switch clus-
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ ter (DSC) key back on.
• GLP/GDP80VX, GLP/GDP80VX9, 7. Remove coil nut. See Figure 30.
8. Loosen pilot pin adjustment screw lock nut. See
GDP190VX) (A909)
Figure 30.
2. To prevent truck from moving, block front and rear
9. Slowly increase the current to the lower function by
wheels while the engine is operating.
pushing forward on the lever or joystick.
3. Ensure hydraulic oil is at operating temperature,
NOTE: A 1/4 turn will change the value approximately
which is 122° to 150°.
130 mA. Turn clockwise or IN to increase value and
NOTE: Always attempt to re-calibrate the threshold set- counterclockwise or OUT to decrease value.
ting through the display switch cluster (DSC) to elimi-
10. If the forks move before the current reaches 550
nate the symptoms below before adjusting the pilot pin.
mA or appear to drop suddenly, turn the pilot pin
4. Monitor the EHPV coil current. adjustment screw approximately 15° clockwise to
increase the value.
a. Method 1: Connect a current probe to either of
the lift EHPV coil leads. 11. Repeat the adjustment until the forks begin to move
between 550 mA and 650 mA.
b. Method 2: Monitor the current using the display
switch cluster (DSC). See Diagnostic Trou- 12. If the forks have not started to move prior to reach-
bleshooting Manual 9000 YRM 1112 for the ing 650 mA, turn the pilot adjustment screw approx-
procedure. imately 15° counterclockwise to reduce the value.
5. Start vehicle and raise forks to approximately 2 m

(6.5 ft) above the ground.
Figure 30. Lowering Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment


1. SOLENOID TUBE ASSEMBLY 6. COIL
2. O-RING 7. PILOT PIN AND BIAS SPRING
3. PILOT PIN ADJUSTMENT SCREW LOCK NUT 8. POPPET ASSEMBLY
4. COIL NUT 9. CAGE ASSEMBLY
5. PILOT PIN ADJUSTMENT SCREW
13. Repeat the adjustment until the forks begin to move See Frame 100 YRM 1316 for lift truck models
between 550 mA and 650 mA. • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/
14. Tighten pilot pin adjustment screw lock nut while D879)
holding the pilot pin adjustment screw to prevent
slipping. Slipping of the adjustment screw will See Frame 100 YRM 1321 for lift truck models
cause threshold to increase. See Figure 30. • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
15. Replace coil nut. • GLP/GDP80VX, GLP/GDP80VX9,
16. Repeat test to verify that fork movement occurs be-
GDP190VX) (A909)
tween 550 mA and 650 mA.
17. Install side covers, floor plates, seal plate and dash. Abnormal/Erroneous EHPV Adjustment

CAUTION
GC/GLC040SVX (C809) While only minor adjustments may be necessary,
• GLP/GDP16VX, GLP/GDP18VX, the design of the EHPV is such that the adjustment
GLP/GDP20SVX (GP/GLP/GDP030VX, screw could erroneously be backed out to the point
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) where the EHPV is normally open. This presents an
(C810) extreme condition that is not likely, but is possible.
• GLC20-35VX (GC/GLC040-070VX, If this occurs on lift function and lower function simulta-
GC/GLC055SVX) (A910) neously, the pump flow will bypass directly to tank and
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) there will be no hydraulic functionality. If this occurs
(B875) on the lift function only (with lower function calibrated
See Frame 100 YRM 1243 for lift truck models correctly), the mast will raise as soon as the engine is
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, turned on. If this occurs on the lower function only (with
100, 120VX; GC/GLC080, 100VXBCS; the lift function calibrated correctly, the auxiliary and tilt
GC/GLC120SVX; GC/GLC120VXPRS) (E818) functions will be operational, but the forks will not raise.
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, See Figure 29 or Figure 30.
GDP080, 090, 100, 110, 120VX) (F813, G813)

2000 YRM 1137 Manual Main Control Valve
Manual Main Control Valve

DESCRIPTION See Figure 32 for lift truck models:
The manual control valve is an open-center valve which GDC135VX, GC/GLC/GDC155VX) (C879, D879)
utilizes parallel hydraulic circuitry. The valve is used • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
with a fixed displacement pump. The hydraulic circuitry GDP135VX, GP/GLP/GDP155VX) (C878, D878)
incorporates dual pressure logic. The lift function op-
erates on the primary relief pressure setting. The tilt NOTE: Lift truck models listed below may be equipped
and auxiliary functions operate on the lower secondary with a manual main control valve with operator pres-
relief pressure setting. If the lift function is operated si- ence system (OPS).
multaneously with the tilt and/or auxiliary function, the • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX
maximum lift pressure is limited to the secondary relief (C809)
pressure setting. • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX
The manual main control valve assembly without oper- GP/GLP/GDP040SVX) (C810)
ator presence system (OPS) is divided in the following • GLC20-35VX (GC/GLC040-070VX,
sections: GC/GLC055SVX) (A910)
• Steering Control Unit (SCU) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
• Monoblock (lift and tilt control) (B875)
• Auxiliary • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100,
• Outlet 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX;
• Mid-Inlet* (Primary Pump Inlet) GC/GLC120VXPRS) (E818)
*Mid-inlet (primary pump inlet) section is used only on
the main control valve of lift truck models
090, 100, 110, 120VX) (F813, G813)
See Figure 31 for lift truck models: • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX
• GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (GDP170VX, GDP175VX36, GDP190VX) (A909)
(C809)
NOTE: Lift truck models listed below are only equipped
with a three-function manual main control valve with op-
erator presence system (OPS).
• GLC050LX (A967)
• GLP050LX (A974)
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) The manual main control valve with OPS is divided into
(B875) the following sections. See Figure 33.
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, • Steering Control Unit (SCU)
120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; • Monoblock (lift and tilt control)
GC/GLC120VXPRS) (E818) • Auxiliary
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ • Outlet
090, 100, 110, 120VX) (F813, G813)

Manual Main Control Valve 2000 YRM 1137
1. STEERING CONTROL UNIT (SCU) 7. AUXILIARY II VALVE SECTION/SPOOL

2. SCU MOUNTING CAPSCREW 8. SECONDARY RELIEF VALVE
3. MONOBLOCK VALVE SECTION 9. OUTLET SECTION
4. LIFT/LOWER SPOOL 10. EF PORT
5. TILT SPOOL 11. PRIMARY RELIEF VALVE
6. AUXILIARY I VALVE SECTION/SPOOL
Figure 31. Manual Control Valve Without OPS, Lift Truck Models GC/GLC030VX, GC/GLC035VX,

1. STEERING CONTROL UNIT (SCU) 7. AUXILIARY I VALVE SECTION/SPOOL

2. SCU MOUNTING CAPSCREW 8. AUXILIARY II VALVE SECTION/SPOOL
3. MID-INLET SECTION 9. SECONDARY RELIEF VALVE
5. LIFT/LOWER SPOOL 11. PRIMARY RELIEF VALVE
6. TILT SPOOL 12. EF PORT
Figure 32. Manual Control Valve Without OPS, Lift Truck Models GLC/GDC60VX, GLC/GDC70VX

NOTE: FOUR-FUNCTION MAIN CONTROL VALVE SHOWN. THREE-FUNCTION MAIN CONTROL VALVE FOR
LIFT TRUCK MODELS GLC050LX (A967) AND GLP050LX (A974) IS SIMILAR.
1. STEERING CONTROL UNIT (SCU) 7. AUXILIARY II VALVE SECTION/SPOOL
2. SCU MOUNTING CAPSCREW 8. SECONDARY RELIEF VALVE
4. LIFT/LOWER SPOOL 10. MANUAL LOWERING VALVE
5. TILT SPOOL 11. PRIMARY RELIEF VALVE
6. AUXILIARY I VALVE SECTION/SPOOL
Figure 33. Manual Main Control Valve With OPS

REMOVE See Frame 100 YRM 1243 for lift truck models
WARNING 100, 120VX; GC/GLC080, 100VXBCS;
Lower carriage completely before working on con-
trol valve or hydraulic system. Do not work under
a raised carriage. Put mast in a vertical position,
GDP080, 090, 100, 110, 120VX) (F813, G813)
with no forward or back tilt, and lower carriage com-
pletely before disconnecting any parts of hydraulic See Frame 100 YRM 1316 for lift truck models
system. The mast can lower suddenly and cause • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/
injury if the carriage is not lowered. GDC135VX, GC/GLC/GDC155VX) (C879,
D879)
NOTE: Most of the individual valve components can
be removed and replaced while the control valve is in- See Frame 100 YRM 1321 for lift truck models
stalled in the truck. Removal of the control valve for • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
repairs is normally only required to replace a valve sec- GDP135VX, GP/GLP/GDP155VX) (C878, D878)
tion, replace the O-rings between the sections, or to re- • GLP/GDP80VX, GLP/GDP80VX9,
move a manual valve control spool. GLP/GDP90VX (GDP170VX, GDP175VX36,
GDP190VX) (A909)
1. Power wash the interior of the operator compart-
ment to remove any dirt or debris. See Frame 100 YRM 1423 for lift truck models
• GLC050LX (A967)
2. Move truck to disassembly area and shut off engine.
• GLP050LX (A974)
WARNING Before disconnecting any hydraulic hoses or re-

Cleaning solvents can be flammable and toxic and moving any parts from the control valve, clean the
cause skin irritation. When cleaning solvents are outside of the valve either by steam cleaning or with
used, always follow the solvent manufacturer’s cleaning solvent.
recommended safety procedures. Wear protective
4. Disconnect the hydraulic levers by removing the
goggles or a face shield to prevent eye injuries.
locking ring cotter pins and rod end pins that con-
NOTE: Take all necessary steps to prevent debris, dust, nect the hydraulic lever linkages to the spools. Re-
or other contaminants from entering the valve cavities, move three capscrews and the hydraulic lever as-
hydraulic lines, or replacement parts. sembly from the cowl.
3. Remove the floor plate, kick panel, seal plate, and See Figure 34
dashboard. • For lift truck models without OPS
See Frame 100 YRM 1120 for lift truck models See Figure 35
• GC/GLC030VX, GC/GLC035VX, • For lift truck models with OPS
GC/GLC040SVX (C809)
5. To remove the accelerator pedal or Foot Directional
Control pedal assembly, disconnect the cowl wiring
harness from the pedal assembly wiring harness
and remove three mounting capscrews. See Fig-
(C810)
ure 36.
(B875)

1. CAPSCREW
2. HYDRAULIC LEVER ASSEMBLY
3. LOCKING RING COTTER PINS
4. MANUAL CONTROL VALVE
5. ROD END PINS 1. CAPSCREW
2. HYDRAULIC LEVER ASSEMBLY
Figure 34. Hydraulic Lever Removal - Without OPS 3. LOCKING RING COTTER PINS
4. MANUAL CONTROL VALVE
5. ROD END PINS
Figure 35. Hydraulic Lever Attachment - With OPS

NOTE: Lift truck models GLP/GDP20-35VX (GP/GLP/

GDP040-070VX) (B875) may be equipped with an op-
tional Quick-Lok™ hydraulic inlet hose and adapter be-
tween the steering control unit and hydraulic gear pump.
NOTE: To aid in correctly connecting hydraulic hoses

during installation, tag each hose prior to disconnecting
from the control valve.
6. Disconnect hydraulic hoses from the control valve.

Install plugs or caps on all open hose ends and
control valve ports to prevent contamination.
See Figure 37 for the following lift truck models with-

out OPS:
GC/GLC040SVX (C809)
(C810)
(B875)
100, 120VX; GC/GLC080, 100VXBCS;
NOTE: ACCELERATOR PEDAL NOT SHOWN, HOW- • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
EVER, REMOVAL IS THE SAME. GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (F813, G813)
2. FOOT DIRECTIONAL CONTROL PEDAL See Figure 38 for the following lift truck models with-
ASSEMBLY
3. PEDAL ASSEMBLY WIRING HARNESS out OPS:
Figure 36. Foot Directional Control Pedal Removal GDC135VX, GC/GLC/GDC155VX) (C879,
D879)
CAUTION GDP135VX, GP/GLP/GDP155VX) (C878, D878)
To prevent any foreign matter from getting into
either the hydraulic hoses or the hydraulic control See Figure 39
valve sections, all openings must have plugs or • For lift truck models equipped with manual control
covers installed immediately after hoses are dis- valve with OPS.
connected from the control valve. This also applies
if any other items are removed from the control
valve.


2. SCU MOUNTING CAPSCREWS 7. TILT HOSE
5. HYDRAULIC INLET HOSE 10. RETURN HOSE
Figure 37. Hydraulic Hose Removal, Manual Control Valve Without OPS, Lift Truck Models
GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809), GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX
(GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910), GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GLC40, 45, 55VX; GLC55SVX;
(GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818),
110, 120VX) (F813, G813)

1. STEERING SYSTEM HOSES 6. TILT HOSE

2. SCU MOUNTING CAPSCREWS 7. AUXILIARY I HOSE
3. STEERING CONTROL UNIT (SCU) 8. AUXILIARY II HOSE
4. STEERING COLUMN 9. RETURN HOSE
5. MID INLET HYDRAULIC HOSE (MAIN PUMP 10. LIFT/LOWER HOSE
HOSE)
Figure 38. Hydraulic Hose Removal, Manual Control Valve Without OPS, Lift Truck Models GLC/GDC60VX,
GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) and GLP/GDP60VX, GLP/GDP70VX

1. STEERING SYSTEM HOSES 6. AUXILIARY I HOSE
2. SCU MOUNTING CAPSCREW 7. AUXILIARY II HOSE
3. STEERING CONTROL UNIT (SCU) 8. RETURN HOSE
4. STEERING COLUMN 9. LIFT/LOWER HOSE
5. TILT HOSE 10. HYDRAULIC INLET HOSE
Figure 39. Hydraulic Hose Removal - Manual Control Valve With OPS

7. Remove the two SCU mounting capscrews, and See Figure 41

move the SCU approximately 1.3 cm (0.5 in.) to • For lift truck models with OPS.
the left. Lower the SCU until the steering shaft is
disengaged. Remove the SCU from the lift truck.
See Figure 31 for lift truck models without OPS:

GC/GLC040SVX (C809)
(C810)
(B875)
100, 120VX; GC/GLC080, 100VXBCS;
GDP080, 090, 100, 110, 120VX) (F813, G813)
1. COWL 5. MAIN CONTROL
See Figure 32 for lift truck models without OPS: 2. INSERT VALVE
• GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ 3. WASHER 6. FRAME
4. CAPSCREW
D879) Figure 40. Manual Main Control Valve Without OPS
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ Removal
See Figure 33:

• For lift truck models with OPS.
8. Remove and discard two O-rings from the main

control valve. For lift truck models equipped with
manual control valve, with or without OPS, the two
O-rings are located between the SCU and control
valve.
9. For lift truck models equipped with manual control

valve with OPS, disconnect solenoid assemblies
from cowl wire harness.
WARNING
the main control valve to avoid the possibility of
1. COWL
10. Support the main control valve. Remove three 2. INSERT
mounting capscrews, washers, inserts and the 3. WASHER
manual control valve from the lift truck. 4. CAPSCREW
5. MANUAL CONTROL VALVE WITH OPS
See Figure 40
• For lift truck models without OPS. Figure 41. Manual Main Control Valve With OPS
Removal

OPS SOLENOID ASSEMBLY Remove

General 1. Remove two capscrews from solenoid lockout as-
sembly and seal plates at top of lift/tilt section. See
There are two OPS solenoid assemblies. See Figure 42 Figure 44.
and Figure 44 for configurations.
2. Remove two capscrews from solenoid lockout as-
sembly and seal plates at top of auxiliary section(s).
See Figure 44.
3. Depress needle rollers and remove solenoid lock-

out assembly from seal plate and between valve
spools. See Figure 43 and Figure 44.
NOTE: NEEDLE ROLLERS SHOWN IN DEPRESSED

POSITION; LINK IS PUSHED UPWARD WHEN NEE-
DLE ROLLERS ARE DEPRESSED.
A. 3-FUNCTION MANUAL CONTROL VALVE 1. LINK 2. NEEDLE ROLLER
B. 4-FUNCTION MANUAL CONTROL VALVE
Figure 43. Needle Rollers, Depressed
1. 1-FUNCTION SOLENOID LOCKOUT ASSEMBLY
Figure 42. OPS Solenoid Assemblies

Figure 44. Solenoid Lockout and Manual Control Valve


A. 3-FUNCTION MANUAL CONTROL VALVE B. 4-FUNCTION MANUAL CONTROL VALVE
1. 1-FUNCTION SOLENOID LOCKOUT ASSEMBLY 4. SEAL PLATE
2. 2-FUNCTION SOLENOID LOCKOUT ASSEMBLY 5. LIFT/TILT SECTION
3. CAPSCREW 6. AUXILIARY SECTION
Clean and Inspect
WARNING
WARNING
1. Clean metal components with cleaning solvents

and dry with compressed air.
2. Clean all other components with a lint-free cloth.
3. Inspect all components for damage; replace if dam-

aged.
Install
1. Install needle rollers into solenoid lockout assembly.
See Figure 45. 1. 1-FUNCTION SOLENOID LOCKOUT ASSEMBLY
2. Install solenoid lockout assembly by depressing 3. NEEDLE ROLLER
needle rollers and placing solenoid between valve
spools. See Figure 43 and Figure 44. Figure 45. Solenoid Assembly and Needle Rollers
- OPS II
3. Install two capscrews onto solenoid lockout assem-
bly and seal plates at top of valve section(s). See
Figure 44. Torque capscrews to 9.5 ±1.4 N•m (84
±12 lbf in).

MANUAL CONTROL VALVE SECTIONS Disassemble
General 1. Remove the secondary relief valve plug from the

outlet control valve section and discard the O-ring.
CAUTION See Figure 46
While working on the manual control valve sec- • For lift trucks without OPS.
tions, place a cover over the remaining sections of
the control valve to prevent the possibility of con- See Figure 47
taminants getting into the control valve openings • For lift trucks with OPS.
which could cause damage to the control valve.
NOTE: Perform Step 2 through Step 6 only if it is ab-
solutely necessary to disassemble the secondary relief
CAUTION valve.
If O-rings are to be replaced between two sections
that have a hydraulic oil leak, replace all O-rings be- 2. Remove the plug from the adjusting nut. Remove
tween all sections. This eliminates the possibility and discard the O-ring from the plug. Remove and
of a subsequent oil leak or possible damage to an- discard the backup rings and O-ring from the ad-
other O-ring. justing nut.
NOTE: Disassemble the manual control valve only as See Figure 46

necessary for repairs. Most repairs to the control valve • For lift trucks without OPS.
will be for the replacement of O-rings to stop leaks be- See Figure 47
tween sections. • For lift trucks with OPS.
The manual control valve will be disassembled starting 3. While holding the adjusting nut in place, loosen the
with the outlet control valve section. jam nut.
Outlet Control Valve Section See Figure 46
• For lift trucks without OPS.
Remove
See Figure 47
1. Remove four nuts from the control valve tie rods. • For lift trucks with OPS.
See Figure 46 NOTE: While performing Step 4, count and note the
• For lift trucks without OPS. number of turns used to remove the adjusting nut.
See Figure 47 4. Remove the adjusting nut and jam nut assembly
• For lift trucks with OPS. from the relief valve plug and discard the O-ring on
2. Remove the outlet control valve section from the the adjusting nut.
four tie rods and discard three O-rings from the aux- See Figure 46
iliary control valve section. • For lift trucks without OPS.
See Figure 48 See Figure 47
• For lift trucks without OPS. • For lift trucks with OPS.
See Figure 49
• For lift trucks with OPS.

1. PLUG 7. WASHER
2. O-RING 8. SPRING
3. OUTLET VALVE SECTION 9. JAM NUT
4. BACKUP RING 10. ADJUSTING NUT
5. SECONDARY RELIEF VALVE PLUG 11. CONTROL VALVE TIE ROD
6. POPPET 12. NUT
Figure 46. Outlet Control Valve Section, Manual Main Control Valves Without OPS

1. PLUG 8. POPPET
2. O-RING 9. SECONDARY RELIEF VALVE PLUG
3. BACKUP RING 10. SECONDARY RELIEF VALVE ASSEMBLY
4. ADJUSTING NUT 11. OUTLET VALVE SECTION
5. JAM NUT 12. NUT
6. SPRING 13. CONTROL VALVE TIE ROD
7. WASHER
Figure 47. Outlet Control Valve Section, Manual Main Control Valve With OPS

5. Remove the spring, washer, and poppet from the NOTE: If the outlet control valve section is not to be
relief valve plug. reassembled immediately, coat surfaces with clean hy-
See Figure 46 outlet control valve section with a clean, dry, lint-free
• For lift trucks without OPS. cloth to prevent the possibility of contaminants entering
the outlet control valve section.
See Figure 47
• For lift trucks with OPS. Assemble
6. Remove and discard the backup ring from the relief NOTE: Coat all backup rings and O-rings with a light
valve plug. coat of clean hydraulic oil to make installation easier.
See Figure 46 NOTE: Perform Step 1 through Step 7 only if the sec-
• For lift trucks without OPS. ondary relief valve was repaired.
See Figure 47 1. Install a new backup ring on the relief valve plug.
See Figure 46
Clean • For lift trucks without OPS.
WARNING See Figure 47

can cause skin irritation. When using cleaning 2. Install the poppet, washer, and spring into the relief
solvents, always follow the solvent manufacturer’s valve plug.
See Figure 46
WARNING • For lift trucks without OPS.
Compressed air can move particles so they cause See Figure 47
injury to the user or to other personnel. Make sure • For lift trucks with OPS.
sonnel. Wear protective goggles or a face shield to 3. Install a new O-ring on the adjusting nut, and install
prevent injury to the eyes. the adjusting nut and jam nut assembly into the re-
lief valve plug the number of turns noted during dis-
1. If all components of the outlet control valve section assembly.
have been removed, clean the outlet control valve
section using cleaning solvent and dry using com- See Figure 46
pressed air. • For lift trucks without OPS.
2. If not all components have been removed, clean the See Figure 47
outlet control valve section using a lint-free cloth. • For lift trucks with OPS.
Inspect 4. While holding the adjusting nut in place, tighten the

jam nut to 24 ±3 N•m (18 ±2 lbf ft).
Inspect the outlet control valve section mating surfaces
and the bore of the secondary relief valve, if removed, See Figure 46
for damage. If either the mating surface or the sec- • For lift trucks without OPS.
ondary relief valve bore are damaged, replace the outlet
control valve section. See Figure 47
If disassembled, inspect the components of the sec-
ondary relief valve. If any components other than 5. Install a backup ring, O-ring, and backup ring into
O-rings, backup rings, and the spring are damaged, the adjusting nut.
replace the secondary relief valve.
See Figure 46

See Figure 47 Auxiliary Control Valve Sections

Remove
6. Install a new O-ring onto the plug. Install the plug
into the adjusting nut. 1. Remove the outlet valve. See Outlet Control Valve
Section, Remove.
See Figure 46
• For lift trucks without OPS. NOTE: Step 2 is used if a four-section control valve is
being disassembled. If a three-section control valve is
See Figure 47 being disassembled, go to Step 3.
2. Remove the auxiliary II control valve section from
7. If removed, install secondary relief valve into outlet the four tie rods. Remove and discard three O-rings
control valve section. from the auxiliary I control valve section.
See Figure 46 3. Remove the auxiliary I control valve section from

• For lift trucks without OPS. the four tie rods. Remove and discard three O-rings
from the lift and tilt control valve section.
See Figure 47
• For lift trucks with OPS. See Figure 50 for lift truck models listed below with-
out OPS
Tighten relief valve plug to 45 N•m (33 lbf ft). See • GC/GLC030VX, GC/GLC035VX,
the section Pressure Relief Valve Check and Ad- GC/GLC040SVX (C809)
justment to adjust the secondary relief valve and • GLP/GDP16VX, GLP/GDP18VX,
check the pressure. GLP/GDP20SVX (GP/GLP/GDP030VX,
8. Install new O-ring on plug and install in the outlet
(C810)
valve section.
See Figure 46 GC/GLC055SVX) (A910)
• For lift trucks without OPS. • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875)
See Figure 47 • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
• For lift trucks with OPS. 100, 120VX; GC/GLC080, 100VXBCS;
Install • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
1. Install three new O-rings into the auxiliary valve
GDP080, 090, 100, 110, 120VX) (F813, G813)
section. See Figure 48 and Figure 49.
Figure 51 for lift trucks listed below without OPS
See Figure 48
See Figure 49 D879)
• For lift trucks with OPS. • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
2. Install the outlet control valve section on the four tie
rods. Install the four nuts on the tie rods and tighten See Figure 52
to 19 ±2 N•m (168 ±18 lbf in). • For lift trucks equipped with OPS.
See Figure 46 Disassemble

NOTE: On lift trucks equipped with a four-function con-
See Figure 47 trol valve, the disassembly procedures are the same for
• For lift trucks with OPS. both auxiliary I and II control valve sections.
1. Remove two socket head capscrews, end cap, and

seal plate from the auxiliary control valve section.

See Figure 48 Figure 49

• For lift trucks without OPS. • For lift trucks with OPS.
1. SOCKET HEAD CAPSCREW 8. O-RING

2. END CAP 9. SPOOL
3. SPOOL END FASTENER 10. POPPET
4. SPRING SEAT 11. SPRING
5. SPRING 12. PLUG
6. SEAL PLATE 13. AUXILIARY CONTROL VALVE SECTION
7. WIPER
Figure 48. Auxiliary Control Valve I and II Sections, Manual Control Valve Without OPS

1. SOCKET HEAD CAPSCREW 7. WIPER

2. END CAP 8. O-RING
3. SPOOL END FASTENER 9. SPOOL
4. SPRING SEAT 10. POPPET
5. SPRING 11. PLUG
6. SEAL PLATE 12. AUXILIARY CONTROL VALVE SECTION
Figure 49. Auxiliary Control Valve I and II Sections, Manual Control Valve With OPS

2. Remove the spool assembly and wiper from the auxiliary control valve section with a clean, dry, lint-free
auxiliary control valve section. cloth to prevent the possibility of contaminants entering
the auxiliary control valve section.
3. Remove the spool end fastener, spring seat, spring,
spring seat, and O-ring from the spool assembly. Assemble
4. Remove two socket head capscrews, seal plate, NOTE: Coat all backup rings and O-rings with a light
wiper, and O-ring from the auxiliary control valve coat of clean hydraulic oil to make installation easier.
section.
1. Install two poppets, springs, and plugs, with new
5. Remove two plugs, springs, and poppets from the O-rings installed, into the auxiliary control valve
auxiliary control valve section. On manual main section. On manual main control valves with OPS,
control valves with OPS, there is only one spring there is only one spring and poppet. Tighten the
and poppet. See Figure 49. Remove and discard plugs to 45 ±5 N•m (33 ±4 lbf ft).
the O-rings from the plugs.
See Figure 48
Clean • For lift trucks without OPS.
Figure 49
WARNING • For lift trucks with OPS.
can cause skin irritation. When using cleaning 2. Install new O-ring, new wiper, seal plate, and two
solvents, always follow the solvent manufacturer’s socket head capscrews on the auxiliary control
recommended safety procedures. valve section. Tighten the socket head screws to
9.5 ±1 N•m (84 ±12 lbf in).
WARNING 3. Install the new O-ring, spring seat, spring, spring
Compressed air can move particles so they cause seat, and spool end fastener on the spool. Tighten
injury to the user or to other personnel. Make sure the spool end fastener to 9.5 ±1 N•m (84 ±12 lbf in).
sonnel. Wear protective goggles or a face shield to 4. Install the new wiper and spool assembly into the
prevent injury to the eyes. auxiliary control valve section.
1. If all components of the auxiliary control valve sec- 5. Install seal plate, end cap, and two socket head
tion have been removed, clean the auxiliary control capscrews into the auxiliary control valve section.
valve section using cleaning solvent and dry using Tighten the socket head screws to 9.5 ±1 N•m (84
compressed air. ±12 lbf in).
2. If not all components have been removed, clean the Install

auxiliary control valve section using a lint-free cloth.
NOTE: Step 1 and Step 2 are used if a four-section
Inspect control valve is being installed. If a three-section control
valve is being installed, use Step 1, then go to Step 3.
Inspect the auxiliary control valve section mating sur-
faces and the bore of the spool, if removed, for dam- 1. Install three new O-rings on the lift and tilt control
age. If either the mating surfaces or the spool bore are valve section. Install the auxiliary I control valve
damaged, replace the auxiliary control valve section. section on the four tie rods.
If disassembled, inspect the components of the spool. 2. Install three new O-rings on the auxiliary I control
If any components are damaged, replace the compo- valve section. Install the auxiliary II control valve
nents. If the spool is damaged, replace the auxiliary section on the four tie rods.
3. Install the outlet valve. See Outlet Control Valve
NOTE: If the auxiliary control valve section is not to be Section, Install.
reassembled immediately, coat surfaces with clean hy-

Lift/Tilt Control Valve Section See Figure 52

• For lift trucks equipped with OPS.
Remove
2. Disassemble tilt spool as specified below:
1. Remove the outlet control valve section. See Outlet
Control Valve Section, Remove. a. On lift truck models listed below, equipped with
manual control valve without OPS, remove the
2. Remove the auxiliary control valve section(s). See spool end fastener, O-ring, spring seat, spring,
Auxiliary Control Valve Sections, Remove. spring seat, spring, and piston from the tilt
spool. Discard the O-rings from the tilt spool.
Disassemble
See Figure 50.
NOTE: Remove only those components required to re- • GC/GLC030VX, GC/GLC035VX,
pair the lift/tilt control valve section. GC/GLC040SVX (C809)
• GLP/GDP16VX, GLP/GDP18VX, GLP/
NOTE: Step 1 through Step 3 are for the disassembly GDP20SVX (GP/GLP/GDP030VX, GP/GLP/
of the tilt side of the lift/tilt control valve section. GDP035VX, GP/GLP/GDP040SVX) (C810)
1. Remove two socket head screws, end cap, seal GC/GLC055SVX) (A910)
plate, and tilt spool assembly from the tilt side of • GLP/GDP20-35VX (GP/GLP/GDP040-
the lift/tilt control valve section. Remove and dis- 070VX) (B875)
card the wiper from the tilt bore of the lift/tilt control • GLC40, 45, 55VX; GLC55SVX;
valve section. (GC/GLC080, 100, 120VX; GC/GLC080,
100VXBCS; GC/GLC120SVX;
See Figure 50 for lift truck models listed below with-
out OPS
GLP/GDP45VX6; GLP/GDP50-55VX
GC/GLC040SVX (C809)
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813)
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) b. On lift truck models listed below, equipped with
(C810) manual control valve without OPS, remove the
• GLC20-35VX (GC/GLC040-070VX, spool end fastener, O-ring, spring seat, spring,
GC/GLC055SVX) (A910) and spring seat form the tilt spool. Discard the
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) O-rings from the tilt spool. See Figure 51.
(B875) • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, GDC135VX, GC/GLC/GDC155VX) (C879,
100, 120VX; GC/GLC080, 100VXBCS; D879)
GC/GLC120SVX; GC/GLC120VXPRS) (E818) • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GDP135VX, GP/GLP/GDP155VX) (C878,
GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ D878)
GDP080, 090, 100, 110, 120VX) (F813, G813)
c. On lift truck models equipped with manual con-
Figure 51 for lift trucks listed below without OPS trol valve with OPS, remove the spool end fas-
• GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ tener, O-ring, spring seat, spring, spring seat,
GDC135VX, GC/GLC/GDC155VX) (C879, spring, and piston from the tilt spool. Discard
D879) the O-rings from the tilt spool. See Figure 52.

Figure 50. Lift/Tilt Control Valve Section, Manual Main Control Valve Without OPS, Lift Truck Models
110, 120VX) (F813, G813)


1. SOCKET HEAD CAPSCREW 13. POPPET
2. END CAP 14. SEAL PLATE
3. O-RING 15. LIFT/TILT CONTROL VALVE SECTION
4. SPOOL END FASTENER 16. BACKUP RING
5. SPRING 17. RELIEF VALVE PLUG
6. PISTON 18. POPPET
7. SPRING SEAT 19. WASHER
8. SEAL PLATE 20. LOCK NUT
9. WIPER 21. ADJUSTING NUT
10. O-RING 22. PLUG
11. TILT SPOOL 23. LIFT SPOOL
12. PLUG 24. SPOOL END FASTENER

1. SOCKET HEAD CAPSCREW 13. SEAL PLATE

2. END CAP 14. LIFT/TILT CONTROL VALVE SECTION
3. O-RING 15. BACKUP RING
4. SPOOL END FASTENER 16. RELIEF VALVE PLUG
5. SPRING 17. POPPET
6. SPRING SEAT 18. WASHER
7. SEAL PLATE 19. LOCK NUT
8. WIPER 20. ADJUSTING NUT
9. O-RING 21. PLUG
10. TILT SPOOL 22. LIFT SPOOL
11. PLUG 23. SPOOL END FASTENER
12. POPPET
Figure 51. Lift/Tilt Control Valve Section, Manual Main Control Valve Without OPS, Lift Truck Models
GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) and GLP/GDP60VX,
GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878)

Figure 52. Lift/Tilt Control Valve Section, Manual Main Control Valve With OPS


1. END CAP 12. RELIEF VALVE ASSEMBLY
2. SOCKET HEAD CAPSCREW 13. MANUAL LOWERING VALVE
3. PLUG 14. SCREW
4. O-RING 15. SEAL PLATE
5. BACKUP RING 16. WIPER
6. ADJUSTING NUT 17. SPRING SEAT
7. LOCKNUT 18. SPOOL END FASTENER
8. SPRING 19. PISTON
9. WASHER 20. LIFT SPOOL
10. POPPET 21. TILT SPOOL
11. RELIEF VALVE PLUG
3. Remove two socket head screws and seal plate 5. Remove the spool end fastener, spring seat, spring,
from the tilt side of the lift/tilt control valve section. spring seat, and O-ring from the lift spool assembly.
Remove and discard the wiper and O-ring from the Discard the O-ring.
tilt bore of the lift/tilt control valve section.
6. Remove two socket head screws and seal plate
NOTE: Step 4 through Step 6 are for the disassembly from the lift side of the lift/tilt control valve section.
of the lift side of the lift/tilt control valve section. Remove and discard the wiper and O-ring from the
lift bore of the lift/tilt control valve section.
4. Remove two socket head screws, end cap, seal
plate, and lift spool assembly from the lift side of 7. Remove three plugs, springs, and poppets from the
the lift/tilt control valve section. Remove and dis- lift/tilt control valve section. Remove and discard
card the wiper from the lift bore of the lift/tilt control the O-rings from the plugs.
valve section.
8. On lift trucks equipped with a manual main control
See Figure 50 for lift truck models listed below with- valve with OPS, remove the manual lowering valve
out OPS from the lift/tilt control valve section. Remove and
• GC/GLC030VX, GC/GLC035VX, discard the O-ring. See Figure 52.
GC/GLC040SVX (C809)
• GLP/GDP16VX, GLP/GDP18VX, NOTE: Perform Step 9 through Step 13 only if it is nec-
GLP/GDP20SVX (GP/GLP/GDP030VX, essary to disassemble the primary relief valve.
9. Remove the plug from the adjusting nut. Remove
(C810)
and discard the O-ring from the plug. Remove and
discard the backup rings and O-ring from the ad-
justing nut.
(B875) 10. While holding the adjusting nut in place, loosen the
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, jam nut.
100, 120VX; GC/GLC080, 100VXBCS;
GC/GLC120SVX; GC/GLC120VXPRS) (E818) NOTE: While performing Step 11, count and note the
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, number of turns used to remove the adjusting nut.
GDP080, 090, 100, 110, 120VX) (F813, G813) 11. Remove the adjusting nut and jam nut assembly
from the relief valve plug and discard the O-ring on
Figure 51 for lift trucks listed below without OPS the adjusting nut.
GDC135VX, GC/GLC/GDC155VX) (C879, 12. Remove the spring, washer, and poppet from the
D879) relief valve plug.
13. Remove and discard the backup ring from the relief
valve plug.
See Figure 52

Clean 1. Install the new backup ring on the relief valve plug.

WARNING out OPS
Cleaning solvents can be flammable and toxic and • GC/GLC030VX, GC/GLC035VX,
can cause skin irritation. When using cleaning GC/GLC040SVX (C809)
solvents, always follow the solvent manufacturer’s • GLP/GDP16VX, GLP/GDP18VX,
recommended safety procedures. GLP/GDP20SVX (GP/GLP/GDP030VX,
WARNING (C810)
Compressed air can move particles so they cause • GLC20-35VX (GC/GLC040-070VX,
injury to the user or to other personnel. Make sure GC/GLC055SVX) (A910)
the path of the compressed air is away from all per- • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
sonnel. Wear protective goggles or a face shield to (B875)
prevent injury to the eyes. • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
100, 120VX; GC/GLC080, 100VXBCS;
1. If all components of the lift/tilt control valve section GC/GLC120SVX; GC/GLC120VXPRS) (E818)
have been removed, clean the lift/tilt control valve • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
section using cleaning solvent and dry using com- GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
pressed air. GDP080, 090, 100, 110, 120VX) (F813, G813)
2. If not all components have been removed, clean the Figure 51 for lift trucks listed below without OPS
lift/tilt control valve section using a lint-free cloth. • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/
Inspect D879)
Inspect the lift/tilt control valve section mating surfaces.
Inspect the bore of the primary relief valve, if removed,
for damage. Inspect the bores of the lift and tilt spools, if See Figure 52
removed. If the mating surface, the primary relief valve • For lift trucks equipped with OPS.
bore, or either the lift or tilt spool bores are damaged,
replace the lift/tilt control valve section. 2. Install the poppet, washer, and spring into the relief
valve plug.
If disassembled, inspect the components of the pri-
mary relief valve. If any components other than O-rings, 3. Install a new O-ring on the adjusting nut. Install
backup rings, and the spring are damaged, replace the the adjusting nut and jam nut assembly in the re-
primary relief valve. lief valve plug the number of turns noted during re-
moval.
NOTE: If the lift/tilt control valve section is not to be
reassembled immediately, coat surfaces with clean hy- 4. While holding the adjusting nut in place, tighten the
draulic oil to prevent the possibility of rust. Cover the jam nut to 24 ±3 N•m (18 ±2 lbf ft).
lift/tilt control valve section with a clean, dry, lint-free
cloth to prevent the possibility of contaminants enter- 5. Install a new backup ring, O-ring, and backup ring
ing the lift/tilt control valve section. into the adjusting nut.
Assemble 6. Install a new O-ring onto the plug. Install the plug
into the adjusting nut.
NOTE: Coat all backup rings and O-rings with a light
coat of clean hydraulic oil to make installation easier.
NOTE: Perform Step 1 through Step 7 only if the pri-

mary relief valve was repaired.

7. Install primary relief valve into lift side of the lift/tilt 11. Install a new O-ring on the lift spool. Install the
control valve section. Tighten primary relief valve spring seat, spring, spring seat, and spool end fas-
plug to 45 N•m (33 lbf ft). tener on the lift spool assembly. Tighten the spool
end fastener to 9.5 ±1 N•m (84 ±12 lbf in).
out OPS 12. Install new the wiper into the lift bore of the lift/tilt
• GC/GLC030VX, GC/GLC035VX, control valve section. Install the lift spool assembly,
GC/GLC040SVX (C809) seal plate, end cap, and two socket head screws
• GLP/GDP16VX, GLP/GDP18VX, into the lift side of the lift/tilt control valve section.
GLP/GDP20SVX (GP/GLP/GDP030VX, Tighten the socket head screws to 9.5 ±1 N•m (84
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) ±12 lbf in).
(C810)
• GLC20-35VX (GC/GLC040-070VX, 13. Install the new O-ring and wiper in the tilt bore of
GC/GLC055SVX) (A910) the lift/tilt control valve section. Install the seal plate
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) and two socket head screws on the tilt side of the
(B875) lift/tilt control valve section. Tighten the socket head
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, screws to 9.5 ±1 N•m (84 ±12 lbf in).
100, 120VX; GC/GLC080, 100VXBCS;
14. Assemble tilt spool as specified below:
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, a. On lift truck models listed below, equipped with
GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ manual control valve without OPS, install a
GDP080, 090, 100, 110, 120VX) (F813, G813) new O-ring on the tilt spool. Install the piston,
spring, spring seat, spring, spring seat, and
Figure 51 for lift trucks listed below without OPS
spool end fastener on the tilt spool assembly.
Tighten the spool end fastener to 9.5 ±1 N•m
(84 ±12 lbf in).
D879)
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ See Figure 50 for lift trucks without OPS
GDP135VX, GP/GLP/GDP155VX) (C878, D878) • GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809)
See Figure 52
• GLP/GDP16VX, GLP/GDP18VX, GLP/
GDP20SVX (GP/GLP/GDP030VX, GP/GLP/
See the section Pressure Relief Valve Check and GDP035VX, GP/GLP/GDP040SVX) (C810)
Adjustment to adjust the primary relief valve and • GLC20-35VX (GC/GLC040-070VX,
check the pressure. GC/GLC055SVX) (A910)
• GLP/GDP20-35VX (GP/GLP/GDP040-
8. On lift trucks equipped with a manual main control 070VX) (B875)
valve with OPS, install the manual lowering valve, • GLC40, 45, 55VX; GLC55SVX;
with a new O-ring installed, into the lift/tilt control (GC/GLC080, 100, 120VX; GC/GLC080,
valve section. Tighten to 14 ±1 N•m (120 ±12 lbf in). 100VXBCS; GC/GLC120SVX;
9. Install three poppets, springs, and plugs, with new • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
O-rings installed, in the lift/tilt control valve section. GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
10. Install the new O-ring and wiper in the lift bore of
(F813, G813)
the lift/tilt control valve section. Install the seal plate
and two socket head screws on the lift side of the
lift/tilt control valve section. Tighten the socket head
screws to 9.5 ±1 N•m (84 ±12 lbf in).

b. On lift truck models listed below, equipped with 1. Remove three socket head capscrews and wash-
manual control valve without OPS, install a new ers that secure the mid-inlet section to the lift/tilt
O-ring on the tilt spool. Install the spring seat, (monoblock) section. See Figure 53.
spring, spring seat, and spool end fastener on
the tilt spool assembly. Tighten the spool end 2. Remove mid-inlet section from the lift/tilt section.
fastener to 9.5 ±1 N•m (84 ±12 lbf in). Discard four O-rings.
See Figure 51 for lift trucks without OPS: 3. Remove socket head plug and discard O-ring.
D879)
GDP135VX, GP/GLP/GDP155VX) (C878,
D878)
c. On lift truck models, equipped with manual con-

trol valve with OPS, install a new O-ring on the
tilt spool. Install the piston, spring, spring seat,
spring, spring seat, and spool end fastener on
the tilt spool assembly. Tighten the spool end
fastener to 9.5 ±1 N•m (84 ±12 lbf in). See Fig-
ure 52.
15. Install new the wiper into the tilt bore of the lift/tilt
control valve section. Install the tilt spool assembly, 1. MID-INLET SECTION
seal plate, end cap, and two socket head screws 2. SOCKET HEAD PLUG
into the tilt side of the lift/tilt control valve section. 3. O-RING
Tighten the socket head screws to 9.5 ±1 N•m (84 4. SOCKET HEAD CAPSCREW
±12 lbf in). 5. WASHER
Install Figure 53. Mid-Inlet Section
1. Install the auxiliary control valve section(s). See Clean

Auxiliary Control Valve Sections, Install.
WARNING
2. Install the outlet valve. See Outlet Control Valve Cleaning solvents can be flammable and toxic and
Section, Install. can cause skin irritation. When using cleaning
Mid-Inlet Section recommended safety procedures.
Remove
WARNING
NOTE: The mid-inlet section is used only on lift truck
models listed below equipped with manual control valve
without OPS.
GDP135VX, GP/GLP/GDP155VX) (C878, D878) Clean the mid-inlet control valve section using cleaning
solvent and dry using compressed air.
Remove the mid-inlet section only as necessary for re-
pair. Most repairs to the mid-inlet section will be for the
replacement of O-rings to stop leaks. There are no dis-
assembly or assembly procedures for the mid-inlet sec-
tion.

Inspect
Inspect the mid-inlet control valve section and mating

surfaces. If either the mating surfaces or mid-inlet con-
trol valve section are damaged, replace the mid-inlet
Install
NOTE: If the mid-inlet control valve section is not to be

installed immediately, coat surfaces with clean hydraulic
oil to prevent the possibility of rust. Cover the mid-inlet
control valve section with a clean, dry, lint-free cloth to
prevent the possibility of contaminants entering the mid-
inlet control valve section.
NOTE: Coat all O-rings with a light coat of clean hy-

draulic oil to make installation easier.
1. Install new O-ring on socket head plug. Install plug

into mid-inlet section. See Figure 53. 1. COWL 5. MAIN CONTROL
2. INSERT VALVE
2. Install new O-rings on mating surfaces of mid-inlet 3. WASHER 6. FRAME
section. 4. CAPSCREW
3. Install mid-inlet section to lift/tilt section using three Figure 54. Manual Main Control Valve Without OPS
socket head capscrews and washers. Tighten cap- Installation
screws to 45 to 55 N•m (33 to 41 lbf ft).
INSTALL
WARNING
the main control valve, to avoid the possibility of
1. While supporting the main control valve in place on

the cowl, install three mounting capscrews, wash-
ers, and inserts through the front of the cowl into
the control valve. Tighten the capscrews to 19 N•m
(14 lbf ft).
See Figure 54
Figure 55
• For lift trucks with OPS. 1. COWL
2. INSERT
3. WASHER
4. CAPSCREW
5. MANUAL CONTROL VALVE WITH OPS
Figure 55. Manual Main Control Valve With OPS

Installation

2. On lift trucks equipped with manual main control See Figure 33

valve with OPS, connect solenoid assemblies to • For lift truck models equipped with OPS.
cowl wire harness.
3. For lift truck models equipped with manual control GDP040-070VX) (B875) may be equipped with an op-
valve, with or without OPS, coat two new O-rings tional Quick-Lok™ hydraulic inlet hose and adapter be-
with hydraulic oil. Install the O-rings between con- tween the steering control unit and hydraulic gear pump.
trol valve section and SCU.
5. Remove all caps and plugs from the control valve
4. Position the SCU under the steering shaft and and hose fittings. Connect hydraulic hoses to the
raise the SCU to engage the steering shaft. When control valve as noted during removal.
the steering shaft is completely engaged, position
the SCU against the main control valve, and install See Figure 56 for lift truck models without OPS:
two mounting capscrews and washers. Tighten to • GC/GLC030VX, GC/GLC035VX,
45-55 N•m (33-41 lbf ft). GC/GLC040SVX (C809)
See Figure 31 for lift truck models without OPS: GLP/GDP20SVX (GP/GLP/GDP030VX,
• GC/GLC030VX, GC/GLC035VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
GC/GLC040SVX (C809) (C810)
• GLP/GDP16VX, GLP/GDP18VX, • GLC20-35VX (GC/GLC040-070VX,
GLP/GDP20SVX (GP/GLP/GDP030VX, GC/GLC055SVX) (A910)
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(C810) (B875)
• 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,
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
100, 120VX; GC/GLC080, 100VXBCS; GDP080, 090, 100, 110, 120VX) (F813, G813)
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, Figure 57 for lift truck models without OPS:
GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/
GDP080, 090, 100, 110, 120VX) (F813, G813) GDC135VX, GC/GLC/GDC155VX) (C879,
D879)
See Figure 32 for lift truck models without OPS: • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
• GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ GDP135VX, GP/GLP/GDP155VX) (C878, D878)
D879) See Figure 58
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ • For lift trucks equipped with OPS.


2. SCU MOUNTING CAPSCREWS 7. TILT HOSE
5. HYDRAULIC INLET HOSE 10. RETURN HOSE
Figure 56. Hydraulic Hose Installation, Manual Control Valve Without OPS, Lift Truck Models
110, 120VX) (F813, G813)

1. STEERING SYSTEM HOSES 6. TILT HOSE

2. SCU MOUNTING CAPSCREWS 7. AUXILIARY I HOSE
3. STEERING CONTROL UNIT (SCU) 8. AUXILIARY II HOSE
4. STEERING COLUMN 9. RETURN HOSE
5. MID INLET HYDRAULIC HOSE (MAIN PUMP 10. LIFT/LOWER HOSE
HOSE)
Figure 57. Hydraulic Hose Installation, Manual Control Valve Without OPS, Lift Truck Models
GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) and GLP/GDP60VX,
GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878)

1. STEERING SYSTEM HOSES 6. AUXILIARY I HOSE
2. SCU MOUNTING CAPSCREW 7. AUXILIARY II HOSE
3. STEERING CONTROL UNIT (SCU) 8. RETURN HOSE
4. STEERING COLUMN 9. LIFT/LOWER HOSE
5. TILT HOSE 10. HYDRAULIC INLET HOSE
Figure 58. Hydraulic Hose Installation - Manual Control Valve With OPS

6. Apply adhesive compound, Yale Part No. 7. Using three capscrews, mount the hydraulic lever
501702904, to the three mounting capscrews. assembly to the cowl. Install the rods into the valve
Using the three capscrews that hold the throttle section spool clevis. Install the rod end pins and
base to the cowl, install the pedal assembly on the lock ring cotter pins. See Figure 34.
lift truck. Connect the cowl wiring harness to the
pedal assembly wiring harness. Tighten the bolts 8. Install the dashboard, seal plate, kick panel, and
to 19 to 25 N•m (168 to 221 lbf in). See Figure 59. floor plate.

GC/GLC040SVX (C809)
(C810)
(B875)

100, 120VX; GC/GLC080, 100VXBCS;
GDP080, 090, 100, 110, 120VX) (F813, G813)

D879)

NOTE: ACCELERATOR PEDAL NOT SHOWN, HOW- • GLP/GDP80VX, GLP/GDP80VX9,
EVER, INSTALL IS THE SAME. GLP/GDP90VX (GDP170VX, GDP175VX36,
GDP190VX) (A909)
1. MOUNTING CAPSCREWS
2. FOOT DIRECTIONAL CONTROL PEDAL See Frame 100 YRM 1423 for lift truck models
ASSEMBLY • GLC050LX (A967)
3. PEDAL ASSEMBLY WIRING HARNESS • GLP050LX (A974)
Figure 59. Foot Directional Control Pedal Install

Pressure Relief Valve Check and Adjustment 2000 YRM 1137
Pressure Relief Valve Check and Adjustment

NOTE: The main control valve has two relief valves: a • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX
primary relief valve and a secondary relief valve. The (GP/GLP/GDP030VX, GP/GLP/GDP035VX,
primary relief valve is in the inlet section of the control GP/GLP/GDP040SVX) (C810)
valve. The secondary relief valve is in the outlet section • GLC20-35VX (GC/GLC040-070VX,
of the control valve. If lift truck is equipped with a elec- GC/GLC055SVX) (A910)
tro-hydraulic control valve: • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875)
See Figure 2 for lift truck models: • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100,
• GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX;
(C809) GC/GLC120VXPRS) (E818)
• GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
(GP/GLP/GDP030VX, GP/GLP/GDP035VX, GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080,
GP/GLP/GDP040SVX) (C810) 090, 100, 110, 120VX) (F813, G813)
GC/GLC055SVX) (A910) See Figure 32 for lift truck models without OPS:
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/
(B875) GDC135VX, GC/GLC/GDC155VX) (C879, D879)
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GDP135VX, GP/GLP/GDP155VX) (C878, D878)
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ See Figure 33:
GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, • For lift truck models with OPS
090, 100, 110, 120VX) (F813, G813)
PRIMARY RELIEF VALVE
• GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ WARNING
GDC135VX, GC/GLC/GDC155VX) (C879, D879) Never allow anyone under a raised carriage. Do not
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ put any part of your body in or through the lift mech-
GDP135VX, GP/GLP/GDP155VX) (C878, D878) anism unless all parts of the mast are completely
See Figure 4 for lift truck models listed below equipped lowered and the key switch is OFF.
with anti-stall solenoid 1. Remove cap from EF port. If lift truck is equipped
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, with a electro-hydraulic control valve.
GC/GLC120VXPRS) (E818) See Figure 2 for lift truck models:
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ • GC/GLC030VX, GC/GLC035VX,
GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, GC/GLC040SVX (C809)
090, 100, 110, 120VX) (F813, G813) • GLP/GDP16VX, GLP/GDP18VX,
• GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GLP/GDP20SVX (GP/GLP/GDP030VX,
GDC135VX, GC/GLC/GDC155VX) (D879) GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ (C810)
GDP135VX, GP/GLP/GDP155VX) (D878) • GLC20-35VX (GC/GLC040-070VX,
• GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (B875)
(GDP170VX, GDP175VX36, GDP190VX) (A909) • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
If lift truck is equipped with a manual control valve, 100, 120VX; GC/GLC080, 100VXBCS;
See Figure 31 for lift truck models without OPS: • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
• GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
(C809) GDP080, 090, 100, 110, 120VX) (F813, G813)

2000 YRM 1137 Pressure Relief Valve Check and Adjustment

• GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ (B875)
GDC135VX, GC/GLC/GDC155VX) (C879, • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
D879) 100, 120VX; GC/GLC080, 100VXBCS;
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GC/GLC120SVX; GC/GLC120VXPRS) (E818)
GDP135VX, GP/GLP/GDP155VX) (C878, D878) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
If lift truck is equipped with a manual control valve, GDP080, 090, 100, 110, 120VX) (F813, G813)
See Figure 31 for lift truck models without OPS: See Figure 22 for lift truck models:
(C810)
• GLC20-35VX (GC/GLC040-070VX, For lift trucks equipped with a manual control valve,
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) See Figure 50 for lift truck models without OPS:
(B875) • 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) • GLC20-35VX (GC/GLC040-070VX,
See Figure 32 for lift truck models without OPS: • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
• GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ (B875)
GDC135VX, GC/GLC/GDC155VX) (C879, • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
D879) 100, 120VX; GC/GLC080, 100VXBCS;
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GC/GLC120SVX; GC/GLC120VXPRS) (E818)
GDP135VX, GP/GLP/GDP155VX) (C878, D878) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
See Figure 33: GDP080, 090, 100, 110, 120VX) (F813, G813)
• For lift truck models with OPS.
Install a 24 MPa (3500 psi) pressure gauge into the • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/
EF port. GDC135VX, GC/GLC/GDC155VX) (C879,
D879)
2. Loosen lock nut. For lift truck equipped with an
electro-hydraulic control valve.
See Figure 52
GC/GLC040SVX (C809)
• GLP/GDP16VX, GLP/GDP18VX, 3. Operate the hydraulic system to warm the oil tem-
GLP/GDP20SVX (GP/GLP/GDP030VX, perature to 50 to 65°C (122 to 149°F).
(C810)

opens. Turn the adjustment screw, as necessary,

CAUTION to change the setting. See Table 1 for the correct
During this test, the mast must be fully extended. relief valve setting for your lift truck model. Tighten
Make sure there is enough overhead clearance in the jam nut when the adjustment is correct.
the building, or do the test outdoors.
5. Remove the gauge when the checks are complete.
4. Raise the mast until it stops. Hold the lever and
check the reading of the gauge when the relief valve
Table 1. Relief Valve Settings
Truck Model Primary Relief Valve Setting Secondary Relief Valve Setting
GC/GLC030VX, GC/GLC035VX, 19.30 ±0.48 MPa (2800 ±70 psi) 15.90 ±0.48 MPa (2306 ±70 psi)
GC/GLC040SVX (C809),
GLP/GDP16VX, GLP/GDP18VX,
GLP/GDP20SVX (GP/GLP/
GDP030VX, GP/GLP/GDP035VX,
GLC20-30VX (GC/GLC040- 21.37 ±0.48 MPa (3099 ±70 psi) 15.51 ±0.48 MPa (2250 ±70 psi)
060VX, GC/GLC055SVX)
(A910), GLP/GDP20-30VX
(GP/GLP/GDP040-060VX) (B875),
GLC050LX (A967), GLP050LX
(A974)
GLC35VX (GC/GLC070VX) 23.44 ±0.48 MPa (3400 ±70 psi) 15.51 ±0.48 MPa (2250 ±70 psi)
(A910), GLP/GDP35VX
(GP/GLP/GDP070VX) (B875)
GLC40, 45, 55VX; 22.10 ±0.48 MPa (3205 ±70 psi) 15.51 ±0.48 MPa (2250 ±70 psi)
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)
GLC/GDC60VX, GLC/GDC70VX 22.10 ±0.48 MPa (3205 ±70 psi) 15.51 ±0.48 MPa (2250 ±70 psi)
(GC/GLC/GDC135VX,
GC/GLC/GDC155VX) (C879,
D879) and GLP/GDP60VX, GLP/
GDP70VX (GP/GLP/GDP135VX,
GP/GLP/GDP155VX) (C878, D878)
GLP/GDP80VX, GLP/GDP80VX9, 22.10 ±0.48 MPa (3205 ±70 psi) 17.2 ±0.50 MPa (2500 ±70 psi)
GLP/GDP90VX (GDP170VX,
GDP175VX36, GDP190VX) (A909)

SECONDARY RELIEF VALVE • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,

100, 120VX; GC/GLC080, 100VXBCS;
1. Remove cap from EF port. If lift truck is equipped GC/GLC120SVX; GC/GLC120VXPRS) (E818)
with a electro-hydraulic control valve, • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GDP080, 090, 100, 110, 120VX) (F813, G813)
GC/GLC040SVX (C809) See Figure 32 for lift truck models without OPS:
• GLP/GDP16VX, GLP/GDP18VX, • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/
GLP/GDP20SVX (GP/GLP/GDP030VX, GDC135VX, GC/GLC/GDC155VX) (C879,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) D879)
(C810) • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
• GLC20-35VX (GC/GLC040-070VX, GDP135VX, GP/GLP/GDP155VX) (C878, D878)
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) See Figure 33
(B875) • For lift trucks with OPS.
100, 120VX; GC/GLC080, 100VXBCS; Install a 24 MPa (3500 psi) pressure gauge into the
GC/GLC120SVX; GC/GLC120VXPRS) (E818) EF port.
2. Loosen jam nut. For lift truck equipped with an elec-
tro-hydraulic control valve, see Figure 60.
GDP080, 090, 100, 110, 120VX) (F813, G813)
For lift trucks equipped with a manual control valve,
• GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ See Figure 61
GDC135VX, GC/GLC/GDC155VX) (C879, • For lift trucks without OPS.
D879)
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ See Figure 62
GDP135VX, GP/GLP/GDP155VX) (C878, D878) • For lift trucks with OPS.
If lift truck is equipped with a manual control valve, 3. Operate the hydraulic system to warm the oil tem-
perature to 50 to 65°C (122 to 149°F).
• GC/GLC030VX, GC/GLC035VX, 4. Tilt the mast until it stops. Hold the lever and check
GC/GLC040SVX (C809) the reading of the gauge when the relief valve
• GLP/GDP16VX, GLP/GDP18VX, opens. Turn the adjustment screw, as necessary,
GLP/GDP20SVX (GP/GLP/GDP030VX, to change the setting. See Table 1 for the correct
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) relief valve setting for your lift truck model. Tighten
(C810) the jam nut when the adjustment is correct.
GC/GLC055SVX) (A910) 5. Remove the gauge when the checks are complete.
(B875)

Figure 60. Secondary Relief Valve, Electro-Hydraulic Main Control Valve

NOTE: SECONDARY RELIEF VALVE ASSEMBLY IS THE SAME FOR BOTH OUTLET SECTIONS COVERED IN
FIGURE 60.
A. OUTLET SECTION USED ON LIFT TRUCK MODEL COVERED IN THIS SERVICE MANUAL THAT ARE
EQUIPPED WITH AN ANTI-STALL PORT ON OUTLET SECTION.
B. OUTLET SECTION USED ON LIFT TRUCK MODELS, EXCEPT GLP/GDP80VX, GLP/GDP80VX9,
GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909), COVERED IN THIS SERVICE MANUAL
THAT ARE NOT EQUIPPED WITH AN ANTI-STALL PORT ON OUTLET SECTION.
1. O-RING 8. SPRING
2. PLUG 9. JAM NUT
3. OUTLET VALVE SECTION 10. ADJUSTING NUT
4. BACKUP RING 11. CONTROL VALVE TIE ROD
5. SECONDARY RELIEF VALVE PLUG 12. NUT
6. POPPET 13. ANTI-STALL PORT
7. WASHER 14. SECONDARY RELIEF VALVE ASSEMBLY

1. O-RING 7. WASHER
2. PLUG 8. SPRING
3. OUTLET VALVE SECTION 9. JAM NUT
4. BACKUP RING 10. ADJUSTING NUT
5. SECONDARY RELIEF VALVE PLUG 11. CONTROL VALVE TIE ROD
6. POPPET 12. NUT
Figure 61. Secondary Relief Valve, Manual Hydraulic Main Control Valve Without OPS

1. PLUG 8. POPPET
2. O-RING 9. SECONDARY RELIEF VALVE PLUG
3. BACKUP RING 10. SECONDARY RELIEF VALVE ASSEMBLY
4. ADJUSTING NUT 11. OUTLET VALVE SECTION
5. JAM NUT 12. NUT
6. SPRING 13. CONTROL VALVE TIE ROD
7. WASHER
Figure 62. Secondary Relief Valve, Manual Hydraulic Main Control Valve With OPS

Steering Control Unit Repair 2000 YRM 1137
Steering Control Unit Repair

STEERING CONTROL UNIT, REMOVE • GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/
D879)
WARNING
Lower carriage completely before working on con- See Frame 100 YRM 1321 for lift truck models
trol valve or hydraulic system. Do not work under • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
a raised carriage. Put mast in a vertical position GDP135VX, GP/GLP/GDP155VX) (C878, D878)
and lower carriage completely before disconnect- • GLP/GDP80VX, GLP/GDP80VX9,
ing any parts of hydraulic system. The mast can GLP/GDP90VX (GDP170VX, GDP175VX36,
lower suddenly and cause injury if the carriage is GDP190VX) (A909)
not lowered.
1. Power wash the interior of the operator compart- • GLC050LX (A967)
ment to remove any dirt or debris. • GLP050LX (A974)
2. Move truck to disassembly area and shut off engine.
CAUTION
WARNING To prevent any foreign matter from getting into
either the hydraulic hoses or the hydraulic control
valve sections, all openings must have plugs or
cause skin irritation. When cleaning solvents are
covers installed immediately after hoses are dis-
used, always follow the solvent manufacturer’s
connected from the control valve. This also applies
recommended safety procedures. Wear protective
if any other items are removed from the control
goggles or a face shield to prevent eye injuries.
valve.
NOTE: Take any necessary steps to prevent debris,
dust, or other contaminants from entering the valve cav-
GDP040-070VX) (B875) may be equipped with an op-
ities, hydraulic lines, or replacement parts.
tional Quick-Lok™ hydraulic inlet hose and adapter be-
3. Remove the floor plate, kick panel, seal plate, and tween the steering control unit and hydraulic gear pump.
dashboard.
NOTE: To aid in the correct connection of hydraulic
See Frame 100 YRM 1120 for lift truck models hoses during installation, tag each hose prior to discon-
• GC/GLC030VX, GC/GLC035VX, necting from the control valve.
GC/GLC040SVX (C809)
4. Disconnect hydraulic hoses from the steering con-
trol unit. Install plugs or caps on all open hose ends
and control valve ports to prevent contamination.
(C810) See Figure 63 for lift truck models:
• GLC20-35VX (GC/GLC040-070VX, • GC/GLC030VX, GC/GLC035VX,
GC/GLC055SVX) (A910) GC/GLC040SVX (C809)
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) • GLP/GDP16VX, GLP/GDP18VX,
(B875) GLP/GDP20SVX (GP/GLP/GDP030VX,
(C810)
100, 120VX; GC/GLC080, 100VXBCS;
(B875)
GDP080, 090, 100, 110, 120VX) (F813, G813)
100, 120VX; GC/GLC080, 100VXBCS;
See Frame 100 YRM 1316 for lift truck models GC/GLC120SVX; GC/GLC120VXPRS) (E818)

2000 YRM 1137 Steering Control Unit Repair
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/

GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878)
GDP080, 090, 100, 110, 120VX) (F813, G813) • GLP/GDP80VX, GLP/GDP80VX9,
See Figure 64 for lift truck models: GDP190VX) (A909)
D879)
Figure 63. Steering Control Unit, Lift Truck Models GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX

NOTE: ELECTRO-HYDRAULIC MAIN CONTROL VALVE SHOWN. LIFT TRUCK MODELS GLC050LX (A967) AND
GLP050LX (A974) EQUIPPED WITH MANUAL MAIN CONTROL VALVE ONLY, BUT REPAIR OF STEERING CON-
TROL UNIT IS THE SAME.
1. "L" STEERING SYSTEM HOSE 4. SCU MOUNTING CAPSCREWS
2. "R" STEERING SYSTEM HOSE 5. STEERING CONTROL UNIT (SCU)
3. HYDRAULIC INLET HOSE 6. STEERING COLUMN
1. "R" STEERING SYSTEM HOSE 4. STEERING COLUMN

2. "L" STEERING SYSTEM HOSE 5. SCU MOUNTING CAPSCREWS
3. STEERING CONTROL UNIT (SCU) 6. HYDRAULIC INLET HOSE
Figure 64. Steering Control Unit, Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX,
GC/GLC/GDC155VX) (C879, D879), GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX,
GP/GLP/GDP155VX) (C878, D878), and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX,
GDP175VX36, GDP190VX) (A909)
5. Remove the two SCU mounting bolts and move • GLP/GDP16VX, GLP/GDP18VX,
the SCU approximately 1.3 cm (0.5 in.) to the left, GLP/GDP20SVX (GP/GLP/GDP030VX,
and lower the SCU until the steering shaft is disen- GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
gaged. Remove the SCU from the lift truck. (C810)
See Figure 63 for lift truck models: GC/GLC055SVX) (A910)
• GC/GLC030VX, GC/GLC035VX, • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
GC/GLC040SVX (C809) (B875)

• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 7. Coat the machined surface of the main control valve
100, 120VX; GC/GLC080, 100VXBCS; with a light coat of hydraulic oil to prevent the possi-
GC/GLC120SVX; GC/GLC120VXPRS) (E818) bility of rust. Cover the exposed machined surface
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, of the main control valve to prevent the possibility
GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ of foreign matter getting into the main control valve.
GDP080, 090, 100, 110, 120VX) (F813, G813)
STEERING CONTROL UNIT,
See Figure 64 for lift truck models: DISASSEMBLE
GDC135VX, GC/GLC/GDC155VX) (C879, 1. Place the steering pump into a soft-jaw vise with the
D879) splined end facing down.
GDP135VX, GP/GLP/GDP155VX) (C878, D878) NOTE: Note the position of the special screws when
• GLP/GDP80VX, GLP/GDP80VX9, removed, so that they will be installed in the same po-
GLP/GDP90VX (GDP170VX, GDP175VX36, sitions at assembly of the steering control unit.
GDP190VX) (A909)
2. Remove the capscrews, special screws, and wash-
6. Remove and discard two O-rings from between the ers. Rotate the steering pump 90 degrees sideways
SCU and the main control valve. in the vise. See Figure 65.
Figure 65. Steering Control Unit


1. CAPSCREW 15. THRUST WASHER
2. SPECIAL SCREW 16. THRUST BEARING
3. WASHER 17. SEAL
4. END COVER 18. EMERGENCY STEER SEAT
5. O-RING 19. EMERGENCY STEER CHECK BALL
6. GEAR RING 20. STEERING CONTROL UNIT HOUSING
7. GEAR 21. SYSTEM RELIEF VALVE
8. DISTRIBUTOR PLATE 22. CAP
9. CARDAN SHAFT 23. MOUNTING BOLT
10. SPRING SET 24. LOCKWASHER
11. SLEEVE 25. LOAD SENSE PLUG
12. CROSS PIN 26. LOAD SENSE CHECK BALL
13. SPOOL 27. LOAD SENSE SEAT
14. RETAINING RING
3. Remove the end cover, O-ring, gear ring, O-ring, needs to be repaired, go to Relief Valve, Disas-
gear, distributor plate, and O-ring from the steering semble.
control unit. Discard the O-rings.
STEERING CONTROL UNIT, CLEAN
4. Remove the cardan shaft from the spool assembly.
5. Remove the spool assembly from the steering con- WARNING

trol unit housing. Cleaning solvents can be flammable and toxic and
6. Remove the thrust washer, thrust bearing, and solvents, always follow the solvent manufacturer’s
thrust washer from the shaft end of the spool as- recommended safety precautions.
sembly.
7. Remove the retaining ring from the spool assembly. WARNING

Compressed air can move particles so that they
8. Press the cross pin out of the spool assembly. cause injury to the user or to other personnel.
9. Press the spool from the sleeve. Remove the Make sure that the path of the compressed air is
springs from the spool. away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.
NOTE: To aid in installation of the emergency steering
seat and emergency steering check ball, note the hole Clean all the parts in solvent. Dry the parts with com-
position of the emergency steering seat and emergency pressed air. Do not dry the parts with a cloth. Make sure
steering check ball during removal. all surfaces are free of scratches and sharp edges.
10. Remove the emergency steering seat and emer- STEERING CONTROL UNIT, INSPECT
gency steering check ball from the steering control
Inspect all parts for damage, if any parts other than
unit housing.
those parts contained in parts kits Yale 580054569 (seal
NOTE: To aid in installation of the load sense check ball kit) or Yale P/N 58006021 (capscrew kit) are damaged,
and seat, note the hole position of the load sense seat replace the steering control unit. If the Steering control
and load sense check ball during removal. unit is not going to be installed on the main control valve
immediately, coat the machined mating surface with a
11. Remove the load sense seat and load sense check light coat of hydraulic oil and install plugs in any open
ball from the steering control unit. ports to prevent the possibility of any foreign matter get-
ting into the steering control unit.
12. Remove the shaft seals from the pump housing.
Discard the seals.
13. Remove the cap and system relief valve from the
steering control unit. If the system relief valve

STEERING CONTROL UNIT, ASSEMBLE 14. Install new O-ring, gear, and new O-ring onto the
gear ring and install the gear ring onto the distrib-
NOTE: Apply a light coat of clean hydraulic oil to O-rings utor plate, making sure that the holes are properly
and seals to assist in installation. aligned.
1. Using a seal installer, install the shaft seals in the 15. Install a new O-ring onto the gear ring. Install end
steering control unit housing. cover, special capscrews, and washers as noted
during disassembly. Tighten all capscrews to 30
2. Install the spool into the sleeve with the key slots
±6 N•m (265 ±53 lbf in).
opposite each other. See Figure 65.
16. If removed, install the system relief valve. Place
3. Insert the curved springs between the flat springs.
the torque tool in the notches on the cartridge
NOTE: The retaining ring must be able to rotate unim- body (see Figure 66). Tighten to 18 ±6 N•m (160
peded by the springs. ±53 lbf in). Install the tamper proof cap into the
steering control unit housing.
4. Center the springs in the spool assembly, and install
the retaining ring over the springs. RELIEF VALVE, DISASSEMBLE
5. Install the cross pin into the spool assembly. 1. Remove the snap ring and anti-tamper ring from the
cartridge body. See Figure 66.
6. Install the thrust washer, thrust bearing, and thrust
washer on the spool. NOTE: Note the number of turns to remove plug from
cartridge body to aid in installation.
7. Place the pump housing in a soft-jawed vise in the
horizontal position. Install the spool assembly into 2. Remove the plug, spring, and seat from the car-
the housing while holding the cross pin in a hori- tridge body.
zontal position.
3. Remove and discard small O-ring, backup ring, and
8. With the pump housing still in the horizontal posi- large O-ring from the cartridge body.
tion, install the spool so that the pin in the spool
is in the horizontal position. When the spool is in-
stalled rotate the steering control unit to the vertical
position.
9. Install the emergency steering check ball, and

emergency steering seat in the steering control
unit housing as noted during removal. Tighten
the emergency steering seat to 1.5 ±0.3 N•m (13
±2.5 lbf in).
10. Install the load sense check ball and load sense
seat in the steering control unit as noted during re-
moval. Tighten the load sense seat to 1.5 ±0.3 N•m
(13 ±2.5 lbf in).
11. Install a new O-ring on the steering control unit

housing, and place the distributor plate on the 1. SNAP RING 5. SEAT
steering control unit housing, with the holes prop- 2. ANTI-TAMPER 6. CARTRIDGE BODY
RING 7. O-RING
erly aligned with the steering control unit housing. 3. PLUG 8. BACKUP RING
4. SPRING
12. Install the cardan shaft and rotate it until it is en-
gaged with the pin in the spool assembly. Figure 66. System Relief Valve
13. Install the gear ring onto the cardan shaft.

RELIEF VALVE, CLEAN STEERING CONTROL UNIT, INSTALL

1. Coat the two O-rings to be installed on the main
WARNING control valve with clean hydraulic oil. Install the
Cleaning solvents can be flammable and toxic and two O-rings between the main control valve and the
can cause skin irritation. When using cleaning SCU.
recommended safety precautions. NOTE: During the performance of Step 2, use care not
to damage the O-rings on the main control valve.
WARNING 2. Position the SCU under the steering shaft and raise
Compressed air can move particles so that they the SCU to completely engage the steering shaft.
cause injury to the user or to other personnel. When the steering shaft is completely engaged,
Make sure that the path of the compressed air is position the SCU against the main control valve,
away from all personnel. Wear protective goggles and install two mounting capscrews and washers.
or a face shield to prevent injury to the eyes. Tighten to 45 to 55 N•m (33 to 41 lbf ft).
Clean all the parts in solvent. Dry the parts with com- NOTE: Lift truck models GLP/GDP20-35VX (GP/GLP/
pressed air. Do not dry the parts with a cloth. Make sure GDP040-070VX) (B875) may be equipped with an op-
all surfaces are free of scratches and sharp edges. tional Quick-Lok™ hydraulic inlet hose and adapter be-
tween the steering control unit and hydraulic gear pump.
RELIEF VALVE, INSPECT
3. Remove all plugs and caps and install the hydraulic
Inspect all parts for damage, if any parts other than hoses as noted during removal.
those parts contained in parts kits Yale P/N 580054569
(seal kit) are damaged, replace the relief valve. If the 4. Install dashboard, seal plate, kick panel, and floor
relief valve is not going to be installed in the steering plate.
control housing immediately, coat the valve with a light
coat of hydraulic oil. See Frame 100 YRM 1120 for lift truck models
RELIEF VALVE, ASSEMBLE GC/GLC040SVX (C809)
NOTE: Apply a light coat of clean hydraulic oil to O-rings GLP/GDP20SVX (GP/GLP/GDP030VX,
and seals to assist in installation. GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810)
1. Install the large O-ring, backup ring, and small • GLC20-35VX (GC/GLC040-070VX,
O-ring on the cartridge body. See Figure 66. GC/GLC055SVX) (A910)
2. Install the seat and spring into the cartridge body.
(B875)
3. Install plug the number of turns noted during disas-
sembly.
4. Install the anti-tamper ring and snap ring into the 100, 120VX; GC/GLC080, 100VXBCS;
cartridge body. GC/GLC120SVX; GC/GLC120VXPRS) (E818)
5. Install the system relief valve into steering control GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/
unit housing. Place the torque tool in the notches GDP080, 090, 100, 110, 120VX) (F813, G813)
on the cartridge body (see Figure 66). Tighten to 18
±6 N•m (160 ±53 lbf in). Install the cap onto system
relief valve. See Figure 65.

See Frame 100 YRM 1316 for lift truck models See Frame 100 YRM 1423 for lift truck models
• GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/ • GLC050LX (A967)
GDC135VX, GC/GLC/GDC155VX) (C879, • GLP050LX (A974)
D879)
5. Check the steering relief pressure. See Table 2.
See Frame 100 YRM 1321 for lift truck models If the steering relief pressure is not correct, adjust
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ the pressure by turning the plug clockwise (in-
GDP135VX, GP/GLP/GDP155VX) (C878, D878) crease pressure) or counterclockwise (decrease
• GLP/GDP80VX, GLP/GDP80VX9, pressure) until the correct pressure is reached.
GLP/GDP90VX (GDP170VX, GDP175VX36, See Figure 66.
GDP190VX) (A909)
Table 2. Steering Relief Pressures
Lift Truck Model Steering Relief Pressure @ 800 RPM

GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX 7.25 ±0.3 MPa (1051 ±43.5 psi)
(C809) and GLP/GDP16VX, GLP/GDP18VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810)
GLC20-30VX (GC/GLC040-060VX, GC/GLC055SVX) 11.0 ±0.3 MPa (1595 ±43.5 psi)
(A910) and GLP/GDP20-30VX (GP/GLP/GDP040-
060VX) (B875), GLC050LX (A967), GLP050LX (A974)
GLC35VX (GC/GLC070VX) (A910) and 12.0 ±0.3 MPa (1740 ±43.5 psi)
GLP/GDP35VX (GP/GLP/GDP070VX) (B875)
GLC40, 45, 55VX; GLC55SVX (GC/GLC080, 100, 10.3 ±0.3 MPa (1494 ±43.5 psi)
GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ 12.4 ±0.3 MPa (1798 ±43.5 psi)
090, 100, 110, 120VX) (F813, G813)
GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ 12.4 ±0.3 MPa (1798 ±43.5 psi)
GDC135VX, GC/GLC/GDC155VX) (C879, D879) and
GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX,
GP/GLP/GDP155VX) (C878, D878)
GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX 15.5 ±0.3 MPa (2250 ±43.5 psi)

NOTES
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
108
Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011
2000 YRM 1137 6/11 (5/10)(4/09)(2/09)(7/08)(2/08)(10/07)(6/07)(4/07)(3/07)(6/06)(3/06) Printed in U.S.A.

Main Control Valve: Maintenance

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Main Control Valve: Maintenance

Uploaded by

Copyright:

Available Formats

Maintenance

MAIN CONTROL VALVE

PART NO. 524223767 2000 YRM 1137

• 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.

©2011 Yale Materials Handling Corp. i

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

NOTE: Lift truck models GLC050LX (A967) and

NOTE: MAJOR COMPONENTS NOT SHOWN FOR

Figure 1. Main Control Valve Mounting, Typical

Confidential/Proprietary - Do Not Copy or Duplicate 1

Electro-Hydraulic Main Control Valve

See Figure 4 for lift truck models below, equipped with

2 Confidential/Proprietary - Do Not Copy or Duplicate

1. STEERING CONTROL UNIT (SCU) 7. AUXILIARY I SECTION

Confidential/Proprietary - Do Not Copy or Duplicate 3

1. STEERING CONTROL UNIT (SCU) 7. AUXILIARY I SECTION

4 Confidential/Proprietary - Do Not Copy or Duplicate

1. STEERING CONTROL UNIT (SCU) 7. TILT SECTION

Confidential/Proprietary - Do Not Copy or Duplicate 5

1. STEERING CONTROL UNIT (SCU) 8. AUXILIARY I SECTION

6 Confidential/Proprietary - Do Not Copy or Duplicate

1. STEERING CONTROL UNIT (SCU) 7. AUXILIARY I SECTION

Confidential/Proprietary - Do Not Copy or Duplicate 7

1. STEERING CONTROL UNIT (SCU) 7. AUXILIARY I SECTION

REMOVE NOTE: Most of the individual valve components can

8 Confidential/Proprietary - Do Not Copy or Duplicate

NOTE: Take all necessary steps to prevent debris, dust,

3. Remove the floor plate, kick panel, seal plate, and

See Frame 100 YRM 1120 for lift truck models

See Frame 100 YRM 1243 for lift truck models

Confidential/Proprietary - Do Not Copy or Duplicate 9

10 Confidential/Proprietary - Do Not Copy or Duplicate

NOTE: HARNESS CONNECTORS FOR GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/

Confidential/Proprietary - Do Not Copy or Duplicate 11

NOTE: QUICK-LOK™ HYDRAULIC INLET HOSE AND ADAPTER NOT SHOWN.

12 Confidential/Proprietary - Do Not Copy or Duplicate

See Figure 3 for lift truck models:

See Figure 4 for lift truck models:

See Figure 5 for the following lift truck models:

Confidential/Proprietary - Do Not Copy or Duplicate 13

ELECTRO-HYDRAULIC CONTROL VALVE

Disassemble the electro-hydraulic control valve only as

14 Confidential/Proprietary - Do Not Copy or Duplicate

Figure 13. Outlet Control Valve Section

Confidential/Proprietary - Do Not Copy or Duplicate 15

Legend for Figure 13

NOTE: While performing Step 7, count and note the Inspect

16 Confidential/Proprietary - Do Not Copy or Duplicate

1. Remove the outlet control valve section. See Outlet

NOTE: Step 2 and Step 3 are for a three-function control

NOTE: If lift truck is equipped with either an anti-stall

Confidential/Proprietary - Do Not Copy or Duplicate 17

18 Confidential/Proprietary - Do Not Copy or Duplicate

Confidential/Proprietary - Do Not Copy or Duplicate 19

20 Confidential/Proprietary - Do Not Copy or Duplicate

Legend for Figure 15

Confidential/Proprietary - Do Not Copy or Duplicate 21

22 Confidential/Proprietary - Do Not Copy or Duplicate