Maintenance: Yanmar Diesel Engines

Maintenance
YANMAR DIESEL ENGINES

2.6L, 3.0L AND 3.3L
GDP16VX, GDP18VX, GDP20SVX
(GDP030VX, GDP035VX, GDP040SVX) [C810];
GDP20-35VX (GDP040-070VX) [B875, C875];
GDP20-25LX (GDP050LX) [A974];
GDP16-18VX, GDP20SVX
(GDP030-035VX, GDP040SVX) [D810];
GDP20VX, GDP25VX, GDP30VX, GDP35VX
(GDP040VX, GDP050VX, GDP060VX, GDP070VX )
[D875];
GDP20-25LX (GDP050LX) [B974];
GP20-30MX (GP040-060MX) [A390]
PART NO. 524240453 0600 YRM 1205

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.
Table of Contents
TABLE OF CONTENTS
General ..................................................................................................................................................................... 1
Engine Identification ............................................................................................................................................. 1
Major Engine Component Identification ........................................................................................................... 1
Location of Labels ............................................................................................................................................ 2
Engine Removal and Installation .............................................................................................................................. 3
Cylinder Head Assembly Repair ...............................................................................................................................3
Glow Plugs ........................................................................................................................................................... 6
Remove ............................................................................................................................................................6
Install ................................................................................................................................................................6
Valve Cover .......................................................................................................................................................... 6
Remove ............................................................................................................................................................6
Clean and Inspect ............................................................................................................................................ 7
Install ................................................................................................................................................................7
Rocker Arm Assembly .......................................................................................................................................... 7
Remove ............................................................................................................................................................7
Disassemble .....................................................................................................................................................8
Clean and Inspect ............................................................................................................................................ 9
Push Rods ................................................................................................................................................... 9
Rocker Arm Assembly ................................................................................................................................. 9
Assemble ......................................................................................................................................................... 9
Install ..............................................................................................................................................................10
Valve Clearance Adjustments ............................................................................................................................ 10
Cylinder Head Assembly .................................................................................................................................... 11
Remove ..........................................................................................................................................................11
Disassemble ...................................................................................................................................................16
Valves and Valve Springs, Remove ...........................................................................................................16
Valve Guides, Remove .............................................................................................................................. 16
Clean and Inspect .......................................................................................................................................... 17
Cylinder Head ............................................................................................................................................ 17
Valve Guides ..............................................................................................................................................18
Valves ........................................................................................................................................................ 18
Valve Sink ..................................................................................................................................................18
Valve Seat ..................................................................................................................................................19
Valve Springs .............................................................................................................................................19
Assemble ....................................................................................................................................................... 20
Valve Guides, Install .................................................................................................................................. 20
Valves and Valve Springs, Install ...............................................................................................................20
Install ..............................................................................................................................................................21
Timing Gear Case and Timing Gears Repair ......................................................................................................... 23
Timing Gear Case Cover ....................................................................................................................................23
Remove ..........................................................................................................................................................23
Install ..............................................................................................................................................................24
Timing Gears ...................................................................................................................................................... 24
Crankshaft Gear .............................................................................................................................................25
Remove ......................................................................................................................................................25
Install ..........................................................................................................................................................25
Idler Gear ....................................................................................................................................................... 25
Remove ......................................................................................................................................................25
Inspect ....................................................................................................................................................... 26
©2017 Yale Materials Handling Corp. i

Table of Contents
TABLE OF CONTENTS (Continued)

Install ..........................................................................................................................................................26
Camshaft Gear ...............................................................................................................................................26
Remove ......................................................................................................................................................26
Install ..........................................................................................................................................................27
Timing Gear Case .............................................................................................................................................. 27
Remove ..........................................................................................................................................................27
Install ..............................................................................................................................................................28
Drive Train, Camshaft, and Cylinder Block Repair ................................................................................................. 29
Remove .............................................................................................................................................................. 29
Disassemble ....................................................................................................................................................... 30
Pistons and Connecting Rods ........................................................................................................................30
Crankshaft ......................................................................................................................................................30
Camshaft ........................................................................................................................................................33
Clean and Inspect ...............................................................................................................................................34
Cylinder Block ................................................................................................................................................ 34
Honing and Boring ..................................................................................................................................... 37
Pistons ........................................................................................................................................................... 38
Piston Pin ....................................................................................................................................................... 38
Connecting Rod ............................................................................................................................................. 39
Tappets .......................................................................................................................................................... 39
Crankshaft ......................................................................................................................................................40
Camshaft ........................................................................................................................................................41
Camshaft Bushing ..........................................................................................................................................42
Assemble ............................................................................................................................................................42
Camshaft ........................................................................................................................................................42
Crankshaft ......................................................................................................................................................42
Pistons and Connecting Rods ........................................................................................................................43
Install .................................................................................................................................................................. 44
Lubrication System Repair ......................................................................................................................................45
Engine Oil and Oil Filter Change ........................................................................................................................ 45
Oil Pan ................................................................................................................................................................45
Remove ..........................................................................................................................................................45
Install ..............................................................................................................................................................46
Oil Suction Tube ................................................................................................................................................. 46
Remove ..........................................................................................................................................................46
Clean ..............................................................................................................................................................47
Install ..............................................................................................................................................................47
Oil Pump .............................................................................................................................................................47
Remove ..........................................................................................................................................................47
Outer Rotor Outside Clearance ................................................................................................................. 48
Outer Rotor to Inner Rotor Tip Clearance ..................................................................................................49
Outer Rotor Side Clearance .......................................................................................................................49
Rotor Shaft Clearance ............................................................................................................................... 49
Install ..............................................................................................................................................................50
Fuel System Repair ................................................................................................................................................ 51
Fuel Injectors ...................................................................................................................................................... 51
Remove ..........................................................................................................................................................51
Inspect ............................................................................................................................................................52
ii
Table of Contents

Clean ..............................................................................................................................................................52
Test ................................................................................................................................................................ 52
Install ..............................................................................................................................................................55
Electronic Throttle System ..................................................................................................................................55
Remove ..........................................................................................................................................................55
Install ..............................................................................................................................................................58
Inspect ............................................................................................................................................................59
Adjust ............................................................................................................................................................. 60
Manual Throttle System ......................................................................................................................................61
Fuel Injection Pump ............................................................................................................................................61
Remove ..........................................................................................................................................................61
Install ..............................................................................................................................................................65
Check/Adjust Fuel Injection Timing ................................................................................................................66
Cooling System Repair ........................................................................................................................................... 68
V-Belt ..................................................................................................................................................................68
Remove ..........................................................................................................................................................68
Inspect ............................................................................................................................................................68
Install ..............................................................................................................................................................68
Adjust ............................................................................................................................................................. 68
Water Pump ........................................................................................................................................................70
4TNE92-NMHA, 4TNE92-NMHA/, 4TNE92-SNMU, and 4TNE98-SNMU Engines 580090035..................... 70
Remove ......................................................................................................................................................70
Install ..........................................................................................................................................................71
4TNE92-NMH, 4TNE98-NMH, 4TNE92-NMH/, and 4TNE98-BNMH Engines 580090036............................ 72
Remove ......................................................................................................................................................72
Install ..........................................................................................................................................................73
Thermostat ......................................................................................................................................................... 75
Remove ..........................................................................................................................................................75
Inspect ............................................................................................................................................................76
Install ..............................................................................................................................................................76
Flywheel and Flywheel Housing ............................................................................................................................. 77
Flywheel ............................................................................................................................................................. 77
Remove ..........................................................................................................................................................77
Install ..............................................................................................................................................................78
Flywheel Housing ............................................................................................................................................... 78
Remove ..........................................................................................................................................................78
Install ..............................................................................................................................................................78
Electrical Equipment Repair ................................................................................................................................... 80
Alternator ............................................................................................................................................................ 80
Remove ..........................................................................................................................................................80
Bench Test ..................................................................................................................................................... 82
Regulate Voltage Check ................................................................................................................................ 82
No Load Test ..................................................................................................................................................84
Output Test .................................................................................................................................................... 84
Install ..............................................................................................................................................................84
Starter .................................................................................................................................................................85
Remove ..........................................................................................................................................................86
No Load Test ..................................................................................................................................................86
Install ..............................................................................................................................................................87
iii
Table of Contents

Engine Specifications ............................................................................................................................................. 88
Engine Data ........................................................................................................................................................88
Engine Tuning .................................................................................................................................................... 96
Cylinder Head .....................................................................................................................................................96
Intake/Exhaust Valve and Guide ........................................................................................................................ 97
Valve Spring ....................................................................................................................................................... 97
Rocker Arm and Shaft ........................................................................................................................................ 97
Push Rod ............................................................................................................................................................98
Gear Train and Camshaft ................................................................................................................................... 98
Camshaft ........................................................................................................................................................98
Idle Gear Shaft and Bushing .......................................................................................................................... 98
Backlash of Each Gear .................................................................................................................................. 99
Cylinder Block .....................................................................................................................................................99
Crankshaft .......................................................................................................................................................... 99
Thrust Bearing .................................................................................................................................................. 100
Piston ................................................................................................................................................................100
Piston Ring ....................................................................................................................................................... 100
Connecting Rod ................................................................................................................................................101
Rod Small End ............................................................................................................................................. 101
Tappet .......................................................................................................................................................... 101
Oil Pump ...........................................................................................................................................................102
Engine Oil Pressure ..................................................................................................................................... 102
Outer Rotor Outside Clearance ....................................................................................................................102
Outer Rotor Side Clearance .........................................................................................................................102
Outer Rotor to Inner Rotor Tip Clearance .................................................................................................... 102
Rotor Shaft Clearance ..................................................................................................................................102
Standard Torque Specifications ............................................................................................................................103
Standard Torque Chart .....................................................................................................................................103
Special Torque Specifications .............................................................................................................................. 104
Special Tools ........................................................................................................................................................ 105
This section is for the following models:
GDP16VX, GDP18VX, GDP20SVX (GDP030VX, GDP035VX, GDP040SVX) [C810];

GDP20-35VX (GDP040-070VX) [B875, C875];
GDP20-25LX (GDP050LX) [A974];
GDP16-18VX, GDP20SVX (GDP030-035VX, GDP040SVX) [D810];
GDP20VX, GDP25VX, GDP30VX, GDP35VX (GDP040VX, GDP050VX, GDP060VX,
GDP070VX ) [D875];
GDP20-25LX (GDP050LX) [B974];
GP20-30MX (GP040-060MX) [A390]
iv
0600 YRM 1205 General
General
This section has the repair instructions for the
following Yanmar diesel engines:
• 4TNE92-NMH - 2.6L engine (Yale Part No.
580063566), used in lift truck GDP20-35VX
(GDP040-070VX) (B875, C875, D875).
• 4TNE92-NMHA - 2.6L engine (Yale Part No.
580061270), used in lift truck GDP16-18VX,
GDP20SVX (GDP030-035VX, GDP040SVX)
(C810, D810).
• 4TNE98-NMH - 3.3L engine (Yale Part No.
(GDP040-070VX) (B875, C875, D875).
• 4TNE92-NMH/1688273 - 2.6L engine (Yale
Part No. 580090036), used in lift truck
GDP20-35VX (GDP040-070VX) (B875, C875,
D875).
• 4TNE98-BNMH - 3.3L engine (Yale Part No.
(GDP040-070VX) (B875, C875, D875).
• 4TNE92-NMHA/1688253 - 2.6L engine 2008
(Yale Part No. 580090035), used in lift truck 1. TOP FILLER PORT (ENGINE OIL)
models GDP16-18VX, GDP20SVX 2. STARTER MOTOR
(GDP030-035VX, GDP040SVX) (C810, D810) 3. GLOW PLUG
4. WATER PUMP
and GDP20-25LX (GDP050LX) (A974, B974). 5. ALTERNATOR
• 4TNE94L-BSNMH - 3.0L engine (Yale Part No. 6. V-BELT
582023116) used in lift truck GDP20-35VX 7. CRANKSHAFT V-PULLEY
8. SIDE FILLER PORT (ENGINE OIL)
(B875, C875, D875). 9. DRAIN PLUG
• 4TNE98-SNMU - 3.3L engine (Yale Part No. 10. GOVERNOR LEVER
524303672) used in lift trucks GP20-30MX 11. ENGINE OIL FILTER
12. FUEL INJECTION PUMP
(GP040-060MX) (A390) 13. DIPSTICK (ENGINE OIL)
• 4TNE92-SNMU - 2.6L engine (Yale Part No. 14. FUEL FILTER/WATER SEPARATOR
524327442) used in lift trucks GP20-30MX 15. FUEL PRIMING PUMP
(GP040-060MX) (A390) Figure 1. Major Engine Components
ENGINE IDENTIFICATION
Major Engine Component Identification
Figure 1 shows where the major engine components

are located.
1
General 0600 YRM 1205
Location of Labels
The typical location of the emission control

information label is shown in Figure 2.
The typical location of the engine nameplate is shown

in Figure 2. The engine nameplate is shown in
Figure 3.
Figure 3. Engine Nameplate (Typical)
1. ENGINE NAMEPLATE
2. EMISSION CONTROL INFORMATION LABEL
Figure 2. Typical Location of Engine Labels
2
0600 YRM 1205 Engine Removal and Installation
Engine Removal and Installation

The procedures to remove and install the engine are See Frame 0100YRM1754 for lift truck models
not included in this section. • GDP20-35VX (GDP040-070VX) (D875)
See Frame 0100YRM1120 for lift truck models See Frame 0100YRM1423 for lift truck models
• GDP16-18VX, GDP20SVX (GDP030-35VX, • GDP20-25LX (GDP050LX) (A974)
GDP040SVX) (C810)
• GDP20-35VX (GDP040-070VX) (B875) See Frame 0100YRM1766 for lift truck models
• GDP20-25LX (GDP050LX) (B974)
See Frame 0100YRM1735 for lift truck models
• GDP16-18VX, GDP20SVX (GDP030-35VX, See Frame 0100YRM1984 for lift truck models
GDP040SVX) (D810) • GP020-30MX (GP040-060MX) (A390)

• GDP20-35VX (GDP040-070VX) (C875)
Cylinder Head Assembly Repair

Refer to Figure 4 for the cylinder head components.
3
Cylinder Head Assembly Repair 0600 YRM 1205
Figure 4. Cylinder Head Components
4
0600 YRM 1205 Cylinder Head Assembly Repair
Legend for Figure 4
1. VALVE COVER NUT 16. EXHAUST VALVE

2. O-RING 17. CYLINDER HEAD GASKET
3. VALVE COVER 18. CYLINDER HEAD
4. VALVE COVER GASKET 19. GLOW PLUG
5. ROCKER ARM SHAFT 20. GLOW PLUG COVER
6. ROCKER ARM SHAFT RETAINING SCREW 21. PUSH ROD
7. CYLINDER HEAD BOLT 22. SUPPORT BRACKET BOLT
8. GLOW PLUG HARNESS 23. ROCKER ARM SHAFT SPRING
9. VALVE CAP 24. SUPPORT BRACKET STUD
10. VALVE KEEPERS 25. SUPPORT BRACKET
11. SPRING RETAINER 26. ROCKER ARM
12. VALVE SPRING 27. ROCKER ARM SHAFT RETAINING RING
13. VALVE STEM SEAL 28. VALVE ADJUSTING SCREW LOCK NUT
14. VALVE GUIDE 29. VALVE ADJUSTING SCREW
15. INTAKE VALVE 30. SUPPORT BRACKET NUT
5
GLOW PLUGS Install

1. Install glow plugs into the cylinder head.
Remove
2. Connect glow plug harness to glow plugs.
1. Disconnect the negative battery cable at the bat-
tery. 3. Install glow plug covers on each glow plug.
2. Remove the glow plug cover from each of the 4. Connect negative battery cable.
glow plugs. See Figure 5.
VALVE COVER
3. Disconnect the glow plug harness from the glow
plugs.
Remove
4. Remove the glow plugs from the cylinder head.
1. Remove valve cover nuts. See Figure 6.
2. Inspect O-rings on each valve cover nut. Replace

as needed.
3. Remove valve cover.
4. Remove valve cover gasket and discard.
1. GLOW PLUG 3. WIRE HARNESS

2. COVER 4. CYLINDER HEAD
Figure 5. Glow Plugs

1. VALVE COVER NUT 3. VALVE COVER
2. O-RING 4. GASKET
Figure 6. Valve Cover
6
Clean and Inspect Install

1. Lightly grease the new valve cover gasket.
WARNING
Cleaning solvents can be flammable and toxic and 2. Place new valve cover gasket in the groove of the
can cause skin irritation. When using cleaning valve cover.
solvents, always follow the recommendations of
3. Place valve cover in position on the cylinder head.
the manufacturer.
4. Verify that the O-rings are installed on the valve
WARNING cover nuts.
Compressed air can move particles so that they 5. Install and tighten the valve cover nuts. Refer to
cause injury to the user or to other personnel. Standard Torque Specifications.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles ROCKER ARM ASSEMBLY
or a face shield to prevent injury to the eyes.
Remove
CAUTION 1. Remove valve cover. See Valve CoverRemove.
Use caution not to scratch the gasket mating sur-
faces when cleaning the valve cover and cylinder 2. Remove the bolt and locking nuts that retain the
head. rocker arm assembly support brackets to the cyl-
inder head. See Figure 7.
Carefully remove all gasket residue from the valve
cover and cylinder head.
Clean valve cover in cleaning solvent. Dry valve cover

with compressed air. Inspect for wear, cracks, and
any other damage. If necessary, replace valve cover.
7
1. SUPPORT BRACKET NUT 7. SUPPORT BRACKET

2. VALVE ADJUSTING SCREW LOCK NUT 8. ROCKER ARM SHAFT SPRING
3. VALVE ADJUSTING SCREW 9. ROCKER ARM
4. ROCKER ARM SHAFT 10. SUPPORT BRACKET BOLT
5. ROCKER ARM SHAFT RETAINING RING 11. ROCKER ARM SHAFT RETAINING SCREW
6. SUPPORT BRACKET STUD 12. CYLINDER HEAD
Figure 7. Rocker Arm Assembly
3. Lift the rocker arm shaft assembly from the cylin- 2. Remove the retaining rings from the ends of the
der head. rocker arm shaft.
NOTE: Mark the push rods so they can be reinstalled NOTE: Mark the rocker arms so they can be reinstal-
in original location during reassembly. led in original location during reassembly.
4. Remove the push rods from the cylinder head. NOTE: The rocker arm shaft fits tightly in the rocker
arm support brackets. Clamp the support bracket in a
Disassemble padded vise and twist and pull the rocker arm shaft to
remove the shaft.
1. Remove the rocker arm shaft retaining screw from
the support bracket that secures the rocker arm 3. Slide rocker arm shaft out of the rocker arm sup-
shaft. See Figure 7. port brackets, springs, and rocker arms.
8
4. If necessary, remove valve adjusting screw and Rocker Arm Assembly

lock nut from the rocker arms.
Rocker Arm and Support Bracket Inside Diameter
Clean and Inspect - Use a test indicator and micrometer to determine if
the inside diameter of all the rocker arm support
brackets and rocker arms are within limits. Refer to
WARNING the Engine Specifications for the service limit. See
Cleaning solvents can be flammable and toxic and Figure 9.
can cause skin irritation. When using cleaning
the manufacturer.
WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
away from all personnel. Wear protective goggles
Clean all parts in cleaning solvent. Dry parts with

compressed air. Inspect for wear, cracks, and any
other damage. Replace all parts as needed.
Figure 9. Rocker Arm Inside Diameter
Push Rods
1. Place push rods on a flat inspection block.
Shaft Outside Diameter - Use a micrometer to
2. Roll push rods until a gap can be observed be- measure the rocker arm shaft outside diameter. Refer
tween a portion of the push rod and the surface of to the Engine Specifications for the service limit. See
the inspection block. Figure 10.
3. Use a feeler gauge to measure the gap. Refer to

the Engine Specifications for the service limit. See
Figure 8.
Figure 10. Rocker Arm Shaft Outside Diameter
Assemble
NOTE: The rocker arm shaft fits tightly in the rocker
arm support brackets. Clamp the rocker arm shaft in a
Figure 8. Push Rod Inspection padded vise and twist and push the support brackets
onto the rocker arm shaft.
9
NOTE: To properly align the rocker arm shaft with NOTE: Since intake and exhaust valve rocker arms
the support brackets, first install the rocker arm shaft are operated the same and there is a clearance be-
support bracket with the hole for the shaft alignment tween rocker arm and valve generally at top dead
screw. Align the hole in the rocker arm shaft and the center, the position can be checked by means of the
hole in the support bracket. Install the alignment play when the arm head is held with a hand. Also, see
screw. See Figure 7. that the crankshaft pulley top mark is positioned at
zero on the timing scale. If there is no valve clear-
1. Lubricate the rocker arm shaft. Slide the rocker ance, inspection in the disassembled state is neces-
arm support brackets, springs, and rocker arms sary since the valve seat may be worn abnormally.
onto the shaft.
2. Rotate crankshaft clockwise, as seen from the ra-
2. Position the rocker arm assembly on a flat sur- diator side, to bring the number one piston to top
face. Install the retaining rings onto the ends of dead center (TDC) while watching the rocker arm
the rocker arm shaft. See Figure 7. motion, timing scale, and top mark position of the
crankshaft pulley. (Position where both the intake
3. If removed, install the valve adjusting screws and
and exhaust valves are closed.)
lock nuts.
3. Insert a feeler gauge between the rocker arm and
Install valve cap. See Figure 11. Record the measured
valve clearance. The valve clearance should be
1. Install push rods. between 0.15 to 0.25 mm (0.006 to 0.010 in.).
2. Place rocker arm assembly in position on the cyl-
inder head.
3. Install and hand tighten the rocker arm shaft re-

taining bolt and nuts.
4. Align push rods with their respective rocker arms.
5. Tighten rocker arm shaft retaining bolt and nuts.
6. Tighten rocker arm shaft alignment screw.
7. Adjust valve lash. See Valve Clearance Adjust-

ments.
8. Install valve cover. See Valve CoverInstall.
VALVE CLEARANCE ADJUSTMENTS

NOTE: Make measurements and adjustments while 1. FEELER GAUGE
the engine is cold. Figure 11. Valve Clearance Measurement
NOTE: The cylinder to be adjusted first does not
have to be the number one cylinder. Select and adjust
4. If adjustment is needed, loosen the valve adjust-
the cylinder where the piston is the nearest to top
ing screw lock nut and valve adjusting screw on
dead center (TDC) after rotating and make the adjust-
the rocker arm (see Figure 12) and check the
ment for the other cylinders in the order of the ignition
valve for any inclination of valve cap, entrance of
by turning the crankshaft 180 degrees each time.
dirt, or wear. See Figure 13.
1. Remove valve cover. See Valve CoverRemove.
NOTE: The number one piston position is on the fly-

wheel end of the engine, opposite side of the radiator,
and the ignition order is 1 - 3 - 4 - 2 at 180 degree in-
tervals.
10
5. Insert a 0.2 mm (0.008 in.) feeler gauge between

the rocker arm and valve cap and adjust the
clearance so there is a slight drag on the feeler
gauge when sliding it between the rocker arm and
valve cap. Tighten the valve adjusting screw lock
nut and recheck the clearance. The valve clear-
ance should be between 0.15 to 0.25 mm (0.006
to 0.010 in.).
6. Apply clean engine oil to the contact surface be-

tween the adjusting screw and push rod.
7. Turn the crankshaft 180 degrees and make the

measurement and adjustment for the number
three cylinder. Then turn the crankshaft 180 de-
grees and make the measurement and adjust-
ment for the number four cylinder. Then turn the
crankshaft 180 degrees and make the measure-
1. VALVE ADJUSTING SCREW ment and adjustment for the number 2 cylinder.
2. VALVE ADJUSTING SCREW LOCK NUT
8. Install the valve cover. See Valve CoverInstall.
Figure 12. Valve Clearance Adjustment
CYLINDER HEAD ASSEMBLY
Remove
1. Disconnect negative battery cable at the battery.
2. Remove alternator. See Electrical Equipment Re-

pair.
3. Remove water pump. See Cooling System Re-

pair.
4. Disconnect air intake hose from the intake mani-

fold.
A. NORMAL B. ABNORMAL 5. Remove glow plugs. See Glow Plugs, Remove.
1. VALVE CAP
6. Remove fuel injectors and high pressure lines.
Figure 13. Valve Cap Check See Fuel System Repair.
7. If equipped, remove the pull actuator and mount-

ing bracket. See Fuel System Repair.
NOTE: There is a tendency for the clearance to de-
crease slightly when the lock nut is tightened. It is 8. Disconnect the electrical connector for the fuel fil-
suggested that you make the clearance adjustment ter sensor.
slightly on the loose side before tightening the lock
nut.
11
9. Tag and disconnect the fuel hoses from the fuel

filter.
10. Remove the bolts retaining the fuel filter housing

assembly to the intake manifold and remove the
fuel filter housing assembly. See Figure 14.
11. Remove the bolts retaining the intake manifold to

the cylinder head and remove the intake manifold
and gasket. Discard gasket. See Figure 15.
1. BOLTS
2. INTAKE MANIFOLD
3. FUEL SENSOR ELECTRICAL CONNECTOR
4. FUEL FILTER HOUSING ASSEMBLY
Figure 14. Fuel Filter Housing Assembly
12
1. GASKET 3. BOLT
2. INTAKE MANIFOLD 4. CYLINDER HEAD
Figure 15. Intake Manifold
13
12. Remove the nuts retaining the exhaust pipe to the 13. Remove the bolts retaining the exhaust manifold
exhaust manifold and disconnect the exhaust pipe to the cylinder head and remove the exhaust
from the exhaust manifold. manifold and gasket. Discard gasket. See Fig-
ure 16.
1. CYLINDER HEAD 3. EXHAUST MANIFOLD

2. BOLT 4. GASKET
Figure 16. Exhaust Manifold
14
14. Remove the valve cover. See Valve Cover, Re-

move.
15. Remove the rocker arm assembly. See Rocker

Arm Assembly, Remove.
16. Loosen the cylinder head bolts following the se-

quence shown in Figure 17.
A. CAMSHAFT SIDE B. FAN SIDE
Figure 17. Cylinder Head Bolt Loosening

Sequence
17. Remove the cylinder head bolts. See Figure 18.
18. Lift the cylinder head away from the cylinder

block. Place the cylinder head on a work bench to
prevent damage to the combustion chamber. 1. BOLT 3. GASKET
2. CYLINDER HEAD
19. Remove the cylinder head gasket and discard.
Figure 18. Cylinder Head and Gasket
15
Disassemble Legend for Figure 20
1. VALVE CAP 5. VALVE STEM SEAL

Valves and Valve Springs, Remove 2. VALVE KEEPERS 6. VALVES
3. SPRING RETAINER 7. CYLINDER HEAD
1. Using a valve spring compressor tool, compress 4. SPRING
one of the valve springs. See Figure 19.
3. Slowly release the tension on the valve spring.
4. Remove the spring retainer, valve spring, and

valve stem seal.
5. Repeat this procedure until all intake and exhaust

valve springs and valve stem seals are removed.
NOTE: If existing valves are going to be reinstalled in

the cylinder head, mark the valves so they can be in-
stalled in their original location.
Figure 19. Valve Spring Compressor
6. Turn the cylinder head so the exhaust port side
faces down. Remove the intake and exhaust
2. Remove the valve keepers and the valve cap valves from the cylinder head.
from the end of the valve. See Figure 20.
Valve Guides, Remove
Using a drift pin and hammer, drive the valve guides

out of the cylinder head. See Figure 21.
1. VALVE GUIDE 2. CYLINDER HEAD
Figure 21. Valve Guides

Figure 20. Valves and Valve Springs
16
Clean and Inspect Carefully remove all gasket residue from the intake
manifold and cylinder head. Inspect the intake mani-
fold for scratches, cracks, or any other damage. Re-
WARNING pair or replace as needed.
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning Carefully remove all gasket residue from the cylinder
solvents, always follow the recommendations of head and cylinder block. Inspect the cylinder head for
the manufacturer. scratches, cracks, or any other damage. Repair or re-
place as needed.
WARNING
Thoroughly clean all components using a non-metallic
Compressed air can move particles so that they brush and cleaning solvent. Dry the parts with com-
cause injury to the user or to other personnel. pressed air. Each part must be free of carbon, metal
Make sure that the path of the compressed air is filings, and other debris.
or a face shield to prevent injury to the eyes. Visually inspect the parts. Replace any parts that are
obviously discolored, heavily pitted, or otherwise dam-
CAUTION aged. Replace parts that do not meet the specified
limit.
Any part which is found defective as a result of in-
spection or any part whose measured value does
not satisfy the standard or limit must be replaced. Cylinder Head
1. Place the cylinder head flat and inverted (com-
CAUTION bustion side up) on the work bench.
Any part determined to not meet the service 2. Use a straight edge and feeler gauge to measure
standard or limit before the next service, as deter- the amount of cylinder head distortion. Refer to
mined from the state of current rate of wear, the Engine Specifications for the service limit. See
should be replaced even though the part currently Figure 22.
meets the service standard limit.
CAUTION
faces when cleaning the exhaust manifold and
cylinder head.
CAUTION
faces when cleaning the intake manifold and cyl-
inder head.
CAUTION
faces when cleaning the cylinder head and cylin- Figure 22. Cylinder Head Distortion Check
der block.
Carefully remove all gasket residue from the exhaust 3. Use the Magnaflux method and inspect the cylin-
manifold and cylinder head. Inspect the exhaust mani- der head for cracks. Replace the cylinder head if
fold for scratches, cracks, or any other damage. Re- evidence of fractures are found.
pair or replace as needed.
17
Valve Guides Valve Sink
Visually inspect the valve guides for distortions, scor- Insert the valves into their proper places in the cylin-
ing, or other damage. der head and press them down until they are fully
seated. Using a depth micrometer, measure the differ-
Use a test indicator and micrometer to measure the ence between the cylinder head surface and the com-
inside diameter at each end of the valve guide. Refer bustion surface of each exhaust and intake valve. Re-
to the Engine Specifications for the service limit. fer to the Engine Specifications for the service limit.
See Figure 25 and Figure 26.
Valves
Valve Stem Diameter - Use a micrometer to measure

the valve stem diameter. Measure the valve stem
near the combustion end and near the opposite end.
Refer to the Engine Specifications for the service limit.
See Figure 23.
Figure 25. Valve Sink Measurement

A. MEASUREMENT POINTS
Figure 23. Valve Stem Diameter Measurement
Points
Valve Stem Straightness - Place the valve stem on

a flat surface. Roll the valve until a gap can be ob-
served between a portion of the valve stem and the
flat surface. Use a feeler gauge to measure the gap.
Refer to the Engine Specifications for the service limit.
See Figure 24.
Figure 26. Valve Sink
Figure 24. Valve Stem Straightness Check
18
Valve Seat Fractures - Check for fractures on the inside and out-
side portions of the springs. If the valve spring is frac-
Always check the clearance between the valve and tured, replace the spring.
valve guide before correcting the valve seat. See Fig-
ure 27. If the clearance exceeds the limit, replace the Corrosion - Check for corrosion of spring material
valve or valve guide to bring the clearance within the caused by oxidation.
limit.
Squareness - Use a flat surface and a square to
check each spring for squareness. Refer to the En-
gine Specifications for the service limit. See Fig-
ure 28.
1. VALVE SEAT Figure 28. Spring Squareness Check

Figure 27. Valve Seat
Free Length - Use a caliper to measure the length of
the spring. Refer to the Engine Specifications for the
Roughness or burrs will cause poor seating of a service limit. See Figure 29.
valve. Visually inspect the seating of each valve and
determine if lapping or grinding is needed. Grinding is
needed if the cylinder head's seat width exceeds
standard limits. Refer to the Engine Specifications for
the service limit.
Lap the valve seat and the cylinder head with a mix-
ture of valve compound and engine oil.
If the valve requires grinding, lap the valve after grind-

ing. Be sure to thoroughly wash the parts to remove
all grinding powder or compound.
Valve Springs
Inspect the valve springs. If damage or corrosion is

seen, or if measurements exceed the specified limits,
Figure 29. Spring Free Length Check
replace the springs.
19
Assemble Valves and Valve Springs, Install
Valve Guides, Install 1. Place the cylinder head assembly on the exhaust
port side.
1. The valve guides are installed into the cylinder
head with an extremely tight press fit. Before in- 2. Place all the valves in their proper positions, as
stalling the valve guides, place the valve guides in marked when disassembled, in the cylinder head.
a freezer for at least twenty minutes. This will 3. Apply clean engine oil to the lip of the valve stem
cause the valve guides to contract, making it eas- seal. Using a special tool, valve stem seal instal-
ier to install the valve guides into place. lation tool, insert a new valve stem seal on each
2. Immediately after removing the valve guides from of the valves. See Figure 31.
the freezer, insert the valve guides in their proper
positions in the cylinder head.
3. Finish installing the valve guides into the cylinder

head to the proper height using a special tool,
valve guide installation tool. See Figure 30.
1. VALVE STEM SEAL INSTALLATION TOOL

2. VALVE STEM SEAL
3. VALVE GUIDE
4. CYLINDER HEAD
1. VALVE GUIDE INSTALLATION TOOL Figure 31. Valve Stem Seal Installation
2. CYLINDER HEAD
3. VALVE GUIDE
Figure 30. Valve Guide Installation 4. Measure the distance from the cylinder head to
the valve stem seal. Refer to the Engine Specifi-
cations for the clearance specifications. See Fig-
ure 32.
20
Install
1. Carefully clean the combustion surface of the cyl-
inder head and the top surface of the cylinder
block.
2. Place a new cylinder head gasket on the cylinder

block. See Figure 18.
3. Position the cylinder head on the cylinder head

gasket and cylinder block.
4. Lightly oil the threads of the cylinder head bolts.
5. Install the cylinder head bolts and tighten the cyl-

inder head bolts to 49 to 59 N•m (36 to 43 lbf ft) in
the sequence shown in Figure 33. Then tighten
the cylinder head bolts to 103 to 113 N•m (76 to
83 lbf ft) in the same sequence.
1. VALVE STEM SEAL

2. VALVE GUIDE
3. VALVE GUIDE PROTECTION
4. VALVE STEM SEAL PROTECTION
5. CLEARANCE
Figure 32. Valve Stem Seal Clearance
A. CAMSHAFT SIDE B. FAN SIDE

5. Place the cylinder head on the work bench with
Figure 33. Cylinder Head Torque Sequence
the combustion chamber facing down. Install the
valve springs and valve spring retainers. See Fig-
ure 20.
6. Install the push rods and rocker arm assembly.
6. Using the valve compressor tool, compress the See Rocker Arm Assembly, Install.
valve spring.
7. Install the valve cover. See Valve Cover, Install.
7. Install the valve keepers and slowly release the
8. Place a new gasket and the exhaust manifold in
tension in the valve spring.
position on the cylinder head and install the ex-
8. Install the valve cap. haust manifold retaining bolts.
9. Repeat these procedures until all the intake and

exhaust valves are installed.
21
9. Connect the exhaust pipe to the exhaust manifold

and install retaining nuts. WARNING
The radiator or other parts of the cooling system
10. Place a new gasket and the intake manifold in po- may be hot or under pressure and can cause seri-
sition on the cylinder head and install the intake ous injury.
manifold retaining bolts.
23. Start engine and check for leaks.
11. Place the fuel filter housing assembly in position
on the intake manifold and install retaining bolts. 24. Change engine oil and oil filter. See Lubrication
System Repair, Engine Oil and Oil Filter Change.
12. Connect the fuel hoses to the fuel filter.
13. Connect the electrical connector for the fuel filter WARNING
sensor. DO NOT remove the radiator cap from the radiator
when the engine is hot. When the radiator cap is
14. If equipped, install the pull actuator and mounting
removed, pressure will release from the coolant
bracket. See Fuel System Repair.
system. If the coolant system is hot, the steam
15. Install the fuel injectors and high pressure lines. and boiling coolant can cause severe burns.
See Fuel System Repair.
16. Install the glow plugs. See Glow Plugs, Install. WARNING
17. Connect the air intake hose to the intake mani- may be hot or under pressure and can cause seri-
fold. ous injury. Wait 30 minutes for the radiator and
engine to cool before performing maintenance to
18. Install water pump. See Cooling System Repair. the cooling system. After 30 minutes, do a touch
test by touching the radiator with your hand. If the
19. Install alternator. See Electrical Equipment Re-
radiator is still hot to the touch, wait another 30
pair.
minutes before attempting any maintenance to the
cooling system.
CAUTION
Additives may damage the cooling system. Before CAUTION
using additives, contact your local Yale dealer.
Additives may damage the cooling system. Before
20. Fill cooling system with coolant. See Periodic using additives, contact your local Yale dealer.
Maintenance Manual for your lift truck for the
25. Stop engine. If coolant is hot, allow engine time to
correct coolant amount and type.
cool. Check coolant level and fill as required be-
21. Install radiator cap. tween the ADD and FULL marks on the coolant
reservoir.
22. Connect negative battery cable.
WARNING
During engine operation, be careful not to touch
the fan, pulleys, or drive belts. Contact with these
parts can cause serious injury.
22
0600 YRM 1205 Timing Gear Case and Timing Gears Repair
Timing Gear Case and Timing Gears Repair

TIMING GEAR CASE COVER
Remove
1. Remove the engine.

• GDP16-18VX, GDP20SVX (GDP030-35VX,
GDP040SVX) (C810)
• GDP20-35VX (GDP040-070VX) (B875)

GDP040SVX) (D810)

• GDP20-25LX (GDP050LX) (A974)
1. TIMING GEAR CASE
See Frame 0100YRM1672 for lift truck model 2. TIMING GEAR CASE COVER
3. BOLT
• GDP20-35VX (GDP040-070VX) (C875) 4. FRONT OIL SEAL
See Frame 0100YRM1754 for lift truck models Figure 34. Timing Gear Case Cover
• GDP20-35VX (GDP040-070VX) (D875)
See Frame 0100YRM1766 for lift truck models 6. Remove the timing gear case cover.
• GDP20-25LX (GDP050LX) (B974) 7. If necessary, remove the front oil seal from the
timing gear case cover. See Figure 34.
• GP20-30MX (GP040-060MX) (A390) Clean and Inspect
2. Remove the coolant fan, V-belt, and water pump.
See Cooling System Repair. WARNING
Cleaning solvents can be flammable and toxic and
3. Remove the bolt and washer retaining the crank-
shaft pulley.
4. Using a gear puller, remove the crankshaft pulley. the manufacturer.
5. Remove the bolts retaining the timing gear case

cover. See Figure 34.
23
Timing Gear Case and Timing Gears Repair 0600 YRM 1205
6. Install the water pump, V-belt, and coolant fan.

WARNING See Cooling System Repair.
cause injury to the user or to other personnel. 7. Install the engine.
or a face shield to prevent injury to the eyes. • GDP16-18VX, GDP20SVX (GDP030-35VX,
GDP040SVX) (C810)
Clean all old sealant from the timing gear case cover • GDP20-35VX (GDP040-070VX) (B875)
and the timing gear case. Clean the timing gear case
cover in cleaning solvent. Dry the timing gear case See Frame 0100YRM1735 for lift truck models
cover with compressed air. Inspect for wear, cracks, • GDP16-18VX, GDP20SVX (GDP030-35VX,
and any other damage. If necessary, replace timing GDP040SVX) (D810)
gear case cover.
Install • GDP20-25LX (GDP050LX) (A974)
1. Apply a continuous bead of Three Bond Liquid See Frame 0100YRM1672 for lift truck model
Gasket, Yale Part Number 580062478, to the out-
• GDP20-35VX (GDP040-070VX) (C875)
side diameter of a new front oil seal.
2. Using a special tool, install the new front oil seal
into the timing gear case cover. Apply lithium • GDP20-35VX (GDP040-070VX) (D875)
grease to the lip of the front oil seal. See Fig-
ure 35. See Frame 0100YRM1766 for lift truck models
• GDP20-25LX (GDP050LX) (B974)

• GP20-30MX (GP040-060MX) (A390)
8. Fill the engine oil to the correct level. See Peri-

odic Maintenance Manual for your lift truck, for
correct oil amount and type.
9. Start the engine and check for leaks.
TIMING GEARS
NOTE: For removal of the fuel injection pump drive
gear, refer to the section Fuel System Repair.
Figure 35. Front Oil Seal Installation
Before removing any of the timing gears, rotate the
crankshaft to align the alignment marks on the gears
as follows (see Figure 36):
3. Apply a continuous bead of Three Bond Liquid
Gasket, Yale Part Number 580062478, to the • Align mark "A" on the crankshaft gear with
mating surface of the timing gear case cover. mark "A" on the idler gear.
• Align mark "B" on the fuel injection pump gear
4. Place the timing gear case cover in position on
with mark "B" on the idler gear.
the timing gear case and install retaining bolts.
• Align mark "C" on the camshaft gear with mark
5. Install the crankshaft pulley, washer, and bolt to "C" on the idler gear.
retain the crankshaft pulley. Tighten bolt to
117.6 N•m (86.7 lbf ft).
24
1. PARALLEL PIN
1. FUEL INJECTION PUMP DRIVE GEAR 2. KEY
2. CAMSHAFT GEAR 3. CRANKSHAFT GEAR
3. CRANKSHAFT GEAR 4. CRANKSHAFT
4. DIRECTION OF ROTATION
5. OIL PUMP GEAR Figure 37. Crankshaft Gear
6. IDLER GEAR
Figure 36. Timing Gear Alignment

2. Align the alignment mark "A" on the crankshaft
gear with the alignment mark "A" on the idler gear
and install the crankshaft gear onto the crank-
Crankshaft Gear
shaft.
Remove 3. Verify that all alignment marks are properly
aligned. Figure 36.
1. Remove timing gear case cover. See Timing Gear
Case Cover, Remove. 4. Install timing gear case cover. See Timing Gear
Case Cover, Install.
2. Verify that the gears are properly aligned with the
alignment marks. See Figure 36.
Idler Gear
NOTE: If using a gear puller to remove the crank-
shaft gear, be careful not to damage the threads in Remove
the end of the crankshaft.
1. Remove the timing gear case cover. See Timing
3. Remove the crankshaft gear. See Figure 37. Gear Case Cover, Remove.
4. Remove the parallel pin and the key from the 2. Verify that the gears are properly aligned with the
crankshaft. alignment marks. See Figure 36.
3. Remove the bolts from the idler gear shaft. See

Install
Figure 38.
1. Install the parallel pin and the key into the crank-
4. Remove the idler gear shaft, idler gear, and bush-
shaft.
ing.
25
Install
1. Lubricate the idler gear bushing and idler gear
shaft with clean engine oil.
NOTE: Make sure the oil hole in the bushing is facing

toward the top of the engine.
2. Align the alignment mark "B" on the idler gear

with the alignment mark "B" on the fuel injection
pump and the alignment mark "A" on the idler
gear with the alignment mark "A" on the crank-
shaft gear. Install the idler gear, bushing, and idler
gear shaft.
3. Verify that all alignment marks are properly

aligned. See Figure 36
4. Install the idler gear retaining bolts.

1. TIMING GEAR CASE 5. Install the timing gear case cover. See Timing
2. IDLER GEAR
3. BUSHING Gear Case Cover, Install.
4. IDLER GEAR SHAFT
5. BOLT Camshaft Gear
Figure 38. Idler Gear
Remove
Inspect Gear Case Cover, Remove.
1. Measure the outside diameter of the idler gear 2. Verify that the gears are properly aligned with the
shaft. Refer to the Engine Specifications for the alignment marks. See Figure 36.
service limit. See Figure 39.
3. Using a gear puller, remove the camshaft gear.
2. Measure the inside diameter of the idler gear. Re- See Figure 40.
fer to the Engine Specifications for the service
limit. See Figure 39. 4. Remove the key from the camshaft.
1. OUTSIDE DIAMETER
2. IDLER GEAR SHAFT
3. INSIDE DIAMETER
4. IDLER GEAR
Figure 39. Idler Gear and Shaft Measurement
26
See Frame 0100YRM1672 for lift truck model

• GDP20-35VX (GDP040-070VX) (C875)

• GDP20-35VX (GDP040-070VX) (D875)

• GDP20-25LX (GDP050LX) (B974)

• GP20-30MX (GP040-060MX) (A390)

Case Cover, Remove.
1. TIMING GEAR CASE 3. Remove fuel injection pump. See Fuel System
2. CAMSHAFT Repair.
3. CAMSHAFT GEAR
4. Remove timing gears. See Timing Gears.
Figure 40. Camshaft Gear
5. Remove two bolts retaining the camshaft thrust
plate and remove thrust plate.
Install
6. Remove bolts retaining the gear case to the cylin-
1. Install the key into the camshaft. der block and remove the gear case. See Fig-
ure 41.
2. Align the alignment mark "C" on the camshaft
gear with the alignment mark "C" on the idler gear 7. Remove two O-rings from the cylinder block and
and install the camshaft gear onto the camshaft. discard.
3. Align the alignment mark "A" on the crankshaft

gear with the alignment mark "A" on the idler gear
and install the crankshaft gear onto the crank-
shaft.
4. Install the timing gear case cover. See Timing

Gear Case Cover, Install.
TIMING GEAR CASE
Remove

GDP040SVX) (C810)
• GDP20-35VX (GDP040-070VX) (B875)
1. TIMING GEAR CASE
2. BOLT
See Frame 0100YRM1735 for lift truck models 3. O-RINGS
• GDP16-18VX, GDP20SVX (GDP030-35VX, 4. CYLINDER BLOCK
GDP040SVX) (D810)
Figure 41. Timing Gear Case
• GDP20-25LX (GDP050LX) (A974)
27
Clean and Inspect 6. Install the timing gear case cover. See Timing
Gear Case CoverInstall.
WARNING 7. Install the fuel injection pump. See Fuel System

Cleaning solvents can be flammable and toxic and Repair.
solvents, always follow the recommendations of 8. Install the engine.
the manufacturer. See Frame 0100YRM1120 for lift truck models
WARNING GDP040SVX) (C810)
Compressed air can move particles so that they • GDP20-35VX (GDP040-070VX) (B875)
Make sure that the path of the compressed air is See Frame 0100YRM1735 for lift truck models
away from all personnel. Wear protective goggles • GDP16-18VX, GDP20SVX (GDP030-35VX,
or a face shield to prevent injury to the eyes. GDP040SVX) (D810)
Clean all old sealant from the timing gear case cover See Frame 0100YRM1423 for lift truck models
and the timing gear case. Clean the timing gear case
• GDP20-25LX (GDP050LX) (A974)
cover and gear case in cleaning solvent. Dry the tim-
ing gear case cover and gear case with compressed See Frame 0100YRM1672 for lift truck model
air. Inspect for wear, cracks, and any other damage.
• GDP20-35VX (GDP040-070VX) (C875)
Replace components as necessary.
Install
• GDP20-35VX (GDP040-070VX) (D875)
1. Install two new O-rings in the cylinder block.
2. Apply a continuous bead of Three Bond Liquid • GDP20-25LX (GDP050LX) (B974)
Gasket, Yale Part Number 580062478, to the
mating surface of the timing gear case. See Frame 0100YRM1984 for lift truck models
• GP20-30MX (GP040-060MX) (A390)
3. Position the gear case on the cylinder block and
install retaining bolts. 9. Change engine oil and oil filter. See Lubrication
System Repair, Engine Oil and Oil Filter Change
4. Install the timing gears. See Timing Gears.
section.
5. Install the camshaft thrust plate and the retaining
bolts.
28
0600 YRM 1205 Drive Train, Camshaft, and Cylinder Block Repair
Drive Train, Camshaft, and Cylinder Block Repair

REMOVE 3. Remove flywheel and flywheel housing. See Fly-
wheel and Flywheel Housing.
4. Remove alternator. See Electrical Equipment Re-
See Frame 0100YRM1120 for lift truck models pair.
5. Remove water pump. See Cooling System Re-
GDP040SVX) (C810)
pair.
• GDP20-35VX (GDP040-070VX) (B875)
6. Remove fuel injection pump. See Fuel System
See Frame 0100YRM1735 for lift truck models Repair.
7. Remove cylinder head. See Cylinder Head As-
GDP040SVX) (D810)
sembly Repair.
8. Remove oil pan. See Lubrication System Repair.
• GDP20-25LX (GDP050LX) (A974)
9. Remove oil suction tube. See Lubrication System
See Frame 0100YRM1672 for lift truck model Repair.
• GDP20-35VX (GDP040-070VX) (C875)
See Frame 0100YRM1754 for lift truck models Case and Timing Gears Repair.
• GDP20-35VX (GDP040-070VX) (D875) 11. Remove oil pump. See Lubrication System Re-
pair.
• GDP20-25LX (GDP050LX) (B974) NOTE: Do not remove the camshaft gear at this time.
See Frame 0100YRM1984 for lift truck models 12. Remove the crankshaft gear and idler gear. See
• GP20-30MX (GP040-060MX) (A390) Timing Gear Case and Timing Gears Repair.
2. Remove starter. See Electrical Equipment Repair.
29
Drive Train, Camshaft, and Cylinder Block Repair 0600 YRM 1205
DISASSEMBLE
Pistons and Connecting Rods

NOTE: It is necessary to rotate the crankshaft to ac-
cess some of the connecting rod assemblies at the
bottom dead center position.
1. Using a feeler gauge, measure the connecting rod

thrust clearance. See Figure 42. Refer to Engine
Specifications for the standard limit. If the meas-
urement is out of specification, either the crank-
shaft or the connecting rod must be replaced.
1. COMPRESSION RINGS
2. OIL SEAL RING
3. WRIST PIN
4. SNAP RING
5. WRIST PIN BUSHING
6. BEARING HALVES
7. CONNECTING ROD CAP
8. BOLT
9. CONNECTING ROD
10. PISTON
Figure 43. Piston and Connecting Rod
Figure 42. Connecting Rod Thrust Clearance 9. Remove the snap rings retaining the wrist pin.
10. Remove the wrist pin.

2. Remove the two bolts from one of the connecting
rod caps. See Figure 43. 11. Remove the piston from the connecting rod.
3. Remove the connecting rod cap. 12. Remove the wrist pin bushing from the connecting
rod.
4. Remove the bearing halves.
13. Repeat Step 2 through Step 12 for the remaining
5. Tap the piston through the cylinder and remove
pistons and piston rods.
the piston assembly with the connecting rod.
6. Mark the connecting rod cap and the connecting Crankshaft

rod and place the assembly on a bench.
1. Remove the bolts retaining the rear oil seal as-
7. Remove the two compression rings from the pis- sembly and remove the rear oil seal assembly.
ton. See Figure 44.
8. Remove the oil seal ring from the piston.
30
1. CYLINDER BLOCK 7. THRUST BEARINGS

2. PARALLEL PIN 8. CRANKSHAFT
3. KEY 9. REAR OIL SEAL
4. BEARING HALVES 10. REAR OIL SEAL HOUSING
5. MAIN BEARING CAP 11. BOLT
6. BOLT
Figure 44. Crankshaft
31
2. If necessary, remove the rear oil seal.
3. Measure the crankshaft side gap using on of the

following two methods:
a. Install a dial gauge on the cylinder block. Move

the crankshaft back and forth. Measure the
side gap. See Figure 45.
A. STANDARD WIDTH B. THRUST FACE

1. CYLINDER BLOCK 4. SHIM GAUGE
2. CRANKSHAFT 5. CYLINDER BLOCK
3. THRUST METAL
Figure 46. Crankshaft Side Gap Measurement

With Shim Gauge
Figure 45. Crankshaft Side Gap Measurement

With Dial Gauge NOTE: Be sure to note the markings on the main
bearing caps, or mark them yourself, so they can be
reinstalled in the same location as they were re-
b. Using a shim gauge, measure the clearance
moved.
between the thrust metal and crankshaft. See
Figure 46.
32
NOTE: The arrows on the main bearing caps point to 2. Using a gear puller, remove the camshaft gear.
the flywheel end of the engine. See Figure 48.
4. Remove the bolts retaining the main bearing caps 3. Remove the key from the camshaft.
and remove the main bearing caps.
4. Remove the two bolts retaining the thrust plate
5. Remove the bearing halves and thrust bearings. and remove thrust plate.
6. Remove the crankshaft from the cylinder block. NOTE: If the engine is not installed on an engine
stand, position the engine with the mounting flange
Camshaft (flywheel end) facing down. Rotate the camshaft a
few turns to bump the tappets out of the way to pre-
1. Using a feeler gauge, measure the camshaft side vent the tappets from interfering with the removal of
gap. Refer to Engine Specifications for the service the camshaft.
limit. See Figure 47.
5. With the engine installed on an engine stand, ro-
tate the engine so the gravity causes the tappets
to drop away from the camshaft lobes.
6. Slowly pull the camshaft out of the cylinder block.
NOTE: Be sure to mark the tappets so they can be

installed in the same location as they were removed.
7. Remove the tappets.
8. Remove the timing gear case. See Timing Gear

Case and Timing Gears Repair.
9. If damaged, remove the camshaft bushing.
1. THRUST METAL
2. CAMSHAFT
3. SIDE GAP
4. CAMSHAFT PULLEY
Figure 47. Camshaft Side Gap
33
1. CYLINDER BLOCK 7. KEY

2. CAMSHAFT BUSHING 8. THRUST PLATE
3. TIMING GEAR CASE 9. BOLT
4. BOLT 10. CAMSHAFT GEAR
5. TAPPETS 11. O-RINGS
6. CAMSHAFT
Figure 48. Camshaft
CLEAN AND INSPECT Clean all old sealant from all parts. Clean all parts in
cleaning solvent. Dry the parts with compressed air.
Each part must be free of carbon, metal filings, old
WARNING sealant, and other debris. Inspect for wear, cracks,
Cleaning solvents can be flammable and toxic and and any other damage. Replace components as nec-
can cause skin irritation. When using cleaning essary.
the manufacturer. Cylinder Block
1. Verify that oil holes are clear and unobstructed.
WARNING Clear any oil holes as needed.
cause injury to the user or to other personnel. 2. Check for discoloration or evidence of cracks. If
Make sure that the path of the compressed air is evidence of a fracture is found, use the color
away from all personnel. Wear protective goggles check method or the Magnaflux method to deter-
or a face shield to prevent injury to the eyes. mine if the cylinder block is fractured.
34
3. Inspect the cylinder roundness and cylindricity for f. Measure the inside diameter of cylinder num-
evidence of distortions. Collect and record the ber one, near the bottom of the cylinder (c) and
measurements. See Figure 49 and Table 1. in the (e) direction. Record that measurement
as data k.
g. Roundness: Roundness for cylinder number

one is calculated as follows:
f-g=X
h-I=Y
j-k=Z
X is the difference between the f and g meas-

urements at the top of the cylinder.
Y is the difference between the h and I meas-

urements at the center/middle of the cylinder.
Figure 49. Cylinder Measurement Points Z is the difference between the j and k measure-
ments at the bottom of the cylinder.
4. Perform the calculations as follows: Select the greatest of values X, Y and Z, then
record it as V. This value represents the round-
a. Measure the inside diameter of cylinder num- ness of the cylinder.
ber one, near the top of the cylinder (a) and in
the (d) direction. Record that measurement as h. Cylindricity - Cylindricity for cylinder number
data f. one is calculated as follows:
b. Measure the inside diameter of cylinder num- Select the least value of values X, Y and
ber one, near the top of the cylinder (a) and in Z record that value as S. Complete the
the (e) direction. Record that measurement as calculation as follows:
data g. V - S =W
c. Measure the inside diameter of cylinder num- W is the difference between the V and S meas-
ber one, near the center of the cylinder (b) and urements. This value represents the cylindricity
in the (d) direction. Record that measurement of the cylinder.
as data h.
5. Repeat the cylindricity and roundness measure-
d. Measure the inside diameter of cylinder num- ments and calculations for the remaining cylin-
ber one, near the center of the cylinder (b) and ders.
in the (e) direction. Record that measurement
as data I. 6. Compare the worksheet findings with the specifi-
cations listed in Engine Specifications.
e. Measure the inside diameter of cylinder num-
ber one, near the bottom of the cylinder (c) and 7. Consider honing, re-boring, or replacing the cylin-
in the (d) direction. Record that measurement der block if the measurements fall outside the
as data j. specifications.
35
Table 1. Cylinder Measurement Worksheet
Cylinder
Measurements Calculated Values
Number
Greatest of
Top Dimension (d) Dimension (e) f-g=X X, Y and Z = V
(a) f = __________ g = __________ X = __________ Roundness
V = __________
Least of
Cylinder #1 Center Dimension (d) Dimension (e) h-I=Y
X, Y and Z = S
(b) h = __________ I = __________ Y = __________
S = __________
V-S=W
Bottom Dimension (d) Dimension (e) j-k=Z
Cylindricity
(c) j = __________ k = __________ Z = __________
V = __________
Greatest of
(a) f = __________ g = __________ X = __________ Roundness
V = __________
Least of
X, Y and Z = S
(b) h = __________ I = __________ Y = __________
S = __________
V-S=W
Cylindricity
(c) j = __________ k = __________ Z = __________
V = __________
Greatest of
(a) f = __________ g = __________ X = __________ Roundness
V = __________
Least of
X, Y and Z = S
(b) h = __________ I = __________ Y = __________
S = __________
V-S=W
Cylindricity
(c) j = __________ k = __________ Z = __________
V = __________
Greatest of
(a) f = __________ g = __________ X = __________ Roundness
V = __________
Cylinder #4 Least of
Center Dimension (d) Dimension (e) h-I=Y
(As Needed) X, Y and Z = S
(b) h = __________ I = __________ Y = __________
S = __________
V-S=W
Cylindricity
(c) j = __________ k = __________ Z = __________
V = __________
36
Honing and Boring
Pistons must move freely in the cylinders while main-

taining adequate compression and oil sealing. If the
cylinder walls are scuffed, scored, out of round, or
have poor cylindricity, boring or boring and honing
might correct cylinder problems. Re-boring is neces-
sary if the bore dimensions fall outside specified lim-
its. Honing must follow any re-boring operations.
Slight imperfections can be corrected by honing
alone.
1. Boring - Significant cylinder damage might be

corrected by re-boring.
Figure 50. Cylinder Honing Angle
• Boring out a cylinder block can only be
done in a properly equipped machine shop.
• After re-boring, existing pistons must be re-
placed with oversized pistons.
• After re-boring a cylinder block, each cylin-
der must be honed.
2. Honing - Slight cylinder imperfections might be

corrected by honing.
a. Insert the appropriate honing tool into the

chuck of an electric drill.
b. Saturate the cylinder wall with solvent using a Figure 51. Cylinder Honing
50% diesel fuel and 50% engine oil mixture.
c. Rotate the honing tool at 300 to 1200 rpm.

e. Without stopping the honing tool, pull it up
through the entire length of the cylinder in a
CAUTION five-second motion.
DO NOT allow the honing tool to operate in one
f. Maintain the up-and-down motion for 30 to 40
position for any length of time. Damage to the cyl-
seconds.
inder wall will occur. Keep the tool in constant up-
and-down motion.
WARNING
NOTE: Tilt the honing tool at a 30 to 40 degree angle
during the honing operation, to leave a cross hatch
mark on the cylinder wall. See Figure 50.
d. Insert the rotating honing tool into the cylinder away from all personnel. Wear protective goggles
and move it down through the entire length of or a face shield to prevent injury to the eyes.
the cylinder in a five-second motion. See Fig-
ure 51.
37
g. When the honing is completed, wash the cylin-

der block with hot water and soap. Use
brushes to clean all passages and crevices.
Rinse with hot water and blow dry with com-
pressed air. Apply clean engine oil to all steel
surfaces to prevent rusting.
Pistons
1. Using a micrometer, measure the piston diameter
at the skirt. Refer to the Engine Specifications for
the service limit. See Figure 52.
A. WIDTH B. THICKNESS
Figure 53. Piston and Piston Ring Side Clearance
d. Replace the piston if the values fall outside the

specification.
e. Using a feeler gauge, measure the end gap

clearance of the top compression ring. Refer to
the Engine Specifications for the service limit.
f. Measure the rings and ring grooves for the

second compression ring and oil ring using the
Figure 52. Piston Skirt Measurement same method used to measure the top com-
pression ring and groove dimensions.
2. Measure the piston ring and the piston ring 3. Repeat Step 2 for each of the pistons.
groove for cylinder number one.
Piston Pin
a. Using a micrometer, measure the thickness of
the top compression ring. Refer to the Engine Measure the outside diameter of the piston pin
Specifications for the service limit. and the inside diameter of the wrist pin bushing. Cal-
culate the clearance between the piston pin and wrist
b. Place a properly-sized, top compression ring in
pin bushing. Refer to the Engine Specifications for the
the groove as shown in Figure 53. Use a feeler
service limit. See Figure 54.
gauge to measure the gap between the ring
and the piston. Refer to the Engine Specifica-
tions for the service limit.
c. Add the top compression ring groove width and

the top compression ring side clearance to-
gether to determine the top ring groove width.
Refer to the Engine Specifications for the serv-
ice limit.
38
2. Measure the crankpin and connecting rod bearing

halves. Place the connecting rod bearing halves
into the connecting rod and connecting rod cap.
Install the end of the connecting rod to the con-
necting rod cap. Install the bolts and tighten to 54
to 59 N•m (40 to 43 lbf ft).
3. Measure the inside diameter. Refer to the Engine

Specifications for the service limit.
Tappets
NOTE: MEASURE AT POSITIONS A, B, AND C IN 1. Check the tappet contact surfaces with the cam-
DIRECTIONS A AND B. shaft and push rods. Slight surface defects can be
corrected using an oilstone. See Figure 56.
Figure 54. Piston Pin Outside Diameter
Connecting Rod
1. Measure the inside diameter of the connecting
rod small end. Refer to the Engine Specifications
for the service limit. See Figure 55.
1. ABNORMAL CONTACT SURFACE

2. NORMAL CONTACT SURFACE
Figure 56. Tappet Contact Surface
2. Measure the outside diameter of the tappet stem.

Refer to the Engine Specifications for the service
limit. See Figure 57.
1. CYLINDER GAUGE
2. CONNECTING ROD SMALL END
Figure 55. Connecting Rod Small End
Figure 57. Tappet Stem Measurement
39
Crankshaft 2. Inspect the crankshaft for fractures.
1. Measure the trueness of the crankshaft. a. Using the color check method, inspect the
crankshaft for cracks. Replace the crankshaft if
a. Place the crankshaft on V-blocks at the end evidence of fractures are found. See Figure 59.
journals. See Figure 58.
b. Place a dial indicator on a main bearing sur-

face and zero the gauge.
c. Rotate the crankshaft and observe the runout.

ice limit.
d. Repeat this procedure for the remaining bear-

ing surfaces.
Figure 59. Crankshaft Fracture Check
b. If the color check method is not available, use

the Magnaflux method. Inspect the crankshaft
for cracks. Replace the crankshaft if evidence
of fractures are found.
3. Measure the outside diameter of each crankpin

and journal. See Figure 60.
a. If the crankpin clearance exceeds the service

limit, use an undersized bearing. Refer to the
Engine Specifications for the service limit.
b. If the journal clearance exceeds the service

limit, use an undersized bearing. Refer to the
A. BEND B. DEFLECTION Engine Specifications for the service limit.
1. DIAL GAUGE 3. V-BLOCK
2. CRANKSHAFT
Figure 58. Crankshaft Bend Measurement
40
b. Place a dial indicator on the gear side bearing

surface and zero the gauge.
c. Rotate the camshaft and observe the runout.

ice limit.
Figure 61. Camshaft Runout Check
2. Measure the intake/exhaust cam height. Refer to

1. CRANKSHAFT JOURNAL the Engine Specifications for the service limit. See
2. CRANKPIN Figure 62.
Figure 60. Crankpin and Crankshaft Journal
Measurement
Camshaft
1. Measure the trueness of the camshaft.
a. Place the camshaft on V-blocks positioned at

the end journals. See Figure 61.
A. CAM HEIGHT
Figure 62. Intake/Exhaust Cam Height

Measurement
41
3. Measure the gear end bearing surface, intermedi- NOTE: Rotate the cylinder block into a position in
ate position bearing surface, and flywheel end which it allows gravity to keep the tappets in place
bearing surface diameters. See Figure 63. Deter- and out of the way of the camshaft lobes for when the
mine the oil clearance. The oil clearance is calcu- camshaft is installed.
lated by subtracting the measured camshaft bear-
ing surface diameter from the camshaft bushing 4. Install the tappets into the cylinder block in the
inside diameter. Refer to the Engine Specifica- same locations as they were removed.
tions for the service limit.
5. Slowly insert the camshaft through the front of the
engine.
6. Place the camshaft thrust plate in position and in-

stall the retaining bolts. See Figure 48.
7. Install the key on the camshaft.
8. Install the camshaft gear.
Crankshaft
1. Place the crankshaft in position in the cylinder
block.
1. FLYWHEEL END BEARING SURFACE
2. INTERMEDIATE POSITION BEARING SUR- NOTE: The numbers and arrows on the main bearing
FACE caps are for proper positioning. The caps are num-
3. GEAR END BEARING SURFACE bered 1, 2, 3, and 4 with the number 1 cap at the fly-
wheel end of the cylinder block. The arrows on the
Figure 63. Camshaft Bearing Surface
bearing caps should point towards the flywheel end of
Measurements
the cylinder block.
2. Position the bearing halves, thrust bearings, and

Camshaft Bushing bearing caps on the crankshaft. See Figure 44.
If the camshaft bushing is damaged, replace the 3. Lubricate the bearing cap bolts and install the
bushing using the appropriate service tool. bolts.
ASSEMBLE 4. Install a new oil seal in the rear oil seal housing.
5. Apply a continuous bead of ThreeBond Liquid

Camshaft Gasket, Yale Part Number 580062478, to the
mating surface of the rear oil seal housing.
1. Verify that all parts are clean. Lightly lubricate all
parts with clean engine oil. 6. Align the rear oil seal housing with the two dowel
pins on the cylinder block and install the rear oil
2. If removed, install new camshaft bushing.
seal housing. Install the retaining bolts and tighten
3. Install the timing gear case. See Timing Gear to 108 to 118 N•m (80 to 87 lbf ft).
42
Pistons and Connecting Rods 5. Lubricate and install the piston wrist pin through
the piston and wrist pin bushing.
1. Select the parts needed to assemble the piston
and connecting rod for the Number 1 cylinder. 6. Install the second snap ring.
2. Lubricate and insert the wrist pin bushing into the 7. Using piston ring pliers, install the piston rings.
small end of the connecting rod. See Figure 43.
a. Install each piston ring on the piston with the
3. Install one snap ring into the piston. punched manufacture's mark facing upward.
See Figure 65.
4. Position the connecting rod into the piston under
the skirt. The match marks on the connecting rod
must be opposite of the piston identification mark
on the top of the piston. See Figure 64.
Figure 65. Piston Ring Mark
b. Install the top compression ring, second com-

pression ring, and oil ring. See Figure 66.
A. FUEL INJECTION PUMP SIDE

B. FLYWHEEL SIDE
C. CAMSHAFT SIDE
1. PISTON IDENTIFICATION MARK
2. CYLINDER SIZE MARK
3. EMBOSSED MARK (FLYWHEEL SIDE)
4. PUNCHED MARK
Figure 64. Piston and Connecting Rod

Identification Marks 1. TOP COMPRESSION RING
2. SECOND COMPRESSION RING
3. OIL RING
4. PISTON
Figure 66. Piston Rings
43
c. Stagger the piston ring joints at 120 degree in- 12. Install the connecting rod bearing halves and con-
tervals. DO NOT position the top compression necting rod cap. Install the connecting rod bolts
ring joint in line with the piston wrist pin. The and tighten to 54 to 59 N•m (40 to 43 lbf ft).
coil expander joint must be opposite the oil ring
joint. See Figure 67. 13. Perform Step 9 through Step 12 to install the re-
maining pistons in their respective cylinders.
INSTALL
1. Install crankshaft gear and idler gear. See Timing
Gear Case and Timing Gears Repair.
2. Install oil pump. See Lubrication System Repair.
3. Install timing gear case cover. See Timing Gear

4. Install oil suction tube. See Lubrication System

Repair.
5. Install oil pan. See Lubrication System Repair.
6. Install cylinder head. See Cylinder Head Assem-

bly Repair.
7. Install fuel injection pump. See Fuel System Re-

pair.
8. Install water pump. See Cooling System Repair.
9. Install alternator. See Electrical Equipment Re-

pair.
10. Install flywheel and flywheel housing. See Fly-

wheel and Flywheel Housing.
1. TOP COMPRESSION RING 11. Install starter. See Electrical Equipment Repair.
2. SECOND COMPRESSION RING
3. OIL RING 12. Install engine.
4. JOINTS
Figure 67. Piston Rings Staggering
GDP040SVX) (C810)
8. Perform Step 1 through Step 7 for the assembly • GDP20-35VX (GDP040-070VX) (B875)
of the remaining pistons.
9. Lubricate the Number 1 piston and piston rings
with clean engine oil.
GDP040SVX) (D810)
10. Using special tool, piston ring compressor, com-
press the piston rings on the Number 1 piston.
• GDP20-25LX (GDP050LX) (A974)
11. Carefully install the piston into the Number 1 cyl-
inder. Be sure the punched mark on the connect- See Frame 0100YRM1672 for lift truck model
ing rod is facing the fuel injector side and the em- • GDP20-35VX (GDP040-070VX) (C875)
bossed mark is facing the flywheel. See Fig-
ure 64.
44
See Frame 0100YRM1754 for lift truck models 13. If not previously removed, remove and discard
• GDP20-35VX (GDP040-070VX) (D875) engine oil filter. Apply clean oil to gasket of new
filter. Install new filter. Turn filter until gasket
See Frame 0100YRM1766 for lift truck models touches, then tighten ½ to ¾ turn with your hand.
• GDP20-25LX (GDP050LX) (B974) 14. Fill the engine oil to the correct level. See Peri-
odic Maintenance Manual for your lift truck, for
• GP20-30MX (GP040-060MX) (A390)
Lubrication System Repair

ENGINE OIL AND OIL FILTER CHANGE OIL PAN
1. Remove the oil pan drain plug and drain the en- Remove
gine oil into a suitable container. See Figure 68.
WARNING
When putting the lift truck on blocks, make sure
the surface is solid, even, and level. Any blocks
used to support the lift truck must be solid, one-
piece units.
1. Put the lift truck on blocks so that you have ac-

cess under the lift truck. Refer to the Operating
Manual or the section Periodic Maintenance for
your lift truck.
2. Remove the crossmember and the flywheel ac-

cess cover.

1. OIL FILTER 3. DRAIN PLUG
2. BOLT 4. OIL PAN • GDP16-18VX, GDP20SVX
(GDP030-035VX, GDP040SVX) (C810)
Figure 68. Oil Pan • GDP20-35VX (GDP040-070VX) (B875)

2. Remove the engine oil filter.
• GDP16-18VX, GDP20SVX
3. Install the oil pan drain plug. Tighten the drain (GDP030-035VX, GDP040SVX) (D810)
plug to 20 to 24 N•m (15 to 18 lbf ft).
4. Apply clean oil to gasket of new filter. Install new • GDP20-25LX (GDP050LX) (A974)
filter. Turn filter until gasket touches, then tighten
½ to ¾ turn with your hand. See Frame 0100YRM1672 for lift truck models
• GDP20-35VX (GDP040-070VX) (C875)
5. Fill the engine oil to the correct level. See Peri-
odic Maintenance Manual for your lift truck, for See Frame 0100YRM1754 for lift truck models
• GDP20-35VX (GDP040-070VX) (D875)
6. Start engine. Check area around oil filter for
leaks.
• GDP20-25LX (GDP050LX) (B974)
45
Lubrication System Repair 0600 YRM 1205
See Frame 0100YRM1984 for lift truck models See Frame 0100YRM1423 for lift truck models
• GP20-30MX (GP040-060MX) (A390) • GDP20-25LX (GDP050LX) (A974)
3. Remove oil pan drain plug and drain the engine See Frame 0100YRM1672 for lift truck model
oil into a suitable container. See Figure 68. • GDP20-35VX (GDP040-070VX) (C875)
4. Remove oil filter. See Frame 0100YRM1735 for lift truck models
5. Remove bolts retaining the oil pan to the engine • GDP16-18VX, GDP20SVX
block. (GDP030-035VX, GDP040SVX) (D810)
6. Remove oil pan. See Frame 0100YRM1754 for lift truck models
• GDP20-35VX (GDP040-070VX) (D875)
CAUTION See Frame 0100YRM1766 for lift truck models
Use care not to damage the mating surfaces when
• GDP20-25LX (GDP050LX) (B974)
removing old gaskets and sealant residues.
7. Carefully remove old sealant residue from the
mating surfaces of the oil pan and cylinder block. • GP20-30MX (GP040-060MX) (A390)
8. Thoroughly clean the outside and inside surfaces 6. Remove lift truck from blocks.
of the oil pan.
7. Fill engine oil to correct level. See Periodic Main-
tenance Manual for your lift truck, for correct oil
Install
amount and type.
Gasket, Yale Part Number 580062478, around
the sealing surface of the oil pan. OIL SUCTION TUBE
2. Place the oil pan in position and install the retain-
ing bolts. Refer to Standard Torque Specifica- Remove
tions.
1. Remove oil pan. See Oil Pan, Remove.
3. Apply clean oil to gasket of new filter. Install new
2. Remove two bolts retaining the oil suction tube.
filter. Turn filter until gasket touches, then tighten
See Figure 69.
½ to 3/4 turn with your hand.
3. Remove oil suction tube.
4. Install the oil pan drain plug. Tighten the drain
plug to 20 to 24 N•m (14.75 to 17.70 lbf ft). 4. Remove O-ring from oil suction tube and discard.
5. Install the crossmember and the flywheel access
cover.

(GDP030-035VX, GDP040SVX) (C810)
• GDP20-35VX (GDP040-070VX) (B875)
46
0600 YRM 1205 Lubrication System Repair
Clean the oil suction tube in cleaning solvent. Dry the

oil suction tube with compressed air. Inspect for wear
and damage. If necessary, replace oil suction tube.
Install
1. Install a new O-ring on the oil suction tube.
2. Position the oil suction tube in the cylinder block.
3. Install the two bolts to retain the oil suction tube.

Refer to Standard Torque Specifications.
4. Install the oil pan. See Oil Pan, Install.
OIL PUMP
Remove

(GDP030-035VX, GDP040SVX) (C810)
• GDP20-35VX (GDP040-070VX) (B875)
1. O-RING 3. OIL SUCTION TUBE See Frame 0100YRM1423 for lift truck models
2. BOLTS 4. CYLINDER BLOCK • GDP20-25LX (GDP050LX) (A974)
Figure 69. Oil Suction Tube
Clean • GDP20-35VX (GDP040-070VX) (C875)

WARNING • GDP16-18VX, GDP20SVX
Cleaning solvents can be flammable and toxic and (GDP030-035VX, GDP040SVX) (D810)
solvents, always follow the recommendations of See Frame 0100YRM1754 for lift truck models
the manufacturer. • GDP20-35VX (GDP040-070VX) (D875)

WARNING
• GDP20-25LX (GDP050LX) (B974)
cause injury to the user or to other personnel. See Frame 0100YRM1984 for lift truck models
• GP20-30MX (GP040-060MX) (A390)
NOTE: The oil suction tube and screen are to be

serviced as an assembly. DO NOT attempt to repair
the wire mesh portion of the tube and screen assem-
bly.
47
2. Remove the coolant fan, V-belt, and water pump.

See Cooling System Repair. WARNING
3. Remove the bolt and washer retaining the crank- cause injury to the user or to other personnel.
shaft pulley. Make sure that the path of the compressed air is
4. Using a gear puller, remove the crankshaft pulley.
Gear Case and Timing Gears Repair.
CAUTION
6. Remove the bolts retaining the oil pump assembly If any oil pump component clearance exceeds its
and remove the oil pump assembly from the tim- limit, the oil pump must be replaced as an assem-
ing gear case housing. See Figure 70. bly. Failure to replace the complete pump assem-
bly could result in pump failure and damage to the
engine.
Clean all of the parts in cleaning solvent. Dry the parts

with compressed air. Inspect for wear and damage. If
necessary, replace oil pump assembly.
Outer Rotor Outside Clearance
Insert a feeler gauge between the outer rotor and the

timing gear case oil pump cavity and measure the
clearance. Refer to the section Engine Specifications
for the clearance limits. See Figure 71.
1. GEAR CASE HOUSING

2. OUTER ROTOR
3. OIL PUMP ASSEMBLY
4. BOLT
Figure 70. Oil Pump Assembly
7. Remove the outer rotor from the timing gear case

housing. See Figure 70.
Clean and Inspect

1. OUTER ROTOR 3. OIL PUMP CAVITY
2. FEELER GAUGE
WARNING
Cleaning solvents can be flammable and toxic and Figure 71. Outer Rotor Outside Clearance Check
the manufacturer.
48
0600 YRM 1205 Lubrication System Repair
Outer Rotor to Inner Rotor Tip Clearance
Insert a feeler gauge between the top of an inner rotor

tooth and the top of an outer rotor tooth and measure
the clearance. Refer to the section Engine Specifica-
tions for the clearance limits. See Figure 72.
1. DEPTH MICROMETER
2. PUMP CAVITY
3. OUTER ROTOR
Figure 73. Outer Rotor Side Clearance Check
1. FEELER GAUGE 3. OUTER ROTOR

2. INNER ROTOR Rotor Shaft Clearance
Figure 72. Outer Rotor to Inner Rotor Tip
Clearance Check Measure the outside diameter of the rotor shaft and
the bore diameter in the gear case housing to deter-
mine the rotor shaft clearance. Refer to the section
Outer Rotor Side Clearance Engine Specifications for the clearance limits. See
Figure 74.
Using a depth micrometer, measure the depression of
the outer rotor across the pump cavity to determine
the side clearance. Refer to the section Engine Speci-
fications for the clearance limits. See Figure 73.
49
3. Position oil pump assembly in the gear case

housing. Install the bolts to retain the oil pump.
Refer to Standard Torque Specifications. See Fig-
ure 70.
4. Install timing gear case cover. See Timing Gear

5. Install crankshaft pulley, washer, and bolt to retain

the crankshaft pulley. Tighten bolt to
117.6 N•m (86.7 lbf ft).
6. Install water pump, V-belt, and coolant fan. See

Cooling System Repair.
1. ROTOR SHAFT
2. GEAR CASE HOUSING 7. Install engine.
Figure 74. Rotor Shaft Clearance Check
Install (GDP030-035VX, GDP040SVX) (C810)
• GDP20-35VX (GDP040-070VX) (B875)
1. Lubricate the outer rotor and pump bore in the
gear case with clean engine oil. See Frame 0100YRM1423 for lift truck models
NOTE: The punch mark end of the outer rotor must • GDP20-25LX (GDP050LX) (A974)
face away from the gear case housing.
2. Install outer rotor in gear case housing. Verify that • GDP20-35VX (GDP040-070VX) (C875)
the punch mark end of the outer rotor faces away
from the gear case housing. See Figure 75. See Frame 0100YRM1735 for lift truck models
(GDP030-035VX, GDP040SVX) (D810)

• GDP20-35VX (GDP040-070VX) (D875)

• GDP20-25LX (GDP050LX) (B974)

• GP20-30MX (GP040-060MX) (A390)
8. Change engine oil and oil filter. See Engine Oil

and Oil Filter Change.
1. PUNCH MARK 3. TIMING GEAR
2. OUTER ROTOR CASE 9. Start engine and check for leaks.
Figure 75. Outer Rotor
50
0600 YRM 1205 Fuel System Repair
Fuel System Repair

a. First loosen the high pressure fuel line nuts at
CAUTION the fuel injectors.
DO NOT attempt to remove or adjust the tamper-
proof devices from the full-load fuel adjusting
screw or the high-speed throttle limit screw on the
fuel injection pump and governor assembly.
These adjustments have been made at the factory
to meet all applicable emissions regulations and
then sealed.
DO NOT attempt to make any adjustments to

these sealed adjustment screws. If adjustments
are required, they can be made only by a qualified
fuel injection shop that will ensure the injection
pump continues to meet all applicable emissions
regulations and then replace the tamper-proof
seals.
FUEL INJECTORS
Remove
1. Remove the bolt holding the oil dipstick tube
clamp. Rotate the dipstick tube to one side. This
is to allow removal of the high pressure fuel lines.
See Figure 76.
CAUTION
Remove the high pressure fuel lines as an assem- 1. OIL DIPSTICK 3. DIPSTICK TUBE
bly whenever possible. Disassembling the high 2. INTAKE MANIFOLD 4. BOLT
pressure fuel lines from the retainers or bending
any of the fuel lines will make it difficult to rein- Figure 76. Oil Dipstick Tube
stall the fuel lines.
2. Remove the high pressure fuel lines. See Fig- b. Loosen the high pressure fuel line nuts on the
ure 77. fuel injection pump.
CAUTION CAUTION
When loosening or tightening the lines at the fuel DO NOT bend any of the fuel lines when removing
injectors, you must hold the fuel injector with a them.
second wrench to prevent the injector from turn-
ing and damaging the fuel return line fitting. c. Finish loosening all of the high pressure fuel
line nuts and remove the fuel lines as an as-
sembly.
51
Fuel System Repair 0600 YRM 1205
Inspect
Visually inspect the fuel injectors and nozzle protec-

tors for deposits or damage. Clean and repair as nec-
essary.
Clean
1. Clean the exterior of the nozzle, taking care not to
damage the needle.
2. Pull out the needle and clean carefully so as not

to damage it. Avoid use of hard, metallic tools.
3. Check for dents, damage, rusting, and wear. Pay

special attention to the stem and seat of the nee-
dle.
4. When setting the needle on the nozzle body after

thorough cleaning, check that it falls by its own
weight.
Test
1. HIGH PRESSURE LINE 1. Test the fuel injector using a special tool, fuel in-
2. RETURN LINE FITTING jection nozzle tester. Use clean, filtered fuel for
3. RETURN LINE the test.
5. MAGNETIC VALVE (STOP SOLENOID) ELEC-
TRICAL CONNECTOR WARNING
Figure 77. Fuel Injection Pump High Pressure Never inject fuel toward you. Since the fuel is in-
Lines jected at high pressure from the nozzle, it may
penetrate the skin, resulting in injury.
3. Remove the nuts retaining the fuel injector return Never inject fuel toward a fire source. Atomized
line fittings and return lines. fuel is highly flammable and may cause fire or
skin burning.
4. Remove the fuel injector return lines and fittings
as an assembly. 2. Using the correct adapter, connect the fuel injec-
tor to the high pressure pipe of the nozzle tester.
5. Unscrew the fuel injectors from the cylinder head. Aim the fuel injector nozzle into a suitable con-
Also remove the two copper washers and the tainer to catch the fuel spray. See Figure 78.
nozzle protectors from the injector port in the cyl-
inder head.
52
1. INJECTION NOZZLE 2. NOZZLE TESTER

Figure 78. Fuel Injector Tester
3. Pump the operating lever of the tester slowly, ob-

serving the pressure reading at the point where
the fuel injector begins spraying fuel. The fuel in-
jectors should begin spraying fuel at 11.8 to
13.2 MPa (1711 to 1914 psi). The operating pres-
sure may be adjusted by adding or subtracting in- 1. NUT
ternal fuel injector shims. See Figure 79. 2. RETURN LINE FITTING
3. NOZZLE HOLDER
4. Adding or removing a 0.1 mm (0.0039 in.) shim 4. PRESSURE ADJUSTING SHIM
(shims are available in 0.4 mm (0.016 in.) incre- 5. NOZZLE SPRING
6. NOZZLE SPRING SEAT
ments) changes the pressure by 1.2 to 7. VALVE STOP SPACER
2.2 MPa (174 to 319 psi). 8. NOZZLE VALVE
9. NOZZLE BODY
5. Pump the operating lever more rapidly to repeat- 10. NOZZLE CASE
edly “pop” the injector and observe the spray pat-
tern. See Table 2 for examples of “good” and Figure 79. Fuel Injector
“bad” spray patterns.
6. Pump the operating lever slowly to hold the pres- 7. If the fuel injector fails any of these tests, it should
sure steady at a point just below the “pop off” be repaired or replaced as necessary.
pressure point. Observe the injector to see that it
is sealing properly and is not “dripping.”
53
Table 2. Fuel Injector Spray Patterns
A B C D E
Injection
Pattern
Pressure
Gauge
Reading
Pointer Same as A. Pointer stays at Although the pointer Pressure does not
fluctuate a position near reaches the valve increase even when
around the the valve opening pressure, the tester lever is
valve opening opening the pressure drop is operated.
pressure. pressure. large.
Atomization Roughly Atomization is Although Bar shape with Drops (bar shape).
Pattern uniform. excessively one atomized, the excessive after
sided. needle does not drops.
pulsate (burner
like shape).
Possible (Normal) 1. Normally 1. Caused 1. Damage to the 1. Sticking of
Cause caused by by seat. needle.
carbon excessive 2. Contamination 2. Excessively
contaminat carbon of seat by fine damaged or
ion of the contamin foreign worn seat.
nozzle tip. ation of particles.
the 3. Contaminatio
2. Sometime 3. Excessively n of seat by
s caused nozzle
tip. worn seat. foreign
by flaws in matter.
or damage 2. Sometim
to the es 4. Damaged or
needle tip. caused broken
by internal parts
contamin of nozzle
ation. holder.
54
Install b. Tighten high pressure fuel line nuts on the fuel

injection pump. Refer to Standard Torque
1. Install a new copper washer at the bottom of the Specifications.
injector well.
2. Install nozzle protector in injector well. CAUTION

When loosening or tightening the lines at the fuel
3. Install second new copper washer on top of noz-
injectors, you must hold the fuel injector with a
zle protector.
second wrench to prevent the injector from turn-
4. Install fuel injectors. Tighten fuel injectors to ing and damaging the fuel return line fitting.
39 N•m (29 lbf ft).
c. Tighten high pressure fuel line nuts on fuel in-
5. Install fuel return lines and fittings as an assembly jectors. Refer to Standard Torque Specifica-
using new copper washers. tions.
6. Install fuel return line fitting retaining nuts and 9. Rotate dipstick tube back to original position. In-
tighten to 44 N•m (33 lbf ft). stall retaining bolt to hold oil dipstick tube clamp
to intake manifold. See Figure 76.
7. Connect fuel injector return line to fuel pump.
10. Prime fuel system and check for leaks.
8. Install high pressure fuel lines.
ELECTRONIC THROTTLE SYSTEM
CAUTION Remove
DO NOT bend any of the fuel lines when installing
them. 1. Remove capscrews and nuts to the linkage as-
sembly and remove linkage assembly. See Fig-
NOTE: Replace high pressure fuel lines as an as- ure 80.
sembly.
a. Start all high pressure fuel line nuts by hand,

leaving the nuts on the fuel injection pump and
the fuel injectors loose.
55
1. THROTTLE POSITION SENSOR 5. NUT

2. CAPSCREW 6. PULL ACTUATOR
3. NUT 7. CLEVIS
4. LINKAGE ASSEMBLY 8. CAPSCREW
Figure 80. Electronic Throttle System
56
2. Disconnect the electrical connector for the pull ac- 4. If necessary, remove the clevis with linkage as-
tuator. sembly, lockwasher, and nut from the pull actua-
tor. See Figure 82.
3. Remove the capscrews and nuts retaining the pull
actuator to the mounting bracket and remove the
pull actuator. See Figure 81.
1. PULL ACTUATOR
2. NUT
3. LOCKWASHER
4. CLEVIS WITH LINKAGE ASSEMBLY
Figure 82. Pull Actuator and Linkage Assembly
5. Disconnect the electrical connector from the throt-

tle position sensor (TPS).
6. Remove the Torx-head screws retaining the TPS

1. MOUNTING BRACKET and remove the TPS. See Figure 83.
2. INTAKE MANIFOLD
3. FUEL PUMP
4. CAPSCREW
5. PULL ACTUATOR
6. NUT
Figure 81. Pull Actuator Mounting
57
Install
1. Install TPS rotor.
NOTE: The TPS mounting screws are non-magnetic

stainless steel to avoid interference with the sensor
magnet and must be reused if the TPS is replaced.
2. Place TPS bracket in position and install Torx-

head screws. Tighten Torx-head screws to
10.5 N•m (93 lbf in).
NOTE: When installing the TPS, rotate sensor rotor

clockwise to match D-shape on TPS rotor. See Fig-
ure 84.
3. Place TPS in position and install Torx-head

screws. Tighten Torx-head screws to
2.25 N•m (20 lbf in).
4. Connect the throttle position sensor (TPS) electri-

cal connector.
5. Turn the lever clockwise to verify that the TPS

does not bind or stick.
1. LOCKWASHER
2. TORX-HEAD SCREW
3. TPS BRACKET
4. WASHER
5. TORX-HEAD SCREW
6. THROTTLE POSITION SENSOR (TPS)
7. TPS ROTOR
8. THROTTLE LEVER
9. FUEL PUMP
Figure 83. Throttle Position Sensor (TPS)

Assembly 1. SENSOR ROTOR 3. TPS ROTOR
2. TPS 4. D-SHAPE
7. Remove the Torx-head screws retaining the TPS Figure 84. TPS and Rotor
bracket and remove bracket.
8. Remove the TPS rotor. 6. Install the nut and lockwasher onto the threaded
end of the pull actuator rod. See Figure 82.
NOTE: DO NOT tighten the clevis into the nut on the

pull actuator rod. Always tighten the nut towards the
clevis.
58
7. Install the clevis with linkage assembly onto the

threaded end of the pull actuator rod and then
tighten the nut toward the clevis. Tighten the nut
to 6.8 N•m (60 lbf in).
8. Place pull actuator in position on the mounting

bracket and install capscrews and nuts hand tight
only to retain the pull actuator to the mounting
bracket. See Figure 81.
9. Verify that the clevis is in the position shown in

Figure 80. Adjust as needed.
10. Verify that the rod ends of the linkage assembly

are parallel to each other. Adjust as needed. See
Figure 85.
1. CLEVIS 3. OUTER HOLE

2. ROD END 4. THROTTLE LEVER
Figure 86. Rod End and Throttle Lever Alignment
12. Slide the pull actuator forward in the mounting

bracket slots until the rod end hole is 2 to
3 mm (0.0787 to 0.1181 in.) past the inner hole in
the throttle lever. Tighten the pull actuator to
mounting bracket capscrews and nuts.
13. Push the actuator rod in toward the actuator until

1. PULL ACTUATOR
2. NUT the rod end hole aligns with the inner throttle lever
3. CLEVIS hole and install the capscrew and nut to retain the
4. NUT rod end to the throttle lever.
5. TURNBUCKLE
6. ROD ENDS (MUST BE PARALLEL TO EACH 14. Connect the electrical connector for the pull ac-
OTHER) tuator.
Figure 85. Linkage Assembly
Inspect
1. Check the low idle stop position to see if the throt-
NOTE: DO NOT force the lever or pull actuator rod
tle lever is in contact with the low idle stop. If ad-
when installing. The actuator component and the
justment is necessary, refer to the section Adjust.
lever need to be at rest when installing.
2. When the condition in Step 1 is met, check if the
NOTE: The outer hole of the throttle lever is used for
actuator is fully extended by turning the actuator
manual throttles only. The inner hole on the throttle
to the high idle position by hand to see if the throt-
lever is used for electronic throttles only.
tle lever will contact the high idle stop. Verify that
11. Place the other rod end on the top side of the the sensor rotates freely, without binding or stick-
throttle lever and align the rod end hole with the ing.
inner hole on the throttle lever. See Figure 86.
59
Adjust
CAUTION
DO NOT attempt to adjust the low or high idle
speed limit screws. This may impair the safety
and performance of the lift truck and shorten it's
engine life. If the idle speed limit screws require
adjustment, see your authorized Yanmar indus-
trial engine dealer or distributor. Figure 87. Adjustment Rod Ends
NOTE: If adjustment is required, disassemble the link
from the throttle pump lever and adjust the length of
6. With the engine OFF and power ON, navigate dis-
the link. See Figure 80.
play console menus to read throttle position sen-
1. Make sure the linkage length between rod ends sor "A” voltage under no-run data display menu.
are 72.5 ±0.51 mm (2.85 ±0.02 in.). See Fig- The PC Service Tool can also be used. With ac-
ure 87. celerator released and throttle pump lever against
low idle stop, throttle sensor "A" voltage must be
2. The link should be in line between the throttle ac- within 2.25 - 2.45 volts.
tuator and the throttle pump lever. If necessary,
loosen the actuator mounting screws and adjust NOTE: Step 7 will immediately set a fault code since
the throttle actuator up or down to align the link the throttle position sensor exceeds the command.
then tighten the mounting screws. The fault code must be cleared after performing
Step 7.
NOTE: DO NOT adjust the low speed or high speed
stop screws. 7. Manually rotate the throttle pump lever to full
throttle position. With the throttle pump lever
3. Check the prestroke on the actuator. Disassemble against high idle stop, throttle position sensor "A"
the link from the throttle pump lever. Check the voltage must be within 3.15-4.70 volts. See Fig-
distance that the hole in the link end extends be- ure 88.
yond the inner hole in the throttle pump lever.
This distance should be 2-3 mm (0.08-0.11 in.). If
the distance is out of adjustment, loosen the cle-
vis jam nut. Rotate the clevis while holding the ac-
tuator rod to adjust then tighten the clevis jam nut.
If additional adjustment is required, adjust the
length of the link.
4. After proper adjustment is achieved, push the link

toward the actuator to align the hole in the link
with the inner hole in the throttle pump lever and
reassemble the link hardware. Verify that the
lever contacts both the low and high idle stops
when the lever is rotated manually.
5. Make sure the throttle position sensor is not bind-

ing. Bend or replace the TPS mounting bracket if 1. LOW IDLE STOP SCREW
2. THROTTLE PUMP LEVER
necessary. 3. HIGH IDLE STOP SCREW
Figure 88. Throttle Lever Stop Screws
60
8. If after adjustment, the TPS voltage does not fall • Frame 0100YRM1120
within the correct ranges, refer to Diagnostic for lift truck model GDP16-18VX, GDP20SVX
Troubleshooting Manual 9000YRM1112 for the (GDP030-035VX, GDP040SVX) (C810, D810).
TPS diagnostic procedure. • Frame 0100YRM1754
for lift truck model GDP20-35VX
NOTE: DO NOT lubricate the linkage or actuator
(GDP040-070VX) (B875, C875, D875).
shaft with a wet lubricant.
• Frame 0100YRM1766
9. Clean any dust and debris from the linkage ends for lift truck model GDP20-25LX (GDP050LX)
and the return spring on the fuel pump. Make sure (A975, B975).
the linkage is not binding or sticking. Make sure
• Frame 0100YRM1984
the rod ends are parallel to each other and all the
for lift truck model GP20-30MX
hardware is installed properly.
(GP040-060MX) (A390).
NOTE: Dust on the actuator plunger can cause this
sticking. Lift truck model GP20-30MX (GP040-060MX) (A390)
may also be equipped with the traction limit group.
10. Make sure the actuator is not sticking. With the See Frame 0100YRM1984 for repair and adjustment
engine OFF and power ON, depress the throttle procedures.
pedal from idle to full throttle while watching the
actuator. The actuator should operate smoothly FUEL INJECTION PUMP
from the idle position to the full throttle position
without sticking or erratic movement. Replace the Remove
actuator if necessary.
1. Disconnect fuel supply line from the fuel injection
NOTE: DTC 51-7 may be set due to a change in the pump.
injection pump throttle lever force during an out-of-fuel
condition. 2. Disconnect fuel tank return line.
11. Check fuel level as necessary. 3. Disconnect fuel injector return line from the fuel
pump. See Figure 89.
MANUAL THROTTLE SYSTEM
For repair and adjustment procedures to the manual

throttle system on your lift truck see
61
1. FUEL INJECTOR 7. L-SHAPED BRACKET

2. HIGH PRESSURE FUEL LINE 8. DIPSTICK TUBE
3. RETURN LINE FITTINGS 9. COLD START AID
4. RETURN LINE 10. MAGNETIC VALVE (STOP SOLENOID) ELEC-
5. FUEL INJECTION PUMP TRICAL CONNECTOR
6. BOLT 11. COLD START AID ELECTRICAL CONNECTOR
Figure 89. Fuel Injection Pump
4. Disconnect electrical connection to the magnetic 6. If equipped, remove the electronic throttle system.
valve (stop solenoid). See Electronic Throttle System, Remove.
5. Disconnect electrical connection to the cold start 7. If equipped, disconnect throttle cable.
aid.
62

• GDP16-18VX, GDP20SVX CAUTION
(GDP030-035VX, GDP040SVX) (C810) DO NOT bend any of the fuel lines when removing
them.
• GDP20-35VX (GDP040-070VX) (B875)
c. Finish loosening all of the high pressure fuel
line nuts and remove the fuel lines as an as-
• GDP20-25LX (GDP050LX) (A974) sembly.
See Frame 0100YRM1672 for lift truck model 10. Remove the bolts retaining the L-shaped brackets
• GDP20-35VX (GDP040-070VX) (C875) and remove brackets. See Figure 89.
See Frame 0100YRM1735 for lift truck models 11. Remove the V-belt and fan assembly. See Cool-
ing System Repair.
(GDP030-035VX, GDP040SVX) (D810) 12. Remove the bolts from the fuel injection pump
cover on the front of the timing gear case cover.
Remove the fuel injection pump cover. See Fig-
• GDP20-35VX (GDP040-070VX) (D875) ure 90.
• GDP20-25LX (GDP050LX) (B974)

• GP20-30MX (GP040-060MX) (A390)
8. Remove the bolt holding the oil dipstick tube

clamp. Rotate the dipstick tube to one side. This
is to allow removal of the high pressure fuel lines.
See Figure 76.
CAUTION
Remove the high pressure fuel lines as an assem-
bly whenever possible. Disassembling the high
pressure fuel lines from the retainers or bending
any of the fuel lines will make it difficult to rein-
stall the fuel lines.
9. Remove the high pressure fuel lines. See Fig-

1. TIMING GEAR CASE COVER
ure 77. 2. BOLT
3. FUEL INJECTION PUMP COVER
CAUTION Figure 90. Fuel Injection Pump Cover
When loosening or tightening the lines at the fuel
injectors, you must hold the fuel injector with a
second wrench to prevent the injector from turn- 13. To aid in reassembly, mark one tooth on the idler
ing and damaging the fuel return line fitting. gear and two teeth on the fuel injection pump
drive gear with a dot of white paint. See Fig-
a. First loosen the high pressure fuel line nuts at ure 91.
the fuel injectors.
b. Loosen the high pressure fuel line nuts on the

fuel injection pump.
63
15. While holding the engine from turning with a

wrench on the crankshaft pulley bolt, remove the
fuel injection pump drive gear retaining nut and
lockwasher. See Figure 93.
1. FUEL INJECTION PUMP DRIVE GEAR

2. CAMSHAFT GEAR
3. CRANKSHAFT GEAR
4. DIRECTION OF ROTATION
5. OIL PUMP GEAR
6. IDLER GEAR
Figure 91. Timing Gear Alignment
14. Make matching marks on the rear of the timing

gear case housing and on the fuel injection pump
mounting flange before loosening the fuel injec-
1. TIMING GEAR CASE
tion pump mounting bolts. See Figure 92. 2. FUEL INJECTION PUMP DRIVE GEAR
3. LOCKWASHER
4. NUT
Figure 93. Fuel Injection Pump Drive Gear
NOTE: The fuel injection pump shaft is tapered with

a woodruff key. Once you have applied some pres-
sure with a puller, a slight tap with a hammer on the
center puller bolt will help pop the gear from the shaft.
16. Using a two-bolt gear puller, remove the fuel in-

jection pump drive gear from the fuel injection
pump shaft.
17. Remove the three nuts securing the fuel injection

pump to the rear of the timing gear case.
18. Remove the fuel injection pump.
19. If the fuel injection pump requires servicing, it

1. ALIGNMENT MARKS must be taken to an authorized ZEXEL fuel injec-
tion shop or the fuel injection pump assembly
Figure 92. Fuel Injection Pump Alignment Marks must be replaced.
64
Clean and Inspect

CAUTION
Clean all old sealant from the timing gear case cover When loosening or tightening the lines at the fuel
and the fuel injection pump drive gear cover. Inspect injectors, you must hold the fuel injector with a
all parts for damage. Replace as needed. second wrench to prevent the injector from turn-
ing and damaging the fuel return line fitting.
Install
c. Tighten the high pressure fuel line nuts on the
1. Place the fuel injection pump in position and align fuel injectors. Refer to Standard Torque Speci-
the matching marks on the timing gear case hous- fications.
ing and the fuel injection pump flange. Install the
retaining nuts. Refer to Standard Torque Specifi- 9. Rotate the dipstick tube back to original position.
cations. See Figure 92. Install the retaining bolt to hold the oil dipstick
tube clamp to the intake manifold. See Figure 76.
2. Install the fuel injection pump drive gear onto the
fuel injection pump shaft while lining up the two 10. If equipped, connect the throttle cable.
marks made on the pump drive gear with the See Frame 0100YRM1120 for lift truck models
mark made on the idler gear.
• GDP16VX, GDP18VX, GDP20SVX
3. Install the drive gear retaining nut and washer. (GDP030VX, GDP035VX, GDP040SVX)
While holding the engine from turning with a (C810)
wrench on the crankshaft pulley bolt, tighten the • GDP20-35VX (GDP040-070VX) (B875)
retaining nut to 59 to 69 N•m (44 to 51 lbf ft).
Gasket, Yale Part Number 580062478, to the • GDP20-25LX (GDP050LX) (A974)
mating surface of the fuel injection pump cover. See Frame 0100YRM1672 for lift truck model
5. Place the fuel injection pump cover in position on • GDP20-35VX (GDP040-070VX) (C875)
the timing gear case cover and install retaining
bolts. Refer to Standard Torque Specifications. See Frame 0100YRM1735 for lift truck models
6. Install the fan assembly and V-belt. See Cooling (GDP030-035VX, GDP040SVX) (D810)
System Repair.
7. Install the L-shaped brackets and bolts to retain
brackets. Refer to Standard Torque Specifica- • GDP20-35VX (GDP040-070VX) (D875)
tions. See Figure 89. See Frame 0100YRM1766 for lift truck model
8. Install the high pressure fuel lines. • GDP20-25LX (GDP050LX) (B974)

CAUTION • GP20-30MX (GP040-060MX) (A390)
DO NOT bend any of the fuel lines when installing
them. 11. If equipped, install the electronic throttle system.
See Electronic Throttle System, Install.
NOTE: Replace the high pressure fuel lines as an as-
sembly. 12. Connect the electrical connection to the cold start
aid.
a. Start all high pressure fuel line nuts by hand,
leaving the nuts on the fuel injection pump and 13. Connect the electrical connection to the magnetic
the fuel injectors loose. valve (stop solenoid).
b. Tighten the high pressure fuel line nuts on the 14. Connect the fuel injector return line to the fuel
fuel injection pump. Refer to Standard Torque pump. See Figure 89.
Specifications.
65
15. Connect the fuel tank return line. NOTE: The dial indicator is not included with timing
tool. Collet size 8 mm (0.31 in.) and equivalent.
16. Connect the fuel supply line to the fuel injection
pump. Refer to Standard Torque Specifications. 3. Locate special timing tool. Install a dial indicator
into the timing tool. See Figure 95.
17. Prime the fuel system and check for leaks.
Check/Adjust Fuel Injection Timing

1. Using a wrench on the front crankshaft pulley bolt,
rotate the engine clockwise until the timing mark
on the crankshaft pulley is aligned with the “O” or
TDC (Top Dead Center) mark on the timing grid
of the gear case cover.
2. Remove the center bolt and sealing washer from

the rear of the fuel injection pump. See Figure 94.
1. TIMING TOOL 2. DIAL INDICATOR
Figure 95. Fuel Injection Pump Timing Tool
NOTE: The dial indicator is not included with timing

tool. Collet size 8 mm (0.31 in.) and equivalent.
4. Install the timing tool into the port where the cen-
ter bolt was removed. This will provide a reading
of the fuel injection pump plunger lift. See Fig-
ure 96.
1. CENTER BOLT
Figure 94. Fuel Injection Pump Center Bolt
66
6. Set the dial indicator to “0.”
NOTE: Timing for the 4TNE92- is 4 degrees ATDC

(After Top Dead Center). Timing for the 4TNE98-(Tier
2) is 6 degrees ATDC. Timing for the 4TNE98-(Tier 3)
is 8.5 degrees ATDC. Timing for the 4TNE98-(Tier 4)
is 6 degrees ATDC.
7. Rotate the engine in the clockwise rotation until

the timing mark on the crankshaft pulley is aligned
with the mark at 4 degrees, 6 degrees, or 8.5 de-
grees ATDC (After Top Dead Center) on the tim-
ing grid on the gear case cover.
8. If the injection timing is correct, the dial indicator

should read 0.97 to 1.03 mm (0.038 to 0.041 in.).
NOTE: Rotating the injection pump away from the

engine advances the injection timing. Rotating the in-
jection pump toward the engine retards the injection
timing.
9. If the injection timing is not correct, loosen the

three fuel Injection pump mounting nuts and the
bolts retaining the bottom / rear L-shaped injec-
tion pump mounting brackets. Rotate the injection
1. TIMING TOOL pump to bring the dial indicator reading into the
Figure 96. Fuel Injection Pump Timing Tool correct range.
Installation
10. Retighten the pump mounting nuts and the
mounting bracket bolts.
5. Rotate the engine about 25 degrees in the coun-
terclockwise direction. The dial indicator should 11. Remove the timing tool and dial indicator. Re-
move for approximately the first 10 degrees of en- place and tighten the center bolt and sealing
gine rotation and then stop. When you reach ap- washer into the injection pump port.
proximately the 25 degrees position, rotate the
engine slightly back and forth to make sure the
needle of the dial indicator does not move.
67
Cooling System Repair 0600 YRM 1205
Cooling System Repair

V-BELT Inspect
Remove Inspect the V-belt for cracks, oil, wear, and damage. If
any of these conditions exist, replace the V-belt.
WARNING Install
the fan, pulleys, or drive belts. Contact with these 1. Place the V-belt over the pulleys.
2. Adjust the tension of the V-belt as shown in the
section Adjust.
WARNING
The radiator or other parts of the cooling system 3. Tighten the set bolt for the alternator to
may be hot or under pressure and can cause seri- 25.5 N•m (18.8 lbf ft).
ous injury. Wait 30 minutes for the radiator to 4. Install the fan assembly.
cool. Do a touch test by touching the radiator with
your hand. If the radiator is still hot to the touch, See Cooling System 0700YRM1123 for lift truck
wait another 30 minutes before attempting to models
check or fix any part of the cooling system.
• GDP20-35VX (GDP040-070VX) (B875)
1. Turn the ignition switch to the OFF position.
See Cooling System 0700YRM1756 for lift truck
2. Remove the fan assembly. models
• GDP20-35VX (GDP040-070VX) (C875)
models See Cooling System 0700YRM1756 for lift truck
• GDP20-35VX (GDP040-070VX) (B875) models
• GDP20-35VX (GDP040-070VX) (D875)
models See Cooling System 0700YRM1986 for lift truck
• GDP20-35VX (GDP040-070VX) (C875) models
• GP20-35MX (GP040-060MX) (A390)
models Adjust
• GDP20-35VX (GDP040-070VX) (D875)
NOTE: The V-belt can be checked at any of the three
See Cooling System 0700YRM1986 for lift truck positions: A, B, or C shown in Figure 97. The correct
models deflection for a used and new V-belt is shown in Ta-
• GP20-35MX (GP040-060MX) (A390) ble 3.
3. Loosen the alternator set bolt and pivot the alter- 1. Press the V-belt down with your thumb with a
nator toward the engine. force of approximately 98 N•m (72 lbf ft) to check
the deflection.
4. Remove the V-belt from the pulleys.
68
0600 YRM 1205 Cooling System Repair
2. If adjustment is necessary, loosen the alternator

set bolt and move the alternator with a pry bar to
tighten the V-belt. See Figure 98.
Figure 97. V-Belt Tension Check Points
Table 3. V-Belt Deflection Table

Used V-Belt Tension New V-Belt Tension
A B C A B C
10-13 mm 7-10 mm 8-13 mm 8-11 mm 5-8 mm 7-11 mm
(0.375-0.5 in.) (0.250-0.375 in.) (0.3125-0.5 in.) (0.3125-0.4375 in.) (0.1875-0.3125 in.) (0.250-0.4375 in.)
69
the cooling system. After 30 minutes, do a touch

cooling system.
CAUTION
Disposal of lubricants must meet local environ-
mental regulations.
3. Remove the radiator cap.
4. Loosen the lower radiator hose and drain the

coolant from the coolant system.
5. Remove the coolant drain plug and drain the cool-

ant from the engine block. See Figure 99.
1. SET BOLT 3. PRY BAR

2. ALTERNATOR
Figure 98. V-Belt Adjustment
3. When the tension is correct, tighten the set bolt to

25.5 N•m (18.8 lbf ft). Check the belt tension
again to verify the tension is still correct.
WATER PUMP
4TNE92-NMHA, 4TNE92-NMHA/580090035,
4TNE92-SNMU, and 4TNE98-SNMU Engines
Remove
1. COOLANT DRAIN PLUG
Figure 99. Engine Block Coolant Drain Plug
tery.
6. Remove the fan assembly.
WARNING See Cooling System 0700YRM1123 for lift truck
DO NOT remove the radiator cap from the radiator models
when the engine is hot. When the radiator cap is • GDP20-35VX (GDP040-070VX) (B875)
system. If the coolant system is hot, the steam See Cooling System 0700YRM1674 for lift truck
and boiling coolant can cause severe burns. models
• GDP20-35VX (GDP040-070VX) (C875)
WARNING
The radiator or other parts of the cooling system models
may be hot or under pressure and can cause seri-
ous injury. Wait 30 minutes for the radiator and • GDP20-35VX (GDP040-070VX) (D875)
70

models
• GP20-30MX (GP040-060MX) (A390)
7. Remove V-belt. See V-Belt, Remove.
8. Remove fan pulley.
9. Pivot alternator away from engine.
10. Disconnect electrical connector for the coolant

temperature sensor. See Figure 100.
1. GASKET 6. BOLT
2. COVER 7. GASKET
3. GASKET 8. FLANGE
4. WATER PUMP 9. O-RING
5. BOLT 10. BOLT
Figure 101. Water Pump
14. Remove bolt holding cover on water pump.
15. Remove and discard cover gasket.
16. Remove O-ring, flange, and mechanical seal.
17. Remove thermostat cover, gasket, thermostat,

and O-ring. See Thermostat, Remove.
Install
1. Install new O-ring, thermostat, new gasket, and
thermostat cover. See Thermostat, Install.
1. ELECTRICAL CONNECTOR 2. Install new water pump cover gasket and water
2. COOLANT TEMPERATURE SENSOR pump cover. Install bolt to retain cover to water
pump.
Figure 100. Coolant Temperature Sensor
3. Install the O-ring, flange, and mechanical seal.
11. If necessary, remove coolant temperature sensor. 4. Position water pump with new gasket between
water pump and cylinder head on the engine. See
12. Disconnect coolant hoses from water pump. Figure 101.
13. Remove water pump bolts and remove water 5. Install water pump retaining bolts.
pump. See Figure 101.
71
6. Connect the coolant hoses to the water pump.

WARNING
7. If removed, install the coolant temperature sensor The radiator or other parts of the cooling system
and tighten to 24.5 to 34.3 N•m (18.1 to may be hot or under pressure and can cause seri-
25.3 lbf ft). ous injury.
8. Connect the electrical connector for the coolant 17. Start engine and check cooling system for leaks.
temperature sensor.
9. Install the fan pulley. WARNING

DO NOT remove the radiator cap from the radiator
10. Install the V-belt. See V-Belt, Install.
11. Install the fan assembly. removed, pressure will release from the coolant
See Cooling System 0700YRM1123 for lift truck and boiling coolant can cause severe burns.
models
• GDP20-35VX (GDP040-070VX) (B875) WARNING
See Cooling System 0700YRM1674 for lift truck The radiator or other parts of the cooling system
models may be hot or under pressure and can cause seri-
ous injury. Wait 30 minutes for the radiator and
• GDP20-35VX (GDP040-070VX) (C875) engine to cool before performing maintenance to
See Cooling System 0700YRM1756 for lift truck the cooling system. After 30 minutes, do a touch
models test by touching the radiator with your hand. If the
• GDP20-35VX (GDP040-070VX) (D875) minutes before attempting any maintenance to the
cooling system.
models
• GP20-30MX (GP040-060MX) (A390) CAUTION
12. Connect lower radiator hose. using additives, contact your local Yale dealer.
13. Install coolant drain plug in engine block. See Fig- 18. Stop engine. If coolant is hot, allow engine time to
ure 99. cool. Check coolant level and fill as required be-
tween the ADD and FULL marks on the coolant
CAUTION reservoir.
4TNE92-NMH, 4TNE98-NMH, 4TNE92-NMH/
580090036, and 4TNE98-BNMH Engines
14. Fill cooling system with coolant. See Periodic
Maintenance Manual for your lift truck for the Remove
15. Install radiator cap.
16. Connect negative battery cable. tery.
WARNING
72
11. If necessary, remove the coolant temperature

WARNING sensor.
when the engine is hot. When the radiator cap is 12. Disconnect the coolant hoses from the water
removed, pressure will release from the coolant pump.
13. Remove the water pump bolts and remove the
and boiling coolant can cause severe burns.
water pump. See Figure 102.
WARNING
cooling system.
CAUTION
Disposal of lubricants must meet local environ-
mental regulations.
3. Remove the radiator cap.

1. GASKET 5. BOLT
2. COVER 6. O-RING
4. Loosen the lower radiator hose and drain the 3. GASKET 7. PIPE
coolant from the coolant system. 4. WATER PUMP 8. BOLT
5. Remove the coolant drain plug and drain the cool- Figure 102. Water Pump
ant from the engine block. See Figure 99.
6. Remove the fan assembly. 14. Remove the water pump pipe. Remove and dis-
See Cooling System 0700YRM1123 for lift truck card O-rings.
models 15. Remove the bolts holding the cover on the water
• GDP20-35VX (GDP040-070VX) (B875) pump.
See Cooling System 0700YRM1674 for lift truck 16. Remove and discard cover gasket.
models
17. Remove the thermostat cover, gasket, thermostat,
• GDP20-35VX (GDP040-070VX) (C875)
and O-ring. See Thermostat, Remove.
models Install
• GDP20-35VX (GDP040-070VX) (D875) 1. Install new O-ring, thermostat, new gasket, and
thermostat cover. See Thermostat, Install.
7. Remove the V-belt. See V-Belt, Remove.
2. Install new water pump cover gasket and water
8. Remove the fan pulley.
pump cover. Install bolts to retain cover to water
9. Pivot the alternator away from the engine. pump.
10. Disconnect the electrical connector for the coolant 3. Install new O-rings on coolant pipe and install
temperature sensor. See Figure 100. coolant pipe to water pump.
73
4. Position water pump with new gasket between 15. Install the radiator cap.
water pump and cylinder head on the engine. Ver-
ify the coolant pipe is positioned properly in the 16. Connect the negative battery cable.
engine and water pump. See Figure 101.
5. Install water pump retaining bolts. WARNING

6. Connect the coolant hoses to the water pump. the fan, pulleys, or drive belts. Contact with these
7. If removed, install the coolant temperature sensor
and tighten to 24.5 to 34.3 N•m (18.1 to
25.3 lbf ft). WARNING
8. Connect the electrical connector for the coolant may be hot or under pressure and can cause seri-
temperature sensor. ous injury.
9. Install the fan pulley. 17. Start the engine and check cooling system for
leaks.
10. Install the V-belt. See V-Belt, Install.
11. Install the fan assembly. WARNING

See Cooling System 0700YRM1123 for lift truck DO NOT remove the radiator cap from the radiator
models when the engine is hot. When the radiator cap is
• GDP20-35VX (GDP040-070VX) (B875)
See Cooling System 0700YRM1674 for lift truck and boiling coolant can cause severe burns.
models
• GDP20-35VX (GDP040-070VX) (C875) WARNING
See Cooling System 0700YRM1756 for lift truck may be hot or under pressure and can cause seri-
models ous injury. Wait 30 minutes for the radiator and
• GDP20-35VX (GDP040-070VX) (D875) engine to cool before performing maintenance to
12. Connect the lower radiator hose. test by touching the radiator with your hand. If the
13. Install the coolant drain plug in the engine block.
See Figure 99.
cooling system.
CAUTION
CAUTION
14. Fill the cooling system with coolant. See Periodic
18. Stop engine. If coolant is hot, allow engine time to
reservoir.
74
THERMOSTAT
Remove
WARNING
cooling system.
1. BOLT
CAUTION 2. THERMOSTAT COVER
3. GASKET
DO NOT operate the engine without a thermostat. 4. THERMOSTAT
The engine and cooling system can be damaged. 5. O-RING
6. WATER PUMP
CAUTION Figure 103. Thermostat - 4TNE92-NMHA, 4TNE92-

Disposal of lubricants must meet local environ- NMHA/580090035, 4TNE98-SNMU, and 4TNE92-
mental regulations. SNMU Engines
1. Drain the cooling system to the level of the ther-

mostat.
2. Disconnect the coolant hose from the thermostat

cover.
3. Remove the bolts retaining the thermostat cover

and remove thermostat cover and gasket. Discard
gasket. See Figure 103 and Figure 104.
1. BOLT
2. THERMOSTAT COVER
3. GASKET
4. THERMOSTAT
5. O-RING
6. WATER PUMP
Figure 104. Thermostat - 4TNE92-NMH, 4TNE98-
NMH, 4TNE92-NMH/580090036, and 4TNE98-
BNMH Engines
75
4. Remove thermostat and O-ring. 4. Fill the cooling system with coolant. See Periodic
Inspect correct coolant amount and type.
1. Place the thermostat and an accurate thermome-

ter in warm water. See Figure 105. WARNING
WARNING
ous injury.
5. Start the engine and check cooling system for

leaks.
WARNING
1. THERMOMETER 2. THERMOSTAT and boiling coolant can cause severe burns.
Figure 105. Thermostat Check
WARNING
2. Slowly increase the temperature of the water.
3. The thermostat is operating correctly if it starts to ous injury. Wait 30 minutes for the radiator and
open at the temperature value stamped on the engine to cool before performing maintenance to
flange of the thermostat and fully opens as the the cooling system. After 30 minutes, do a touch
temperature of the water is increased. test by touching the radiator with your hand. If the
Install minutes before attempting any maintenance to the
cooling system.
1. Install a new O-ring and the thermostat.
2. Install the thermostat cover and a new gasket. In- CAUTION

stall the bolts to retain the thermostat cover. Additives may damage the cooling system. Before
Tighten bolts to 23 to 28 N•m (17 to 21 lbf ft). using additives, contact your local Yale dealer.
3. Connect the coolant hose to the thermostat cover. 6. Stop engine. If coolant is hot, allow engine time to
CAUTION reservoir.
76
0600 YRM 1205 Flywheel and Flywheel Housing
Flywheel and Flywheel Housing

FLYWHEEL 2. Remove the bolts retaining the flex plate to the
flywheel and remove the flex plate. See Fig-
Remove ure 106.
1. Remove the engine. See Engine Removal and In- 3. Remove the bolts retaining the flywheel to the
stallation. crankshaft flange and remove the flywheel.
A. TORQUE SEQUENCE
1. FLYWHEEL HOUSING 5. FLEX PLATE
2. FLYWHEEL 6. WASHER
3. WASHER 7. BOLT
4. BOLT
Figure 106. Flywheel
77
Flywheel and Flywheel Housing 0600 YRM 1205
Install 2. Remove the bolts retaining the flywheel housing

to the cylinder block. See Figure 107.
1. Place the flywheel in position on the crankshaft
flange and install retaining bolts. Tighten bolts to 3. Remove the flywheel housing.
155 N•m (114 lbf ft) in the torque sequence
shown in Figure 106. Install
2. Place the flex plate in position on the flywheel and 1. Place the flywheel housing in position on the cyl-
install retaining bolts. Tighten bolts to inder block and install bolts. Tighten the bolts to
52 N•m (38 lbf ft). 44 to 54 N•m (32 to 40 lbf ft).
3. Install the engine. See Engine Removal and In- 2. Install the flywheel. See Flywheel, Install.
stallation.
FLYWHEEL HOUSING
Remove
1. Remove the flywheel. See Flywheel, Remove.
78
0600 YRM 1205 Flywheel and Flywheel Housing
1. CYLINDER BLOCK 3. WASHER

2. FLYWHEEL HOUSING 4. BOLT
Figure 107. Flywheel Housing
79
Electrical Equipment Repair 0600 YRM 1205
Electrical Equipment Repair

ALTERNATOR Remove
The alternator specifications are listed in Table 4.

WARNING
Table 4. Alternator Specifications Always disconnect the cables at the battery be-
fore you make repairs to the engine. Disconnect
Rating Continuous the cable at the negative terminal first. Install a
Battery Voltage 12 Volts tag on the battery terminals so that no one con-
nects the cables on the terminals.
Nominal Output (12 Volts 60 Amps
Heat) 1. Disconnect battery negative cable at negative ter-
minal.
No Load Test Maximum 1300 rpm (min−1)
rpm 2. Disconnect the battery positive cable at positive
Output Test Minimum 13.5 V @ 5000 rpm (min terminal.
Current (Cool) −1
)
3. Put labels on wires prior to disconnecting to aid in
Grounding Negative (−) Side of correct installation.
Characteristics Circuit
4. Disconnect wires from alternator.
Direction of Revolution Clockwise
(Viewed from Pulley) 5. Loosen the set bolt on the alternator and tilt the
Rotor Coil Resistance 2.9 Ohms alternator towards the engine.
Outside Diameter of 69.2 mm (2.7 in.) 6. Remove the V-belt from the alternator pulley.
Pulley
7. Remove the set bolt from the alternator. See Fig-
Standard
ure 108.
Brush Length 10.5 mm (0.41 in.)
Limit 8.4 mm (0.33 in.)
80
0600 YRM 1205 Electrical Equipment Repair
1. WATER PUMP 5. BOLT

2. SET BOLT 6. TIMING GEAR CASE
3. ALTERNATOR ADJUSTMENT BRACKET 7. NUT
4. ALTERNATOR 8. BOLT
Figure 108. Alternator
81
8. If necessary, remove the bolt retaining the alter-

nator adjustment bracket to the water pump and
remove the bracket.
9. Remove the nut and bolt retaining the alternator

to the gear case and remove the alternator.
Bench Test
1. Verify that the test bench is set up and that the
charge light is on.
2. Place the alternator in position on the test bench.
3. Insert the main wiring harness inspection connec-

tor into the alternator. See Figure 109. 1. ALTERNATOR
2. VOLTMETER POSITIVE SIDE (+)
4. Connect the main wiring harness and sub-wiring 3. VOLTMETER NEGATIVE SIDE (−)
harness C. 4. TO BATTERY NEGATIVE (−) TERMINAL
5. TO AMMETER POSITIVE (+) TERMINAL
5. Connect the voltmeter and ammeter as shown in 6. MAIN WIRING HARNESS
Figure 109. 7. SUB-WIRING HARNESS C
8. CHARGE LIGHT
9. TERMINAL B
6. Turn SW1 ON and check that the main wiring har-
ness light (charge light) turns ON. Figure 109. Alternator Bench Test
NOTE: If terminal S is disconnected during inspec-
tion, the charge light may remain ON continuously. In
this case, use sub-wiring harness B instead of sub- Regulate Voltage Check
wiring harness C. Connect terminal S of sub-wiring
harness B to terminal S on the alternator, turn SW1 Refer to Figure 110 for the wiring diagrams for the
ON, connect IG and L and check the light again. test wiring of the alternator.
7. Turn the test bench motor ON, increase speed

and check that the charge light turns OFF.
82
A. WIRING DIAGRAM FOR ALTERNATORS WITH D. WIRING DIAGRAM FOR ALTERNATORS WITH
A M TYPE REGULATOR A GL TYPE REGULATOR, ALWAYS WIRE THE
B. WIRING DIAGRAM FOR ALTERNATORS WITH CHARGE LIGHT FOR THE GL TYPE REGULA-
A GS TYPE REGULATOR TOR
C. WIRING DIAGRAM FOR ALTERNATORS WITH
A D OR GA TYPE REGULATOR
Figure 110. Alternator Test Wiring Diagrams
83
1. Turn battery switch S1 ON. Output Test

2. Run the alternator. Turn the load switch S2 ON Refer to Figure 110 for the wiring diagrams for the
when output current exceeds 0 amperes. test wiring of the alternator.
3. Adjust the speed and load to the standard values.
1. Turn the battery switch S1 ON and load switch S2
NOTE: Regulated voltage has the temperature char- ON.
acteristics shown in Figure 111. Perform the meas-
urement quickly. 2. Run the alternator.
4. Check that the voltage is within the standard val- 3. While adjusting the speed and load resistance,
ues. set the speed and the voltage to the standard val-
ues.
4. Check that the current is within the standard val-

ues.
Install
1. If removed, place the alternator adjustment
bracket in position and install the bolt to retain the
bracket to the water pump. Tighten the bolt to
26 N•m (19 lbf ft).
2. Position the alternator on the gear case. Install

the nut and bolt to retain the alternator to the gear
case, but do not tighten.
3. Install the set bolt for the alternator and adjust-

ment bracket but do not tighten.
4. Connect the electrical wires to the alternator.

Tighten the nut to 7.8 N•m (69.04 lbf in).
A. REGULATED VOLTAGE VALUES 5. Install the V-belt and adjust to the proper tension.
B. REGULATED VOLTAGE See V-Belt, Adjust.
C. TEMPERATURE OF THE IC REGULATOR
6. Tighten the set bolt to 25.5 N•m (18.8 lbf ft).
Figure 111. Regulated Voltage Scale
7. Tighten the pivot bolt to 30 N•m (22 lbf ft).
No Load Test 8. Connect battery positive cable at positive termi-

nal.
Refer to Figure 110 for the wiring diagrams for the
9. Connect battery negative cable at negative termi-
test wiring of the alternator.
nal.
1. Turn battery switch S1 ON. 10. Start the engine and listen for any unusual
sounds from the alternator.
2. Run the alternator. Turn S1 OFF when output cur-
rent exceeds 0 amperes. 11. Verify that the charge indicator is ON while the
engine is operating. If the charge indicator is not
3. Adjust the speed and the voltage to the standard
ON, repair the problem before operating the en-
values.
gine.
4. Check that the speed is within the standard val-
ues.
84
STARTER
The starter specifications are shown in Table 5.
Table 5. Starter Specifications
Hitachi Model Number S13-204

Nominal Output 2.3 kW (3.0 hp)
Weight 5.5 kg (12.1 lb)
Revolution Direction (As Viewed from Pinion) Clockwise
Engagement System Magnetic Shift
Terminal Voltage / Current 11 V / 140 A max
No-load
Revolution 4100 rpm min
Terminal Voltage / Current 2.5 V / 1050 A max
Loaded 24.5 N•m, 2.5 kgf•m
Torque
(18.1 lbf ft) min
Clutch System Overrunning
Pinion Projection Voltage at 100°C (212°F) 8.6 V max
Pinion DP or Module / Number of Teeth M3 / 9
Difference (O-ring, Oil Seal) Dry (none)
Application Standard
Spring Force 35 N, 3.6 kgf (7.868 lbf)
Brush Standard 15 mm (0.591 in.)
Height
Limit 9 mm (0.354 in.)
Series Coil Resistance 0.27 Ω at 20°C (68°F)
Magnetic Switch
Shunt Coil Resistance 0.60 Ω at 20°C (68°F)
Standard 36.5 mm (1.437 in.)
Outside Diameter
Limit 35 mm (1.398 in.)
Commutator Run-Out
Limit 0.2 mm (0.008 in.)
Standard 0.5 to 0.8 mm (0.020 to 0.031 in.)
Insulation Depth
Limit 0.2 mm (0.008 in.)
Armature Run-Out
Limit 0.2 mm (0.008 in.)
Armature Front 6903DDU
Armature Rear 608DDU
Bearing Type Nominal Number
Pinion Front 60004DDU
Pinion Rear 6904DDU
Pinion Projection Length (Length L) 0.3 to 1.5 mm (0.012 to 0.059 in.)
85
Remove No Load Test
WARNING CAUTION
Always disconnect the cables at the battery be- The starter motor can be damaged if operated
fore you make repairs to the engine. Disconnect continuously for longer than 30 seconds while
the cable at the negative terminal first. Install a performing the no load test.
tag on the battery terminals so that no one con-
nects the cables on the terminals. 1. Secure the starter in a soft-jawed vise or other
suitable fixture.
1. Disconnect battery negative cable at negative ter-
minal. 2. Connect an ammeter in series with the battery
positive terminal and the S terminal of the starter
2. Disconnect the battery positive cable at positive solenoid. See Figure 113.
terminal.
3. Put labels on wires and cables prior to discon-

necting to aid in correct installation.
4. Disconnect wires and cables from starter.
5. Hold starter so it won't fall. Remove the two M12

bolts that fasten the starter to the flywheel hous-
ing. Remove starter from flywheel housing. See
Figure 112.
1. AMMETER 4. S TERMINAL
2. BATTERY 5. BATTERY POSITIVE
3. VOLTMETER TERMINAL
Figure 113. No Load Test
1. FLYWHEEL HOUSING
2. BOLT
3. STARTER
Figure 112. Starter
86
3. Connect a voltmeter between the solenoid M ter- 4. Connect battery negative cable at negative termi-
minal and the frame of the starter. nal.
4. Attach a tachometer in the current line or hold a

vibration tachometer against the starter.
5. Attach a switch in the current line.
6. Turn the switch to the ON position. Observe the

starter rpm, amperage draw, and voltage read-
ings. The specifications are listed in Table 6.
Table 6. No Load Test Specifications
Terminal Voltage/Current 11 Volts/140 Amps maxi-

mum
Revolution 140 rpm minimum
Install
1. Place starter in position in flywheel housing. In-
stall the two M12 bolts to fasten the starter to the
flywheel housing.
1. M8 NUT 3. M4 SCREW
2. Connect wires and cables as labeled in removal. 2. COVER 4. STARTER
Tighten the M8 nut, B terminal, to 7.9 to
9.8 N•m (70 to 87 lbf in). Tighten the M4 screw, S Figure 114. Starter Connections
terminal, to 1.7 to 2.4 N•m (15 to 21 lbf in). Be
sure to place the cover over the M4 screw con-
nection. See Figure 114.
3. Connect battery positive cable at positive termi-

nal.
87
Engine Specifications 0600 YRM 1205
Engine Specifications
ENGINE DATA
Table 7. 4TNE92-NMH Engine
Engine Model 4TNE92-NMH (Yale Part No. 580063566)

Version VM
Type Vertical Inline Diesel Engine
Combustion System Indirect Injection
Aspiration Natural
No. of Cylinders 4
Ignition Order 1-3-4-2
Bore × Stroke 92 × 100 mm (3.62 × 3.94 in.)
Displacement 2.659 liter (162.3 cu in.)
Max. Rated Output (Net) rpm 2450
(min-1)
hp SAE 45.1
kW 33.6
PS 45.7
High Idle Speed (Bare Engine) 2700 +50 rpm
Low Idle Speed (Bare Engine) 825 +50 rpm
Engine Weight (Dry)* 194 ±10 kg (427 ±22 lb)
Direction of Rotation Counterclockwise Viewed From Flywheel Side
Cooling System Liquid-Cooled With Radiator
Lubricating System Forced Lubrication With Trochoid Pump
At rated speeds, oil pressure is 0.29 to 0.39 MPa (42 to 57 psi)
At low idle, oil pressure is: No less than 0.06 MPa (8.5 psi)
Starting System Electric Starting - Starter Motor: DC12V, 2.3 kW (3.1 hp)
Alternator: DC12V, 60A
Recommended Battery Capacity: 12V, 622 CCA (Cold Cranking Amps)
Dimensions (L × W × H)* 632 × 498 × 711 mm (24.9 × 19.6 × 28.0 in.)
Engine Oil Pan Capacity 8.8 / 6.8 liter (9.3 / 7.2 qt)
(Dipstick Upper Limit / Lower Limit)
Engine Coolant Capacity 4.2 liter (1.11 gal) Engine Only
*Engine Specifications do not include height of lifting eyes nor dimensions or specifications for the Cooling Fan, Radiator,
Muffler, and Air Cleaner.
88
0600 YRM 1205 Engine Specifications
Table 8. 4TNE92-NMHA Engine
Engine Model 4TNE92-NMHA (Yale Part No. 580061270)

Version VM
Aspiration Natural
No. of Cylinders 4
Bore × Stroke 92 × 100 mm (3.62 × 3.94 in.)
(min-1)
hp SAE 39.0
kW 29.1
PS 39.6
High Idle Speed (Bare Engine) 2450 ±25 rpm

*Engine Specifications Without Cooling Fan, Radiator, Muffler, and Air Cleaner.
89

Version VM
Aspiration Natural
No. of Cylinders 4
Bore × Stroke 98 × 110 mm (3.86 × 4.33 in.)
(min-1)
hp SAE 63.6
kW 47.4
PS 64.4
Low Idle Speed (Bare Engine) 825 ±25 rpm
Engine Weight (Dry)* 194 kg (491.6 lb)
90

Version VM
Aspiration Natural
No. of Cylinders 4
Bore × Stroke 92 × 100 mm (3.62 × 3.94 in.)
(min-1)
hp SAE 45.1
kW 33.6
PS 45.7
91
Table 11. 4TNE92-NMHA Engine
Engine Model 4TNE92-NMHA (Yale Part No. 580090035)

Version VM
Aspiration Natural
No. of Cylinders 4
Bore × Stroke 92 × 100 mm (3.62 × 3.94 in.)
(min-1)
hp SAE 39.0
kW 29.1
PS 39.6

92
Table 12. 4TNE98-BNMH Engine

Version VM
Aspiration Natural
No. of Cylinders 4
Bore × Stroke 98 × 110 mm (3.86 × 4.33 in.)
(min-1)
hp SAE 63.6
kW 43.0
PS 58.4
Engine Weight (Dry)* 194 ±10 kg (427.7 ±22 lb)
93
Table 13. 4TNE92-SNMU Engine
Engine Model 4TNE92-SNMU (Yale Part No. 524327442)

Version VM
Aspiration Natural
No. of Cylinders 4
Bore × Stroke 92 × 100 mm (3.62 × 3.94 in.)
(min-1)
hp SAE 45.1
kW 33.6
PS 45.7
94
Table 14. 4TNE98-SNMU Engine
Engine Model 4TNE98-SNMU (Yale Part No. 524303672)

Version VM
Aspiration Natural
No. of Cylinders 4
Bore × Stroke 98 × 110 mm (3.86 × 4.33 in.)
(min-1)
hp SAE 63.6
kW 47.4
PS 64.4
Engine Weight (Dry)* 194 kg (491.6 lb)
95
ENGINE TUNING
Inspection Item Standard Limit
Valve Gap Intake/Exhaust (Engine Cold) 0.15 to 0.25 mm -
(0.006 to 0.010 in.)
Fuel Injection Pressure 11.8 to 12.7 MPa -
(1711 to 1842 psi)
Fuel Injection Timing with Plunger Lifted 6° ±1° ATDC -
1 mm (0.039 in.)
Compression Pressure at 250 rpm 2.84 to 3.04 MPa 2.35 MPa
(412 to 441 psi) (341 psi)
Lubricating Oil Pressure Max. (when cold) 0.59 MPa -
(86 psi)
At rated output 0.29 to 0.39 MPa -
(42 to 57 psi)
When idling 0.06 MPa or greater -
(8.7 psi)
Thermostat Valve Opening Temperature Full Opening Lift
Temperature
69 to 73°C 8 mm (0.32 in.) or
(156 to 163°F) Above 85°C (185°F)
Coolant Temperature Switch 107 to 113°C -
(225 to 235°F)
CYLINDER HEAD
Combustion Surface Distortion (Flatness) 0.05 mm (0.0020 in.) 0.15 mm (0.0059 in.)
Valve Sink Intake 0.5 to 0.7 mm (0.020 to 1.0 mm (0.039 in.)
0.028 in.)
Exhaust 0.6 to 0.8 mm (0.024 to 1.1 mm (0.043 in.)
0.032 in.)
Valve Seat Angle Intake 120° -
Exhaust 90° -
96
INTAKE/EXHAUST VALVE AND GUIDE

Intake Valve Guide Inside Diameter 8.015 to 8.030 mm (0.3156 to 8.10 mm (0.3189 in.)
0.3161 in.)
Valve Stem Outside Diameter 7.965 to 7.980 mm (0.3136 to 7.90 mm (0.3110 in.)
0.3142 in.)
Oil Clearance 0.035 to 0.065 mm (0.0014 to 0.18 mm (0.0071 in.)
0.0026 in.)
Exhaust Valve Guide Inside Diameter 8.015 to 8.030 mm (0.3156 to 8.10 mm (0.3189 in.)
0.3161 in.)
Valve Stem Outside Diameter 7.965 to 7.970 mm (0.3136 to 7.90 mm (0.3110 in.)
0.3138 in.)
Oil Clearance 0.045 to 0.075 mm (0.0018 to 0.18 mm (0.0071 in.)
0.0030 in.)
Valve Guide Projection From Cylinder Head 14.7 to 15.0 mm (0.58 to -
0.60 in.)
Valve Guide Driving-in Method Cold-fitted -
VALVE SPRING
Free Length 47.5 mm -
(1.87 in.)
Inclination - 1.2 mm
(0.05 in.)
ROCKER ARM AND SHAFT

Arm Shaft Hole Diameter 18.50 to 18.52 mm 18.57 mm
(0.7283 to 0.7291 in.) (0.7311 in.)
Shaft Outside Diameter 18.47 to 18.49 mm 18.42 mm
(0.7272 to 0.7280 in.) (0.7252 in.)
Clearance 0.01 to 0.05 mm 0.15 mm
(0.0004 to 0.0020 in.) (0.0059 in.)
97
PUSH ROD
Push Rod Bend - 0.03 mm
(0.0012 in.)
GEAR TRAIN AND CAMSHAFT
Camshaft

Side Gap 0.05 to 0.20 mm (0.0020 to 0.30 mm
0.0079 in.) (0.0118 in.)
Bending (½ the dial gauge reading) 0 to 0.02 mm (0 to 0.05 mm
0.0008 in.) (0.0020 in.)
Cam Height 42.435 to 42.565 mm 42.185 mm
(1.6707 to 1.6758 in.) (1.6608 in.)
Camshaft Oil Gear End Bushing Inside 49.990 to 50.055 mm 50.130 mm
Clearance Diameter (1.9681 to 1.9707 in.) (1.9736 in.)
Camshaft Outside 49.925 to 49.950 mm 49.890 mm
Diameter (1.9656 to 1.9665 in.) (1.9642 in.)
Clearance 0.04 to 0.130 mm (0.0016 to 0.240 mm
0.0051 in.) (0.0094 in.)
Intermediate Bushing Inside 50.000 to 50.025 mm 50.100 mm
Diameter (1.9685 to 1.9695 in.) (1.9724 in.)
Diameter (1.9650 to 1.9659 in.) (1.9636 in.)
Clearance 0.065 to 0.115 mm (0.0026 0.225 mm
to 0.0045 in.) (0.0089 in.)
Flywheel End Bushing Inside 50.000 to 50.025 mm 50.100 mm
Diameter (1.9685 to 1.9695 in.) (1.9724 in.)
Diameter (1.9656 to 1.9665 in.) (1.9642 in.)
Clearance 0.050 to 0.100 mm (0.0020 0.210 mm
to 0.0039 in.) (0.0083 in.)
Idle Gear Shaft and Bushing

Shaft Outside Diameter 45.950 to 49.975 mm 45.900 mm
(1.8091 to 1.9675 in.) (1.8071 in.)
Bushing Inside Diameter 46.000 to 46.025 mm 46.075 mm
(1.8110 to 1.8120 in.) (1.8140 in.)
(0.0010 to 0.0030 in.) (0.0069 in.)
98
Backlash of Each Gear

Crank Gear, Cam Gear, Idle Gear, Fuel Injection Pump 0.08 to 0.14 mm 0.16 mm
Gear, and PTO Gear (0.0031 to 0.0055 in.) (0.0063 in.)
Lubricating Oil Pump Gear 0.09 to 0.15 mm 0.17 mm
(0.0035 to 0.0059 in.) (0.0067 in.)
CYLINDER BLOCK
Cylinder Inside Diameter 4TNE92 92.000 to 92.030 mm (3.6220 to 92.130 mm
3.6232 in.) (3.6272 in.)
4TNE98 98.000 to 98.030 mm (3.8583 to 98.130 mm
3.8594 in.) (3.8634 in.)
Cylinder Bore Roundness 0.01 mm (0.0004 in.) or less 0.03 mm
Inclination (0.0012 in.)
CRANKSHAFT
Bending (½ the dial gauge reading) - 0.02 mm
(0.0008 in.)
Connecting Rod Journals Pin Outside Diameter 57.952 to 57.962 mm (2.2816 to 57.902 mm
2.2820 in.) (2.2796 in.)
Metal Inside Diameter 58.000 to 58.026 mm (2.2835 to -
2.2845 in.)
Metal Thickness 1.492 to 1.500 mm (0.0587 to -
0.0591 in.)
0.0029 in.) (0.0059 in.)
Crank Journal Selective Journal Outside Diameter 64.952 to 64.962 mm (2.5572 to 64.902 mm
Pairing 2.5576 in.) (2.5552 in.)
Metal Inside Diameter 65.000 to 65.020 mm (2.5591 to -
2.5598 in.)
Metal Thickness 1.995 to 2.010 mm (0.0785 to -
0.0791 in.)
0.0027 in.) (0.0059 in.)
99
THRUST BEARING
Crankshaft Side Gap 0.11 to 0.21 mm (0.0043 to 0.28 mm
0.0083 in.) (0.0110 in.)
PISTON
Piston Outside Diameter (Meas- 4TNE92 91.945 to 91.975 mm (3.6199 to 91.900 mm
ure in the Direction Vertical to 3.6211 in.) (3.6181 in.)
the Piston Pin.) 4TNE98 97.940 to 97.950 mm (3.8559 to 97.900 mm
3.8563 in.) (3.8543 in.)
Piston Diameter Measure Position (Upward From the 22.000 mm (0.8661 in.)
-
Bottom End of the Piston.)
Piston Pin Hole Inside Diameter 30.000 to 30.009 mm (1.1811 to 30.039 mm
1.1815 in.) (1.1826 in.)
Pin Outside Diameter 29.989 to 30.000 mm (1.1807 to 29.959 mm
1.1811 in.) (1.1795 in.)
0.0008 in.) (0.0032 in.)
PISTON RING
Top Ring Ring Groove Width 2.040 to 2.060 mm (0.0803 to -
0.0811 in.)
Ring Width 1.940 to 1.960 mm (0.0764 to 1.920 mm
0.0772 in.) (0.0756 in.)
Side Clearance 0.080 to 0.120 mm (0.0032 to -
0.0047 in.)
End Clearance 0.250 to 0.450 mm (0.0098 to 0.540 mm
0.0177 in.) (0.0213 in.)
Second Ring Ring Groove Width 2.080 to 2.095 mm (0.0819 to 2.195 mm
0.0825 in.) (0.0864 in.)
0.0783 in.) (0.0768 in.)
Side Clearance 0.090 to 0.125 mm (0.0035 to 0.245 mm
0.0049 in.) (0.0096 in.)
0.0256 in.) (0.0287 in.)
100

Oil Ring Ring Groove Width 3.015 to 3.030 mm (0.1187 to 3.130 mm
0.1193 in.) (0.1232 in.)
0.1177 in.) (0.1161 in.)
Side Clearance 0.025 to 0.060 mm (0.0010 to 0.180 mm
0.0024 in.) (0.0071 in.)
0.0177 in.) (0.0217 in.)
CONNECTING ROD
Thrust Clearance 0.13 to 0.23 mm (0.0051 to -
0.0091 in.)
Rod Small End

Bushing Outside Diameter 30.025 to 30.038 mm 30.068 mm
(1.1821 to 1.1826 in.) (1.1838 in.)
Pin Outside Diameter 29.987 to 30.000 mm 29.959 mm
(1.1806 to 1.1811 in.) (1.1795 in.)
(0.0010 to 0.0020 in.) (0.0043 in.)
Tappet

Tappet Hole (Block) Inside Diameter 12.000 to 12.018 mm 12.038 mm
(0.4724 to 0.4732 in.) (0.4739 in.)
Tappet Stem Outside Diameter 11.975 to 11.990 mm 11.955 mm
(0.4715 to 0.4720 in.) (0.4707 in.)
(0.0004 to 0.0017 in.) (0.0033 in.)
101
OIL PUMP
Engine Oil Pressure
Model Number at Rated Engine rpm at Low Idle Speed

All models 0.29 to 0.39 MPa (42.06 to 56.56 psi) 0.06 MPa (8.7 psi) or greater
Outer Rotor Outside Clearance
Model Standard Limit

All models 0.100 to 0.155 mm (0.0039 to 0.25 mm (0.0098 in.)
0.0061 in.)
Outer Rotor Side Clearance

All models 0.05 to 0.10 mm (0.0020 to 0.15 mm (0.0059 in.)
0.0039 in.)
Outer Rotor to Inner Rotor Tip Clearance

All models - 0.16 mm (0.0063 in.)
Rotor Shaft Clearance
Model Inspection Item Standard Limit

All models Gear Case Bearing I.D. 12.980 to 13.020 mm (0.5110 to 13.05 mm
0.5126 in.) (0.5138 in.)
Rotor Shaft O.D. 12.925 to 12.970 mm (0.5089 to 12.915 mm
0.5106 in.) (0.5085 in.)
Rotor Clearance 0.010 to 0.065 mm (0.0004 to 0.105 mm
0.0026 in.) (0.0041 in.)
102
0600 YRM 1205 Standard Torque Specifications
Standard Torque Specifications

STANDARD TORQUE CHART
Nominal Thread Diam-
Item × Pitch Tightening Torque
eter
Hexagon Bolt (7T) and Nut M6 × 1.0 mm 9.8 to 11.8 N•m (87 to
104 lbf in)
NOTE: Use 80% of the value of M8 × 1.25 mm 22.6 to 28.4 N•m (17 to 21 lbf ft)
the Tightening Torque when the M10 × 1.5 mm 44.1 to 53.9 N•m (33 to 40 lbf ft)
tightening part is aluminum.
M12 × 1.75 mm 78.4 to 98.0 N•m (58 to 72 lbf ft)
Use 60% of the value of the Tight-
ening Torque for 4T bolts and lock M14 × 1.5 mm 127.5 to 147.1 N•m (94 to
nuts. 108 lbf ft)
M16 × 1.5 mm 215.7 to 235.4 N•m (159 to
174 lbf ft)
PT Plug 1/8 mm 9.8 N•m (87 lbf in)
1/4 mm 19.6 N•m (14 lbf ft)
3/8 mm 29.4 N•m (22 lbf ft)
1/2 mm 58.8 N•m (43 lbf ft)
Pipe Joint Bolt M8 12.7 to 16.7 N•m (112 to
148 lbf in)
M10 19.6 to 18.73 N•m (14 to
19 lbf ft)
M12 24.5 to 34.3 N•m (18 to 25 lbf ft)
M14 39.2 to 49.0 N•m (29 to 36 lbf ft)
M16 49.0 to 58.8 N•m (36 to 43 lbf ft)
NOTE: Lubricating oil is not applied to threaded portion and seat surface.
103
Special Torque Specifications 0600 YRM 1205
Special Torque Specifications

Alternator Adjuster/Set Bolt Flywheel Bolts
25.5 N•m (18.8 lbf ft) 155 N•m (114 lbf ft)
Alternator Pivot Bolt Flywheel Housing Bolts

30 N•m (22 lbf ft) 44 to 54 N•m (32 to 40 lbf ft)
Alternator Terminal Nut Fuel Injector

7.8 N•m (69 lbf in) 39 N•m (29 lbf ft)
Bearing Cap Set Bolt Fuel Pump Drive Gear Set Nut
108.1 to 117.9 N•m (79.7 to 87.0 lbf ft) 59 to 69 N•m (43 to 51 lbf ft)
Connecting Rod Bolt Fuel Return Line Retaining Nut

54 to 59 N•m (40 to 43 lbf ft) 44 N•m (33 lbf ft)
Coolant Temperature Sensor Starter Solenoid Nut (B Terminal)

24.5 to 34.3 N•m (18.1 to 25.3 lbf ft) 7.9 to 9.8 N•m (70 to 87 lbf in)
Crankshaft Pulley Bolt Starter Solenoid Screw (S Terminal)

117.6 N•m (86.7 lbf ft) 1.7 to 2.4 N•m (15 to 21 lbf in)
Cylinder Head Bolt Thermostat Cover Bolts

First Pass: 49 to 59 N•m (36 to 43 lbf ft) 23 to 28 N•m (17 to 21 lbf ft)
Second Pass: 103 to 113 N•m (76 to 83 lbf ft)
Engine Oil Drain Plug

20 to 24 N•m (14.75 to 17.7 lbf ft)
104
0600 YRM 1205 Special Tools
Special Tools
No. Tool Name Applicable Model and Tool Size Illustration

1 Valve Guide Tool
(for Extracting L1 L2 d1 d2
Valve Guide) 20 mm 75 mm 7.5 mm 11 mm
(0.787 in.) (2.953 in.) (0.295 in.) (0.433 in.)
Locally Manufactured
2 Valve Guide Tool
(for Inserting L1 L2 d1 d2
Valve Guide) 15 mm 65 mm 14 mm 20 mm
(0.591 in.) (2.559 in.) (0.551 in.) (0.787 in.)
3 Connecting Rod
Bushing Replacer L1 L2 d1 d2
(for Removal/ 20 mm 100 mm 30 mm 33 mm
Installation of (0.787 in.) (3.937 in.) (1.181 in.) (1.299 in.)
Connecting Rod
Bushing)
4 Valve Spring
Compressor (for
Removal/Installa- Yale Part No. 580064717
tion of Valve
Spring)
5 Stem Seal In-
serter (for Insert- d1 d2 d3 L1 L2 L3
ing Stem Seal) 16.2 mm 22 mm 13.5 mm 17.0 mm 65 mm 4 mm
(0.638 in.) (0.866 in.) (0.531 in.) (0.669 in.) (2.560 in.) (0.157 in.)
6 Filter Wrench (for

Removal/Installa-
Available Locally
tion of Engine Oil
Filter)
105
Special Tools 0600 YRM 1205
No. Tool Name Applicable Model and Tool Size Illustration

7 Camshaft Bush-
ing Tool (for Ex- L1 L2 d1 d2
tracting Camshaft 18 mm 70 mm 50 mm 53 mm
Bushing) (0.709 in.) (2.756 in.) (1.969 in.) (2.087 in.)
Allowance d1: −03 to −0.6 mm (0.012 to 0.024 in.)
Allowance d2: −03 to −0.6 mm (0.012 to 0.024 in.)
8 Flex-Hone (for
Preparation of Model Part Number Cylinder Bore
Cylinder Walls) 4TNE92 Yale Part No. 83 to 95 mm ( in.)
580064718
Yale Part No. 89 to 101 mm ( in.)
4TNE98
580062800
9 Piston Ring Yale Part No. 580064719

Compressor (for The Piston Insertion Tool is Applicable for
Inserting Piston) 60 to 125 mm (2.362 to 4.921 in.)
Diameter Pistons
10 Piston Ring Re- Available Locally

placer (for Re-
moval/Installation
of Piston Ring)
106
No. Instrument Name Application Illustration

1 Dial Indicator Measurements of shaft bending, and strain
and gap of surfaces.
2 Test Indicator Measurements of narrow or deep portions

that cannot be measured by dial Indicator.
3 Magnetic Stand For holding the dial gauge when measuring.
4 Micrometer For measuring the outside diameters of crank-

shaft, pistons, piston pins, etc.
5 Cylinder Gauge For measuring the inside diameters of cylin-

der liners, rod metal, etc.
6 Calipers For measuring outside diameters, depth,

thickness, and width.
7 Depth Micrometer For measuring of valve sink.
8 Square For measuring valve spring inclination and

straightness of parts.
107

9 V-Block For measuring shaft bend.
10 Torque Wrench For tightening nuts and bolts to the specified

torque.
11 Thickness Gauge ("Feeler" For measuring gaps between ring and ring
Gauge) groove and shaft joints during assembly.
12 Cooling System Tester For checking water leakage
13 Battery Coolant Tester For checking concentration of antifreeze and

the battery electrolyte charge status.
14 Fuel Injector Tester For measuring injection spray pattern of fuel

injection nozzle and injection pressure.
108

15 Fuel Injection Pump Timing Tool Used to check and adjust fuel injection timing.
Yale Part No. 580064716
16 Digital Thermometer For measuring temperature.
17 Tachometer Contact Type For measuring revolution by contacting the re-

volving shaft.
Photoelectric For measuring revolution by sensing the re-

Type flecting mark on the outer periphery of the re-
volving shaft.
Fuel High Pres- This measures the revolution regardless of

sure Pipe the center of periphery of the revolving object.
Clamp Type
18 Circuit Tester For measuring resistance, voltage, and con-
tinuity of electrical circuits.
109

19 Compression Gauge Kit For measuring compression pressure.
New Compression Test Adapter Adapter for direct injection 2-valve cylinder
head. Yale Part No. 580064720
110
0600 YRM 1205 1/17 (7/16)(12/14)(4/14)(12/12)(7/11)

Maintenance: Yanmar Diesel Engines

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Maintenance: Yanmar Diesel Engines

Uploaded by

Copyright:

Available Formats

Maintenance

YANMAR DIESEL ENGINES

PART NO. 524240453 0600 YRM 1205

©2017 Yale Materials Handling Corp. i

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

This section is for the following models:

GDP16VX, GDP18VX, GDP20SVX (GDP030VX, GDP035VX, GDP040SVX) [C810];

Major Engine Component Identification

Figure 1 shows where the major engine components

The typical location of the emission control

The typical location of the engine nameplate is shown

Figure 3. Engine Nameplate (Typical)

Engine Removal and Installation

See Frame 0100YRM1672 for lift truck models

Cylinder Head Assembly Repair

Figure 4. Cylinder Head Components

Legend for Figure 4

1. VALVE COVER NUT 16. EXHAUST VALVE

GLOW PLUGS Install

2. Inspect O-rings on each valve cover nut. Replace

3. Remove valve cover.

4. Remove valve cover gasket and discard.

1. GLOW PLUG 3. WIRE HARNESS

Figure 5. Glow Plugs

Figure 6. Valve Cover

Clean and Inspect Install

Clean valve cover in cleaning solvent. Dry valve cover

1. SUPPORT BRACKET NUT 7. SUPPORT BRACKET

Figure 7. Rocker Arm Assembly

4. If necessary, remove valve adjusting screw and Rocker Arm Assembly

Clean all parts in cleaning solvent. Dry parts with

3. Use a feeler gauge to measure the gap. Refer to

Figure 10. Rocker Arm Shaft Outside Diameter

3. Install and hand tighten the rocker arm shaft re-

4. Align push rods with their respective rocker arms.

5. Tighten rocker arm shaft retaining bolt and nuts.

6. Tighten rocker arm shaft alignment screw.

7. Adjust valve lash. See Valve Clearance Adjust-

8. Install valve cover. See Valve CoverInstall.

VALVE CLEARANCE ADJUSTMENTS

NOTE: The number one piston position is on the fly-

5. Insert a 0.2 mm (0.008 in.) feeler gauge between

6. Apply clean engine oil to the contact surface be-

7. Turn the crankshaft 180 degrees and make the

2. Remove alternator. See Electrical Equipment Re-

3. Remove water pump. See Cooling System Re-

4. Disconnect air intake hose from the intake mani-

7. If equipped, remove the pull actuator and mount-

9. Tag and disconnect the fuel hoses from the fuel

10. Remove the bolts retaining the fuel filter housing

11. Remove the bolts retaining the intake manifold to

Figure 14. Fuel Filter Housing Assembly

Figure 15. Intake Manifold

1. CYLINDER HEAD 3. EXHAUST MANIFOLD

Figure 16. Exhaust Manifold

14. Remove the valve cover. See Valve Cover, Re-

15. Remove the rocker arm assembly. See Rocker

16. Loosen the cylinder head bolts following the se-

A. CAMSHAFT SIDE B. FAN SIDE

Figure 17. Cylinder Head Bolt Loosening

17. Remove the cylinder head bolts. See Figure 18.