550030170-Single Speed Powershift Aluminum Chain Drive-Us

Maintenance
SINGLE SPEED
POWERSHIFT
ALUMINUM CHAIN DRIVE TRANSMISSION
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]; GLC050LX [A967];
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) [B875];
GLP/GDP20-25LX (GLP/GDP050LX) [A974]
PART NO. 550030170 1300 YRM 1447

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product.
Updated technical service information may be available from your local authorized Yale® dealer. Service Manuals
provide general guidelines for maintenance and service and are intended for use by trained and experienced techni-
cians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in
damage to the products, personal injury, property damage or death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being
lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Discon-
nect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS
in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications
of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to
follow the necessary safety precautions when handling these fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure
the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange background.
The CAUTION symbol and word are on yellow background.
Single Speed Powershift Table of Contents
TABLE OF CONTENTS
General................................................................................................................................................................ 1
Serial Number ................................................................................................................................................. 1
Hydraulic Gear Pump .......................................................................................................................................... 2
Remove ........................................................................................................................................................... 2
Install............................................................................................................................................................... 2
Housing Fittings Replacement............................................................................................................................. 2
Remove ........................................................................................................................................................... 2
Disassemble.................................................................................................................................................... 3
Assemble ........................................................................................................................................................ 3
Install............................................................................................................................................................... 3
Charge Pump Repair........................................................................................................................................... 3
Lift Trucks Manufactured Before July, 2013..................................................................................................... 3
Remove....................................................................................................................................................... 3
Disassemble ............................................................................................................................................... 5
Clean .......................................................................................................................................................... 5
Inspect ........................................................................................................................................................ 5
Assemble .................................................................................................................................................... 5
Install .......................................................................................................................................................... 5
Lift Trucks Manufactured After July, 2013........................................................................................................ 7
Remove....................................................................................................................................................... 7
Clean .......................................................................................................................................................... 7
Inspect ........................................................................................................................................................ 7
Install .......................................................................................................................................................... 8
Torque Converter Replacement........................................................................................................................... 11
Remove ........................................................................................................................................................... 11
Clean and Inspect ........................................................................................................................................... 11
Install............................................................................................................................................................... 11
Stator Support Assembly Repair ......................................................................................................................... 13
Remove ........................................................................................................................................................... 13
Disassemble.................................................................................................................................................... 18
Clean............................................................................................................................................................... 22
Inspect............................................................................................................................................................. 22
Assemble ........................................................................................................................................................ 23
Install............................................................................................................................................................... 23
Clutch Packs Repair ............................................................................................................................................ 26
Remove ........................................................................................................................................................... 26
Disassemble.................................................................................................................................................... 27
Housings ..................................................................................................................................................... 27
Clutch Packs ............................................................................................................................................... 32
Forward Clutch Pack............................................................................................................................... 32
Reverse Clutch Pack .............................................................................................................................. 37
Clean............................................................................................................................................................... 43
Inspect............................................................................................................................................................. 43
Assemble ........................................................................................................................................................ 44
Clutch Packs ............................................................................................................................................... 44
Reverse Clutch Pack .............................................................................................................................. 44
Forward Clutch Pack............................................................................................................................... 51
Housings ..................................................................................................................................................... 58
Install............................................................................................................................................................... 58
Drive Chains and Sprockets ................................................................................................................................ 64
Remove ........................................................................................................................................................... 64
©2013 Yale Materials Handling Corp. i

Table of Contents Single Speed Powershift
TABLE OF CONTENTS (Continued)

Clean............................................................................................................................................................... 66
Inspect............................................................................................................................................................. 66
Install............................................................................................................................................................... 66
Proportional and Enable Solenoid Valves ........................................................................................................... 67
Proportional Valves ......................................................................................................................................... 67
Remove....................................................................................................................................................... 67
Disassemble ............................................................................................................................................... 67
Clean and Inspect ....................................................................................................................................... 67
Assemble .................................................................................................................................................... 70
Install .......................................................................................................................................................... 70
Enable Solenoid Valve .................................................................................................................................... 70
Remove....................................................................................................................................................... 70
Disassemble ............................................................................................................................................... 71
Clean and Inspect ....................................................................................................................................... 71
Assemble .................................................................................................................................................... 71
Install .......................................................................................................................................................... 71
Foot Directional Control Pedal Repair ................................................................................................................. 73
Remove and Disassemble .............................................................................................................................. 73
Clean and Inspect ........................................................................................................................................... 77
Assemble and Install ....................................................................................................................................... 77
This section is for the following models:
GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX [C809];

GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) [C810];
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) [A910];
GLC050LX [A967];
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) [B875];
GLP/GDP20-25LX (GLP/GDP050LX) [A974]
ii
1300 YRM 1447 General
General
This section has repair procedures for the single-speed
powershift aluminum chain drive transmission.
SERIAL NUMBER
The transmission serial number is located on the top of
the transmission housing. See Figure 1.
1. TORQUE CONVERTER HOUSING

2. TRANSMISSION HOUSING
3. SERIAL NUMBER LOCATION
Figure 1. Serial Number
1
Housing Fittings Replacement 1300 YRM 1447
Hydraulic Gear Pump

REMOVE CAUTION
Lift truck models GLP/GDP20-35VX (B875) may be Disposal of lubricants and fluids must meet local
equipped with a Variable Displacement Pump (VDP). environmental regulations.
See service manual Hydraulic Gear Pump 1900 YRM
2. Dispose of drain pan contents.
1136 for more information.
CAUTION
Prior to removing hydraulic gear pump or VDP,
cover charge pump with liquid-proof covering to
prevent damage.
NOTE: Lift truck models GLP/GDP20-35VX (GP/GLP/

GDP040-070VX) (B875) may be equipped with an op-
tional Quick-Lok™ hydraulic hose and adapter. See
service manual Hydraulic Gear Pump 1900 YRM 1136
for more information.
1. Put a drain pan under hydraulic gear pump or VDP.

Remove and plug all hydraulic lines connected to
pump. Remove two flange head capscrews and hy-
draulic gear pump from transmission housing. See
Figure 2.
INSTALL
NOTE: Remove liquid-proof covering from charge
pump prior to operating lift truck.
NOTE: Apply a 3 to 5 mm (0.12 to 0.20 in.) bead of NOTE: HYDRAULIC GEAR PUMP SHOWN. THE RE-
sealant to either hydraulic gear pump or VDP or trans- MOVAL AND INSTALLATION OF THE VARIABLE DIS-
mission housing face at insertion point of flange head PLACEMENT PUMP IS THE SAME.
capscrews.
NOTE: CHARGE PUMP FOR LIFT TRUCKS MANU-
1. Install hydraulic gear pump or VDP and two flange FACTURED BEFORE JULY, 2013 SHOWN.
head capscrews on transmission housing. See Fig-
ure 2. Tighten capscrews to 38 N•m (28 lbf ft). 2. FLANGE HEAD CAPSCREW
3. HYDRAULIC GEAR PUMP
Figure 2. Hydraulic Gear Pump
Housing Fittings Replacement

REMOVE 2. Remove fittings from converter housing and trans-
mission housing. See Figure 3.
1. Remove hole plug from top of converter housing.
See Figure 3.
2
1300 YRM 1447 Charge Pump Repair
DISASSEMBLE INSTALL
1. Remove and discard O-rings from fittings. 1. Install hole plug on top of converter housing. See
Figure 3.
ASSEMBLE
2. Install fittings on converter housing and transmis-
1. Install new O-rings on fittings. sion housing. See Figure 3.
Charge Pump Repair

LIFT TRUCKS MANUFACTURED BEFORE See section Frame 100 YRM 1423 for removal pro-
JULY, 2013 cedures for lift truck models listed below:
• GLC050LX (A967)
Remove • GLP/GDP20-25LX (GLP/GDP050LX) (A974)
2. Using a lifting device, remove transmission from lift

WARNING truck.
Make sure engine and transmission are held in po-
sition so that they will not fall and cause an injury See section Frame 100 YRM 1120 for removal pro-
and damage to equipment. cedures for lift truck models listed below:
• GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809)
WARNING • GLP/GDP16VX, GLP/GDP18VX,
The engine and transmission are heavy. Make sure GLP/GDP20SVX (GP/GLP/GDP030VX,
that any lifting device has enough capacity to lift the GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
engine and transmission. (C810)
• GLC20-35VX (GC/GLC040-070VX,
The engine can weigh approximately 194 kg (428 lb).
GC/GLC055SVX) (A910)
The transmission can weigh approximately 84 kg • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(185 lb). (B875)
NOTE: Charge pump can be removed from transmis- See section Frame 100 YRM 1423 for removal pro-
sion while it is still in lift truck. However, for the sake cedures for lift truck models listed below:
of clarity, illustrations in following steps are shown with • GLC050LX (A967)
transmission removed from lift truck. • GLP/GDP20-25LX (GLP/GDP050LX) (A974)
NOTE: Perform Step 1 through Step 4 if engine and 3. Remove torque converter from torque converter
transmission are removed from lift truck. housing. See Torque Converter Replacement in
this manual for procedure.
1. Using a lifting device, remove engine from lift truck.
4. Place transmission on torque converter housing
See section Frame 100 YRM 1120 for removal pro- face. See Figure 4.
cedures for lift truck models listed below:
• GC/GLC030VX, GC/GLC035VX, 5. Remove seven capscrews, seven washers, charge
GC/GLC040SVX (C809) pump, and charge pump gasket from transmission
• GLP/GDP16VX, GLP/GDP18VX, housing. Discard charge pump gasket. See Fig-
GLP/GDP20SVX (GP/GLP/GDP030VX, ure 4.
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
6. Remove suction screen spring and suction screen
(C810)
from transmission housing. See Figure 4.
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875)
3
Charge Pump Repair 1300 YRM 1447
NOTE: CHARGE PUMP FOR LIFT TRUCKS MANUFACTURED BEFORE JULY, 2013 SHOWN.
A. TRANSMISSION HOUSING B. CONVERTER HOUSING
1. FITTING 2. HOLE PLUG
Figure 3. Housing Fittings and Hole Plug
4
solvents, always follow the manufacturer’s recom-

mended safety procedures.
Compressed air can move particles so they cause

injury to the user or to other personnel. Make sure
the path of the compressed air is away from all per-
sonnel. Wear protective goggles or a face shield to
prevent injury to the eyes.
1. Clean metal components with solvent and dry with

compressed air.
2. Clean rubber or plastic components with warm

soapy water and dry with a lint-free cloth.
Inspect
1. Inspect splines on shaft of charge pump for damage
or worn areas that could affect operation of pump.
Replace charge pump if damaged.
2. Inspect capscrews for damaged threads. Replace

capscrews if damaged.
3. Inspect suction screen for foreign material. Clean

screen or replace if damaged.
Assemble
1. Install new O-ring, charge pump cover, and four
2. CAPSCREW socket head screws on charge pump body. See
3. WASHER Figure 5.
4. CHARGE PUMP
5. CHARGE PUMP GASKET Install
6. SUCTION SCREEN
7. SUCTION SCREEN SPRING 1. Install suction screen and suction screen spring in
8. TORQUE CONVERTER HOUSING
transmission housing. See Figure 4.
Figure 4. Charge Pump
2. Install charge pump gasket, charge pump, seven
washers, and seven capscrews on transmission
Disassemble housing. See Figure 4. Tighten capscrews to
1. Remove four socket head screws, charge pump 19 N•m (168 lbf in).
cover, and O-ring from charge pump body. Discard
NOTE: Perform Step 3 and Step 5 if engine and trans-
O-ring. See Figure 5.
mission were removed from lift truck.
Clean 3. Move transmission to upright position. Install
torque converter in torque converter housing. See
WARNING Torque Converter Replacement in this manual for
Cleaning solvents can be flammable and toxic and procedures.
can cause skin irritation. When using cleaning
5
(B875)
See section Frame 100 YRM 1423 for install pro-

• GLC050LX (A967)
• GLP/GDP20-25LX (GLP/GDP050LX) (A974)
WARNING
sition so that they will not fall and cause an injury
and damage to equipment.
WARNING
The engine and transmission are heavy. Make sure
that any lifting device has enough capacity to lift the
1. CHARGE PUMP BODY engine and transmission.
2. O-RING
3. CHARGE PUMP COVER The engine can weigh approximately 194 kg (428 lb).
4. SOCKET HEAD SCREW
The transmission can weigh approximately 84 kg
Figure 5. Charge Pump Assembly (185 lb).
WARNING 5. Using lifting device, install engine in lift truck.

The engine and transmission are heavy. Make sure See section Frame 100 YRM 1120 for install pro-
that any lifting device has enough capacity to lift the cedures for lift truck models listed below:
engine and transmission. • GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809)
• GLP/GDP16VX, GLP/GDP18VX,
The transmission can weigh approximately 84 kg GLP/GDP20SVX (GP/GLP/GDP030VX,
(185 lb). GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810)
CAUTION GC/GLC055SVX) (A910)
Be careful that you DO NOT damage parts of the • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
torque converter or transmission when transmis- (B875)
sion is installed.
4. Using a lifting device, carefully install transmission cedures for lift truck models listed below:
on lift truck frame. Place blocks under transmission • GLC050LX (A967)
for stability. • GLP/GDP20-25LX (GLP/GDP050LX) (A974)
See section Frame 100 YRM 1120 for install pro- 6. Remove lifting device from eyebolt bracket.
GC/GLC040SVX (C809) CAUTION
• GLP/GDP16VX, GLP/GDP18VX, Disposal of lubricants and fluids must meet local
GLP/GDP20SVX (GP/GLP/GDP030VX, environmental regulations.
7. Dispose of drip pan contents.
(C810)
6
LIFT TRUCKS MANUFACTURED AFTER • GLP/GDP16VX, GLP/GDP18VX,

JULY, 2013 GLP/GDP20SVX (GP/GLP/GDP030VX,
Remove (C810)
WARNING GC/GLC055SVX) (A910)
(B875)
and damage to equipment. See section Frame 100 YRM 1423 for removal pro-
WARNING • GLC050LX (A967)
that any lifting device has enough capacity to lift the 3. Remove torque converter from torque converter
engine and transmission. housing. See Torque Converter Replacement in
this manual for procedure.
4. Remove seven capscrews, seven washers, charge
pump, and charge pump gasket from transmission
(185 lb).
housing. Discard charge pump gasket. See Fig-
NOTE: Charge pump can be removed from transmis- ure 6.
sion while it is still in lift truck. However, for the sake
5. Remove suction screen spring and suction screen
of clarity, illustrations in following steps are shown with
from transmission housing. See Figure 6.
transmission removed from lift truck.
NOTE: Perform Step 1 through Step 3 if engine and Clean

transmission are removed from lift truck.
WARNING
Cleaning solvents can be flammable and toxic and
See section Frame 100 YRM 1120 for removal pro- can cause skin irritation. When using cleaning
cedures for lift truck models listed below: solvents, always follow the manufacturer’s recom-
• GC/GLC030VX, GC/GLC035VX, mended safety procedures.
GC/GLC040SVX (C809)
GLP/GDP20SVX (GP/GLP/GDP030VX,
(C810)
GC/GLC055SVX) (A910) 1. Clean metal components with solvent and dry with
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) compressed air.
(B875)
See section Frame 100 YRM 1423 for removal pro- soapy water and dry with a lint-free cloth.
• GLC050LX (A967) Inspect
1. Inspect splines on shaft of charge pump for damage
2. Using a lifting device, remove transmission from lift or worn areas that could affect operation of pump.
truck. Replace charge pump if damaged. See Figure 7.
See section Frame 100 YRM 1120 for removal pro- 2. Inspect capscrews for damaged threads. Replace
cedures for lift truck models listed below: capscrews if damaged.
GC/GLC040SVX (C809)
7
3. Inspect suction screen for foreign material. Clean

screen or replace if damaged. See Figure 6. CAUTION
Be careful that you DO NOT damage parts of the
Install torque converter or transmission when transmis-
sion is installed.
1. Install suction screen and suction screen spring in
transmission housing. See Figure 6. NOTE: Perform Step 3 and Step 4 if engine and trans-
mission were removed from lift truck.
2. Using seven washers and seven capscrews, install
charge pump gasket and charge pump onto trans- 3. Using a lifting device, carefully install transmission
mission housing. See Figure 6. Tighten capscrews on lift truck frame. Place blocks under transmission
(item 1 in Figure 8) to 19 N•m (168 lbf in). for stability.
Tighten capscrews (item 2 in Figure 8) in star pat- See section Frame 100 YRM 1120 for install pro-
tern to 6 N•m (53 lbf in) on first pass. On second cedures for lift truck models listed below:
pass, tighten capscrews (item 2 in Figure 8) in star • GC/GLC030VX, GC/GLC035VX,
pattern to 19 N•m (168 lbf in). GC/GLC040SVX (C809)
WARNING
The engine and transmission are heavy. Make sure (C810)
that any lifting device has enough capacity to lift the • GLC20-35VX (GC/GLC040-070VX,
engine and transmission. GC/GLC055SVX) (A910)
The engine can weigh approximately 194 kg (428 lb). • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875)
(185 lb). See section Frame 100 YRM 1423 for install pro-
• GLC050LX (A967)
8
1. WASHER 4. CHARGE PUMP GASKET

2. CAPSCREW 5. SUCTION SCREEN SPRING
3. CHARGE PUMP 6. SUCTION SCREEN
Figure 6. Charge Pump
9
WARNING
WARNING
engine and transmission.

(185 lb).
1. DRIVE SHAFT 2. CHARGE PUMP 4. Using lifting device, install engine in lift truck.
Figure 7. Charge Pump Inspection See section Frame 100 YRM 1120 for install pro-
GC/GLC040SVX (C809)
(C810)
(B875)

• GLC050LX (A967)
5. Remove lifting device from eyebolt bracket.
CAUTION
Figure 8. Charge Pump Torque Tightening Disposal of lubricants and fluids must meet local
Sequence environmental regulations.
10
1300 YRM 1447 Torque Converter Replacement
Torque Converter Replacement

REMOVE • GLP/GDP16VX, GLP/GDP18VX,
WARNING GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810)
Make sure the engine and transmission are held in
position so that they will not fall and cause an injury
(B875)
WARNING
The engine and transmission are heavy. Make sure See section Frame 100 YRM 1423 for removal pro-
that any lifting device has enough capacity to lift the cedures for lift truck models listed below:
engine and transmission. • GLC050LX (A967)
3. Remove hydraulic gear pump or variable displace-
The transmission can weigh approximately 84 kg ment pump from transmission housing. See sec-
(185 lb). tion Hydraulic Gear Pump in this manual for proce-
dures.
NOTE: The torque converter cannot be repaired and
See section Frame 100 YRM 1120 for removal pro- must be replaced as a unit, if damaged.
• GC/GLC030VX, GC/GLC035VX, 4. Place a drip pan under transmission and carefully
GC/GLC040SVX (C809) remove torque converter from stator support. See
• GLP/GDP16VX, GLP/GDP18VX, Figure 9.
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) 5. Remove and discard oil seal from stator support.
(C810) See Figure 9.
GC/GLC055SVX) (A910) CLEAN AND INSPECT
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) 1. Clean all components with a lint-free cloth.
(B875)
2. Inspect torque converter, replace as needed.
See section Frame 100 YRM 1423 for removal pro-
cedures for lift truck models listed below: 3. Inspect bolts and capscrews for damaged threads,
• GLC050LX (A967) replace if damaged.
INSTALL
truck. 1. Install new oil seal on stator support. See Figure 9.
See section Frame 100 YRM 1120 for removal pro- 2. Carefully install torque converter on stator support.
cedures for lift truck models listed below: Ensure that torque converter is fully seated. See
• GC/GLC030VX, GC/GLC035VX, Figure 9.
GC/GLC040SVX (C809)
11
Torque Converter Replacement 1300 YRM 1447
(B875)

• GLC050LX (A967)
5. Install hydraulic gear pump or variable displace-

ment pump on transmission housing. See section
Hydraulic Gear Pump in this manual for procedures.
WARNING
1. TORQUE CONVERTER
2. STATOR SUPPORT
3. OIL SEAL WARNING
Figure 9. Torque Converter
3. If removed, connect a lifting device to eyebolt engine and transmission.
bracket.
WARNING The transmission can weigh approximately 84 kg

Make sure engine and transmission are held in po- (185 lb).
6. Using a lifting device, install engine in lift truck.
WARNING cedures for lift truck models listed below:
The engine and transmission are heavy. Make sure • GC/GLC030VX, GC/GLC035VX,
that any lifting device has enough capacity to lift the GC/GLC040SVX (C809)
engine and transmission. • GLP/GDP16VX, GLP/GDP18VX,
The engine can weigh approximately 194 kg (428 lb). GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810)
The transmission can weigh approximately 84 kg • GLC20-35VX (GC/GLC040-070VX,
(185 lb). GC/GLC055SVX) (A910)
4. Using lifting device, carefully install transmission
(B875)
assembly on lift truck frame. Place blocks under
transmission for stability. See section Frame 100 YRM 1423 for install pro-
• GLC050LX (A967)
GC/GLC040SVX (C809) 7. Remove lifting device from eyebolt bracket.
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) CAUTION
(C810) Disposal of lubricants and fluids must meet local
• GLC20-35VX (GC/GLC040-070VX, environmental regulations.
12
1300 YRM 1447 Stator Support Assembly Repair
Stator Support Assembly Repair

REMOVE See section Frame 100 YRM 1423 for removal pro-
WARNING • GLC050LX (A967)
position so that they will not fall and cause and in- 3. Remove hydraulic gear pump or variable displace-
jury and damage to equipment. ment pump. See section Hydraulic Gear Pump for
procedures.
WARNING
NOTE: Place drip pan under transmission.
that any lifting device has enough capacity to lift the 4. Remove torque converter from stator support. See
engine and transmission. section Torque Converter Replacement for proce-
dures.
5. Remove charge pump from transmission housing.
See section Charge Pump Repair for procedures.
(185 lb).
6. Remove transmission filter and filter post fitting from
GC/GLC040SVX (C809)
(C810)
(B875)

• GLC050LX (A967)

truck.

GC/GLC040SVX (C809) NOTE: CHARGE PUMP FOR LIFT TRUCKS MANU-
• GLP/GDP16VX, GLP/GDP18VX, FACTURED BEFORE JULY, 2013 SHOWN.
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) 1. TRANSMISSION HOUSING
2. TRANSMISSION FILTER
(C810) 3. FILTER POST FITTING
GC/GLC055SVX) (A910) Figure 10. Transmission Filter and Fitting
(B875)
13
Stator Support Assembly Repair 1300 YRM 1447
7. Remove four capscrews and two proportional See Figure 11 for lift truck models
valves from transmission housing. • GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809)
See Figure 11 for lift truck models • GLP/GDP16VX, GLP/GDP18VX,
• GC/GLC030VX, GC/GLC035VX, GLP/GDP20SVX (GP/GLP/GDP030VX,
GC/GLC040SVX (C809) GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
• GLP/GDP16VX, GLP/GDP18VX, (C810)
GLP/GDP20SVX (GP/GLP/GDP030VX, • GLC20-35VX (GC/GLC040-070VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) GC/GLC055SVX) (A910)
(C810) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
• GLC20-35VX (GC/GLC040-070VX, (B875)
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) See Figure 12 for lift truck models
(B875) • GLC050LX (A967)
See Figure 12 for lift truck models
• GLC050LX (A967) 10. If equipped, remove capscrew, lockwasher, and
• GLP/GDP20-25LX (GLP/GDP050LX) (A974) TOSS speed sensor from transmission housing.
See Figure 11.
8. Remove two capscrews and enable solenoid valve
from transmission housing. 11. If equipped, remove capscrew, lockwasher, and
TISS speed sensor from transmission housing.
See Figure 11. for lift truck models See Figure 11.
GC/GLC040SVX (C809) 12. If equipped, remove two capscrews, two lockwash-
• GLP/GDP16VX, GLP/GDP18VX, ers, and two transmission sensor plugs from trans-
GLP/GDP20SVX (GP/GLP/GDP030VX, mission housing. Remove and discard O-rings from
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) plugs. See Figure 12.
(C810)
• GLC20-35VX (GC/GLC040-070VX, 13. Remove dipstick, breather assembly, and tempera-
GC/GLC055SVX) (A910) ture sensor from converter housing. See Figure 13.
14. Remove two flange bolts and eyebolt bracket from
(B875)
housings. See Figure 14.
15. Remove twenty-four flange bolts from transmission
• GLC050LX (A967)
housing and converter housing. See Figure 14.
9. Remove two pressure transducers from transmis-

sion housing.
14
Legend for Figure 11

FACTURED BEFORE JULY, 2013 SHOWN.
2. PROPORTIONAL VALVE
3. TOSS SPEED SENSOR
4. TISS SPEED SENSOR
5. PRESSURE TRANSDUCER
6. ENABLE SOLENOID VALVE
7. CAPSCREW
8. LOCKWASHER
Figure 11. Transmission Housing Components

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), and
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)
15
3. CAPSCREW
4. TRANSDUCER 1. CONVERTER HOUSING
5. ENABLE SOLENOID VALVE 2. DIPSTICK
6. TRANSMISSION SENSOR PLUG 3. BREATHER ASSEMBLY
7. LOCKWASHER 4. TEMPERATURE SENSOR
8. O-RING
Figure 13. Converter Housing Components
for Lift Truck Models GLC050LX (A967) and
GLP/GDP20-25LX (GLP/GDP050LX) (A974)
16
1. TRANSMISSION HOUSING 4. O-RING

2. FLANGE BOLT 5. CONVERTER HOUSING
3. GASKET 6. EYEBOLT BRACKET
Figure 14. Transmission and Converter Housings
17
16. Using a small pry bar in the designated pry points 22. Remove four capscrews, four lockwashers, stator
remove converter housing from transmission hous- support assembly, and sealing ring from input gear.
ing. See Figure 15. Remove and discard O-rings from converter hous-
ing. Remove and discard sealing ring from stator
17. Remove and discard gasket and O-rings from trans- support assembly. See Figure 19.
mission housing. See Figure 14.
DISASSEMBLE
18. Converter housing to be face down on a bench or
work surface as shown. Pull forward clutch assem- 1. Remove fitting with O-ring, pack regulator spring,
bly straight out of stator support. See Figure 16. and pack regulator spool from stator support hous-
ing. Remove and discard O-ring from fitting. See
19. Pull reverse clutch assembly straight out of torque
Figure 20.
converter housing. See Figure 17.
2. Remove fitting with O-ring, converter relief spring,
20. Remove output gear from output gear cover. See
and ball converter relief from stator support assem-
Figure 18.
bly housing. Remove and discard O-ring from fit-
21. Remove output gear cover from pins in converter ting. See Figure 20.
housing. See Figure 18.
3. Remove bushing from stator support housing. See
NOTE: Be careful when removing stator support, input Figure 20.
gear may hang up.
18
A. LEFT SIDE AS VIEWED FROM DRIVERS SEAT B. RIGHT SIDE AS VIEWED FROM DRIVERS SEAT
1. CONVERTER HOUSING 3. PRY POINT
Figure 15. Pry Points
19
1. REVERSE CLUTCH ASSEMBLY

2. CONVERTER HOUSING
Figure 17. Reverse Clutch

1. FORWARD CLUTCH ASSEMBLY
2. STATOR SUPPORT ASSEMBLY
Figure 16. Forward Clutch
20

1. TRANSMISSION OUTPUT GEAR 2. CAPSCREW
2. OUTPUT GEAR COVER 3. LOCKWASHER
3. PIN 4. SEALING RING
4. CONVERTER HOUSING 5. O-RING
6. INPUT GEAR
Figure 18. Output Gear 7. CONVERTER HOUSING
Figure 19. Stator Support
21
CLEAN
WARNING
solvents, always follow the solvent manufacturer’s
recommended safety procedures.

CAUTION
DO NOT allow cleaning solvent to come in contact
with rubber or plastic components as it can damage
those components.
1. Clean all metal components in solvent and dry with

compressed air.

soapy water and dry with a lint-free cloth.
INSPECT
1. Make sure there are no scratches or damage on
the pack regulator spool. Make sure spool moves
freely in bore. Replace spool if damaged.
2. Make sure there are no scratches or damage to ball

converter relief assembly. Replace ball converter
relief assembly if damaged.
3. Make sure there are no scratches or damage in the

bores of the stator support housing. If bores are
1. FITTING WITH O-RING damaged, replace stator support assembly.
2. PACK REGULATOR SPRING
3. PACK REGULATOR SPOOL 4. Inspect bushing for damage. Replace if damaged.
4. HYDRAULIC PLUG
5. BUSHING 5. Check that the springs are not bent or damaged.
6. BALL CONVERTER RELIEF Replace if damaged.
7. CONVERTER RELIEF SPRING
8. STATOR SUPPORT HOUSING 6. Measure pack regulator spring. Replace if specifi-
cation shown below is not met. See Figure 21.
Figure 20. Stator Support Assembly
22
7. Measure converter relief spring. Replace if specifi-

cation shown below is not met. See Figure 22.
ASSEMBLE
1. If necessary, install new bushing in stator support
2. Install new O-ring on fitting. Install ball converter

relief, converter relief spring, and fitting with O-ring
in stator support housing. See Figure 20.
3. Install new O-ring on fitting. Install pack regulator

spool, pack regulator spring, and fitting with O-ring
in stator support housing. See Figure 20.
INSTALL
1. Install new O-rings on converter housing. See Fig-
ure 19.
Figure 21. Pack Regulator Spring - Free-Length
2. Install new sealing ring on stator support assembly. Measurement
See Figure 19.
3. Install stator support assembly, four lockwashers,

and four capscrews on input gear. Tighten cap-
screws to 38 N•m (28 lbf ft). See Figure 19.
4. Install output gear cover on pins in converter hous-

ing. See Figure 18.
5. Install output gear on output gear cover. See Fig-

ure 18.
6. Push reverse clutch assembly straight into con-

verter housing. See Figure 17.
7. Push forward clutch assembly straight into stator

support assembly. See Figure 16.
8. Verify two pins in converter housing. Check for cor-

rection installation, see Figure 23.
Figure 22. Converter Relief Spring - Free-Length
9. Install new O-rings and gasket on converter hous- Measurement
ing. See Figure 14.
10. Install transmission housing on converter housing.

Install twenty-four flange bolts on transmission
housing and converter housing. Tighten flange
bolts to 38 N•m (28 lbf ft). See Figure 14.
23
17. If equipped, install transmission sensor plugs, two

lockwashers, and two capscrews on transmission
housing. See Figure 12. Tighten capscrew to 6 to
9 N•m (53 to 80 lbf in).
18. Install two pressure transducers on transmission

housing.

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

• GLC050LX (A967)
NOTE: GEARS AND CLUTCH PACKS NOT SHOWN • GLP/GDP20-25LX (GLP/GDP050LX) (A974)
FOR CLARITY.
19. Install enable solenoid valve and two capscrews on
NOTE: CHARGE PUMP FOR LIFT TRUCKS MANU- transmission housing. Tighten capscrews to 3 to
FACTURED BEFORE JULY, 2013 SHOWN. 4 N•m (27 to 35 lbf in).
2. TRANSMISSION HOUSING See Figure 11 for lift truck models
3. PIN • GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809)
Figure 23. Alignment Pin Installation • GLP/GDP16VX, GLP/GDP18VX,
11. Install eyebolt bracket and two flange bolts on trans- GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
mission housing and converter housing. Tighten (C810)
flange bolts to 38 N•m (28 lbf ft). See Figure 14. • GLC20-35VX (GC/GLC040-070VX,
12. Install temperature sensor on converter housing.
Tighten sensor to 20 N•m (117 lbf in). See Fig-
(B875)
ure 13.
13. Install breather assembly and dipstick on converter
• GLC050LX (A967)
14. If equipped, install TISS speed sensor, lockwasher,
20. Install two proportional valves and four capscrews
and capscrew on transmission housing. See Fig-
on transmission housing. Tighten capscrews to 3
ure 11. Tighten capscrew to 6 to 9 N•m (53 to
to 4 N•m (27 to 35 lbf in).
80 lbf in).
15. If equipped, install TOSS speed sensor, lock-
washer, and capscrew on transmission housing.
GC/GLC040SVX (C809)
See Figure 11. Tighten capscrew to 6 to 9 N•m (53
to 80 lbf in).
16. If equipped, install new O-rings on transmission GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
sensor plugs. See Figure 12. (C810)
24
• GLC20-35VX (GC/GLC040-070VX, See section Frame 100 YRM 1423 for installation
GC/GLC055SVX) (A910) procedures for lift truck models listed below:
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) • GLC050LX (A967)
(B875) • GLP/GDP20-25LX (GLP/GDP050LX) (A974)
See Figure 12 for lift truck models 26. Install hydraulic gear pump or variable displace-
• GLC050LX (A967) ment pump. See section Hydraulic Gear Pump for
• GLP/GDP20-25LX (GLP/GDP050LX) (A974) installation procedures.
21. Install filter post fitting and transmission filter on

transmission housing. See Figure 10. WARNING
22. Install charge pump on transmission housing. See position so that they will not fall and cause an injury
section Charge Pump Repair for installation proce- and damage to equipment.
dures.
23. Install torque converter on stator support. See WARNING

Torque Converter Replacement for procedures. The engine and transmission are heavy. Make sure
24. If removed, connect a lifting device to eyebolt engine and transmission.
bracket.
WARNING The transmission can weigh approximately 84 kg
Make sure the engine and transmission are held in (185 lb).
position so that they will not fall and cause injury
and damage to equipment. 27. Using a lifting device, install engine into lift truck.
See section Frame 100 YRM 1120 for lift truck mod-
WARNING els listed below:
The engine and transmission are heavy. Make sure • GC/GLC030VX, GC/GLC035VX,
that any lifting device has enough capacity to lift the GC/GLC040SVX (C809)
engine and transmission. • GLP/GDP16VX, GLP/GDP18VX,
The engine can weigh approximately 194 kg (428 lb). GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
The transmission can weigh approximately 84 kg (C810)
(185 lb). • GLC20-35VX (GC/GLC040-070VX,
25. Using lifting device, carefully install transmission in • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
lift truck frame. Place blocks under transmission for (B875)
stability.
See section Frame 100 YRM 1120 for installation els listed below:
procedures for lift truck models listed below: • GLC050LX (A967)
• GC/GLC030VX, GC/GLC035VX, • GLP/GDP20-25LX (GLP/GDP050LX) (A974)
GC/GLC040SVX (C809)
• GLP/GDP16VX, GLP/GDP18VX, 28. Remove lifting device from eyebolt bracket and en-
GLP/GDP20SVX (GP/GLP/GDP030VX, gine eyebolts.
(C810) CAUTION
• GLC20-35VX (GC/GLC040-070VX, Disposal of lubricants and fluids must meet local
GC/GLC055SVX) (A910) environmental regulations.
(B875) 29. Dispose of drip pan contents.
25
Clutch Packs Repair 1300 YRM 1447
Clutch Packs Repair

REMOVE • GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809)
WARNING • GLP/GDP16VX, GLP/GDP18VX,
(C810)
WARNING • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
The engine and transmission are heavy. Make sure (B875)
engine and transmission. See section Frame 100 YRM 1423 for removal pro-
The engine can weigh approximately 194 kg (428 lb). • GLC050LX (A967)
(185 lb). 3. Remove hydraulic gear pump or variable displace-
ment pump. See section Hydraulic Gear Pump for
1. Using lifting device, remove engine from lift truck. procedures.
See section Frame 100 YRM 1120 for lift truck mod- NOTE: Place drip pan under transmission.
els listed below:
• GC/GLC030VX, GC/GLC035VX, 4. Remove torque converter from stator support. See
GC/GLC040SVX (C809) section Torque Converter Replacement in this man-
• GLP/GDP16VX, GLP/GDP18VX, ual for procedures.
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) 5. Remove charge pump from transmission housing.
(C810) See section Charge Pump Repair for removal pro-
• GLC20-35VX (GC/GLC040-070VX, cedures.
6. Remove transmission filter and filter post fitting from
(B875)
7. Remove four capscrews and two proportional
valves from transmission housing.
els listed below:
• GLC050LX (A967) See Figure 25 for lift truck models
• GLP/GDP20-25LX (GLP/GDP050LX) (A974) • GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809)
truck.

26
1300 YRM 1447 Clutch Packs Repair
• 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)
GC/GLC055SVX) (A910) See Figure 26 for lift truck models
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) • GLC050LX (A967)
(B875) • GLP/GDP20-25LX (GLP/GDP050LX) (A974)
See Figure 26 for lift truck models 10. If equipped, remove capscrew, lockwasher, and
• GLC050LX (A967) TOSS speed sensor from transmission housing.
• GLP/GDP20-25LX (GLP/GDP050LX) (A974) See Figure 25.
8. Remove two capscrews and enable solenoid valve 11. If equipped, remove capscrew, lockwasher, and
from transmission housing. TISS speed sensor from transmission housing.
See Figure 25.
• GC/GLC030VX, GC/GLC035VX, 12. If equipped, remove two capscrews, two lockwash-
GC/GLC040SVX (C809) ers, and two transmission sensor plugs from trans-
• GLP/GDP16VX, GLP/GDP18VX, mission housing. Remove and discard O-ring from
GLP/GDP20SVX (GP/GLP/GDP030VX, plug. See Figure 26.
13. Remove dipstick, breather assembly, and tempera-
(C810)
ture sensor from converter housing. See Figure 27.
DISASSEMBLE
(B875) Housings
See Figure 26 for lift truck models 1. Remove two flange bolts and eyebolt bracket from
• GLC050LX (A967) housings. See Figure 28.
2. Remove twenty-four flange bolts from transmission
9. Remove two pressure transducers from transmis- housing and converter housing. See Figure 28.
sion housing.
3. Using a small pry bar in the designated pry points,
See Figure 25 for lift truck models remove converter housing from transmission hous-
• GC/GLC030VX, GC/GLC035VX, ing. See Figure 29.
GC/GLC040SVX (C809)
• GLP/GDP16VX, GLP/GDP18VX, 4. Remove and discard gasket and O-rings from trans-
GLP/GDP20SVX (GP/GLP/GDP030VX, mission housing. See Figure 28.
(C810)
27

3. FILTER POST FITTING
Figure 24. Transmission Filter and Fitting FACTURED BEFORE JULY, 2013 SHOWN.
3. TOSS SPEED SENSOR
4. TISS SPEED SENSOR
5. PRESSURE TRANSDUCER
6. ENABLE SOLENOID VALVE
7. CAPSCREW
8. LOCKWASHER

for Lift Truck Models GC/GLC030VX,
28
3. CAPSCREW
4. TRANSDUCER 1. CONVERTER HOUSING
5. ENABLE SOLENOID VALVE 2. DIPSTICK
6. TRANSMISSION SENSOR PLUG 3. BREATHER ASSEMBLY
7. LOCKWASHER 4. TEMPERATURE SENSOR
8. O-RING
for Lift Truck Models GLC050LX (A967) and
29

3. GASKET 6. EYEBOLT BRACKET
Figure 28. Transmission and Converter Housings
30
A. LEFT SIDE AS VIEWED FROM DRIVERS SEAT B. RIGHT SIDE AS VIEWED FROM DRIVERS SEAT
1. CONVERTER HOUSING 3. PRY POINT
Figure 29. Pry Points
31
Clutch Packs
Forward Clutch Pack
STEP 1.
Converter housing to be face down on a bench or work
surface as shown. Pull forward clutch assembly straight
out of stator support assembly.

STEP 2.
Remove shaft seal and bearing from input shaft. Dis-
card shaft seal.
1. SHAFT SEAL 3. INPUT SHAFT

2. BEARING
32
STEP 3.
Remove snap ring from output gear. Remove output
gear from input shaft.
1. SNAP RING 3. BEARING

2. OUTPUT GEAR
STEP 4.
Remove bearing, snap ring, and bearing from output
gear.
1. BEARING 3. OUTPUT GEAR

2. SNAP RING
33
STEP 5.
Remove snap ring and pressure plate from gear assem-
bly drum. Remove and discard O-ring from pressure
plate.
1. SNAP RING
2. PRESSURE PLATE
3. O-RING
4. GEAR ASSEMBLY DRUM
STEP 6.
Remove friction disks and separator plates alternately
until all have been removed from gear assembly drum.
1. FRICTION DISK
2. SEPARATOR PLATE
34
STEP 7.
Remove conical plate from gear assembly drum.
1. CONICAL PLATE
WARNING
The springs for the piston are compressed. Make sure the springs and spring retainer cannot cause injury
when the snap ring is removed.
NOTE: Remove piston only if there is a problem with the piston or piston seals.
STEP 8.
Using spring compression tool, Yale P/N 150121831,
and a press, place spring compression tool on spring
guide with opening of tool above opening of snap ring,
and compress large and small springs just enough to
allow removal of snap ring from spring guide. Slowly
release press to compress springs.
1. SPRING COMPRESSION TOOL

2. SNAP RING
3. SPRING GUIDE
35
STEP 9.
Remove snap ring, spring guide, large spring, and small
spring from input shaft.
1. SNAP RING 4. SMALL SPRING

2. SPRING GUIDE 5. INPUT SHAFT
3. LARGE SPRING
STEP 10.
Remove shaft seal and piston from gear assembly
drum. Remove piston seal from piston. Discard shaft
seal and piston seal.
1. SHAFT SEAL
2. PISTON
3. PISTON SEAL
36
STEP 11.
Remove shaft seals and bearing from input shaft. Dis-
card shaft seals.
1. INPUT SHAFT 3. BEARING

2. SHAFT SEAL
Reverse Clutch Pack
STEP 1.
Converter housing to be face down on a bench or work
surface as shown. Pull reverse clutch assembly straight
out of converter housing.

37
STEP 2.
Remove bearing from center shaft.
1. CENTER SHAFT 2. BEARING
STEP 3.
Remove snap ring from output gear. Remove output
gear from center shaft.
1. OUTPUT GEAR 3. SNAP RING

2. CENTER SHAFT
38
STEP 4.
Remove bearing, snap ring, and bearing from output
gear.
1. BEARING 3. SNAP RING

2. OUTPUT GEAR
STEP 5.
Remove snap ring and pressure plate from gear assem-
bly drum. Remove and discard O-ring from pressure
plate.
1. SNAP RING
2. PRESSURE PLATE
3. O-RING
39
STEP 6.
Remove friction disks and separator plates alternately
until all have been removed from gear assembly drum.
1. FRICTION DISK
2. SEPARATOR PLATE
STEP 7.
Remove conical plate from gear assembly drum.
1. CONICAL PLATE
WARNING
The springs for the piston are compressed. Make sure the springs and spring retainer cannot cause injury
when the snap ring is removed.
NOTE: Remove the piston only if there is a problem with the piston or piston seals.
40
STEP 8.
guide with the opening of the tool above the opening of
snap ring, and compress large and small springs just
enough to allow removal of snap ring from spring guide.
Slowly release the press to decompress springs.

2. SNAP RING
3. SPRING GUIDE
STEP 9.
Remove snap ring, spring guide, large spring, and small
spring from center shaft.

2. SPRING GUIDE 5. CENTER SHAFT
3. LARGE SPRING
41
STEP 10.
Remove piston from gear assembly drum. Remove and
discard piston seal from piston. Remove and discard
shaft seal from center shaft.
1. PISTON
2. PISTON SEAL
4. SHAFT SEAL
5. CENTER SHAFT
STEP 11.
Remove shaft seals and bearing from center shaft. Dis-
card shaft seals.
1. SHAFT SEAL 3. CENTER SHAFT

2. BEARING
42
CLEAN
WARNING
recommended safety procedures.
Clean all metal parts with cleaning solvent and place

on a lint-free cloth to dry. Ensure that the cleaning and
assembly environment is free of dust, dirt, and any other
foreign matter that would affect the performance of the Figure 30. Conical Plate Inspection
parts. 8. Inspect piston for damage. Make sure that sealing
surfaces are good. Make sure orifice is clean.
INSPECT
9. Check for grooves or other damage on machined
1. Inspect gear teeth on clutch assemblies and all
surfaces of clutch pack shafts and transmission
other gears for wear or damage. Replace gears if
housing. Check mounting and sealing surfaces in
damaged.
housing for damage. Replace housing if damaged.
2. Check all parts that have splines for damage to Replace clutch pack if clutch pack shaft is dam-
splines. Check for notches worn in splines. Re- aged.
place clutch pack or gears if damaged.
10. Inspect all hardware and mounting surfaces for
3. Inspect friction disks for burned lining or bent sur- presence of rust, sealing compounds, and usable
faces. Check for small holes in lining. Replace fric- condition. If hardware is to be reused, clean all
tion disks if one-half the depth of the oil grooves is rust and sealing compounds from threaded areas.
worn away or the disks are damaged. Discard a If hardware is not in usable condition, replace
friction disk that has a thickness less than 2.2 mm hardware.
(0.087 in.).
CAUTION
4. The conical plate and separator plates must not be
The dowel pins are used to properly align the hous-
bent, have damaged surfaces, or have large blue
ings for proper mating to each other. If the align-
areas from too much heat. If any of the above con-
ment is not correct, damage to the transmission as-
ditions exist, replace the damaged component.
sembly could occur.
5. Check the "H" dimensions of the conical plate
11. Inspect dowel pins and dowel pin holes. If any
as shown in Figure 30. If dimension is less than
dowel pin is damaged at all, replace the dowel pin.
3.2 mm (0.126 in.), replace conical plate.
If a dowel pin hole is damaged, replace housing.
6. Check the "t" dimension of the conical plate as
12. Check fit of bearings in transmission housings. If
shown in Figure 30. If dimension is less than
bearings fit too loosely into housings, this could
2.4 mm (0.094 in.), replace conical plate.
mean that the bores are oversized. Replace hous-
7. Inspect bearings for wear or damage. Replace if ing as necessary.
damaged.
43
ASSEMBLE
Clutch Packs
Reverse Clutch Pack
1. SEAL 8. SNAP RING

2. BEARING 9. CONICAL PLATE
3. GEAR ASSEMBLY DRUM 10. FRICTION DISK
4. PISTON SEAL 11. SEPARATOR PLATE
5. PISTON 12. PRESSURE PLATE O-RING
6. SPRING 13. PRESSURE PLATE
7. SPRING GUIDE 14. OUTPUT GEAR
Figure 31. Reverse Clutch Pack Assembly
44
STEP 1.
Lubricate shaft seals with clean transmission oil. Install
bearing and new shaft seals on center shaft.
1. SHAFT SEAL 3. CENTER SHAFT

2. BEARING
NOTE: Perform STEP 2 through STEP 4 only if piston was removed.
STEP 2.
Lubricate all parts with clean transmission oil. Install
new shaft seal on center shaft. Install new piston seal
on piston. Install piston into gear assembly drum.
1. PISTON
2. PISTON SEAL
4. SHAFT SEAL
5. CENTER SHAFT
45
STEP 3.
Install small spring, large spring, spring guide, and snap
ring on center shaft.

2. SPRING GUIDE 5. CENTER SHAFT
3. LARGE SPRING
STEP 4.
guide with the opening of tool above opening of snap
ring, and compress the large and small springs just
enough to allow installation of snap ring in spring guide.
Slowly release press.

2. SNAP RING
3. SPRING GUIDE
NOTE: The conical plate is properly installed when the inner diameter is touching the piston, and the outer diameter
of the conical plate is touching the outer diameter of the friction disk.
46
STEP 5.
Install conical plate in gear assembly drum.
1. CONICAL PLATE
STEP 6.
Install friction disks and separator plates alternately un-
til all have been installed in gear assembly drum. See
Figure 31 for installation order.
1. FRICTION DISK
2. SEPARATOR PLATE
47
STEP 7.
Lubricate O-ring and install in pressure plate. Install
pressure plate and snap ring in gear assembly drum.
Using a dial indicator or feeler gauge, check the clear-
ance between snap ring and pressure plate. There must
be 1.8 ±0.2 mm (0.071 ±0.008 in.) of clearance. If clear-
ance is not correct, see the Parts Manual for correct
pressure plate.
1. SNAP RING
2. PRESSURE PLATE
3. O-RING
STEP 8.
Install bearing, snap ring, and bearing in output gear.
1. BEARING 3. SNAP RING

2. OUTPUT GEAR
48
STEP 9.
Install output gear and snap ring on center shaft.
1. OUTPUT GEAR 3. SNAP RING

2. CENTER SHAFT
STEP 10.
Install bearing on center shaft.
1. CENTER SHAFT 2. BEARING
49
STEP 11.
Torque converter housing to be face down on a bench or
work surface as shown. Install reverse clutch assembly
straight into converter housing.

50
Forward Clutch Pack
1. SEAL 8. SNAP RING

2. BEARING 9. CONICAL PLATE
3. GEAR ASSEMBLY DRUM 10. FRICTION DISK
4. PISTON SEAL 11. SEPARATOR PLATE
5. PISTON 12. PRESSURE PLATE O-RING
6. SPRING 13. PRESSURE PLATE
7. SPRING GUIDE 14. OUTPUT GEAR
Figure 32. Forward Clutch Pack Assembly
51
STEP 1.
Lubricate shaft seals with clean transmission oil. Install
bearing and shaft seals on input shaft.
1. INPUT SHAFT 3. BEARING

2. SHAFT SEAL
NOTE: Perform STEP 2 through STEP 4 only if piston was removed.
STEP 2.
Lubricate all parts with clean transmission oil. Install
new piston seal on piston. Install piston and new shaft
seal into gear assembly drum.
1. SHAFT SEAL
2. PISTON
3. PISTON SEAL
52
STEP 3.
Install small spring, large spring, spring guide, and snap
ring on input shaft.

2. SPRING GUIDE 5. INPUT SHAFT
3. LARGE SPRING
STEP 4.
guide with the opening of the tool above opening of
snap ring, and compress the large and small springs
just enough to allow installation of snap ring in spring
guide. Slowly release press.

2. SNAP RING
3. SPRING GUIDE
NOTE: The conical plate is properly installed when the inner diameter is touching the piston, and the outer diameter
of the conical plate is touching the outer diameter of the friction disk.
53
STEP 5.
Install conical plate in gear assembly drum.
1. CONICAL PLATE
STEP 6.
Install friction disks and separator plates alternately un-
til all have been installed in gear assembly drum. See
Figure 32 for installation order.
1. FRICTION DISK
2. SEPARATOR PLATE
54
STEP 7.
Lubricate O-ring and install into pressure plate. Install
pressure plate and snap ring into gear assembly drum.
Using a dial indicator or feeler gauge, check the clear-
ance between snap ring and pressure plate. There must
be 1.8 ±0.2 mm (0.071 ±0.008 in.) of clearance. If clear-
ance is not correct, see Parts Manual for correct pres-
sure plate.
1. SNAP RING
2. PRESSURE PLATE
3. O-RING
STEP 8.
Install bearing, snap ring, and bearing into output gear.
1. BEARING 3. OUTPUT GEAR

2. SNAP RING
55
STEP 9.
Install output gear and snap ring on input shaft.
1. SNAP RING 3. BEARING

2. OUTPUT GEAR
STEP 10.
Lubricate new shaft seal with clean transmission oil. In-
stall bearing and shaft seal on input shaft.
1. SHAFT SEAL 3. INPUT SHAFT

2. BEARING
56
STEP 11.
Torque converter housing to be face down on a bench or
work surface as shown. Install forward clutch assembly
straight into stator support assembly.

57
Housings Tighten capscrew to 6 to 9 N•m (53 to 80 lbf in).

See Figure 36.
1. Install new gasket and O-rings on transmission
2. Verify two pins in converter housing. Check for cor-

rect installation, see Figure 33.
3. Position transmission housing and converter hous-

ing together and install twenty-four flange bolts.
Tighten flange bolts to 38 N•m (28 lbf ft). See
Figure 34. See Figure 34.
4. Install eyebolt bracket and two flange bolts on trans-

mission housing and converter housing. Tighten
flange bolts to 38 N•m (28 lbf ft).
INSTALL
1. Install temperature sensor on converter housing.
Tighten sensor to 20 N•m (117 lbf in). See Fig-
ure 35.
2. Install breather assembly, and dipstick on converter

3. If equipped, install TISS speed sensor, lockwasher,
and capscrew on transmission housing. Tighten
capscrew to 6 to 9 N•m (53 to 80 lbf in). See Fig- 1. TORQUE CONVERTER HOUSING
ure 36. 2. TRANSMISSION HOUSING
3. PIN
4. If equipped, install TOSS speed sensor, lock-
washer, and capscrew on transmission housing. Figure 33. Alignment Pin Installation
58

3. GASKET 6. EYE BOLT BRACKET
Figure 34. Transmission and Torque Converter Housings
59
(C810)
(B875)

• GLC050LX (A967)
8. Install enable solenoid valve and two capscrews on

transmission housing. Tighten capscrews to 3 to
4 N•m (27 to 35 lbf in).

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

• GLC050LX (A967)
1. CONVERTER HOUSING 9. Install two proportional valves and four capscrews

2. DIPSTICK on transmission housing. Tighten capscrews to 3
3. BREATHER ASSEMBLY to 4 N•m (27 to 35 lbf in).
4. TEMPERATURE SENSOR
5. If equipped, install new O-ring on transmission sen- GC/GLC040SVX (C809)
sor plugs. See Figure 37. • GLP/GDP16VX, GLP/GDP18VX,
6. If equipped, install two transmission sensor plugs, GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
two lockwashers, and two capscrews. Tighten cap- (C810)
screw to 6 to 9 N•m (53 to 80 lbf in). See Figure 37. • GLC20-35VX (GC/GLC040-070VX,
7. Install two pressure transducers on transmission • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
housing. (B875)
See Figure 36 for lift truck models See Figure 37 for lift truck models
• GC/GLC030VX, GC/GLC035VX, • GLC050LX (A967)
GC/GLC040SVX (C809) • GLP/GDP20-25LX (GLP/GDP050LX) (A974)
60


2. PROPORTIONAL VALVE 1. TRANSMISSION HOUSING
3. TOSS SPEED SENSOR 2. PROPORTIONAL VALVE
4. TISS SPEED SENSOR 3. CAPSCREW
5. PRESSURE TRANSDUCER 4. TRANSDUCER
6. ENABLE SOLENOID VALVE 5. ENABLE SOLENOID VALVE
7. CAPSCREW 6. TRANSMISSION SENSOR PLUG
8. LOCKWASHER 7. LOCKWASHER
8. O-RING
for Lift Truck Models GC/GLC030VX, Figure 37. Transmission Housing Components
GC/GLC035VX, GC/GLC040SVX (C809), for Lift Truck Models GLC050LX (A967) and
GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX GLP/GDP20-25LX (GLP/GDP050LX) (A974)
61
10. Install filter post fitting and transmission filter on

11. Install charge pump on transmission housing. See

section Charge Pump Repair for installation proce-
dures.
12. Install torque converter on stator support. See

Torque Converter Replacement for procedures.
13. If removed, connect a lifting device to eyebolt

bracket.
WARNING
position so that they will not fall and cause injury
WARNING
The engine can weigh approximately 194 kg (428 lb). NOTE: CHARGE PUMP FOR LIFT TRUCKS MANU-
(185 lb). 1. TRANSMISSION HOUSING
14. Using a lifting device, carefully install transmission 3. FILTER POST FITTING
on lift truck frame. Place blocks under transmission Figure 38. Transmission Filter and Fitting
for stability.
62
See section Frame 100 YRM 1120 for install pro- The engine can weigh approximately 194 kg (428 lb).
• GC/GLC030VX, GC/GLC035VX, The transmission can weigh approximately 84 kg
GC/GLC040SVX (C809) (185 lb).
16. Using a lifting device, install engine into lift truck.
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) See section Frame 100 YRM 1120 for lift truck mod-
(C810) els listed below:
• 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)
• GLC050LX (A967)
15. Install hydraulic gear pump or variable displace- (B875)
ment pump. See section Hydraulic Gear Pump for
installation procedures.
els listed below:
• GLC050LX (A967)
WARNING • GLP/GDP20-25LX (GLP/GDP050LX) (A974)
position so that they will not fall and cause an injury 17. Remove lifting device from eyebolt bracket and en-
and damage to equipment. gine eyebolts.
WARNING CAUTION
The engine and transmission are heavy. Make sure Disposal of lubricants and fluids must meet local
that any lifting device has enough capacity to lift the environmental regulations.
63
Drive Chains and Sprockets 1300 YRM 1447
Drive Chains and Sprockets

REMOVE
1. Remove clutch packs and stator support, follow Re-
move procedures in section Stator Support Assem-
bly Repair of this manual.
NOTE: Note placement and orientation of components

during removal to aid in installation.
2. Remove small drive chain from upper and lower

driven sprocket assemblies. See Figure 39.
3. Remove large drive chain from upper driven

sprocket assembly and driving sprocket assembly.
See Figure 40.
4. Remove bearing, driven sprocket, and bearing from

5. Remove bearing and two driven sprockets from

1. LARGE DRIVE CHAIN
NOTE: Note orientation of angular bearing prior to re- 2. UPPER DRIVEN SPROCKET ASSEMBLY
moval to aid in installation. 3. DRIVING SPROCKET ASSEMBLY
6. Remove bearing, driving sprocket, angular bearing, Figure 40. Large Drive Chain
and O-ring from converter housing. Discard O-ring.
See Figure 43.
1. SMALL DRIVE CHAIN 1. BEARING

2. UPPER DRIVEN SPROCKET ASSEMBLY 2. DRIVEN SPROCKET
3. LOWER DRIVEN SPROCKET ASSEMBLY 3. CONVERTER HOUSING
Figure 39. Small Drive Chain Figure 41. Lower Driven Sprocket Assembly
64
1300 YRM 1447 Drive Chains and Sprockets
1. BEARING
2. DRIVEN SPROCKET
3. DRIVEN SPROCKET
4. CONVERTER HOUSING 1. BEARING
2. DRIVING SPROCKET
Figure 42. Upper Driven Sprocket Assembly 3. ANGULAR BEARING
4. O-RING
Figure 43. Driving Sprocket Assembly
65
Drive Chains and Sprockets 1300 YRM 1447
7. If necessary, remove two capscrews, two lockwash- 2. Install new O-ring on converter housing. Install an-
ers, and baffle plate from converter housing. See gular bearing, as noted during removal, on con-
Figure 44. verter housing. Install driving sprocket, and bear-
ing on converter housing. See Figure 43.
CLEAN
3. Install two driven sprockets and bearing on con-
verter housing. See Figure 42.
WARNING
Cleaning solvents can be flammable and toxic and 4. Install bearing, driven sprocket, and bearing on
can cause skin irritation. When using ceaning converter housing. See Figure 41.
recommended safety procedures. 5. Install large drive chain on driving sprocket assem-
bly and driven sprocket assembly. See Figure 40.
injury to the user or to other personnel. Make sure 6. Install small drive chain on both driven sprocket as-
the path of the compressed air is away from all per- semblies. See Figure 39.
prevent injury to the eyes. 7. Install stator support and clutch packs, follow In-
stall procedures in section Stator Support Assem-
bly Repair of this manual.
CAUTION
DO NOT allow cleaning solvent to come in contact
with rubber or plastic components as it can damage
those components.
1. Clean all metal components in solvent and dry with

compressed air.

soapy water and dry with lint-free cloth.
INSPECT
1. Inspect bearings for wear or damage. Replace if
damaged.
2. Inspect sprocket teeth for wear or breakage. Re-

place if worn or broken.
3. Check fit of bearings in converter housing. If bear-

ings fit too loosely, housing bores my be oversized.
Replace housings as necessary. 1. CAPSCREW
2. LOCKWASHER
3. BAFFLE PLATE
INSTALL 4. CONVERTER HOUSING
1. If removed, install baffle plate, two lockwashers, Figure 44. Baffle Plate
and two capscrews. See Figure 44. Tighten cap-
screws to 3 to 4 N•m (27 to 35 lbf in).
66
1300 YRM 1447 Proportional and Enable Solenoid Valves
Proportional and Enable Solenoid Valves

PROPORTIONAL VALVES • GLC050LX (A967)
Remove
Disassemble
CAUTION 1. Remove and discard O-rings from proportional
Use care when disconnecting the wiring harness valves. See Figure 49.
from the connectors. The connectors are easily
damaged. Clean and Inspect
NOTE: Tag wiring harness and valve connectors prior 1. Clean proportional valves with lint-free cloth.
to removal to aid in installation.
2. Inspect the connectors on the valves, if damaged,
1. Disconnect wiring harness connectors from propor- replace valve.
tional valves and enable solenoid valve connectors.

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

• GLC050LX (A967)
2. Remove four capscrews and two proportional

valves from transmission housing.
See Figure 45 for lift truck models 1. CAPSCREW

• GC/GLC030VX, GC/GLC035VX, 2. PROPORTIONAL VALVE
GC/GLC040SVX (C809)
• GLP/GDP16VX, GLP/GDP18VX, Figure 45. Proportional Valves for Lift Truck Models
GLP/GDP20SVX (GP/GLP/GDP030VX, GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C809), GLP/GDP16VX, GLP/GDP18VX,
(C810) GLP/GDP20SVX (GP/GLP/GDP030VX,
• GLC20-35VX (GC/GLC040-070VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
GC/GLC055SVX) (A910) (C810), GLC20-35VX (GC/GLC040-070VX,
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) GC/GLC055SVX) (A910), and GLP/GDP20-35VX
(B875) (GP/GLP/GDP040-070VX) (B875)
67
Proportional and Enable Solenoid Valves 1300 YRM 1447
1. CAPSCREW
3. TRANSMISSION HOUSING 1. WIRING HARNESS
2. PROPORTIONAL VALVE CONNECTOR
Figure 46. Proportional Valves for Lift Truck 3. ENABLE SOLENOID VALVE CONNECTOR
Models GLC050LX (A967) and GLP/GDP20-25LX
Figure 47. Wiring Harness and Valve
(GLP/GDP050LX) (A974)
Connectors for Lift Truck Models GC/GLC030VX,
68
1. WIRING HARNESS
2. PROPORTIONAL VALVE CONNECTOR
3. ENABLE SOLENOID VALVE CONNECTOR
Figure 48. Wiring Harness and Valve Connectors 1. ENABLE SOLENOID VALVE
for Lift Truck Models GLC050LX (A967) and 3. O-RING
Figure 49. Valves and O-rings
69
Assemble • GLC20-35VX (GC/GLC040-070VX,

1. Install new O-rings onto proportional valves as • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
noted in disassembly. See Figure 49. (B875)
Install See Figure 48 for lift truck models

• GLC050LX (A967)
1. Install two proportional valves and four capscrews • GLP/GDP20-25LX (GLP/GDP050LX) (A974)
on transmission housing. Tighten capscrews to 3
to 4 N•m (27 to 35 lbf in). ENABLE SOLENOID VALVE
Remove
GC/GLC040SVX (C809)
• GLP/GDP16VX, GLP/GDP18VX, CAUTION
GLP/GDP20SVX (GP/GLP/GDP030VX, Use care when disconnecting the wiring harness
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) from the connectors. The connectors are easily
(C810) damaged.
GC/GLC055SVX) (A910) NOTE: Tag wiring harness and valve connectors prior
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) to removal to aid in installation.
(B875)
1. Disconnect wiring harness connectors from enable
See Figure 46 for lift truck models solenoid valve connector.
• GLC050LX (A967)
GC/GLC040SVX (C809)
CAUTION • GLP/GDP16VX, GLP/GDP18VX,
Use care when connecting the wiring harness to the GLP/GDP20SVX (GP/GLP/GDP030VX,
connectors. The connectors are easily damaged. GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810)
2. Connect proportional valve and enable solenoid • GLC20-35VX (GC/GLC040-070VX,
valve to wiring harness connectors as tagged dur- GC/GLC055SVX) (A910)
ing removal. • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875)
• GC/GLC030VX, GC/GLC035VX, See Figure 48 for lift truck models
GC/GLC040SVX (C809) • GLC050LX (A967)
• GLP/GDP16VX, GLP/GDP18VX, • GLP/GDP20-25LX (GLP/GDP050LX) (A974)
(C810)
70
2. Remove capscrews and enable solenoid valve from See Figure 50 for lift truck models
transmission housing. • GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809)
See Figure 50 for lift truck models • GLP/GDP16VX, GLP/GDP18VX,
• GC/GLC030VX, GC/GLC035VX, GLP/GDP20SVX (GP/GLP/GDP030VX,
GC/GLC040SVX (C809) GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
• GLP/GDP16VX, GLP/GDP18VX, (C810)
GLP/GDP20SVX (GP/GLP/GDP030VX, • GLC20-35VX (GC/GLC040-070VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) GC/GLC055SVX) (A910)
(C810) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
• GLC20-35VX (GC/GLC040-070VX, (B875)
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) See Figure 51 for lift truck models
(B875) • GLC050LX (A967)
• GLC050LX (A967)
• GLP/GDP20-25LX (GLP/GDP050LX) (A974) CAUTION
Use care when connecting the wiring harness to the
Disassemble connectors. The connectors are easily damaged.
1. Remove and discard O-rings from enable solenoid 2. Connect enable solenoid valve connector to wiring
valve. See Figure 49. harness connector as tagged during removal.
Clean and Inspect See Figure 47 for lift truck models

1. Clean enable solenoid valve with lint-free cloth. GC/GLC040SVX (C809)
2. Inspect the connector on the valve, if damaged, re- GLP/GDP20SVX (GP/GLP/GDP030VX,
place valve. GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810)
Assemble • GLC20-35VX (GC/GLC040-070VX,
1. Install new O-rings onto enable solenoid valve. See
Figure 49.
(B875)
Install See Figure 48 for lift truck models
1. Install enable solenoid valve and capscrew on • GLC050LX (A967)
transmission housing. Tighten capscrew to 3 to • GLP/GDP20-25LX (GLP/GDP050LX) (A974)
4 N•m (37 to 35 lbf in).
71
1. CAPSCREW 1. CAPSCREW
2. ENABLE SOLENOID VALVE 2. ENABLE SOLENOID VALVE
3. TRANSMISSION HOUSING 3. TRANSMISSION HOUSING
Figure 50. Enable Solenoid Valve for Lift Figure 51. Enable Solenoid Valve for Lift Truck
Truck Models GC/GLC030VX, GC/GLC035VX, Models GLC050LX (A967) and GLP/GDP20-25LX
GC/GLC040SVX (C809), GLP/GDP16VX, GLP/ (GLP/GDP050LX) (A974)
GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX,
(C810), GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910), and GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875)
72
1300 YRM 1447 Foot Directional Control Pedal Repair
Foot Directional Control Pedal Repair

REMOVE AND DISASSEMBLE
1. Remove five screws, dash panel, and kick plate
from lift truck.
els listed below:
GC/GLC040SVX (C809)
(C810)
(B875)
2. Remove three capscrews from hydraulic lever as-

sembly. Swing hydraulic lever assembly toward op-
erator’s seat. See Figure 52.
3. Disconnect two cable assemblies from pedal as-

sembly.
4. Remove three capscrews and pedal assembly from

cowl. Remove pedal assembly from lift truck. See
Figure 53.
1. CAPSCREW
2. HYDRAULIC LEVER ASSEMBLY
5. Remove two pan head screws, lockwashers, and
accelerator position sensor from throttle base. See Figure 52. Hydraulic Lever Relocation
Figure 54.
73
Foot Directional Control Pedal Repair 1300 YRM 1447
NOTE: Remove only those components necessary to

complete repair of pedal.
6. Remove connector from connector holder on throt-

tle base. See Figure 54.
7. Remove outer and inner springs from throttle base

and pedal assembly. See Figure 54.
8. Remove e-clip and throttle base from throttle pedal

shaft. See Figure 54.
9. Remove roll pin and throttle pedal shaft from pedal

assembly. Discard roll pin. See Figure 54.
NOTE: Tag wires prior to removing from microswitches

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

from pedal frame. See Figure 55.
11. Remove four pan head screws, lockwashers, wash-

ers, pedal pad and springs from pedal frame. If any
metal inserts in pedal pad are damaged, replace as
necessary. See Figure 55.
12. Remove two hex head screws, lockwashers, nuts,

and microswitch from pedal pad. Repeat for re-
1. CAPSCREW 3. COWL maining microswitch and remove wiring harness
2. PEDAL ASSEMBLY
from pedal frame. See Figure 55.
Figure 53. Foot Directional Control Pedal Assembly 13. If damaged, remove stop screw and nut from pedal
and Cowl frame. See Figure 55.
CAUTION
Use care when removing the connector from its
holder as the connector can be easily damaged.
74
1. PAN HEAD SCREW 8. ROLL PIN

2. LOCKWASHER 9. INNER AND OUTER SPRINGS
3. ACCELERATOR POSITION SENSOR (APS) 10. FOOT DIRECTIONAL CONTROL PEDAL
4. THROTTLE BASE ASSEMBLY
5. CONNECTOR 11. CONNECTOR HOLDER
6. THROTTLE PEDAL SHAFT 12. THROTTLE PEDAL SHAFT
7. E-CLIP
Figure 54. Foot Directional Control Pedal Bracket
75
1. WIRING HARNESS 9. METAL INSERT

2. FOAM LOCK SEAL 10. NUT
3. U-CLIP 11. LOCKWASHER
4. PAN HEAD SCREW 12. MICROSWITCH
5. LOCKWASHER 13. HEX HEAD SCREW
6. WASHER 14. SPRING
7. STOP SCREW 15. PEDAL PAD
8. NUT 16. PEDAL FRAME
Figure 55. Foot Directional Control Pedal
76
CLEAN AND INSPECT ASSEMBLE AND INSTALL

1. If removed, install stop screw and nut on pedal
WARNING frame. See Figure 55.
can cause skin irritation. When using cleaning 2. Install microswitch and two hex head screws in
solvents, always follow the solvent manufacturer’s pedal pad. Coat exposed threads of hex head
recommended safety procedures. screws with Loctite™ 222. Install two lockwashers
and nuts on hex head screws. DO NOT tighten
Compressed air can move articles so they cause in- nuts at this time. Repeat for other microswitch.
jury to the user or to other personnel. Make sure See Figure 55.
sonnel. Wear protective goggles or a face shield to 3. Put wires through hole in pedal frame. The white
prevent injury to the eyes. banded wire is for the reverse microswitch, and the
blue banded wire is for the forward microswitch. Ad-
just each microswitch in its mount so that the mea-
CAUTION
surement between the edge of the mount and the
DO NOT allow cleaning solvent to come in contact base of the microswitch equals 0.0 to 0.5 mm (0.0
with rubber or plastic components as it can damage to 0.02 in.). Tighten mounting nuts of each mi-
those components. croswitch as adjustment is completed. See Fig-
1. Clean all metal components in solvent and dry with ure 56.
compressed air. 4. Install wiring harness in pedal frame. Install foam
2. Clean rubber or plastic components in warm soapy lock seal and u-clip. Install pedal pad and springs in
water and dry with lint-free cloth. pedal frame. Coat threads of four pan head screws
with Loctite™ 222. Install pan head screws, lock-
3. Inspect all components for damage. Replace if washers, and washers in pedal pad. See Figure 55.
damaged. Tighten pan head screws to 2.25 to 2.50 N•m (19
to 32 lbf in).
77
5. Using an ohmmeter, check for continuity between bolts to 19 to 25 N•m (168 to 221 lbf in). See Fig-
pins 3 and 4 of wiring harness connector with pedal ure 53.
in reverse position, and between pins 1 and 2 with
pedal in forward position. See Figure 57. 10. Connect two cable assemblies to pedal assembly.
Swing hydraulic lever assembly toward cowl and
6. Install throttle pedal shaft and new roll pin in pedal install three capscrews. See Figure 52.
assembly. Install throttle base and e-clip on throttle
pedal shaft. See Figure 54. 11. Install kick panel and dashboard on lift truck.
CAUTION els listed below:
Use care when installing the connector in its holder • GC/GLC030VX, GC/GLC035VX,
as the connector can be easily damaged. GC/GLC040SVX (C809)
7. Install inner and outer springs on throttle base and GLP/GDP20SVX (GP/GLP/GDP030VX,
pedal assembly. Install connector in connector GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
holder. on throttle base. See Figure 54. (C810)
8. Install actuator and magnet in throttle base. Install GC/GLC055SVX) (A910)
accelerator position sensor, lockwashers, and two • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
pan head screws in throttle base. Tighten screws (B875)
to 2.25 N•m (19 lbf in).
12. Depress pedal until it stops. Unscrew stop screw
9. Apply adhesive compound to three mounting bolts. until it contacts metal floor plate. Tighten nut to
Using three capscrews that hold throttle base to 10 N•m (89 lbf in).
cowl, install pedal assembly on lift truck. Tighten
78
1. WIRING HARNESS CONNECTOR

2. WIRING HARNESS
Figure 57. Microswitch Continuity Check
1. MICROSWITCH MOUNT
2. MICROSWITCH BASE
Figure 56. Microswitch Adjustment
79
NOTES
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80
Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011
1300 YRM 1447 8/13 (8/12)(7/11)(6/11)(11/10) Printed in U.S.A.

550030170-Single Speed Powershift Aluminum Chain Drive-Us

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Maintenance

PART NO. 550030170 1300 YRM 1447

• 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.

©2013 Yale Materials Handling Corp. i

TABLE OF CONTENTS (Continued)

This section is for the following models:

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

1. TORQUE CONVERTER HOUSING

Figure 1. Serial Number

Hydraulic Gear Pump

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

1. Put a drain pan under hydraulic gear pump or VDP.

Figure 2. Hydraulic Gear Pump

Housing Fittings Replacement

Charge Pump Repair

2. Using a lifting device, remove transmission from lift

Figure 3. Housing Fittings and Hole Plug

solvents, always follow the manufacturer’s recom-

Compressed air can move particles so they cause

1. Clean metal components with solvent and dry with

2. Clean rubber or plastic components with warm

2. Inspect capscrews for damaged threads. Replace

3. Inspect suction screen for foreign material. Clean

See section Frame 100 YRM 1423 for install pro-

WARNING 5. Using lifting device, install engine in lift truck.

LIFT TRUCKS MANUFACTURED AFTER • GLP/GDP16VX, GLP/GDP18VX,

NOTE: Perform Step 1 through Step 3 if engine and Clean

3. Inspect suction screen for foreign material. Clean

1. WASHER 4. CHARGE PUMP GASKET

Figure 6. Charge Pump

The engine can weigh approximately 194 kg (428 lb).

The transmission can weigh approximately 84 kg

See section Frame 100 YRM 1423 for install pro-

5. Remove lifting device from eyebolt bracket.

6. Dispose of drip pan contents.

Torque Converter Replacement

See section Frame 100 YRM 1423 for install pro-

5. Install hydraulic gear pump or variable displace-

WARNING The transmission can weigh approximately 84 kg

Stator Support Assembly Repair

See section Frame 100 YRM 1423 for removal pro-

2. Using a lifting device, remove transmission from lift

See section Frame 100 YRM 1120 for removal pro-

9. Remove two pressure transducers from transmis-

Legend for Figure 11

NOTE: CHARGE PUMP FOR LIFT TRUCKS MANU-

Figure 11. Transmission Housing Components

1. TRANSMISSION HOUSING 4. O-RING

Figure 14. Transmission and Converter Housings

Figure 15. Pry Points

1. REVERSE CLUTCH ASSEMBLY

Figure 17. Reverse Clutch

Figure 16. Forward Clutch

1. STATOR SUPPORT ASSEMBLY

Figure 19. Stator Support