Maintenance
BRAKE SYSTEM
GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX,
GP/GLP/GDP155VX) [C878, D878, E878]; GLC/GDC60VX,
GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) [C879,
D879, E879, F879]; GLC40, 45, 55VX; GLC55SVX (GC/GLC080,
100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX;
GC/GLC120VXPRS) [E818]; GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090,
100, 110, 120VX) [F813, G813, H813]; GLP/GDP80VX,
GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36,
GLP/GDP190VX) [A909, B909]
PART NO. 524262279 1800 YRM 1247
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.
Brake System Table of Contents
TABLE OF CONTENTS
General ................................................................................................................................................................ 1
Dry Brake System ........................................................................................................................................... 1
Wet Brake System........................................................................................................................................... 1
Service Brakes Repair (Dry Brake) ..................................................................................................................... 4
Remove and Disassemble .............................................................................................................................. 4
Clean ............................................................................................................................................................... 6
Inspect ............................................................................................................................................................. 7
Assemble and Install ....................................................................................................................................... 7
Adjust .............................................................................................................................................................. 11
Parking Brake Repair........................................................................................................................................... 11
Remove and Disassemble .............................................................................................................................. 11
Assemble and Install ....................................................................................................................................... 19
Adjust .............................................................................................................................................................. 20
Dry Brake System ....................................................................................................................................... 20
Wet Brake System ...................................................................................................................................... 20
Lift Trucks With a Foot Directional Control Pedal or Forward Reverse Lever.............................................. 20
Master Cylinder Repair ........................................................................................................................................ 21
Remove ........................................................................................................................................................... 21
Disassemble.................................................................................................................................................... 24
Clean and Inspect ........................................................................................................................................... 24
Assemble ........................................................................................................................................................ 24
Install and Adjust ............................................................................................................................................. 24
Accumulator......................................................................................................................................................... 27
Pre-Charge Check .......................................................................................................................................... 27
Remove ........................................................................................................................................................... 29
Install ............................................................................................................................................................... 30
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator .............................................................. 31
Remove ........................................................................................................................................................... 31
Modulating Brake Valve................................................................................................................................... 32
Disassemble ............................................................................................................................................... 32
Clean and Inspect ....................................................................................................................................... 33
Assemble .................................................................................................................................................... 33
Accumulator Charge Valve .............................................................................................................................. 34
Disassemble ............................................................................................................................................... 34
Clean and Inspect ....................................................................................................................................... 36
Assemble .................................................................................................................................................... 36
Install ............................................................................................................................................................... 37
Pressure Checks ............................................................................................................................................. 37
Accumulator Charge Valve Check .............................................................................................................. 37
Accumulator Check ..................................................................................................................................... 38
Service Brakes Adjustment (Dry Brake) .............................................................................................................. 38
Service Brakes Adjustment ............................................................................................................................. 38
Brake System Air Removal .................................................................................................................................. 40
Using Pressure Bleed System ........................................................................................................................ 40
Using Brake Pedal Pressure ........................................................................................................................... 40
Lift Truck Models with Master Cylinder ....................................................................................................... 40
Lift Truck Models with Modulating Brake Valve ........................................................................................... 41
Brake Pedal Adjustment ...................................................................................................................................... 42
For Lift Truck Models GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080,
100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818), GLP/GDP40VX5/VX6;
GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX)
©2013 Yale Materials Handling Corp. i
Table of Contents Brake System
TABLE OF CONTENTS (Continued)
(F813, G813, H813), GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
(C879, D879, E879, F879), and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX,
GP/GLP/GDP155VX) (C878, D878, E878) ..................................................................................................... 42
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX,
GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) ..................................................................................... 43
Free Pedal Adjustment ........................................................................................................................................ 44
Torque Specifications .......................................................................................................................................... 45
For Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX,
GC/GLC/GDC155VX) (C879, D879, E879, F879), GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX ) (F813,
G813, H813)GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080,
100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) and GLP/GDP60VX, GLP/GDP70VX
(GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)............................................................. 45
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX,
GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) ................................................................................. 45
This section is for the following models:
GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX)
[C878, D878, E878];
GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
[C879, D879, E879, F879];
GLC40, 45, 55VX; GLC55SVX (GC/GLC080, 100, 120VX; GC/GLC080,
100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) [E818];
GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX) [F813, G813, H813];
GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX,
GLP/GDP175VX36, GLP/GDP190VX) [A909, B909]
ii
1800 YRM 1247 General
General
DRY BRAKE SYSTEM
NOTE: The dry brake system is used only on lift truck
models
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100,
120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX;
GC/GLC120VXPRS) (E818)
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080,
090, 100, 110, 120VX) (F813, G813, H813)
This section has service procedures for the dry brake
system. The dry brake system includes the following
parts: master cylinder and parking brake system (see
Figure 1) and brake shoes and wheel cylinders (see
Figure 6).
WET BRAKE SYSTEM
NOTE: The wet brake system is used on all lift truck
models covered in this YRM.
The wet brake system in this section includes the follow-
ing parts: master cylinder and parking brake system.
See Figure 2 for lift truck models
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100,
120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX;
GC/GLC120VXPRS) (E818)
See Figure 3 for lift truck models
• GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/
GDC135VX, GC/GLC/GDC155VX) (C879, D879,
E879, F879)
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
GDP135VX, GP/GLP/GDP155VX) (C878, D878,
E878)
See Figure 4 for lift truck models
• GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX
(GLP/GDP170VX, GLP/GDP175VX36, GLP/
GDP190VX) (A909, B909)
See Figure 5 for lift truck models
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080,
090, 100, 110, 120VX ) (F813, G813, H813)
The wet disc brakes are a component of the wet brake
drive axle. The brake discs are located inside the plan-
etary carrier housing at each end of the drive axle. For
the removal, assembly and installation procedures see:
1. PARK BRAKE HANDLE ASSEMBLY
2. ADJUSTMENT KNOB
3. PARK BRAKE CABLES
4. INCHING/BRAKE PEDAL
5. MASTER CYLINDER AND BOOSTER
6. BRAKE ASSEMBLY
7. BRAKE POSITION SENSOR (RIGHT-HAND
SIDE)
Figure 1. Dry Brake System
Drive Axle and Differential Assembly Repair, (Wet
Brake) 1400 YRM 1246 for lift truck models
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100,
120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX;
GC/GLC120VXPRS) (E818)
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080,
090, 100, 110, 120VX) (F813, G813, H813)
1
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