Maintenance

BRAKE SYSTEM
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]; GLC050LX [A967];
GLP/GDP20-25LX (GLP/GDP050LX) [A974]

PART NO. 524223765 1800 YRM 1135

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed
the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and when
working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING
Indicates a hazardous situation which, if not avoided, could result in death or
serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange background.
The CAUTION symbol and word are on yellow background.
Brake System Table of Contents

TABLE OF CONTENTS

General................................................................................................................................................................ 1
Dry Brake System ........................................................................................................................................... 1
Wet Brake System........................................................................................................................................... 1
Service Brakes Repair (Dry Brake) ..................................................................................................................... 2
Remove and Disassemble .............................................................................................................................. 2
Clean............................................................................................................................................................... 9
Inspect............................................................................................................................................................. 10
Assemble and Install ....................................................................................................................................... 10
Adjust .............................................................................................................................................................. 17
Inching Overlap Adjustment ............................................................................................................................ 18
Parking Brake Repair........................................................................................................................................... 18
Remove and Disassemble .............................................................................................................................. 18
Assemble and Install ....................................................................................................................................... 21
Adjust .............................................................................................................................................................. 21
Master Cylinder Repair........................................................................................................................................ 22
Remove (Dry Brake)........................................................................................................................................ 22
Disassemble (Dry Brake) ................................................................................................................................ 22
Clean and Inspect (Dry Brake)........................................................................................................................ 22
Assemble (Dry Brake) ..................................................................................................................................... 22
Bench Bleed Master Cylinder (Dry Brake) ...................................................................................................... 25
Install and Adjust (Dry Brake) ......................................................................................................................... 25
Remove (Wet Brake) ....................................................................................................................................... 25
Disassemble (Wet Brake)................................................................................................................................ 26
Clean and Inspect (Wet Brake) ....................................................................................................................... 28
Assemble (Wet Brake) .................................................................................................................................... 28
Install and Adjust (Wet Brake)......................................................................................................................... 28
Service Brakes Adjustment (Dry Brake) .............................................................................................................. 29
Brake System Air Removal.................................................................................................................................. 29
Using Pressure Bleed System ........................................................................................................................ 29
Using Brake Pedal Pressure ........................................................................................................................... 30
Brake Pedal Adjustment ...................................................................................................................................... 31
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),GLC050LX (A967),GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GLP/GDP20-25LX
(GLP/GDP050LX) (A974)................................................................................................................................ 31
Free Pedal Adjustment ........................................................................................................................................ 32
Torque Specifications .......................................................................................................................................... 33

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];
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) [B875];
GLC050LX [A967];
GLP/GDP20-25LX (GLP/GDP050LX) [A974]

©2011 Yale Materials Handling Corp. i

1800 YRM 1135 General

General
DRY BRAKE SYSTEM WET BRAKE SYSTEM
This section has service procedures for the dry brake The wet brake system in this section includes the follow-
system. The dry brake system includes the following ing parts: master cylinder and parking brake system.
parts: master cylinder, brake shoes, wheel cylinders, See Figure 2.
and parking brake system.
The wet disc brakes are a component of the wet brake
drive axle. The brake discs are located inside the plan-
etary carrier housing on the left side of the drive axle.
See Drive Axle Repair, (Wet Brake) 1400 YRM 1215
for Remove, Assemble and Install procedures. See Fig-
ure 2.

1. PARK BRAKE 7. BRAKE OIL

HAND LEVER SUPPLY HOSE
2. INCH/BRAKE 8. ADJUSTMENT
1. PARK BRAKE LEVER PEDAL KNOB
2. ADJUSTMENT KNOB 3. MASTER 9. BRAKE POSITION
3. PARK BRAKE CABLES CYLINDER AND SENSOR
4. INCHING/BRAKE PEDAL BOOSTER 10. BRAKE POSITION
5. MASTER CYLINDER 4. PARK BRAKE SENSOR
6. BRAKE ASSEMBLY LEVER CONNECTOR
7. BRAKE POSITION SENSOR (RIGHT HAND 5. WET DISC BRAKE 11. BRAKE OIL
SIDE) HOUSING RESERVOIR
6. PLANETARY 12. PARKING BRAKE
CARRIER CABLE BRACKET
Figure 1. Brake System HOUSING (RIGHT 13. PARKING BRAKE
SIDE SHOWN) CABLE

Figure 2. Wet Brake System for Lift Truck Model

GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)

1
Service Brakes Repair (Dry Brake) 1800 YRM 1135

Service Brakes Repair (Dry Brake)

REMOVE AND DISASSEMBLE • GLC050LX (A967)
• GLP/GDP20-25LX (GLP/GDP050LX) (A974)
WARNING a. Bend bearing lockwasher tabs to release lock-
Brake linings can contain dangerous fibers. nut.
Breathing the dust from these brake linings is
a cancer or lung disease hazard. DO NOT create b. Remove nut, lockwasher, locknut, and roller
dust! DO NOT clean brake parts with compressed bearing from hub/brake assembly. See Fig-
air or by brushing. Use vacuum equipment ap- ure 3.
proved for brake dust or follow the cleaning pro-
cedure in this section. When the brake drums are WARNING
removed, DO NOT create dust.
When the brake shoes are removed, do not create
DO NOT sand, grind, chisel, hammer, or change lin- dust in the air. See the Clean procedure in this sec-
ings in any way that will create dust. Any changes tion.
to brake linings must be done in a restricted area
c. Pull the wheel assembly from the lift truck. If
with special ventilation. Protective clothing and a
the wheel assembly cannot be removed easily,
respirator must be used.
use a small screwdriver to push the adjuster
1. Remove the capscrews that hold the axle shaft to actuator away from the adjuster wheel. Use a
the hub. Remove the axle shaft. brake adjustment tool or a screwdriver to turn
the adjuster wheel to loosen the brake shoes.
2. See the procedure How to Put Lift Truck on Blocks Remove the hub and drum assembly. DO NOT
in the Periodic Maintenance section for your lift damage the grease seal when removing the
truck or the Operating Manual for your lift truck. hub.
Put the lift truck on blocks so the drive wheels can
be removed. Remove the drive wheels. d. Remove inner oil seal, inner bearing, and wear
sleeve from hub. See Figure 3.
3. Perform the following steps for lift truck models:

2
1800 YRM 1135 Service Brakes Repair (Dry Brake)

1. CAPSCREW 14. LEFT BRAKE LINE

2. DRIVE AXLE SHAFT 15. DRIVE AXLE MOUNTING CAPSCREW
3. LOCKNUT 16. DRIVE AXLE MOUNTING NUT
4. BEARING LOCKWASHER 17. DIFFERENTIAL COVER
5. WASHER 18. RIGHT BRAKE LINE
6. HUB/BRAKE ASSEMBLY 19. DRIVE AXLE CENTER SECTION UNIVERSAL
7. HUB BOLT JOINT
8. ROLLER BEARING 20. UNIVERSAL JOINT
9. OUTER SEAL 21. DUST COVER
10. INNER BEARING 22. INPUT SHAFT (YOKE)
11. INNER OIL SEAL 23. BRAKE MANIFOLD
12. WEAR SLEEVE 24. HANGER ASSEMBLY
13. BRAKE ASSEMBLY

Figure 3. Drive Axle Components, Lift Truck Models GLC050LX (A967) and GLP/GDP20-25LX
(GLP/GDP050LX) (A974)

3
Service Brakes Repair (Dry Brake) 1800 YRM 1135

4. Perform the following steps for lift truck models: • GC/GLC030-035VX, GC/GLC040SVX [C809]
• GC/GLC030VX, GC/GLC035VX, • GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/
GC/GLC040SVX (C809) GDP030-035VX, GP/GLP/GDP040SVX) [C810]
• GLP/GDP16VX, GLP/GDP18VX, • GLC050LX [A967]
GLP/GDP20SVX (GP/GLP/GDP030VX, • GLP/GDP20-25LX (GLP/GDP050LX) (A974)
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810) 6. Remove the retainers, springs, and anchor pins that
• GLC20-35VX (GC/GLC040-070VX, hold the brake shoes to the back plate.
GC/GLC055SVX) (A910)
7. Disengage the link from the adjuster wheel actua-
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
tor. Remove the link, washer, and pivot plate. Re-
(B875)
move the anchor guide.
a. Bend the lock plate and remove the nut that
8. Move the brake shoes away from each other to dis-
holds the axle bearing. Remove the washer
engage the brake shoes from the wheel cylinder.
and the bearing cone.
Disconnect the parking brake lever from the park-
ing brake cable as the brake assembly is removed
WARNING from the back plate. The parking brake lever has a
When the brake shoes are removed, DO NOT create hook that engages the parking brake cable.
dust in the air. See the Clean procedure in this sec-
tion. NOTE: The adjuster wheel for the left brake is not the
same as the adjuster wheel for the right brake. The
b. Pull the wheel assembly from the lift truck. If adjuster wheel for the left brake has left-hand threads.
the wheel assembly cannot be removed easily,
use a small screwdriver to push the adjuster 9. Remove the parking brake link and spring if they are
actuator away from the adjuster wheel. Use a still engaged with brake shoes. The parking brake
brake adjustment tool or a screwdriver to turn link and spring will often fall from the brake assem-
the adjuster wheel to loosen the brake shoes. bly when the brake assembly is removed from the
Remove the hub and drum assembly. DO NOT back plate. The adjuster wheel will also disengage
damage the grease seal when removing the from the brake shoes after the brake assembly is
hub. removed.

NOTE: Note arrangement of brake parts during disas- 10. Remove the spring for the adjuster wheel actuator.
sembly to aid in assembly. Remove the adjuster wheel actuator from the brake
shoe.
5. Remove the return springs with spring pliers.
11. Use a screwdriver or small pry bar to move apart
See Figure 4 and Figure 5 for lift truck models: the ends of the retainer. Remove the spring washer
• GLC20-35VX (GC/GLC040-070VX, and pivot pin to remove the parking brake lever from
GC/GLC055SVX) [A910] the brake shoe.
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
[B875] 12. Disconnect the brake line from the wheel cylinder.
Remove the capscrews that hold the wheel cylinder
See Figure 6 and Figure 7 for lift truck models: to the back plate and remove the wheel cylinder.

4
1800 YRM 1135 Service Brakes Repair (Dry Brake)

1. WHEEL CYLINDER 11. ADJUSTER WHEEL

2. RETURN SPRING 12. ADJUSTER ASSEMBLY
3. RETURN SPRING 13. PRIMARY BRAKE SHOE
4. ANCHOR 14. PARKING BRAKE LEVER
5. ANCHOR GUIDE 15. LINK, PARKING BRAKE
6. BACK PLATE 16. SPRING, PARKING BRAKE
7. SECONDARY BRAKE SHOE 17. PIVOT PIN, RETAINER, AND SPRING WASHER
8. LEVER 18. ADJUSTER ACTUATOR SPRING
9. PIVOT PLATE 19. SPRING
10. SPRING AND CABLE ASSEMBLY

Figure 4. Brake Assembly (Left-Hand Shown), GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) [A910]

and GLP/GDP20-35VX (GP/GLP/GDP040-070VX) [B875]

5
Service Brakes Repair (Dry Brake) 1800 YRM 1135

NOTE: RIGHT-HAND BRAKE ASSEMBLY SHOWN.

1. WHEEL CYLINDER 12. ADJUSTER ASSEMBLY
2. RETURN SPRING 13. PRIMARY BRAKE SHOE
3. RETURN SPRING 14. PARKING BRAKE LEVER
4. ANCHOR 15. PARKING BRAKE LINK
5. ANCHOR GUIDE 16. PARKING BRAKE SPRING
6. BACK PLATE 17. PIVOT PIN, RETAINER, AND SPRING WASHER
7. SECONDARY BRAKE SHOE 18. ADJUSTER ACTUATOR SPRING
8. LEVER 19. SPRING
9. PIVOT PLATE 20. RETAINING PIN
10. ADJUSTER ACTUATOR LINK 21. RETAINING WASHER
11. ADJUSTER WHEEL 22. PARKING BRAKE CABLE

Figure 5. Service Brake Parts, GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) [A910] and

GLP/GDP20-35VX (GP/GLP/GDP040-070VX) [B875]

6
1800 YRM 1135 Service Brakes Repair (Dry Brake)

1. BACKING PLATE 9. SPRING (ACTUATOR)

2. RETAINING RING 10. PAWL LEVER
3. LEVER PIN 11. SECONDARY BRAKE SHOE
4. GUIDE PLATE 12. ADJUSTER ASSEMBLY
5. WHEEL CYLINDER 13. ADJUSTER SPRING
6. PAWL LEVER STOPPER 14. PARK BRAKE LEVER
7. SPRING (ANTI-RATTLE) 15. PRIMARY BRAKE SHOE
8. RETURN SPRING 16. STRUT

Figure 6. Brake Assembly (Left Hand Side), GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX

(C809), GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GP/GLP/GDP040SVX) (C810), GLC050LX (A967), and GLP/GDP20-25LX (GLP/GDP050LX) (A974)

7
Service Brakes Repair (Dry Brake) 1800 YRM 1135

1. BOLT 13. PAWL LEVER

2. WHEEL CYLINDER 14. PARK BRAKE CABLE
3. STRUT 15. ADJUSTER ASSEMBLY
4. SPRING 16. PLUG
5. SECONDARY BRAKE SHOE 17. SPRING (ADJUSTER)
6. PLATE 18. PRIMARY BRAKE SHOE
7. SPRING 19. PARK BRAKE LEVER
8. LEVER (STOP) 20. PIN
9. SPRING 21. PLUG
10. WASHER 22. BACKING PLATE
11. SPRING (SHOE HOLD DOWN) 23. PIN
12. WASHER

Figure 7. Service Brake Parts, GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809), GLP/GDP16VX,

GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810),
GLC050LX (A967), and GLP/GDP20-25LX (GLP/GDP050LX) (A974)

8
1800 YRM 1135 Service Brakes Repair (Dry Brake)

NOTE: The back plate is not normally removed from the solvents, always follow the safety instructions of
axle housing for brake repairs. Special capscrews are the solvent manufacturer.
used to fasten the back plate to the axle mount, and the
locking function of the capscrews is reduced if they are 1. DO NOT release brake lining dust from the brake
removed. linings into the air when the brake drum is removed.

13. Remove special capscrews if necessary. 2. Use a solvent approved for cleaning of brake parts
to wet the brake lining dust. Follow the instructions
14. Remove the push rods, dust covers, pistons, cups, and cautions of the manufacturer for the use of the
and spring from the wheel cylinder. See Figure 8. solvent. If a solvent spray is used, spray at a dis-
tance so that the dust is not released into the air.
CLEAN
3. When the brake lining dust is wet, clean the parts.
Put any cloth or towels in a plastic bag or an airtight
WARNING
container while they are still wet. Put a DANGER-
DO NOT use an oil solvent to clean the master cylin- OUS FIBERS warning label on the plastic bag or
der, wheel cylinder, or brake linings. Use a solvent airtight container.
approved for cleaning of brake parts. DO NOT per-
mit oil or grease in the brake fluid or on the brake
linings. Oil and grease will cause damage and leaks CAUTION
in the seals of a brake system. The brakes will not DO NOT permit oil or grease on the brake linings.
operate correctly if oil, grease, or brake fluid is on Use a brake cleaning fluid as necessary to clean
the brake linings. linings that will not be replaced.

Cleaning solvents can be flammable and toxic and 4. Any cleaning cloths that will be washed must be
can cause skin irritation. When using cleaning cleaned so that fibers are not released into the air.

1. PUSH ROD (2) 4. CUP (2) 7. INLET PORT

2. DUST COVER (2) 5. SPRING 8. PRESSURE BLEEDER
3. PISTON (2) 6. WHEEL CYLINDER BODY 9. DUST COVER

Figure 8. Wheel Cylinder

9
Service Brakes Repair (Dry Brake) 1800 YRM 1135

INSPECT 6. Make sure the parking brake cables are in good

condition.
1. Inspect the bore of the wheel cylinder for holes or
scratches. Replace the wheel cylinder assembly if 7. Check the grease seals and the surfaces of the
there is any damage. seals for wear or damage.

2. Inspect the return springs for wear and damage. ASSEMBLE AND INSTALL
Inspect the back plate for wear where the brake
shoes touch the back plate. Remove any grooves 1. If removed, install back plate to drive axle. Tighten
or replace a worn or damaged back plate. special screws as indicated below:

a. Eight special capscrews are tightened to 255 to

WARNING 306 N•m (188 to 226 lbf ft) for lift truck models
The brake shoes on both wheels must be replaced • GLC20-35VX (GC/GLC040-070VX,
if any shoe is damaged. The brake performance on GC/GLC055SVX) [A910]
both ends of an axle must be equal, or the lift truck • GLP/GDP20-35VX (GP/GLP/GDP040-
can be difficult to steer when the brakes are applied. 070VX) [B875]
3. Inspect the brake shoes for cracks or damage. If b. Six special capscrews are tightened to 152 to
the linings or shoes are worn or damaged, replace 167 N•m (112 to 123 lbf ft) for lift truck models
the brake shoes. Maximum wear is to within 1 mm • GC/GLC030-035VX, GC/GLC040SVX
(0.039 in.) of contact with the rivets, or the metal [C809]
shoe on bonded linings. Brake shoes must be re- • GLP/GDP16-18VX, GLP/GDP20SVX
placed in complete sets. Inspect the brake drums (GP/GLP/GDP030-035VX, GP/GLP/
for cracks or damage. Replace any damaged parts. GDP040SVX) [C810]
• GLC050LX (A967)
4. Inspect the brake drum for deep grooves or other • GLP/GDP20-25LX (GLP/GDP050LX) (A974)
damage.
2. If the wheel cylinder was disassembled for repair,
NOTE: If grooves must be removed from the brake assemble the wheel cylinder. See Figure 8. Use
drums, DO NOT grind more than 1.5 mm (0.060 in.) only YALE APPROVED parts.
from the internal diameter of the brake drum.
3. Install the wheel cylinder on the back plate and
The maximum limit of the internal diameter of the brake tighten the two capscrews to 18 to 27 N•m (13 to
drum is 312 mm (12.28 in.) for lift truck models 20 lbf ft). Connect the brake line to the wheel cylin-
• GLC20-35VX (GC/GLC040-070VX, der.
GC/GLC055SVX) (A910)
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) 4. Install the parking brake lever. Use the pivot pin,
(B875) spring washer, and retainer to fasten the parking
brake lever to the brake shoe. Close the ends of
The maximum limit of the internal diameter of the brake the retainer to fasten the pivot pin in position.
drum is 255.5 mm (10.06 in.) for lift truck models
• GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX See Figure 5 for lift truck models
(C809) • GLC20-35VX (GC/GLC040-070VX,
• GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX GC/GLC055SVX) (A910)
(GP/GLP/GDP030VX, GP/GLP/GDP035VX, • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
GP/GLP/GDP040SVX) (C810) (B875)
• GLC050LX (A967)
• GLP/GDP20-25LX (GLP/GDP050LX) (A974) See Figure 7 for lift truck models
• GC/GLC030VX, GC/GLC035VX,
If the internal diameter is larger than the limit, replace GC/GLC040SVX (C809)
the brake drum. • GLP/GDP16VX, GLP/GDP18VX,
GLP/GDP20SVX (GP/GLP/GDP030VX,
5. The teeth of the adjuster wheel must not be worn. GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
The adjuster wheel must turn freely. Check the ad- (C810)
juster links for damage.

10
1800 YRM 1135 Service Brakes Repair (Dry Brake)

• GLC050LX (A967) 11. Install the other spring retainer that holds the brake
• GLP/GDP20-25LX (GLP/GDP050LX) (A974) shoes. Make sure the parking brake link and the
spring are correctly engaged after the spring retain-
5. Fasten the adjuster actuator spring to the adjuster ers are installed.
wheel actuator and the brake shoe.
12. Install the anchor guide on the anchor. Install the
6. Put antiseize compound on the threads of the ad- pivot plate on its anchor.
juster wheel. Turn the adjuster wheel into the ad-
juster nut so that the adjuster assembly is in its 13. Lubricate the adjuster cable where it slides in the
shortest position. This action permits the brake pivot plate groove.
drum to be easily installed over the brake shoes.
14. Fasten the link to the adjuster wheel actuator and
put the cable around the pivot plate. Raise the ad-
WARNING juster wheel actuator against the spring tension and
The threads of the adjuster wheel are not the same connect the link to the anchor.
for each side. If the adjuster assemblies are in-
stalled on the wrong side, the brake shoe clearance
CAUTION
will increase each time the brakes are applied. The
adjuster wheel for the right brake has right-hand For GLC20-35VX (GC/GLC040-070VX,
threads. The adjuster wheel for the left brake has GC/GLC055SVX) [A910] and GLP/GDP20-35VX
left-hand threads. (GP/GLP/GDP040-070VX) [B875]: Be sure to install
the white return spring first and then the black
7. Install the adjuster wheel between the two brake return spring. See Figure 10. Improper assembly
shoes. Make sure the adjuster wheel will be toward can result in brake failure and/or component
the rear of the lift truck. Move the brake shoes apart damage.
so that the adjuster wheel is held in position and the
adjuster actuator spring is in tension. NOTE: The shape of the return springs permits them to
be installed correctly in only one position. The arrange-
8. Lubricate the back plate with a small amount of ment of the return springs on the anchors is shown in
lithium grease where the brake shoes touch. In- Figure 9 and Figure 10 for lift truck models
stall the brake shoes on the anchor and engage the • GLC20-35VX (GC/GLC040-070VX,
push rods of the wheel cylinder. Engage the park- GC/GLC055SVX) (A910)
ing brake lever in the slot in the parking brake cable • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
as the brake shoes are installed on the back plate. (B875)

9. Put an anchor pin that holds the brake shoes 15. Using the correct tools, install the return springs as
through the back plate. Put a spring seat, spring, follows:
and retainer on the anchor pin. Push the retainer
onto the anchor pin and rotate the retainer 90 a. Install the white spring.
degrees. Make sure the retainer is in the correct
b. Install the black spring.
position.
c. Verify that the return springs are properly in-
10. Install the link, parking brake, and spring between
stalled as shown in Figure 10.
the parking brake lever and the brake shoe.

11
Service Brakes Repair (Dry Brake) 1800 YRM 1135

1. RETURN SPRING 4. ADJUSTER ACTUATOR LINK

2. ANCHOR GUIDE 5. PIVOT PLATE
3. RETURN SPRING

Figure 9. Return Springs, GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) [A910] and GLP/GDP20-35VX

(GP/GLP/GDP040-070VX) [B875]

NOTE: The shape of the return springs permits them to b. Install washer.
be installed correctly in only one position. The arrange-
ment of the return springs on the anchors is shown in c. Install return spring.
Figure 11 for lift truck models
d. Verify that the return springs are properly in-
• GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX
stalled as shown in Figure 11.
(C809)
• GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX NOTE: Seal and bearings are to be installed flush with
(GP/GLP/GDP030VX, GP/GLP/GDP035VX, the hub. Seal is to be installed with no grease or oil on
GP/GLP/GDP040SVX) (C810) outside surface.
• GLC050LX (A967)
• GLP/GDP20-25LX (GLP/GDP050LX) (A974) 17. Clean the bearings and lubricate them with wheel
bearing grease. Install the bearings and seals in
16. Using the correct tools, install the return springs as the brake drum. Install the assembly on the axle
follows: housing. See Figure 12 and Figure 13.
a. Install return spring.

12
1800 YRM 1135 Service Brakes Repair (Dry Brake)

1. WHITE SPRING 2. BLACK SPRING

Figure 10. Proper Installation of Return Springs, GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) [A910]
and GLP/GDP20-35VX (GP/GLP/GDP040-070VX) [B875]

13
Service Brakes Repair (Dry Brake) 1800 YRM 1135

1. RETURN SPRING 3. RETURN SPRING

2. GUIDE PLATE 4. SPRING ACTUATOR

Figure 11. Return Springs, GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809), GLP/GDP16VX,

GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810),
GLC050LX (A967), and GLP/GDP20-25LX (GLP/GDP050LX) (A974)

NOTE: To prevent damage to the inner oil seal when • GLP/GDP16VX, GLP/GDP18VX,
installing the hub, the hub and drum assembly can be GLP/GDP20SVX (GP/GLP/GDP030VX,
temporarily fastened to the wheel. Align the height of GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
the axle housing with hub bearings. Put grease under (C810)
the wheel and slide the wheel toward the axle housing. • GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910)
18. Install the outer bearing and nut, for lift truck mod- • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
els: (B875)
• GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809) Install the lockwasher, locknut and wheel adjust-
• GLP/GDP16VX, GLP/GDP18VX, ment nut for lift truck models:
GLP/GDP20SVX (GP/GLP/GDP030VX, • GLC050LX (A967)
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) • GLP/GDP20-25LX (GLP/GDP050LX) (A974)
(C810)
• GLC20-35VX (GC/GLC040-070VX, NOTE: Perform steps Step a through Step f for all lift
GC/GLC055SVX) (A910) truck models.
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
a. To align the bearing rollers, tighten the wheel
(B875)
adjustment nut to 14 to 18 N•m (124 to
Install wear sleeve, inner seal, inner bearing, outer 159 lbf in) and rotate the hub 2 revolutions
seal, roller bearing and nut, for lift truck models (see in both directions.
Figure 3:)
b. To seat the wheel bearings, tighten the wheel
• GLC050LX (A967)
adjustment nut to 175 to 215 N•m (129 to
• GLP/GDP20-25LX (GLP/GDP050LX) (A974)
159 lbf ft) for lift truck models
19. Install the washer, lock plate and wheel adjustment • GLC20-35VX (GC/GLC040-070VX,
nut for lift truck models: GC/GLC055SVX) (A910)
• GC/GLC030VX, GC/GLC035VX, • GLP/GDP20-35VX (GP/GLP/GDP040-
GC/GLC040SVX (C809) 070VX) (B875)

14
1800 YRM 1135 Service Brakes Repair (Dry Brake)

1. INNER SEAL 4. INNER BEARING

2. OUTER SEAL 5. OUTER BEARING
3. BRAKE DRUM

Figure 12. Grease Seals and Bearing Locations

c. To seat the wheel bearings, tighten the wheel d. Back off the wheel adjustment nut to zero end
adjustment nut to 120 to 145 N•m (89 to play.
107 lbf ft) for lift truck models
• GC/GLC030VX, GC/GLC035VX, e. Preload the wheel bearings by tightening the
GC/GLC040SVX (C809) wheel adjustment nut to 14 to 18 N•m (124 to
• GLP/GDP16VX, GLP/GDP18VX, GLP/ 159 lbf in). Rotate the hub 3 complete revolu-
GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ tions in both directions.
GDP035VX, GP/GLP/GDP040SVX) (C810)
f. Verify the wheel adjustment nut torque is 14 to
• GLC050LX (A967)
18 N•m (124 to 159 lbf in) and that the torque
• GLP/GDP20-25LX (GLP/GDP050LX) (A974)
stabilizes at that specification.

15
Service Brakes Repair (Dry Brake) 1800 YRM 1135

will not turn. Use a small screwdriver to lift the

actuator away from the adjuster wheel and turn
the adjuster wheel approximately 20 teeth in the
opposite direction. The brakes will adjust to the
correct clearance when they are applied while the
lift truck is traveling in the reverse direction.

22. Put liquid sealant, Yale Part Number 520042831,

on the flange of the axle shaft. Install the axle shaft
and capscrews. Tighten the capscrews in cross
pattern to a torque specified below for your lift truck.

a. Tighten between 90 to 99 N•m (66 to 73 lbf ft).

See Figure 15 for lift truck models
Figure 13. Inner Oil Seal Installation • GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910)
20. Bend the lock plate over the lock nut. See Fig-
ure 14, for lift truck models: b. Tighten between 90 to 108 N•m (66 to 80 lbf ft).
• GC/GLC030VX, GC/GLC035VX, See Figure 16 for lift truck models
GC/GLC040SVX (C809) • GLP/GDP20-35VX (GP/GLP/GDP040-
• GLP/GDP16VX, GLP/GDP18VX, 070VX) (B875)
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)

Bend bearing lockwasher over the lock nut. See

Figure 3 for lift truck models:
• GLC050LX (A967)
• GLP/GDP20-25LX (GLP/GDP050LX) (A974)

CAUTION
If there is too much clearance, the automatic ad-
justers will not operate. If the clearance is too
small, the automatic adjuster cannot turn the ad-
juster wheel to increase the clearance, and the
adjuster wheel will not turn until the brake shoes
wear. If the adjuster wheel does not move for a 1. LOCK PLATE
long operating period, the adjuster link can wear a 2. HUB/BRAKE DRUM ASSEMBLY
3. DOWEL PIN
spot on the adjuster wheel so that it will not turn
correctly. Figure 14. Lock Plate
NOTE: If the brake shoes were not replaced, loosen the c. Tighten between 52 to 62 N•m (39 to 46 lbf ft).
adjuster wheel approximately 20 teeth.
See Figure 15 for lift truck models:
21. Adjust the clearance of the brake shoes. Put a • GC/GLC030VX, GC/GLC035VX,
brake adjustment tool or a screwdriver through GC/GLC040SVX (C809)
the slot in the back plate. Use the tool to rotate • GLP/GDP16VX, GLP/GDP18VX, GLP/
the adjuster wheel. The actuator for the adjuster GDP20SVX (GP/GLP/GDP030VX, GP/GLP/
wheel will only permit rotation in one direction. GDP035VX, GP/GLP/GDP040SVX) (C810)
Turn the adjuster wheel until the brake shoes have • GLC050LX (A967)
expanded against the brake drum and the hub

16
1800 YRM 1135 Service Brakes Repair (Dry Brake)

See Figure 16 for lift truck model: c. Tighten between 155 to 175 N•m (115 to
• GLP/GDP20-25LX (GLP/GDP050LX) (A974) 130 lbf ft) 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)
• GLC050LX (A967)
• GLP/GDP20-25LX (GLP/GDP050LX) (A974)

3. Start the engine and tilt the mast backward to re-

move the blocks. Push on the brake pedal. The
pedal must not touch the floor plate. Move the lift
truck in REVERSE and push on the brake pedal
to permit adjusting mechanism to operate. Repeat
this operation several times.

4. The service brakes must be adjusted before the

parking brake can be adjusted. See Figure 18 and
the following paragraphs in this section for the cor-
rect adjustment of the parking brake.

Figure 15. Axle Shaft Tightening Sequence,

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/GLC055S, and GLC050LX (A967)

ADJUST
1. Remove the air from the brake hydraulic system.
See Brake System Air Removal.

2. Install the wheel on the hub. Tighten the wheel nuts

to the torque specified below for your lift truck.

a. Tighten between 340 to 380 N•m (251 to

280 lbf ft) for lift truck models
• GLC20-35VX (GC/GLC040-070VX, Figure 16. Axle Shaft Torque Sequence,
GC/GLC055SVX) (A910) GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)
and GLP/GDP20-25LX (GLP/GDP050LX) (A974)
b. Tighten between 450 to 500 N•m (332 to
369 lbf ft) for lift truck models
• GLP/GDP20-35VX (GP/GLP/GDP040-
070VX) (B875)

17
Parking Brake Repair 1800 YRM 1135

INCHING OVERLAP ADJUSTMENT

NOTE: Perform the following procedure for lift truck
models:
• GLC050LX (A967)
• GLP/GDP20-25LX (GLP/GDP050LX) (A974)

NOTE: The amount of overlap is adjustable through a

ten-point range with 1 being minimum, 10 the maxi-
mum, and 5 the default.

1. Set inching overlap to default using the following

procedure.

a. Start the engine and check inching overlap in-

dicator on display. Perform Step b or Step c to
adjust overlap.

b. To increase overlap, press Scroll Up button on

display switch cluster. See Figure 17.
1. SCROLL DOWN
c. To decrease overlap, press Scroll Down button 2. SCROLL UP
on display switch cluster. See Figure 17.
Figure 17. Display Switch Cluster

Parking Brake Repair

REMOVE AND DISASSEMBLE 4. Turn the adjuster knob counterclockwise until the
brake cables are loosened. Disconnect the cables
NOTE: For removal and disassembly procedures for a from the link.
dry brake system use Step 1 through Step 5. For a wet
brake system use Step 1 through Step 4 and Step 6. 5. The service brake assembly must be removed be-
fore the parking brake cable can be removed from
If the lever assembly for the parking brake must be re- the back plate of the service brake. A snap ring
moved from the cowl, use the following procedure. For holds the sheath of the parking brake cable in the
the dry brake system see Figure 18 and for the wet back plate of the service brake. Remove the snap
brake system see Figure 19. ring and remove the parking brake cable from the
back plate.
1. Block wheels front and rear side of the wheels to
make sure the lift truck cannot move. Release the 6. For GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
parking brake lever. (B875) lift trucks equipped with a wet brake system.
Remove the cotter pin and clevis pin from the park-
2. Remove the four capscrews that fasten the bracket
ing brake lever. Remove the capscrew, insert and
for the parking brake to the cowl. Remove the
cable clamps from the parking brake cable bracket
bracket and brake lever assembly.
before removing the park brake cable from lift truck.
3. Loosen the jam nuts that fasten the threaded ends
of the brake cables to the brake lever assembly.

18
1800 YRM 1135 Parking Brake Repair

1. PARKING BRAKE LEVER 6. BRAKE ASSEMBLY

2. ADJUSTMENT KNOB 7. BRAKE POSITION SENSOR
3. PARKING BRAKE CABLES 8. ADJUSTMENT SLOT
4. INCHING/BRAKE PEDAL 9. EQUALIZED LINK
5. MASTER CYLINDER 10. NUTS

Figure 18. Parking Brake Lever Adjustment With Dry Brake (Left Side Shown)

19
Parking Brake Repair 1800 YRM 1135

Figure 19. Parking Brake Lever Adjustment With Wet Brake for Lift Truck GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875)

20
1800 YRM 1135 Parking Brake Repair

Legend for Figure 19

A. REAR VIEW SHOWN B. REAR RIGHT SIDE SHOWN
1. PARKING BRAKE LEVER HANDLE 11. PARK BRAKE LEVER
2. BRAKE POSITION SENSOR CONNECTOR 12. UPPER PARKING BRAKE CABLE BRACKET
3. BRAKE POSITION SENSOR 13. CABLE CLAMP
4. ADJUSTMENT KNOB 14. CAPSCREW
5. EQUALIZED LINK 15. INSERT
6. CLEVIS PIN 16. MASTER CYLINDER AND BOOSTER
7. LOCK RING COTTER PIN 17. INCHING/BRAKE PEDAL
8. BRAKE OIL SUPPLY HOSE 18. LOWER PARKING BRAKE CABLE BRACKET
9. DRAIVE AXLE (WET BRAKE) 19. PARKING BRAKE CABLE
10. CLEVIS (PARKING BRAKE CABLE)

ASSEMBLE AND INSTALL 5. Lift trucks equipped with a dry brake system. Install
the round ends of the parking brake cables in their
NOTE: For Assemble and install procedures for a dry slots in the link. Tighten the upper jam nuts to hold
brake system use Step 1, Step 3 through Step 5 and the sheaths of the parking brake cables in their sup-
Step 7. For a wet brake system use Step 2, Step 3, port. See Figure 18.
Step 6 and Step 7.
6. For GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
If the lever assembly for the parking brake was removed (B875) lift trucks that are equipped with a wet brake
from the cowl, use the following procedure for installa- system. Install the clevis end of the parking brake
tion: cable in the slot in the equalized link and install the
clevis pin and lock ring cotter pin. Tighten lower
1. The parking brake cables must be installed in the
parking brake cable bracket to 19 to 21 N•m (14 to
back plate before the service brake is installed. See
15.5 lbf ft) See Figure 19.
Figure 18. A snap ring holds the sheath of the
parking brake cable in the back plate of the service 7. Use the four capscrews, washers, and nuts and fas-
brake. Install the parking brake cable in the back ten the bracket to the inside of the cowl.
plate and install the snap ring that holds the sheath
of the parking brake cable in the back plate. ADJUST
2. For GLP/GDP20-35VX (GP/GLP/GDP040-070VX) Lift trucks equipped with a dry brake system. Make sure
(B875) lift trucks that are equipped with a wet brake the service brakes are adjusted and the operation of
system. The parking brake cable must be installed the automatic adjuster mechanism is correct before the
on the parking brake lever located on the wet brake parking brake is adjusted.
drive axle and the cable loosely clamped to the
parking brake cable bracket in the correct position Lift trucks equipped with a wet brake system. For lift
before connecting the parking brake cable to the truck models GLP/GDP20-35VX (GP/GLP/GDP040-
equalized link located on the park brake assembly. 070VX) (B875) equipped with a wet brake system,
See Figure 19. make sure the wet disc brakes are adjusted before the
parking brake is adjusted. See Drive Axle Repair,
3. Make sure the parking brake lever is in the released (Wet Brake) 1400 YRM 1215.
position. Turn the adjustment knob until the link is
adjusted to the bottom of the adjustment slot. Lift trucks with a Foot Directional Control pedal the
switch energizes the seat warning circuit when hand
4. Lift trucks equipped with a dry brake system. Adjust lever is released. This switch puts the transmission
the jam nuts on the ends of the cable assemblies so in NEUTRAL by de-energizing the direction solenoid.
that the threads of the cable sheaths extend 13 to There is also a switch on the left side of bracket. This
16 mm (0.51 to 0.63 in.) above their support plate switch prevents engine from starting unless parking
in the lever assembly. See Figure 18. brake is applied.

21
Master Cylinder Repair 1800 YRM 1135

thumb or finger to release the lock on the lever when

CAUTION the parking brake is released.
For Lift truck models GLP/GDP20-35VX (GP/GLP/
GDP040-070VX) (B875) equipped with the wet brake 2. For new brakes, test the operation of the parking
system. Check the dash display to verify the trans- brake. The lift truck with a capacity load must not
mission oil is at operating temperature, 49 to 66°C move when parking brake is applied on a 7.5 per-
(120 to 150°F) before adjusting the parking brake cent grade [a slope that increases .75 m in 10 m (9
adjustment knob. in. in 10 ft)].

1. To adjust the parking brake, Turn the adjustment 3. For burnished brakes, test the operation of the park-
knob to raise the equalized link and tighten the ing brake. The lift truck with a capacity load must
parking brake cables shown in Figure 18 and Fig- not move when parking brake is applied on a 15
ure 19. Do not tighten the adjustment so that the percent grade [a slope that increases 1.5 m in 10 m
brake is applied when the lever is released. The (1.5 ft in 10 ft)].
lever for the parking brake has a lock. Use your

Master Cylinder Repair

REMOVE (DRY BRAKE) 1. Remove clevis, push rod, nut, boot, fitting, and seal.
See Figure 21.
1. Remove the floor plate, kick plate, and seal plate
from the lift truck for access to the master cylinder. 2. Remove snap ring, piston seal, and piston.

2. For lift trucks equipped with a dry brake system. 3. Remove spacer, piston cup, retainer, spring, check
Remove the brake hydraulic line from the master valve, and valve seat.
cylinder. Disconnect the wire at the brake pressure
transducer, which is connected to the bottom of the NOTE: Install new seals when the master cylinder is
master cylinder and remove pressure transducer. disassembled for repair.
See Figure 20.
CLEAN AND INSPECT (DRY BRAKE)
3. Disconnect the brake supply hose from the master
cylinder. Plug hose to prevent reservoir from drain-
CAUTION
ing.
DO NOT use an oil solvent to clean the master cylin-
4. Remove the brake fluid reservoir and supply hose der, wheel cylinder, or brake linings. Use a solvent
from the lift truck. approved for cleaning of brake parts. Do not permit
oil or grease in the brake fluid or on the linings.
5. Remove the cotter pin and clevis pin that is attached
to the brake linkage lever arm. Inspect the bore of the master cylinder for holes or
scratches. Replace the master cylinder assembly, if
6. Remove capscrews and nuts that hold master cylin- there is damage.
der to bracket assembly.
ASSEMBLE (DRY BRAKE)
DISASSEMBLE (DRY BRAKE)
1. Install valve seat, check valve, spring, retainer, pis-
ton cup, and spacer.
CAUTION
When the piston is removed or installed, make sure 2. Install the piston, piston seal, and snap ring.
the cylinder bore and piston are not scratched or
damaged. 3. Install seal, fitting, boot, nut, push rod, and clevis.

22
1800 YRM 1135 Master Cylinder Repair

1. RESERVOIR 9. PUSH ROD

2. RESERVE TANK HOLDER 10. NUT
3. BRAKE SUPPLY HOSE 11. CLEVIS
4. CAPSCREW 12. BRACKET
5. CAPSCREW 13. COTTER PIN
6. BRAKE HOSE 14. CLEVIS PIN
7. BRAKE PRESSURE TRANSDUCER 15. CAPSCREW
8. MASTER CYLINDER 16. CAPSCREW

Figure 20. Master Cylinder and Reservoir Assembly (Dry Brake)

23
Master Cylinder Repair 1800 YRM 1135

1. CLEVIS 7. SEAL 13. RETAINER

2. NUT 8. FITTING 14. SPRING
3. PUSH ROD 9. PISTON SEAL 15. CHECK VALVE
4. BOOT 10. PISTON 16. VALVE SEAT
5. SNAP RING 11. SPACER
6. CYLINDER HOUSING 12. PISTON CUP

Figure 21. Master Cylinder (Dry Brake)

24
1800 YRM 1135 Master Cylinder Repair

BENCH BLEED MASTER CYLINDER (DRY d. Turn push rod counterclockwise 1.5 to 1.75
BRAKE) turns.

NOTE: Master cylinder must be bench bled before in- e. Tighten nut to 17 to 23 N•m (12.5 to 17 lbf ft).
stalling it on the lift truck.
f. Verify free pedal is 10 to 12 mm (0.39 to
1. Place the master cylinder horizontally in a 0.47 in.). See Figure 24.
soft-jawed vise.
8. Flush with brake fluid and air bleed system. See
2. Connect the brake fluid reservoir supply hose to the Brake System Air Removal.
master cylinder.
9. Adjust fluid level until level is within 2.5 mm
3. Connect hoses to the pressure ports of the master (0.098 in.) of MAX line or 5 to 7.5 mm (0.19 to
cylinder. Place other end of hoses in a clear con- 0.29 in.) above large rib on reservoir if MAX line is
tainer of brake fluid. not present.

4. Fill the reservoir with brake SAE J-1703 (DOT 3) 10. Verify all connections are leak-free.
brake fluid.
11. Install floor plate, kick plate, and seal plate on lift
5. Stroke the master cylinder until all air is purged from truck.
the master cylinder.
12. Check adjustment of brake pedal as described in
INSTALL AND ADJUST (DRY BRAKE) Brake Pedal Adjustment.

1. Install brake fluid reservoir, supply hose, and mas- REMOVE (WET BRAKE)
ter cylinder on lift truck as an assembly. Install cap-
NOTE: The removal procedure in this section is for
screws and nuts that hold master cylinder to bracket
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)
assembly. See Figure 20.
lift trucks equipped with wet brake systems.
2. Install brake hydraulic line on master cylinder.
1. Remove the floor plate, kick plate, and seal plate
3. Screw assembly of brake pressure transducer into from the lift truck for access to the master cylinder
master cylinder and tighten to 23 to 28 N•m (16.9 and booster assembly.
to 20.6 lbf ft).
2. Remove and tag the brake booster supply and re-
4. Orient master cylinder side of brake hose assembly turn hoses from the master cylinder and booster as-
parallel with brake pressure transducer. sembly. Plug hoses to prevent hoses from drain-
ing. Disconnect the connector at the brake pres-
5. Tighten fitting nuts at each end of brake hose as- sure transducer, and remove brake pressure trans-
sembly to 13 to 18 N•m (84 to 117 lbf in). ducer. See Figure 22.

6. Apply a layer of multipurpose grease to the clevis 3. Disconnect the upper brake oil supply hose from the
pin and, with twisting motion, insert through clevis manifold. Plug hose to prevent brake oil reservoir
and the inching/brake pedal. Install cotter pin into from draining.
the clevis pin.
4. Remove the brake oil reservoir and upper brake oil
7. Adjust free pedal per the following procedure: supply hose from the lift truck.

a. Loosen nut and screw it away from clevis. 5. Remove the lower brake oil supply hose from the
manifold and the master cylinder and booster as-
b. Turn push rod counterclockwise, as viewed sembly.
from top, until push rod can be moved from
side to side. 6. Remove the manifold from the manifold mount.

c. Turn push rod clockwise until it can no longer 7. Remove the cotter pin and rod end pin from the cle-
be moved from side to side. vis that is attached to the brake linkage lever arm.

25
Master Cylinder Repair 1800 YRM 1135

8. Remove capscrews and nuts that hold master cylin-

der and booster assembly to bracket assembly.

DISASSEMBLE (WET BRAKE)

CAUTION
When the piston is removed or installed, make sure
the cylinder bore and piston are not scratched or
damaged.

1. Place master cylinder and booster into a soft jawed

vise.

2. Remove three mounting bolts and the master cylin-

der from booster. See Figure 23.

WARNING
Piston is under extreme pressure. Use care when
removing snap ring to avoid possible injury.

3. Remove the internal snap ring holding the piston.

4. Remove Piston.

5. Remove the spring and retainer from the bore.

6. Remove and discard the pressure seal from the

spring end of the piston.

7. Remove the washer between the pressure seal and

the piston.

8. Remove and discard the retaining seal from the pis-

ton. Note the position of the seal.

1. CAPSCREW
2. BRAKE FLUID RESERVOIR
3. CLAMP
4. UPPER BRAKE OIL SUPPLY HOSE
5. MANIFOLD
6. MOUNT
7. LOWER BRAKE OIL SUPPLY HOSE
8. INSERT
9. BOOSTER RETURN HOSE
10. BRAKE HOSE
11. BRAKE PRESSURE TRANSDUCER
12. BOOSTER SUPPLY HOSE
13. MASTER CYLINDER AND BOOSTER ASSEMBLY
14. MOUNTING BOLT
15. MANIFOLD MOUNT
16. BRACKET
17. COTTER PIN
18. PIN

Figure 22. Master Cylinder and Reservoir

Assembly (Wet Brake)

26
1800 YRM 1135 Master Cylinder Repair

1. BOOSTER ASSEMBLY 6. PRESSURE SEAL

2. HOUSING (MASTER CYLINDER) 7. WASHER
3. SNAP RING 8. RETAINER
4. PISTON 9. SPRING
5. RETAINING SEAL 10. CAPSCREW

Figure 23. Master Cylinder and Booster With Wet Brake for Lift Truck Models GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875)

27
Master Cylinder Repair 1800 YRM 1135

CLEAN AND INSPECT (WET BRAKE) INSTALL AND ADJUST (WET BRAKE)

WARNING WARNING
Small amounts of water in the brake system can Small amounts of water in the brake system can
cause reduced braking performance if the water cause reduced braking performance if the water
reaches the wheel cylinders and is subject to high reaches the wheel cylinders and is subject to high
temperatures. DO NOT allow water entry into the temperatures. DO NOT allow water entry into the
brake system. If water is present, remove all water brake system. If water is present, remove all water
and refill the system with Dexron III from a sealed and refill the system with Dexron III from a sealed
container. Unfiltered shop air can contain sub- container. Unfiltered shop air can contain sub-
stantial amounts of water, therefore, DO NOT use stantial amounts of water, therefore, DO NOT use
unfiltered shop air to blow out components. unfiltered shop air to blow out components.

NOTE: The master cylinder uses Dexron III oil. For the
CAUTION correct amount oil used see the Maintenance Schedule.
DO NOT permit brake cleaning fluid to contact mas-
ter cylinder or wheel cylinders. Brake cleaning fluid 1. Install brake oil reservoir, supply hose, and master
will cause damage and leaks in seals of the brake cylinder and booster assembly on lift truck as an as-
system. sembly. Install capscrews and nuts that hold master
cylinder and booster to bracket assembly. See Fig-
Inspect the bore of the master cylinder and the bore ure 22.
of the Booster Assembly for holes and scratches. Re-
place the master cylinder and booster assembly if there 2. Install brake supply and return lines to booster as-
is damage. See Figure 23. sembly.

Inspect wheel and master cylinder parts for dirt or water. 3. Install the brake pressure transducer into mas-
Clean any dirt or water present in wheel and master ter cylinder and tighten to 23 to 28 N•m (16.9 to
cylinder parts using a clean lint free cloth. 20.6 lbf ft). See Figure 22.

ASSEMBLE (WET BRAKE) 4. Orient master cylinder side of brake supply and re-
turn lines parallel with brake pressure transducer.
NOTE: Install new seals when the master cylinder is
being assembled. 5. Tighten fitting nuts at each end of brake hose as-
sembly to 13 to 18 N•m (84 to 117 lbf in).
1. Install the new retaining seal on the piston, as noted
during removal. 6. Apply a layer of multipurpose grease to the rod end
pin and, with twisting motion, insert through yoke
2. Install the washer between the pressure seal and and the inching/brake pedal. Install cotter pin into
the piston. the rod end pin.

3. Install the new pressure seal and retainer over the 7. Adjust free pedal per the following procedure:
spring end of the plunger.
a. Loosen nut and screw it away from yoke.
4. Install the retainer spring and piston into the bore
of the master cylinder. b. Turn push rod counterclockwise, as viewed
from top, until push rod can be moved from
5. Install the internal snap ring holding the piston. side to side.

6. Install the master cylinder on the booster assembly c. Turn push rod clockwise until it can no longer
with three bolts and tighten to 49 to 59 N•m (36 to be moved from side to side.
43 lbf ft).

28
1800 YRM 1135 Brake System Air Removal

d. Turn push rod counterclockwise 1.5 to 1.75 9. Adjust oil level until level is within 2.5 mm (0.098 in.)
turns. of MAX line or 5 to 7.5 mm (0.19 to 0.29 in.) above
large rib on reservoir if MAX line is not present.
e. Tighten nut to 17 to 23 N•m (12.5 to 17 lbf ft).
10. Verify all connections are leak-free.
f. Verify free pedal is 10 to 12 mm (0.39 to
0.47 in.). See Figure 24. 11. Install floor plate, kick plate, and seal plate on lift
truck.
8. Flush with brake oil and air bleed system. See
Brake System Air Removal. 12. Check adjustment of brake pedal as described in
Figure 24.

Service Brakes Adjustment (Dry Brake)

The following procedure is for newly-installed brake NOTE: If the brake shoes were not replaced, loosen the
shoes. If the lift truck has been operated for more adjuster wheel approximately 20 teeth.
than 25 hours and has correct pedal height, the brakes
normally will not need adjustment. 3. Push the automatic adjuster lever away from the
adjuster wheel with a small screwdriver. Use the
1. See the procedure How to Put Lift Truck on Blocks adjuster tool to loosen the adjuster wheel approxi-
in the Periodic Maintenance section for your lift mately 20 teeth (new brake shoes).
truck or the Operating Manual for your lift truck.
Put the lift truck on blocks so the drive wheels can 4. Install the drive wheels. Remove the lift truck from
be removed. Remove the drive wheels. the blocks. Operate the lift truck in the FORWARD
and REVERSE directions. Stop the lift truck 10
2. Use an adjuster tool to rotate the adjuster wheel so times in each direction. This procedure causes the
that the teeth of the wheel move downward. This brake shoes to wear a small amount and fit the
adjustment expands the brake shoes. Adjust the brake drum better.
brake shoes so that the brake drum will not rotate.

Brake System Air Removal

There are two commonly used methods to remove air 2. Place one end of a rubber hose on the bleeder
from the brake system. The preferred method is using screw of each wheel cylinder. Place the other end
a pressure bleed system. The other method is by ap- of each hose into a clear container of brake fluid.
plying pressure using the brake pedal.
3. Connect a pressure bleeder to the brake fluid reser-
NOTE: Two people are required for the two procedures voir.
below to properly bleed the brake system.
4. Loosen the bleeder screws at the wheel cylinders
USING PRESSURE BLEED SYSTEM one turn.

NOTE: While applying air pressure to the pressure

WARNING bleeder, check the level of the brake fluid in the reser-
On lift trucks with wet brake drive axles, only use voir for the master cylinder. Make sure to obtain the
Dexron III oil in the master cylinder. On lift trucks brake fluid at the correct level to avoid forcing more air
with dry brake drive axles, only use SAE J-1703 into the brake system.
(DOT 3) brake fluid in the master cylinder.
5. Apply 34.5 kPa (5 psi) of air pressure to the pres-
NOTE: Adjust the service brakes before the air is re- sure bleeder, forcing fluid through the lines until all
moved from the brake system. air is removed from the system. Close the bleeder
screws.
1. Fill the brake fluid reservoir with brake fluid.

29
Brake System Air Removal 1800 YRM 1135

6. Check the level of the brake fluid in the reservoir for NOTE: Check the level of the brake fluid in the reservoir
the master cylinder. Fill the brake fluid reservoir to for the master cylinder during the procedure. Make sure
the correct level. to obtain the brake fluid at the correct level.

USING BRAKE PEDAL PRESSURE 3. Loosen the bleeder screw at the wheel cylinder one
turn so that the air can be removed from the brake
system. Slowly push the brake pedal and hold it at
WARNING
the end of its stroke. Close the bleeder screw.
On lift trucks with wet brake drive axles, only use
Dexron III oil in the master cylinder. On lift trucks 4. Repeat the procedures in Step 1 through Step 3
with dry brake drive axles, only use SAE J-1703 until there are no air bubbles in the container.
(DOT 3) brake fluid in the master cylinder.
5. Repeat the procedures in Step 1 through Step 4 for
NOTE: Adjust the service brakes before the air is re- the remaining wheel cylinder.
moved from the brake system.
6. Check the level of the brake fluid in the reservoir for
1. Fill the brake fluid reservoir with brake fluid. the master cylinder. Fill the brake fluid reservoir to
the correct level.
2. Place one end of a rubber hose on the bleeder
screw of the wheel cylinder furthest from the mas-
ter cylinder. Place the other end of the hose into a
clear container of brake fluid.

30
1800 YRM 1135 Brake Pedal Adjustment

Brake Pedal Adjustment

FOR LIFT TRUCK MODELS GC/GLC030VX, 1. Adjust the height (dimension R) of the inching/brake
GC/GLC035VX, GC/GLC040SVX pedal to 31 ±0.4 mm (1.22 ±0.01 in.). Use the up-
(C809), GLP/GDP16VX, GLP/GDP18VX, stop bolt to change the pedal height. Tighten the
nut while keeping the upstop bolt fixed. See Fig-
GLP/GDP20SVX (GP/GLP/GDP030VX, ure 24.
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810), GLC20-35VX (GC/GLC040-070VX, 2. Depress arm V until it stops. Verify gap S between
arm V and tab W is 3.0 to 3.5 mm (0.11 to 0.13 in.).
GC/GLC055SVX) (A910),GLC050LX
If it is not, then Tab W may require bending to obtain
(A967),GLP/GDP20-35VX the proper gap of S. See Figure 24.
(GP/GLP/GDP040-070VX) (B875),
GLP/GDP20-25LX (GLP/GDP050LX) (A974)
NOTE: Measurements are made with the floor mats re-
moved.

1. INCH/BRAKE PEDAL 5. SENSOR MOUNT

2. UPSTOP BOLT 6. BRAKE POSITION SENSOR
3. NUT 7. BUMPER
4. PEDAL PAD

Figure 24. Brake Pedal Adjustment

31
Free Pedal Adjustment 1800 YRM 1135

Free Pedal Adjustment

After the brake pedal adjustment is completed, see
Brake Pedal Adjustment. Perform the following proce-
dure for the free pedal adjustment.

1. Loosen nut and screw it away from clevis See Fig-

ure 25.

2. Turn push rod counterclockwise, as viewed from the

top of the push rod, until push rod can be moved
from side to side.

3. Turn push rod clockwise until it just begins to no

longer be moved from side to side.

4. Turn push rod counterclockwise 1.5 to 1.75 turns.

5. Tighten nut to 17 to 23 N•m (13 to 17 lbf ft).

6. Verify the free pedal is 10 to 12 mm (0.39 to

0.47 in.). See Figure 24.

NOTE: DRY BRAKE SYSTEM SHOWN

1. COTTER PIN
2. WELDMENT
3. PIN
4. MASTER CYLINDER
5. PUSH ROD
6. NUT
7. CLEVIS

Figure 25. Free Pedal Adjustment

32
1800 YRM 1135 Torque Specifications

Torque Specifications
Back Plate to Axle Mount Capscrews Wheel Nuts
GLC20-35VX (GC/GLC040-070VX,
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) [A910]
GC/GLC055SVX) [A910] and GLP/GDP20-35VX 340 to 380 N•m (251 to 280 lbf ft)
(GP/GLP/GDP040-070VX) [B875]
255 to 306 N•m (188 to 226 lbf ft) GLP/GDP20-35VX (GP/GLP/GDP040-
070VX) [B875]
GC/GLC030-035VX, GC/GLC040SVX 450 to 500 N•m (332 to 369 lbf ft)
[C809], GLP/GDP16-18VX, GLP/GDP20SVX
(GP/GLP/GDP030-035VX, GP/GLP/GDP040SVX) GC/GLC030-035VX, GC/GLC040SVX
[C810], GLC050LX (A967), and GLP/GDP20-25LX [C809], GLP/GDP16-18VX, GLP/GDP20SVX
(GLP/GDP050LX) (A974) (GP/GLP/GDP030-035VX, GP/GLP/GDP040SVX)
152 to 167 N•m (112 to 123 lbf ft) [C810], GLC050LX (A967), and GLP/GDP20-25LX
(GLP/GDP050LX) A974)
Wheel Cylinder Capscrews 155 to 175 N•m (115 to 130 lbf ft)
18 to 26 N•m (13 to 19 lbf ft)
Upper Parking Brake Cable Bracket
Axle Shaft Capscrews Capscrews (Wet Brake)
GLC20-35VX (GC/GLC040-070VX, GLP/GDP20-35VX (GP/GLP/GDP040-
GC/GLC055SVX) [A910] 070VX) [B875]
90 to 99 N•m (66 to 73 lbf ft) 38 to 42 N•m (28 to 31 lbf ft)

GLP/GDP20-35VX (GP/GLP/GDP040- Upper Parking Brake Cable Bracket

070VX) [B875] Capscrews (Wet Brake)
90 to 108 N•m (66 to 80 lbf ft) GLP/GDP20-35VX (GP/GLP/GDP040-
070VX) [B875]
GC/GLC030-035VX, GC/GLC040SVX 38 to 42 N•m (28 to 31 lbf ft)
[C809], GLP/GDP16-18VX, GLP/GDP20SVX
(GP/GLP/GDP030-035VX, GP/GLP/GDP040SVX) Brake Pressure Transducer to Master
[C810], GLC050LX (A967), and GLP/GDP20-25LX Cylinder (Wet Brake)
(GLP/GDP050LX) (A974) GLP/GDP20-35VX (GP/GLP/GDP040-
52 to 62 N•m (39 to 46 lbf ft) 070VX) [B875]
23 to 28 N•m (16.9 to 20.6 lbf ft)

Master Cylinder to Booster Capscrews (Wet Brake)

GLP/GDP20-35VX (GP/GLP/GDP040-
070VX) [B875]
49 to 59 N•m (36 to 43 lbf ft)

33
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 Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011

1800 YRM 1135 7/11 (7/10)(5/10)(10/06)(9/06)(6/06)(10/05)(5/05)(12/04) Printed in U.S.A.