Maintenance
MAIN CONTROL VALVE
GLC050LX [A967];
GLP/GDP20-25LX (GLP/GDP050LX) [A974];
GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX [C809];
GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) [C810];
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) [A910];
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) [B875];
GLC40, 45, 55VX; GLC55SVX (GC/GLC080, 100, 120VX; GC/GLC080,
100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS)
[E818, F818];
GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/
GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX )
[F813, G813, H813, J813];
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];
GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/
GDP175VX36, GLP/GDP190VX) [A909, B909]
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 technicians. Failure to properly maintain equipment or to follow instructions con-
tained 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. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK
ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the
specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to re-
move 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 man-
ual:
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 back-
ground. The CAUTION symbol and word are on yellow background.
©2014 Yale Materials Handling Corp.
TABLE OF CONTENTS
General ..................................................................................................................................................................... 1
Electro-Hydraulic Main Control Valve ....................................................................................................................... 2
Description ............................................................................................................................................................2
Remove .............................................................................................................................................................. 10
Electro-Hydraulic Control Valve Sections ........................................................................................................... 17
General .......................................................................................................................................................... 17
Outlet Control Valve Section .......................................................................................................................... 17
Remove ......................................................................................................................................................17
Disassemble .............................................................................................................................................. 17
Clean ..........................................................................................................................................................20
Inspect ....................................................................................................................................................... 20
Assemble ................................................................................................................................................... 21
Install ..........................................................................................................................................................22
Auxiliary Control Valve Sections .................................................................................................................... 22
Remove ......................................................................................................................................................22
Disassemble .............................................................................................................................................. 28
Clean ..........................................................................................................................................................30
Inspect ....................................................................................................................................................... 30
Assemble ................................................................................................................................................... 30
Install ..........................................................................................................................................................32
Tilt Control Valve Section ............................................................................................................................... 33
Remove ......................................................................................................................................................33
Disassemble .............................................................................................................................................. 33
Clean ..........................................................................................................................................................39
Inspect ....................................................................................................................................................... 39
Assemble ................................................................................................................................................... 39
Install ..........................................................................................................................................................40
Lift/Lower Control Valve Section .................................................................................................................... 41
Remove ......................................................................................................................................................41
Disassemble .............................................................................................................................................. 41
Clean ..........................................................................................................................................................51
Inspect ....................................................................................................................................................... 51
Assemble ................................................................................................................................................... 52
Install ..........................................................................................................................................................53
Mid-Inlet Section ............................................................................................................................................ 54
Remove ......................................................................................................................................................54
Clean ..........................................................................................................................................................54
Inspect ....................................................................................................................................................... 54
Install ..........................................................................................................................................................54
Install .................................................................................................................................................................. 55
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment ............................................................................59
Lift Pilot Pin .................................................................................................................................................... 59
Lower Pilot Pin ............................................................................................................................................... 62
Abnormal/Erroneous EHPV Adjustment ........................................................................................................ 64
Manual Main Control Valve ..................................................................................................................................... 65
Description ..........................................................................................................................................................65
Remove .............................................................................................................................................................. 69
OPS Solenoid Assembly .................................................................................................................................... 77
General .......................................................................................................................................................... 77
Remove .......................................................................................................................................................... 78
Table of Contents
i
TABLE OF CONTENTS (Continued)
Clean and Inspect .......................................................................................................................................... 80
Install .............................................................................................................................................................. 80
Manual Control Valve Sections .......................................................................................................................... 81
General .......................................................................................................................................................... 81
Outlet Control Valve Section .......................................................................................................................... 81
Remove ......................................................................................................................................................81
Disassemble .............................................................................................................................................. 81
Clean ..........................................................................................................................................................84
Inspect ....................................................................................................................................................... 84
Assemble ................................................................................................................................................... 84
Install ..........................................................................................................................................................85
Auxiliary Control Valve Sections .................................................................................................................... 86
Remove ......................................................................................................................................................86
Disassemble .............................................................................................................................................. 86
Clean ..........................................................................................................................................................89
Inspect ....................................................................................................................................................... 89
Assemble ................................................................................................................................................... 89
Install ..........................................................................................................................................................90
Lift/Tilt Control Valve Section ......................................................................................................................... 90
Remove ......................................................................................................................................................90
Disassemble .............................................................................................................................................. 90
Clean ..........................................................................................................................................................96
Inspect ....................................................................................................................................................... 96
Assemble ................................................................................................................................................... 97
Install ..........................................................................................................................................................98
Mid-Inlet Section ............................................................................................................................................ 99
Remove ......................................................................................................................................................99
Clean ..........................................................................................................................................................99
Inspect ....................................................................................................................................................... 99
Install ..........................................................................................................................................................99
Install ................................................................................................................................................................ 100
Pressure Relief Valve Check and Adjustment ...................................................................................................... 107
Primary Relief Valve ......................................................................................................................................... 108
Secondary Relief Valve .................................................................................................................................... 111
Steering Control Unit Repair ................................................................................................................................. 115
Steering Control Unit, Remove ......................................................................................................................... 115
Steering Control Unit, Disassemble ..................................................................................................................119
Steering Control Unit, Clean ............................................................................................................................. 121
Steering Control Unit, Inspect ...........................................................................................................................121
Steering Control Unit, Assemble ...................................................................................................................... 121
Relief Valve, Disassemble ................................................................................................................................ 122
Relief Valve, Clean ........................................................................................................................................... 122
Relief Valve, Inspect ......................................................................................................................................... 123
Relief Valve, Assemble .....................................................................................................................................123
Steering Control Unit, Install ............................................................................................................................. 123
Table of Contents
ii
This section is for the following models:
(GLC050LX) [A967];
GLP/GDP20-25LX (GLP/GDP050LX) [A974];
(GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX) [C809];
GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) [C810];
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) [A910];
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) [B875];
GLC40, 45, 55VX; GLC55SVX (GC/GLC080, 100, 120VX; GC/GLC080,
100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) [E818, F818];
GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX ) [F813, G813, H813, J813];
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];
GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/
GDP175VX36, GLP/GDP190VX) [A909, B909]
Table of Contents
iii
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