ring Control Unit Repair Stee! STEERING CONTROL UNIT, REMOVE & warnine 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 and lower carriage completely before disconnect- ing any parts of hydraulic system. The mast can lower suddenly and cause injury if the carriage is not lowered. 4. Power wash the interior of the operator compart- ‘ment to remove any dirt or debris. 2. Move truck to disassembly area and shut off engine. & warnine Cleaning solvents can be flammable and toxic and cause skin iritation. When cleaning solvents are teed, always follow the solvent manufacturer's recommended safety procedures, Wear protective Goggles ot a face shield te prevent aye injuries, NOTE: Take any necessary steps to prevent debris, dust, or other contaminants from entering the valve cav- ities, hydraulic lines, or replacement parts. 3. Remove the floor plate, kick panel, seal plate, and dashboard. ‘Soe Frame 100 YRM 1120 for lft truck models + GCIGLCO30VX, GCIGLCO35VX GCIGLCO40SVx (C809) + GLPIGDP16VX, GLP/GDP18Vx, GLP/GDP20SVX (GP/GLP/GDPO30Vx GPIGLP/GDPO35VX, GP/GLP/GDPO40SVX) (c810) + GLC20-38VX (GCIGLC040-070VX, GCIGLCOSSSVX) (A910) + GLP/GDP20-35VX (GP/GLP/GDPO40-070VX) (8875) ‘See Frame 100 YRM 1243 for lift truck models + GLC40, 45, §5VX; GLOSSSVX; (GC/GLCO8O, 100, 120VX; GC/GLC080, 100VXBCS; GCIGLC120SVX; GC/GLC120VXPRS) (E818) + GLP/GDP40VXSIVX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GPIGLP/GDPO80, 090, 100, 110, 120VX) (F813, 6813) 78 g Control U: 2000 YRM 1137 Repair ‘See Frame 100 YRM 1316 for lft truck models + GLCIGDC6OVX, GLCIGDC70VX, (GC/GLO/ GDC135VX, GCIGLC/GDC155VX) (C873, 0879) ‘See Frame 100 YRM 1321 for lft truck models + GLP/GDP80VX, GLP/GDP70VX (GPIGLP/GDP135VX, GP/GLP/GDP155VX) (c878, D878) + GLP/GDP80VX, GLP/GDP8OVX9, GLPIGDP9OVX (GDP170VX, GDP175Vx36, GDP190VX) (A909) ‘See Frame 100 YRM 1423 for lft truck models. + GLCOSOLX (A967) + GLPOSOLX (A974) &\ caution To prevent any foreign matter from getting into either the hydraulic hoses or the hydraulic control valve sections, all openings must have plugs or covers installed immediately after hoses are dis- connected from the control valve. This also applies if any other items are removed from the control valve. NOTE: To aid in the correct connection of hydraulic, hoses during installation, tag each hose prior to discon- necting from the control valve. ‘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, See Figure 61 or Figure 62 Remove the two SCU mounting bolts and move the SCU approximately 1.3 om (0.5 in.) to the left, and lower the SCU unti the steering shaft is disen- gaged. Remove the SCU from the lift truck. See Figure 61 or Figure 62. 6. Remove and discard two O-rings from between the ‘SCU and the main control valve. 7. Coatthe machined surface of the main control valve with a light coat of hydraulic oil to prevent the possi- bility of rust. Cover the exposed machined surface of the main control valve to prevent the possibility of foreign matter getting into the main control vaive. Confidential/Proprietary - Do Not Copy or Dupli2000 YRM 1137 Steering Control Unit Repair NOTE: ELECTRO-HYDRAULIC MAIN CONTROL VALVE SHOWN. LIFT TRUCK MODELS GLCOSOLX (A967) AND GLPOSOLX (A974) EQUIPPED WITH MANUAL MAIN CONTROL VALVE ONLY, BUT REPAIR OF STEERING CON- TROL UNIT THE SAME. 1. "LY STEERING SYSTEM HOSE 4, SCU MOUNTING CAPSCREWS, 2. "RY STEERING SYSTEM HOSE 5. STEERING CONTROL UNIT (SCU) 3. HYDRAULIC INPUT HOSE 6. STEERING COLUMN Figure 61. Steering Control Unit, Lift Truck Models GCIGLCO30VX, GCIGLCO35VX, GCIGLCO40SVX (C809), GLPIGDP16VX, GLPIGDP18VX, GLPIGDP20SVX (GPIGLPIGDPO30VX, GPIGLPIGDPO35VX, GPIGLPIGDPO40SVX) (C810), GLC20-35VX (GCIGLC040-070VX, GCIGLCOSSSVX) (A910), GLPIGDP20-35VX (GPIGLPIGDP040-070VX) (B875), GLC40, 45, 55VX; GLCS5SVX; (GCIGLC080, 100, 120VX; GCIGLCO8O, 100VXBCS; GCIGLC120SVX; GCIGLC120VXPRS) (E818), GLPIGDP40VXSIVX6; GLPIGDP45SVX5, GLPIGDP45VX6, GLPIGDP50-55VX (GPIGLPIGDPO8O, 090, 100, 110, 120VX) (F813, G813) Confidenti liProprietary - Do Not Copy or Duplicate 79ring Control Unit Repair 2000 YRM 1137 " STEERING SYSTEM HOSE 4, STEERING COLUMN 2) "LY STEERING SYSTEM HOSE 5. SCU MOUNTING CAPSCREWS 3, STEERING CONTROL UNIT (SCU) 6. HYDRAULIC INPUT HOSE Figure 62. Steering Control Unit, Lift Truck Models GLCIGDCS0VX, GLCIGDC7OVX (GCIGLCIGDC135VX, GCIGLCIGDC155VX) (C879, D878), GLPIGDP60VX, GLPIGDP7OVX (GPIGLPIGDP135VX, GPIGLPIGDP155VX) (C878, D878), and GLPIGDP80VX, GLPIGDP80VX9, GLPIGDPSOVX (GDP170VX, GDP175VX36, GDP190VX) (A908) STEERING CONTROL UNIT, ‘4, Remove the cardan shaft from the spool assembly. DISASSEMBLE 5. Remove the spool assembly rom the steering con- 4. Place the steering pump into a softjaw vise with the trol unit housing splined end facing down 6. Remove the thrust washer, thrust bearing, and NOTE: Note the position of the special screws when thrust washer from the shaft end of the spool as- removed, so that they will be installed in the same po- sembly. sions at sssembly of the steering control unit 7. Remove the retaining ring from the spool assembly. 2. Remove the capscrews, special screws, andwash- B12. the cross pin out ofthe spool assembh ers. Rotate the steering pump 90 degrees sideways ress pin ou Ps mbly. in the vise. See Figure 63. 9. Press the spool from the sleeve. Remove the 3. Remove the end cover, O-ring, gear ring, O-ring, springs from the spool gear, distributor plate, and O-ring from the steering control unit, Discard the O-rings. 80 Confidential/Proprietary - Do Not Copy or Duplicate2000 YRM 1137 Steering Control Unit Repair 1. CAPSCREW 418. THRUST WASHER 2, SPECIAL SCREW 46. THRUST BEARING 3. WASHER 17. SEAL 4. END COVER 48. EMERGENCY STEER SEAT 5. O-RING 19. EMERGENCY STEER CHECK BALL 8 GEAR RING 20. STEERING CONTROL UNIT HOUSING 7. GEAR 21. SYSTEM RELIEF VALVE 8, DISTRIBUTOR PLATE 22. CAP 9. CARDAN SHAFT 23. MOUNTING BOLT 40. 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 Figure 63. Steering Control Unit NOTE: To aid in installation of the emergency steering 10. Remove the emergency steering seat and emer seat and emergency steering check ball, note the hole gency steering check ball from the steering control position of the emergency steering seat and emergency Unit housing steering check ball during removal. Confidenti liProprietary - Do Not Copy or Duplicate aSteering Control Unit Repair NOTE: To aid in installation of the load sense check ball and seat, note the hole position of the load sense seat and load sense check ball during removal. 11. Remove the load sense seat and load sense check ball from 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 needs to be repaired, go to Relief Valve, Disas- semble, STEERING CONTROL UNIT, CLEAN A warnine Cleaning selvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer's recommended safety precautions. A warnine Compressed air can move particles so that they cause injury to the user or to other personnel Make sure that the path of the compressed air Is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. Clean all the parts in solvent. Dry the parts with com- pressed air. Donot dry the parts with a cloth, Make sure all surfaces are free of scratches and sharp edges. STEERING CONTROL UNIT, INSPECT Inspect all parts for damage, if any parts other than those parts contained in parts kits Yale 580054569 (seal kit) or Yale PIN 58006021 (capscrew kit) are damaged, replace the steering control unit. If he Steering control Unit is not going to be installed on the main control valve immediately, coat the machined mating surface with a light coat of hydraulic oil and install plugs in any open ports to prevent the possibility of any foreign matter get- ting into the steering control unit. STEERING CONTROL UNIT, ASSEMBLE NOTE: Apply alight coat of clean hydraulic oilto O-rings. and seals to assist in installation, 4. Using a seal installer, install the shaft seals in the steering control unit housing. 82 2000 YRM 1137 2. Install the spool into the sleeve with the key slots opposite each other. See Figure 63, 3. Insert the curved springs between the flat springs. NOTE: The retaining ring must be able to rotate unim- eded by the springs. ‘4, Center the springs n the spool assembly, and install the retaining ring over the springs. 5. Install the cross pin into the spool assembly. 6. Install the thrust washer, thrust bearing, and thrust, washer on the spool 7. Place the pump housing in a soft jawed vise in the horizontal position. Install the spool assembly into the housing while holding the cross pin in a hori- zontal position. 8. With the pump housing stil in the horizontal posi- 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 40.3 Nem (13 #25 Ibf 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 Nem (13 42.5 Ibf in) 14. Install a new O-ring on the steering control unit housing, and place the distributor plate on the steering control unit housing, with the holes prop- erly aligned with the steering control unit housing. 12. Install the cardan shaft and rotate it until it is en- gaged with the pin in the spool assembly. 13. Install the gear ring onto the cardan shaft 14, Install new O-ring, gear, and new O-ring onto the gear ring and install the gear ring onto the distrib- Utor plate, making sure that the holes are properly aligned, 16. Install a new O-ring onto the gear ring. Install ond. cover, special capscrews, and washers as noted during disassembly. Tighten all capscrews to 30 46 Nem (265 253 lf in), Confidential/Proprietary - Do Not Copy or Duplicate2000 YRM 1137 16. If removed, install the system relief valve. Place the torque tool in the notches on the cartridge body (see Figure 64). Tighten to 18 +6 N-m (160 +453 Ibf in). Install the tamper proof cap into the steering control unit housing. RELIEF VALVE, DISASSEMBLE 41. Remove the snap ring and ant-tamperring from the cartridge body. See Figure 64. ig ™ $6 ° 4 By 4. SNAP RING 5. SEAT 2, ANTI-TAMPER 8 CARTRIDGE BODY RING 7. O-RING 3. PLUG. 8 BACKUP RING 4. SPRING Figure 64. System Relief Valve NOTE: Note the number of turns to remove plug from cartridge body to aid in installation. 2. Remove the plug, spring, and seat from the car- tridge body. 3. Remove and discard small O-ring, backup ring, and. large O-ring from the cartridge body. RELIEF VALVE, CLEAN & warnine Cleaning solvents can be flammable and toxic and can cause skin initation. When using cleaning solvents, always follow the selvent manufacturer's recommended safety precautions & warnine Compressed air can move particles so that they cause injury to the user of to other personnel Make sure that the path of the compressed ai Confidenti liProprietary - Do Not Copy or Duplicate Steering Control Unit Repair away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. Clean all the parts in solvent. Dry the parts with com- pressed alr. Donot dry the parts with a cloth. Make sure all surfaces are free of scratches and sharp edges. RELIEF VALVE, INSPECT Inspect all parts for damage, if any parts other than those parts contained in parts kits Yale P/N 580054569, {seal kit) are damaged, replace the relief valve. If the relief valve is not going to be installed in the steering control housing immediately, coat the valve with a light coat of hydraulic ol. RELIEF VALVE, ASSEMBLE NOTE: Apply a light coat of clean hydraulic oilto O-rings and seals to assist in installation. 1. Install the large O-ring, backup ring, and small O-ring on the cartridge body. See Figure 64. Install the seat and spring into the cartridge body. Install plug the number of turns noted during disas- sembly. 4. Install the anti-tamper ring and snap ring into the cartridge body. 5. Install the system relief valve into steering control Unit housing. Place the torque tool in the notches on the cartridge body (see Figure 64). Tighten to 18 +6 Nem (160 +53 [bf in). Install the cap onto system relief valve. See Figure 63, STEERING CONTROL UNIT, INSTALL 1. Coat the two O-rings to be installed on the main control valve with clean hydraulic oil. Install the ‘two O-rings between the main control valve and the cu NOTE: During the performance of Step 2, use care not, to damage the O-rings on the main control valve. 2. Position the SCU under the steering shaft and raise the SCU to completely engage the steering shaft. When the steering shaft is completely engaged, position the SCU against the main control valve, and install two mounting capscrews and washers. Tighten to 45 to 55 Nem (33 to 41 Ibf ft. 3. Remove all plugs and caps and install the hydraulic, hoses as noted during removal. 83ring Control Unit Repair 4, Install dashboard, seal plate, kick panel, and floor plate. ‘See Frame 100 YRM 1120 for lft truck models + GCIGLCO30VX, GC/GLCO35VX, GCIGLCO40SVX (C809) + GLP/GDP16VX, GLP/GDP18VXx, GLP/GDP208VX (GP/GLP/GDPO30VX, GPIGLP/GDPO35VX, GP/GLP/GDPO40SVX) (C810) + GLO20-35VX (GC/GLC040-070VX, GCIGLCOSSSVX) (A910) + GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (6875) ‘See Frame 100 YRM 1243 for lift truck models + GLC40, 45, 55VX; GLCSSSVX; (GCIGLC0BO, 100, 120VX; GC/GLCO80, 100VXBCS; GCIGLC120SVX; GC/GLC120VXPRS) (E818) + GLP/GDP40VXSIVX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDPS0-55VX (GPIGLP/GDPO80, 090, 100, 110, 120VX) (F813, G13) 2000 YRM 1137 ‘See Frame 100 YRM 1316 for lft truck models + GLCIGDC60VX, GLCIGDC70VX, (GC/GLC/ GDC135VX, GCIGLC/GDC155Vx) (C879, D879) See Frame 100 YRM 1321 for lift truck models + GLP/GDP6OVX, GLP/GDP70Vx (GPIGLP/GDP135VX, GP/GLP/GDP155VX) (c878, D878) + GLP/GDP8OVX, GLP/GDPEOVX9, GLP/GDP90VX (GDP170VX, GDP175Vx36, GDP190VX) (A809) ‘See Frame 100 YRM 1423 for lft truck models. + GLCOSOLX (A967) + GLPOSOLX (A974) 5. Check the steering relief pressure. See Table 2. If the steering relief pressure is not correct, adjust the pressure by turning the plug clockwise {in- crease pressure) or counterclockwise (decrease pressure) until the correct pressure is reached. See Figure 64. Table 2. Steering Relief Pressures Lift Truck Model Steering Relief Pressure @ 800 RPM GCIGLCO3OVX, GC/GLCO35VX, GC/GLCO40SVX (C809) and GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GPIGLP/GDPO35VX, GP/GLP/GDPO40SVX) (C810) 7.25 40.3 MPa (1051 243.5 psi) ‘GLC20-30VX (GC/GLC040-060VX, GC/GLCOSSSVX) (A910) and GLP/GDP20-30VX (GP/GLP/GDP040- 060VX) (8875), GL.COSOLX (A967), GLPOSOLX (A974) 11.0 20.3 MPa (1595 £43.5 psi) GLC35VX (GC/GLCO7OVX) (A910) and GLP/GDP35VX (GP/GLP/GDPO70VX) (8875) 12.0 £0.3 MPa (1740 +43.5 psi) GLC40, 45, SSVX; GLCSSSVX (GC/GLCO8O, 100, 120VX; GCIGLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) 10.3 20.3 MPa (1494 243.5 psi) GLP/GDP40VXS/VX6; GLP/GDP4SSVX5, GLP/ GDP45VX6, GLP/GDPS0-55VX (GP/GLP/GDPO80, (090, 100, 110, 120VX) (F813, G813) 12.4 20.3 MPa (1798 243.5 psi) GLCIGDO6OVX, GLCIGDC7OVX (GC/GLCY GDC135VX, GC/GLC/GDC155VX) (C879, D879) and GLP/GDP60VX, GLP/GDP7OVX (GP/GLP/GDP135VX, GPIGLP/GDP155VX) (C878, D878) 12.4 20.3 MPa (1798 243.5 psi) GLP/GDP8OVX, GLP/GDP80VX9, GLP/GDPSOVX (GDP170VX, GDP175VX36, GDP190VX) (A909) 15.8 20.3 MPa (2250 £43.5 psi) 84 Confidential/Proprietary - Do Not Copy or Duplicate