Maintenance

KUBOTA DIESEL 3.6L

ENGINE
GDP40VX5, GDP40VX6, GDP45VX6, GDP45SVX5,
GDP50-55VX (GDP080-120VX) [H813, J813,
K813];GDP60-70VX (GDP135-155VX) [E878,
F878];GDP60VX, GDP70VX, GP70VXS6,
VP70VXS9 (GDP135VX, GDP155VX,
GP155VXS) [G878];GP60VX, GP70VX, GP70SVX,
GP70SVX9, GP80SVX (GP135VX, GP155VX,
GP155SVX, GP170SVX) [H878]

PART NO. 550055279 0600 YRM 1579

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the
load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the
weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks.
Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK
ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use APPROVED parts when making repairs. Replacement parts must meet or exceed the
specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs
repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable.
Be sure to follow the necessary safety precautions when handling these fuels and when working on these
fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area.
Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this 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.

WARNING

California Proposition 65 - Operating, servicing and maintaining a powered industrial truck can expose you to
chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of
California to cause cancer and birth defects or other reproductive harm. For more information, go to
www.P65Warnings.ca.gov.
 Table of Contents

TABLE OF CONTENTS
General....................................................................................................................................................................1
Engine Identification............................................................................................................................................. 1
Major Engine Component Identification............................................................................................................. 1
Location of Labels..............................................................................................................................................1
Crankcase Description..........................................................................................................................................2
Engine Removal and Installation.............................................................................................................................3
Cylinder Head Assembly Repair............................................................................................................................. 4
Valve Covers and Fuel Injectors........................................................................................................................... 4
Remove..............................................................................................................................................................4
Clean and Inspect.............................................................................................................................................. 7
Install..................................................................................................................................................................8
Rocker Arm Assembly........................................................................................................................................ 10
Remove............................................................................................................................................................10
Disassemble.....................................................................................................................................................11
Clean and Inspect............................................................................................................................................ 11
Push Rods..................................................................................................................................................... 11
Rocker Arm Assembly...................................................................................................................................12
Assemble......................................................................................................................................................... 12
Install................................................................................................................................................................12
Valve Clearance Adjustments.............................................................................................................................13
Cylinder Head Assembly.................................................................................................................................... 14
Remove............................................................................................................................................................14
Disassemble.....................................................................................................................................................21
Valves and Valve Springs, Remove...............................................................................................................21
Valve Guides, Remove.................................................................................................................................. 23
Clean and Inspect............................................................................................................................................ 23
Cylinder Head................................................................................................................................................24
Valve Guides................................................................................................................................................. 24
Valves............................................................................................................................................................ 24
Valve Sink......................................................................................................................................................25
Valve Seat..................................................................................................................................................... 25
Valve Springs.................................................................................................................................................25
Assemble......................................................................................................................................................... 26
Valve Guides, Install...................................................................................................................................... 26
Valves and Valve Springs, Install...................................................................................................................27
Install................................................................................................................................................................27
Timing Gear Case and Timing Gears Repair........................................................................................................ 31
Timing Gear Case Cover.................................................................................................................................... 31
Remove............................................................................................................................................................31
Clean and Inspect............................................................................................................................................ 31
Install................................................................................................................................................................31
Timing Gears...................................................................................................................................................... 32
Crankshaft Gear...............................................................................................................................................33
Remove......................................................................................................................................................... 33
Install............................................................................................................................................................. 33
Idler Gear......................................................................................................................................................... 33
Remove......................................................................................................................................................... 33
Inspect...........................................................................................................................................................34
Install............................................................................................................................................................. 34
Camshaft Gear.................................................................................................................................................34
Remove......................................................................................................................................................... 34
Install............................................................................................................................................................. 35

©2021 Yale Materials Handling Corp. i

Table of Contents

TABLE OF CONTENTS (Continued)

Timing Gear Case...............................................................................................................................................35
Remove............................................................................................................................................................35
Clean and Inspect............................................................................................................................................ 36
Install................................................................................................................................................................36
Drive Train, Camshaft, and Cylinder Block Repair................................................................................................37
Remove.............................................................................................................................................................. 37
Disassemble....................................................................................................................................................... 37
Pistons and Connecting Rods..........................................................................................................................37
Crankshaft........................................................................................................................................................38
Camshaft..........................................................................................................................................................40
Clean and Inspect...............................................................................................................................................41
Cylinder Block.................................................................................................................................................. 42
Honing and Boring.........................................................................................................................................44
Cylinder Correction (Oversize)...................................................................................................................... 45
Pistons............................................................................................................................................................. 45
Piston Pin.........................................................................................................................................................46
Connecting Rod............................................................................................................................................... 46
Tappets.............................................................................................................................................................46
Crankshaft........................................................................................................................................................47
Camshaft..........................................................................................................................................................49
Camshaft Bushing............................................................................................................................................50
Assemble............................................................................................................................................................50
Camshaft..........................................................................................................................................................50
Crankshaft........................................................................................................................................................50
Pistons and Connecting Rods..........................................................................................................................50
Install.................................................................................................................................................................. 52
Lubrication System Repair.................................................................................................................................... 54
Engine Oil and Oil Filter Change........................................................................................................................ 54
Oil Pan................................................................................................................................................................55
Remove............................................................................................................................................................55
Install................................................................................................................................................................56
Oil Suction Tube................................................................................................................................................. 56
Remove............................................................................................................................................................56
Clean................................................................................................................................................................57
Install................................................................................................................................................................57
Oil Pump.............................................................................................................................................................57
Remove............................................................................................................................................................57
Clean and Inspect............................................................................................................................................ 57
Outer Rotor Outside Clearance.....................................................................................................................58
Outer Rotor to Inner Rotor Tip Clearance..................................................................................................... 58
Outer Rotor Side Clearance.......................................................................................................................... 58
Rotor Shaft Clearance...................................................................................................................................59
Install................................................................................................................................................................59
Fuel System Repair...............................................................................................................................................60
Fuel Injectors...................................................................................................................................................... 60
Remove............................................................................................................................................................60
Inspect..............................................................................................................................................................60
Clean................................................................................................................................................................60
Replace............................................................................................................................................................60
Install................................................................................................................................................................60
Electronic Throttle System..................................................................................................................................61
Remove............................................................................................................................................................61

ii
 Table of Contents

TABLE OF CONTENTS (Continued)

Throttle Position Sensor Proceedures After September 2018 GDP60-70VX (GDP135-155VX) (F878),
GDP60VX, GDP70VX, GP70VXS6 (GDP135VX. GDP155VX, GP155VXS) (G878), GP60VX, GP70VX,
GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) and GP080VX,
GP090VX, GP100VX, GP100VX, GP120VX (GDP40VX5, GDP40VX6, GDP45VX6, GDP45SVX5,
GDP50VX, GDP55VX) (K813).........................................................................................................................64
Bearing Replacement.......................................................................................................................................65
Install................................................................................................................................................................65
Adjustment....................................................................................................................................................... 66
Fuel Injection Pump............................................................................................................................................67
Remove............................................................................................................................................................67
Disassemble.....................................................................................................................................................70
Clean and Inspect............................................................................................................................................ 72
Assemble......................................................................................................................................................... 72
Install................................................................................................................................................................73
Cooling System Repair..........................................................................................................................................75
Serpentine Belt................................................................................................................................................... 75
Remove............................................................................................................................................................75
Inspect..............................................................................................................................................................75
Install................................................................................................................................................................75
Serpentine Belt, Adjustment.............................................................................................................................75
Water Pump........................................................................................................................................................76
Remove............................................................................................................................................................76
Install................................................................................................................................................................78
Thermostat..........................................................................................................................................................79
Remove............................................................................................................................................................79
Inspect..............................................................................................................................................................80
Install................................................................................................................................................................80
Flywheel and Flywheel Housing............................................................................................................................82
Flywheel..............................................................................................................................................................82
Remove............................................................................................................................................................82
Install................................................................................................................................................................82
Flywheel Housing............................................................................................................................................... 82
Remove............................................................................................................................................................82
Install................................................................................................................................................................82
Electrical Equipment Repair..................................................................................................................................83
Alternator............................................................................................................................................................ 83
Remove............................................................................................................................................................83
Install................................................................................................................................................................84
Starter.................................................................................................................................................................85
Remove............................................................................................................................................................85
Install................................................................................................................................................................85
Engine Specifications............................................................................................................................................86
Engine Data........................................................................................................................................................86
Engine Tuning.....................................................................................................................................................86
Cylinder Head.....................................................................................................................................................87
Intake/Exhaust Valve and Guide.........................................................................................................................87
Valve Spring........................................................................................................................................................88
Rocker Arm and Shaft........................................................................................................................................ 88
Push Rod............................................................................................................................................................88
Gear Train and Camshaft................................................................................................................................... 88
Camshaft..........................................................................................................................................................88
Idle Gear Shaft and Bushing............................................................................................................................88

iii
Table of Contents

TABLE OF CONTENTS (Continued)

Backlash of Each Gear.................................................................................................................................... 89
Cylinder Block.....................................................................................................................................................89
Crankshaft.......................................................................................................................................................... 89
Piston..................................................................................................................................................................89
Piston Ring......................................................................................................................................................... 90
Connecting Rod..................................................................................................................................................90
Rod Small End................................................................................................................................................. 90
Tappet.............................................................................................................................................................. 90
Oil Pump.............................................................................................................................................................91
Engine Oil Pressure......................................................................................................................................... 91
Outer Rotor Outside Clearance........................................................................................................................91
Outer Rotor Side Clearance.............................................................................................................................91
Inner Rotor to Cover.........................................................................................................................................91
Standard Torque Specifications............................................................................................................................ 92
Standard Torque Chart....................................................................................................................................... 92
Special Torque Specifications............................................................................................................................... 93
Special Tools......................................................................................................................................................... 95

iv
0600 YRM 1579 General

General
This section has the repair instructions for the Kubota Location of Labels
3.6L diesel engine.
The typical location of the emission control information
label is shown in Figure 2.
ENGINE IDENTIFICATION
The typical location of the engine nameplate is shown
Major Engine Component Identification in Figure 2. The emissions exempt label is shown in
Figure 1 shows where the major engine components Figure 3.
are located.

1. ENGINE NAMEPLATE
2. EMISSION CONTROL INFORMATION LABEL
3. ENGINE SERIAL NUMBER

Figure 2. Typical Location of Engine Labels

1. TOP FILLER PORT (ENGINE OIL)

2. STARTER MOTOR
3. FUEL INJECTORS/FUEL LINES
4. WATER PUMP
5. ALTERNATOR
6. SERPENTINE BELT
7. CRANKSHAFT PULLEY
8. SIDE FILLER PORT (ENGINE OIL)
9. DRAIN PLUG
10. ENGINE OIL FILTER
11. ENGINE OIL COOLER
12. FUEL INJECTION PUMP Figure 3. Emissions Exempt Label
13. DIPSTICK (ENGINE OIL)
14. FUEL/WATER SEPARATOR
15. TURBO CHARGER

Figure 1. Major Engine Components

1
General 0600 YRM 1579

CRANKCASE DESCRIPTION
The Kubota diesel engine utilizes a split crankcase to
produce greater durability and operate more quietly.
The crankcase is split into two parts, crankcase 1,
which houses combustion components and crankcase
2, which completes crankcase 1 and acts as noise
reduction baffle. See Figure 4.
The Kubota Diesel engine utilizes a hanger type
crankshaft support which allows for easy disassembly/
assembly and a linerless type piston cylinder which
allows for good cooling performance and excellent
resistance to wear. See Figure 4.

1. CRANKCASE 1
2. CRANKCASE 2
3. OIL PAN

Figure 4. Kubota Diesel Crankcase Components

2
0600 YRM 1579 Engine Removal and Installation

Engine Removal and Installation

The procedures to remove and install engine are not • GDP40VX5, GDP40VX6, GDP45VX6,
included in this section. For procedures refer to GDP45SVX5, GDP50-55VX (GDP080-120VX)
(K813)
Frame 0100YRM1243 for lift truck models
Frame 0100YRM1948 for lift truck models
• GDP40VX5, GDP40VX6, GDP45VX6,
GDP45SVX5, GDP50-55VX (GDP080-120VX) • GDP60-70VX (GDP135-155VX) (F878)
(H813, J813) • GDP60VX, GDP70VX, GP70VXS6
Frame 0100YRM1581 for lift truck models (GDP135VX. GDP155VX, GP155VXS) (G878)
GDP60-70VX (GDP135-155VX) (E878) • GP60VX, GP70VX, GP70SVX, GP70SVX9,
•
GP80SVX (GP135VX, GP155VX, GP155SVX,
Frame 0100YRM1891 for lift truck models GP170SVX) (H878)

3
Cylinder Head Assembly Repair 0600 YRM 1579

Cylinder Head Assembly Repair

VALVE COVERS AND FUEL INJECTORS See Figure 6 for lift truck model

Remove • GDP40VX5/VX6, GDP45SVX5, GDP45VX6;

GDP50-55VX (GDP080-120VX) (J813, K813)
1. Disconnect negative battery cable at battery.
See Figure 7 for lift truck model
NOTE: Mark connectors/wires during removal to aid • GDP60VX, GDP70VX (GDP135-155VX) (F878)
in installation. • GDP60VX, GDP70VX, GP70VXS6
2. Unclip engine wiring harness and move to side for (GDP135VX. GDP155VX, GP155VXS) (G878)
better access. • GP60VX, GP70VX, GP70SVX, GP70SVX9,
GP80SVX (GP135VX, GP155VX, GP155SVX,
See Figure 5 for lift truck models GP170SVX) (H878)
• GDP40VX5/VX6; GDP45SVX5,GDP45VX6,
GDP50-55VX (GDP080-120VX) (H813) 5. Remove clamp and breather tube from valve
• GDP60VX, GDP70VX (GDP135-155VX) (E878) cover.

See Figure 6 for lift truck model See Figure 5 for lift truck models

• GDP40VX5/VX6; GDP45SVX5, GDP45VX6; • GDP40VX5/VX6, GDP45SVX5,GDP45VX6,

GDP50-55VX (GDP080-120VX) (J813, K813) GDP50-55VX (GDP080-120VX) (H813)
• GDP60-70VX (GDP135-155VX) (E878)
See Figure 7 for lift truck model
See Figure 6 for lift truck model
• GDP60VX, GDP70VX (GDP135-155VX) (F878,
G878) • GDP40VX5/VX6, GDP45SVX5, GDP45VX6,
• GP60VX, GP70VX, GP70SVX, GP70SVX9, GDP50-55VX (GDP080-120VX) (J813, K813)
GP80SVX (GP135VX, GP155VX, GP155SVX, See Figure 7 for lift truck model
GP170SVX) (H878)
• GDP60VX, GDP70VX (GDP135-155VX) (F878)
3. Disconnect wiring connector from glow plug strip. • GDP60VX, GDP70VX, GP70VXS6
See Figure 5 for lift truck models (GDP135VX. GDP155VX, GP155VXS) (G878)
• GP60VX, GP70VX, GP70SVX, GP70SVX9,
• GDP40VX5/VX6; GDP45SVX5,GDP45VX6, GP80SVX (GP135VX, GP155VX, GP155SVX,
GDP50-55VX (GDP080-120VX) (H813) GP170SVX) (H878)
• GDP60-70VX (GDP135-155VX) (E878)
6. Remove turbo outlet hose from turbocharger and
See Figure 6 for lift truck model
air inlet elbows.
• GDP40VX5/VX6, GDP45SVX5, GDP45VX6,
GDP50-55VX (GDP080-120VX) (J813, K813) See Figure 5 for lift truck models

See Figure 7 for lift truck model • GDP40VX5/VX6, GDP45SVX5, GDP45VX6,

GDP50-55VX (GDP080-120VX) (H813)
• GDP60VX, GDP70VX (GDP135-155VX) (F878) GDP60-70VX (GDP135-155VX) (E878)
•
• GDP60VX, GDP70VX, GP70VXS6
(GDP135VX. GDP155VX, GP155VXS) (G878) See Figure 6 for lift truck model
• GP60VX, GP70VX, GP70SVX, GP70SVX9, • GDP40VX5/VX6, GDP45SVX5, GDP45VX6,
GP80SVX (GP135VX, GP155VX, GP155SVX, GDP50-55VX (GDP080-120VX) (J813, K813)
GP170SVX) (H878) See Figure 7 for lift truck model
4. Loosen two clamps at air filter and turbocharger • GDP60VX, GDP70VX (GDP135-155VX) (F878)
for air intake hose. Remove air intake hose. • GDP60VX, GDP70VX, GP70VXS6
See Figure 5 for lift truck models (GDP135VX. GDP155VX, GP155VXS) (G878)
• GP60VX, GP70VX, GP70SVX, GP70SVX9,
• GDP40VX5/VX6; GDP45SVX5,GDP45VX6, GP80SVX (GP135VX, GP155VX, GP155SVX,
GDP50-55VX (GDP080-120VX) (H813) GP170SVX) (H878)
• GDP60-70VX (GDP135-155VX) (E878)

4
0600 YRM 1579 Cylinder Head Assembly Repair

Legend for Figure 6.

1. ENGINE WIRING HARNESS

2. CLAMP
3. AIR FILTER
4. TURBOCHARGER
5. AIR INTAKE HOSE
6. BREATHER TUBE
7. TURBOCHARGER OUTLET HOUSE
8. GLOW PLUG STRIP CONNECTOR

1. ENGINE WIRING HARNESS

2. CLAMP
3. AIR FILTER
4. TURBOCHARGER
5. AIR INTAKE HOSE
6. BREATHER TUBE
7. TURBOCHARGER OUTLET HOUSE
8. GLOW PLUG STRIP CONNECTOR

Figure 5. Breather Tube and Hoses for Lift Truck

Models and GDP40VX5/VX6, GDP45SVX5,
GDP45VX6, GDP50-55VX (GDP080-120VX)
(H813) GDP60-70VX (GDP135-155VX) (E878)

1. ENGINE WIRING HARNESS

2. CLAMP
3. AIR FILTER
4. TURBOCHARGER
5. AIR INTAKE HOSE
6. BREATHER TUBE
7. TURBOCHARGER OUTLET HOUSE
8. GLOW PLUG STRIP CONNECTOR

Figure 7. Breather Tube and Hoses for Lift Truck

Models GDP60-70VX (GDP135-155VX) (F878) and
GDP60VX, GDP70VX, GP70VXS6 (GDP135VX.
GDP155VX, GP155VXS) (G878), GP60VX, GP70VX,
GP70SVX, GP70SVX9, GP80SVX (GP135VX,
GP155VX, GP155SVX, GP170SVX) (H878)

7. Remove ten bolts, valve cover and gasket from

cylinder head. Discard gasket. See Figure 8.

Figure 6. Breather Tube and Hoses for Lift Truck

Model GDP40VX5/VX6, GDP45SVX5, GDP45VX6,
GDP50-55VX (GDP080-120VX) (J813, K813)

5
Cylinder Head Assembly Repair 0600 YRM 1579

1. CYLINDER HEAD 7. BREATHER TUBE

2. VALVE COVER GASKET 8. CLAMP
3. PLUG 9. VALVE COVER BREATHER
4. BOLT 10. BREATHER COVER
5. O-RING 11. VALVE COVER
6. OIL FILL CAP

Figure 8. Valve Cover

8. Remove four flange nuts. Remove glow plug strip 11. Loosen four fuel lines at fuel injection pump. See
from glow plugs. See Figure 9. Figure 9.

NOTE: Note position and location of fuel line clamps 12. Remove four fuel lines, four nuts, and overflow
during removal to aid in installation. pipe assembly from fuel injectors. Discard nuts.
See Figure 9.
9. Remove two pan head screws and four clamps
from fuel injector lines. See Figure 9.

10. Remove two hose clamps. Disconnect fuel

overflow hoses from overflow pipe assembly. See
Figure 9.

6
0600 YRM 1579 Cylinder Head Assembly Repair

1. CYLINDER HEAD 9. NUT

2. FUEL INJECTION PUMP 10. FUEL INJECTOR
3. HOSE CLAMP 11. GASKET
4. FUEL OVERFLOW HOSE 12. BASE SEAL
5. FUEL LINES 13. FLANGE NUT
6. PAN HEAD SCREW 14. GLOW PLUG STRIP
7. CLAMP 15. GLOW PLUG
8. OVERFLOW PIPE ASSEMBLY

Figure 9. Fuel Injectors and Fuel Lines

13. Remove four injectors, four gaskets and four base Clean and Inspect
seals from cylinder head. Discard gaskets and
base seals. See Figure 9.
WARNING
14. Remove four glow plugs. See Figure 9. Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the recommendations of
the manufacturer.

7
Cylinder Head Assembly Repair 0600 YRM 1579

8. Using four flange nuts, install glow plug strip onto

WARNING glow plugs. See Figure 9.
Compressed air can move particles so that they 9. Lightly grease new valve cover gasket.
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is 10. Place new valve cover gasket into groove of valve
away from all personnel. Wear protective goggles cover.
or a face shield to prevent injury to the eyes.
11. Install valve cover and ten bolts onto cylinder
head. Tighten bolts to
CAUTION 9.8 to 11.2 N•m (86.7 to 99 lbf in). See Figure 8.
Use caution not to scratch the gasket mating
surfaces when cleaning the valve cover and 12. Install outlet hose from turbocharger and air inlet
cylinder head. elbows.
See Figure 5 for lift truck models
Carefully remove all gasket residue from valve cover
and cylinder head. • GDP40VX5/VX6, GDP45SVX5, GDP45VX6,
GDP50-55VX (GDP080-120VX) (H813)
Clean valve cover in cleaning solvent. Dry valve cover
• GDP60-70VX (GDP135-155VX) (E878)
with compressed air. Inspect for wear, cracks, and any
other damage. If necessary, replace valve cover. See Figure 6 for lift truck model
Inspect all O-rings, plugs and grommets for wear, • GDP40VX5/VX6, GDP45SVX5, GDP45VX6,
cracks, and any other damage. Replace where GDP50-55VX (GDP080-120VX) (J813, K813)
necessary. See Figure 7 for lift truck model
Inspect valve cover breather and breather cover for • GDP60VX, GDP70VX (GDP135-155VX) (F878)
cracks, wear, and any other damage (see Figure 8). if
• GDP60VX, GDP70VX, GP70VXS6
necessary see Parts Manual for replacement parts. (GDP135VX. GDP155VX, GP155VXS) (G878)
• GP60VX, GP70VX, GP70SVX, GP70SVX9,
Install GP80SVX (GP135VX, GP155VX, GP155SVX,
1. Install four glow plugs into cylinder head. Tighten GP170SVX) (H878)
to 20 to 24 N•m (15 to 18 lbf ft). See Figure 9.
13. Install breather tube and clamp to valve cover.
2. Install four new gaskets and four new base seals See Figure 5 for lift truck models
onto four fuel injectors. Install four fuel injectors
into cylinder head. Tighten to • GDP40VX5/VX6, GDP45SVX5, GDP45VX6,
GDP50-55VX (GDP080-120VX) (H813)
49 to 68 N•m (37 to 50 lbf ft). See Figure 9.
• GDP60-70VX (GDP135-155VX) (E878)
3. Install overflow pipe assembly and four nuts onto See Figure 6 for lift truck model
fuel injectors. Tighten nuts to
20 to 24 N•m (15 to 18 lbf ft). See Figure 9. • GDP40VX5/VX6, GDP45SVX5, GDP45VX6,
GDP50-55VX (GDP080-120VX) (J813, K813)
4. Install four fuel lines onto fuel injectors. Tighten to See Figure 7 for lift truck model
23 to 36 N•m (17 to 26 lbf ft). See Figure 9.
• GDP60VX, GDP70VX (GDP135-155VX) (F878)
5. Install four fuel lines onto fuel injection pump. • GDP60VX, GDP70VX, GP70VXS6
Tighten to 23 to 36 N•m (17 to 26 lbf ft). See (GDP135VX. GDP155VX, GP155VXS) (G878)
Figure 9. • GP60VX, GP70VX, GP70SVX, GP70SVX9,
GP80SVX (GP135VX, GP155VX, GP155SVX,
6. Using two hose clamps, connect fuel overflow GP170SVX) (H878)
hoses to overflow pipe assembly. See Figure 9.

7. Install four clamps and two pan head screws onto

fuel injector lines as noted during removal. See
Figure 8.

8
0600 YRM 1579 Cylinder Head Assembly Repair

14. Install air intake hose assembly and tighten See Figure 7 for lift truck model
clamps at air filter and turbocharger. GDP60VX, GDP70VX (GDP135-155VX) (F878)
•
See Figure 5 for lift truck models • GDP60VX, GDP70VX, GP70VXS6
• GDP40VX5/VX6, GDP45SVX5, GDP45VX6, (GDP135VX. GDP155VX, GP155VXS) (G878)
GDP50-55VX (GDP080-120VX) (H813) • GP60VX, GP70VX, GP70SVX, GP70SVX9,
• GDP60-70VX (GDP135-155VX) (E878) GP80SVX (GP135VX, GP155VX, GP155SVX,
GP170SVX) (H878)
See Figure 6 for lift truck model
• GDP40VX5/VX6, GDP45SVX5, GDP45VX6, 16. Install engine wiring harness and attach clips as
GDP50-55VX (GDP080-120VX) (J813, K813) noted during removal.
See Figure 7 for lift truck model See Figure 5 for lift truck models
• GDP60VX, GDP70VX (GDP135-155VX) (F878) • GDP40VX5/VX6, GDP45SVX5, GDP45VX6,
GDP50-55VX (GDP080-120VX) (H813)
• GDP60VX, GDP70VX, GP70VXS6
(GDP135VX. GDP155VX, GP155VXS) (G878) • GDP60-70VX (GDP135-155VX) (E878)
• GP60VX, GP70VX, GP70SVX, GP70SVX9, See Figure 6 for lift truck model
GP80SVX (GP135VX, GP155VX, GP155SVX,
• GDP40VX5/VX6, GDP45SVX5, GDP45VX6,
GP170SVX) (H878)
GDP50-55VX (GDP080-120VX) (J813, K813)
15. Connect wiring connector to glow plug strip as See Figure 7 for lift truck model
noted during removal. GDP60VX, GDP70VX (GDP135-155VX) (F878)
•
See Figure 5 for lift truck models • GDP60VX, GDP70VX, GP70VXS6
• GDP40VX5/VX6, GDP45SVX5, GDP45VX6, (GDP135VX. GDP155VX, GP155VXS) (G878)
GDP50-55VX (GDP080-120VX) (H813) • GP60VX, GP70VX, GP70SVX, GP70SVX9,
• GDP60-70VX (GDP135-155VX) (E878) GP80SVX (GP135VX, GP155VX, GP155SVX,
GP170SVX) (H878)
See Figure 6 for lift truck model
• GDP40VX5/VX6, GDP45SVX5, GDP45VX6, 17. Connect negative battery cable at battery.
GDP50-55VX (GDP080-120VX) (J813, K813)

9
Cylinder Head Assembly Repair 0600 YRM 1579

ROCKER ARM ASSEMBLY 2. Remove four flange bolts holding rocker arm
brackets to cylinder head. See Figure 10.
Remove
1. Remove valve cover, fuel injectors, and glow
plugs. See Valve Covers and Fuel Injectors,
Remove.

Figure 10. Rocker Arm Assembly

10
0600 YRM 1579 Cylinder Head Assembly Repair

Legend for Figure 10.

A. EXHAUST VALVE GUIDE LOCATION C. VALVE ARM SHAFT LOCATION

B. INTAKE VALVE ARM LOCATION D. INTAKE VALVE GUIDE LOCATION

1. INTAKE VALVE 12. ROCKER ARM BRACKET

2. EXHAUST VALVE 13. C-CLIP
3. VALVE ARM SHAFT 14. WASHER
4. VALVE GUIDE 15. ROCKER ARM
5. VALVE STEM SEAL 16. ADJUSTING SCREW
6. SPRING 17. LOCK NUT
7. SPRING RETAINER 18. FLANGE BOLT
8. VALVE SPRING COLLAR 19. ROCKER ARM SHAFT
9. VALVE CAP 20. SLOTTED SCREW
10. VALVE ARM 21. SPRING PIN
11. VALVE ARM PAD

3. Lift rocker arm shaft assembly from cylinder head.

See Figure 10. WARNING
NOTE: Mark push rods so they can be reinstalled in Compressed air can move particles so that they
original location during reassembly. cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
4. Remove push rods from cylinder head. away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.
Disassemble
Clean all parts in cleaning solvent. Dry parts with
1. Remove c-clips and washers from each end of
compressed air. Inspect for wear, cracks, and any
rocker arm shafts. Discard washers. See
other damage. Replace all parts as needed.
Figure 10.

NOTE: Mark rocker arms so they can be reinstalled in Push Rods

original location during reassembly. 1. Place push rods on a flat inspection block.
NOTE: The rocker arm shaft fits tightly in rocker arm
support brackets. Clamp support bracket in a padded 2. Roll push rods until a gap can be observed
vise and twist and pull rocker arm shaft to remove between a portion of push rod and surface of
shaft. inspection block.

2. Slide rocker arm shaft out of rocker arm brackets, 3. Use a feeler gauge to measure gap. Refer to
springs, and rocker arms. See Figure 10. Engine Specifications for service limit. See
Figure 11.
3. If necessary, remove adjusting screw and lock nut
from rocker arms. See Figure 10.

Clean and Inspect

WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the recommendations of
the manufacturer.

11
Cylinder Head Assembly Repair 0600 YRM 1579

Figure 13. Rocker Arm Shaft Outside Diameter

Assemble
Figure 11. Push Rod Inspection NOTE: The rocker arm shaft fits tightly in rocker arm
support brackets. Clamp rocker arm shaft in a padded
Rocker Arm Assembly vise and twist and push support brackets onto rocker
arm shaft.
Rocker Arm and Support Bracket Inside Diameter:
Use a test indicator and micrometer to determine if 1. Lubricate rocker arm shaft. Slide rocker arm
inside diameter of all rocker arm support brackets and support brackets, springs, and rocker arms onto
rocker arms are within limits. Refer to Engine shaft, as noted during removal.
Specifications for service limit. See Figure 12.
2. Position rocker arm assembly on a flat surface.
Install washers and c-clips onto ends of rocker
arm shaft. See Figure 10.

3. If removed, install valve adjusting screws and lock

nuts. See Figure 10.

Install
NOTE: When installing push rod, mount it securely in
groove located in bottom of lifter.
1. Install push rods.

2. Place rocker arm assembly in position on cylinder

head.
Figure 12. Rocker Arm Inside Diameter
3. Install and hand tighten rocker arm shaft retaining
Shaft Outside Diameter: Use a micrometer to flange nuts. See Figure 10.
measure rocker arm shaft outside diameter. Refer to
Engine Specifications for service limit. See Figure 13. 4. Align push rods with their respective rocker arms,
as noted during removal.

5. Tighten rocker arm shaft retaining flange nuts.

Tighten nuts to 49 to 55 N•m (37 to 41 lbf in).

6. Adjust valve lash. See Valve Clearance

Adjustments.

7. Install valve cover. See Valve Covers and Fuel

Injectors, Install.

12
0600 YRM 1579 Cylinder Head Assembly Repair

VALVE CLEARANCE ADJUSTMENTS

NOTE: Make measurements and adjustments while
engine is cold.
1. Remove valve cover. See Valve Covers and Fuel
Injectors, Install.

NOTE: The number one piston position is on the fan

end of engine, opposite side of the flywheel, and
ignition order is 1-3-4-2 at 180 degree intervals.
2. Rotate crankshaft clockwise, as seen from
radiator side, to bring number one piston to top
dead center (TDC) (See Fuel Injection Pump for
TDC procedure). See Table 1 for reference to 1. VALVE ADJUSTING SCREW
help determine which valves will be available for 2. VALVE LOCK NUT
adjustment with number one piston at TDC.
Figure 14. Valve Clearance Measurement
Table 1. Available Valves for Adjustment
4. If adjustment is needed, loosen valve adjusting
Adjustable Cylinder Intake Exhaust screw lock nut and valve adjusting screw on
Location Of Piston rocker arm (see Figure 14) and check valve for
When No. 1 1 * * any inclination of valve cap, entrance of dirt, or
piston is at wear. See Figure 15.
2 *
compressio
n top dead 3 *
center 4
When No. 1 1
piston is at 2 *
overlap
position 3 *
4 * *

3. Insert a feeler gauge between rocker arm and

valve cap. See Figure 14. Record measured
valve clearance. The valve clearance should be
A. NORMAL
between 0.23 to 0.27 mm (0.009 to 0.011 in.). B. ABNORMAL

1. VALVE CAP

Figure 15. Valve Cap Check

NOTE: There is a tendency for clearance to decrease

slightly when lock nut is tightened. It is suggested that
you make clearance adjustment slightly on loose side
before tightening lock nut.
5. Insert a feeler gauge between rocker arm and
valve cap and adjust clearance so there is a slight
drag on feeler gauge when sliding it between
rocker arm and valve cap. Tighten valve adjusting
screw lock nut and recheck clearance. The valve
clearance should be between
0.23 to 0.27 mm (0.009 to 0.011 in.).

13
Cylinder Head Assembly Repair 0600 YRM 1579

6. Apply clean engine oil to contact surface between

adjusting screw and push rod.

7. Turn crankshaft 180 degrees and make

measurement and adjustment for number three
cylinder. Then turn crankshaft 180 degrees and
make measurement and adjustment for number
four cylinder. Then turn crankshaft 180 degrees
and make measurement and adjustment for
number 2 cylinder.

8. Install valve cover. See Valve Covers and Fuel

Injectors, Install.

CYLINDER HEAD ASSEMBLY

Remove
1. Disconnect negative battery cable at battery.
1. HOSE CLAMP
2. RETAINING CLAMP
NOTE: Place a suitable container with a capacity of at 3. AIR INTAKE HOSE
least 12.0 liter (13 qt) under radiator and lower radiator
hose. Figure 16. Air Intake Hoses for Lift Truck Models
2. Remove lower radiator hose and radiator cap. GDP60-70VX (GDP135-155VX) (E878)
Allow cooling system to drain.

3. Remove two hose clamps, two retaining clamps

and air intake hoses from air cleaner and
turbocharger.
See Figure 16 for lift truck models
• GDP40VX5/VX6; GDP45SVX5,GDP45VX6,
GDP50-55VX (GDP080-120VX) (H813)
• GDP60-70VX (GDP135-155VX) (E878)
See Figure 17 for lift truck model
• GDP40VX5/VX6; GDP45SVX5, GDP45VX6;
GDP50-55VX (GDP080-120VX) (J813, K813)
See Figure 18 for lift truck model
• GDP60-70VX (GDP135-155VX) (F878)
• GDP60VX, GDP70VX, GP70VXS6
(GDP135VX. GDP155VX, GP155VXS) (G878)
• GP60VX, GP70VX, GP70SVX, GP70SVX9,
GP80SVX (GP135VX, GP155VX, GP155SVX,
GP170SVX) (H878)
1. HOSE CLAMP
2. RETAINING CLAMP
3. AIR INTAKE HOSE

Figure 17. Air Intake Hoses for Lift Truck Model

GDP40VX5/VX6; GDP45SVX5, GDP45VX6;
GDP50-55VX (GDP080-120VX) (J813, K813)

14
0600 YRM 1579 Cylinder Head Assembly Repair

1. HOSE CLAMP
2. RETAINING CLAMP
3. AIR INTAKE HOSE
1. ADJUSTMENT BOLT
Figure 18. Air Intake Hoses for Lift Truck Models 2. ADJUSTER BRACKET
GDP60-70VX (GDP135-155VX) (F878) and 3. RETAINING NUT
GDP60VX, GDP70VX, GP70VXS6 (GDP135VX. 4. MOUNTING BOLT
5. WASHER
GDP155VX, GP155VXS) (G878), GP60VX, GP70VX, 6. MOUNTING BRACKET
GP70SVX, GP70SVX9, GP80SVX (GP135VX, 7. ALTERNATOR
GP155VX, GP155SVX, GP170SVX) (H878)
Figure 19. Alternator Mounting and Adjustment
NOTE: Tag wiring connectors and wiring harness
before removal to aid during installation. 6. Remove three mounting bolts, three retaining
4. Tag and disconnect connectors for engine wiring nuts, mounting bracket and alternator from lift
harness. Move harness aside for better access. truck. See Figure 19.

5. Loosen adjustment bolt for alternator and release 7. Remove three bolts and idler assembly from
tension on serpentine belt. Remove serpentine water pump assembly. See Figure 20.
belt. See Figure 19.

15
Cylinder Head Assembly Repair 0600 YRM 1579

1. IDLER ASSEMBLY
2. BOLT 1. CAPSCREW
3. PULLEY 2. FUEL FILTER ASSEMBLY
4. SPACER 3. INTAKE MANIFOLD
5. COLLAR
6. WATER FLANGE Figure 21. Fuel Filter Assembly
7. WATER PUMP
11. Remove boost compensator hose and fuel
Figure 20. Engine Pulleys
overflow return hose from fuel injection pump.
8. Remove eight bolts, collar, spacer, and two fan See Figure 22.
pulleys from water pump and water flange. See
12. Disconnect lubricating pipe from block just below
Figure 20.
injection pump. See Figure 22.
9. Tag and disconnect fuel hoses from fuel filter.

10. Remove two capscrews holding fuel filter housing

assembly to intake manifold. Remove fuel filter
assembly. See Figure 21.

1. BOOST COMPENSATOR HOSE

2. FUEL OVERFLOW RETURN HOSE
3. LUBRICATING PIPE

Figure 22. Fuel Lines

16
0600 YRM 1579 Cylinder Head Assembly Repair

13. Remove valve cover, fuel injectors and related

parts. See Valve Covers and Fuel Injectors,
Remove section of this manual.

14. Remove fuel injection pump. See Fuel System

Repair section for procedures.

15. Loosen two hose clamps and remove hose from

water pump and oil cooler tube. See Figure 23.

16. Loosen two clamps and remove hose from oil

cooler tube and oil cooler. See Figure 23.

17. Remove oil cooler pipe bolt from engine block.

Remove oil cooler pipe from engine block. See
Figure 23.
1. WATER FLANGE ASSEMBLY
2. CLAMP
3. BYPASS HOSE
4. BOLT
5. GASKET
6. CYLINDER HEAD

Figure 24. Water Flange

21. Remove two bolts, clamp and lifting eye bracket

from cylinder head. See Figure 25.

1. CLAMP
2. HOSE
3. OIL COOLER PIPE
4. BOLT
5. OIL COOLER
6. WATER PUMP

Figure 23. Water Pump Components

18. Loosen two clamps and remove coolant by pass

hose from water pump and water flange
assembly. See Figure 24.

19. Remove water pump. See Cooling System Repair

section for procedures.

20. Remove four bolts, water flange assembly, and

gasket from cylinder. Discard gasket. See
Figure 24.

1. LIFTING EYE BRACKET

2. BOLT
3. STUD
4. FLANGE NUT
5. CLAMP
6. CYLINDER HEAD

Figure 25. Lifting Eye Bracket

17
Cylinder Head Assembly Repair 0600 YRM 1579

22. Remove bolt, flange nut, and lifting eye bracket

from cylinder head. See Figure 25.

23. Remove eight flange bolts, intake manifold and

gasket from cylinder head. Discard gasket. See
Figure 26.

1. DIPSTICK
2. CAPSCREW
3. DIPSTICK TUBE
4. O-RING
5. GUIDE
6. ENGINE BLOCK
7. EXHAUST MANIFOLD
1. INTAKE MANIFOLD ASSEMBLY
2. FLANGE BOLT Figure 27. Engine Oil Dipstick
3. GASKET
4. CYLINDER HEAD 27. Remove two banjo bolts, two washer sets and
turbocharger oil supply line. Discard washer sets.
Figure 26. Intake Manifold See Figure 28.

NOTE: Have container that will hold at least 28. Remove two capscrews, two clamps, oil drain
13.5 liter (14 gal). tube, hose and gasket from turbocharger and
24. Remove oil pan drain plug and drain engine oil block. Discard gasket. See Figure 28.
into container.

25. Remove capscrew from dipstick tube and exhaust

manifold. See Figure 27.

26. Remove dipstick, dipstick tube, O-ring, and

dipstick tube guide from engine block. Discard O-
ring. See Figure 27.

18
0600 YRM 1579 Cylinder Head Assembly Repair

1. OIL FILTER
2. CLAMP
3. HOSE
4. OIL COOLER JOINT
1. BANJO BOLT 5. OIL COOLER
2. WASHER SET 6. O-RING
3. OIL SUPPLY LINE 7. ENGINE BLOCK
4. CAPSCREW
5. CLAMP Figure 29. Oil Cooler
6. DRAIN TUBE
7. HOSE
8. GASKET 32. Remove six flange nuts, two flange bolts, gasket
and turbocharger from exhaust manifold. Discard
Figure 28. Turbocharger Oil Lines gasket. See Figure 30.

29. Remove engine oil filter from oil cooler. See

Figure 29.

30. Remove two clamps and hose from oil cooler and
engine block. See Figure 29.

31. Remove oil cooler joint, oil cooler and O-ring from
engine block. Discard O-ring. See Figure 29.

19
Cylinder Head Assembly Repair 0600 YRM 1579

Frozen CCV systems that have allowed oil to reach

the turbocharger will require the CCV and exhaust
systems to be cleaned. Excessive amounts of oil
that pass into the after-treatment systmem can
result in the DOC/DPF/SCR being damaged.
How to prevent the CCV system from freezing:
Use the proper viscosity oil for the winter
months.
Use a CCV heater (available in kits).
It is still possible to experience freeze up with a
heater kit if the proper oil viscosity is not being
used.

33. Remove two flange bolts from exhaust manifold.

See Figure 31.

34. Remove six flange nuts, gasket and exhaust

manifold from cylinder head. Discard gasket. See
Figure 31.

1. TURBOCHARGER
2. FLANGE NUT
3. FLANGE BOLT
4. GASKET
5. EXHAUST MANIFOLD
6. STUD

Figure 30. Turbocharger

ALERT
In the event that oil is found in the turbocharger
and exhaust, there is a good possibilty that the
issue resides in the breather filter canister and not
the turbocharger itself. When the breather filter 1. FLANGE BOLT
freezes, oil can work its way back through the 2. FLANGE NUT
Closed Crankcase Ventilation (CCV) system into 3. EXHAUST MANIFOLD
4. GASKET
the air inlet that is in front of the turbocharger. 5. CYLINDER HEAD
If oil is found in any of the following checks, it is
likely that the CCV system has frozen: Figure 31. Exhaust Manifold
Check the CCV tubes, hoses, and air feed 35. Remove rocker arm assembly. See Rocker Arm
adapter for signs of oil. Assembly, Remove.
Remove the breather filter from the canister
for inspection. If ice or debris is found, the 36. Remove eighteen cylinder head bolts in sequence
breather should be replaced. shown, from one to eighteen. See Figure 32.
Verify the engine oil viscosity.
If oil is found in the CCV tubes, hoses, air
feed adapter, or ice accumulation is present
in the breather, confirm that oil has not
reached the turbocharger.

20
0600 YRM 1579 Cylinder Head Assembly Repair

38. Remove eight lifters from crankcase. See

Figure 34.

A. TIMING GEAR CASE END

B. FLYWHEEL END

Figure 32. Head Bolt Pattern

NOTE: There are three cylinder head gaskets

available (a, b, or c) for this engine application. Take
note which one is being used during removal. See
Figure 33.

1. LIFTERS
2. CRANKCASE

Figure 34. Lifters

Disassemble
Valves and Valve Springs, Remove
1. Remove four valve arms, four valve arm pads and
four valve arm shafts from cylinder head. See
A. TIMING GEAR CASE END Figure 35.
B. FLYWHEEL END
2. Using a valve spring compressor tool, compress
1. HEAD GASKET valve springs.

Figure 33. Head Gasket 3. Remove valve keepers and valve cap from end of
valve. See Figure 35.
37. Remove cylinder head and gasket from engine
block. Discard gasket.

21
Cylinder Head Assembly Repair 0600 YRM 1579

A. EXHAUST VALVE GUIDE LOCATION C. VALVE ARM SHAFT LOCATION

B. INTAKE VALVE ARM LOCATION D. INTAKE VALVE GUIDE LOCATION

1. INTAKE VALVE 12. ROCKER ARM BRACKET

2. EXHAUST VALVE 13. C-CLIP
3. VALVE ARM SHAFT 14. WASHER
4. VALVE GUIDE 15. ROCKER ARM
5. VALVE STEM SEAL 16. ADJUSTING SCREW
6. SPRING 17. LOCK NUT
7. SPRING RETAINER 18. FLANGE BOLT
8. VALVE KEEPER 19. ROCKER ARM SHAFT
9. VALVE CAP 20. SLOTTED SCREW
10. VALVE ARM 21. SPRING PIN
11. VALVE ARM PAD

Figure 35. Valves and Valve Springs

4. Slowly release tension on valve spring. 6. Repeat this procedure until all intake and exhaust
valve springs and valve stem seals are removed.
5. Remove spring retainer, valve spring, and valve
stem seal.

22
0600 YRM 1579 Cylinder Head Assembly Repair

NOTE: If existing valves are going to be reinstalled in Clean and Inspect

cylinder head, mark valves so they can be installed in
their original location.
7. Turn cylinder head so exhaust port side faces WARNING
down. Remove intake and exhaust valves from Cleaning solvents can be flammable and toxic and
cylinder head. can cause skin irritation. When using cleaning
solvents, always follow the recommendations of
Valve Guides, Remove the manufacturer.

Press out used valve guide using valve guide

replacing tool. See Figure 36.
WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.

CAUTION
Any part which is found defective as a result of
inspection or any part whose measured value does
not satisfy the standard or limit must be replaced.

CAUTION
Any part determined to not meet the service
standard or limit before the next service, as
determined from the state of current rate of wear,
should be replaced even though the part currently
meets the service standard limit.

CAUTION
Use caution not to scratch the gasket mating
surfaces when cleaning the exhaust manifold and
cylinder head.

A. REMOVAL
B. INSTALLATION CAUTION
Use caution not to scratch the gasket mating
1. VALVE GUIDE INSTALLATION TOOL
2. CYLINDER HEAD surfaces when cleaning the intake manifold and
3. VALVE GUIDE cylinder head.

Figure 36. Valve Guide Removal

CAUTION
Use caution not to scratch the gasket mating
surfaces when cleaning the cylinder head and
cylinder block.

Carefully remove all gasket residue from exhaust

manifold and cylinder head. Inspect exhaust manifold

23
Cylinder Head Assembly Repair 0600 YRM 1579

for scratches, cracks, or any other damage. Repair or Valve Guides

replace as needed.
Visually inspect valve guides for distortions, scoring, or
Carefully remove all gasket residue from intake other damage.
manifold and cylinder head. Inspect intake manifold for
scratches, cracks, or any other damage. Repair or Use a test indicator and micrometer to measure inside
replace as needed. diameter at each end of valve guide. Refer to Engine
Specifications for service limit.
Carefully remove all gasket residue from cylinder head
and cylinder block. Inspect cylinder head for scratches, Valves
cracks, or any other damage. Repair or replace as
needed. Valve Stem Diameter: Use a micrometer to measure
valve stem diameter. Measure valve stem near
Thoroughly clean all components using a nonmetallic combustion end and near opposite end. Refer to
brush and cleaning solvent. Dry parts with compressed Engine Specifications for service limit. See Figure 38.
air. Each part must be free of carbon, metal filings, and
other debris.
Visually inspect parts. Replace any parts that are
obviously discolored, heavily pitted, or otherwise
damaged. Replace parts that do not meet specified
limit.

Cylinder Head
1. Place cylinder head flat and inverted (combustion
A. MEASUREMENT POINTS
side up) on work bench.
Figure 38. Valve Stem Diameter Measurement
2. Use a straight edge and feeler gauge to measure Points
amount of cylinder head distortion. Refer to
Engine Specifications for service limit. See Valve Stem Straightness: Place valve stem on a flat
Figure 37. surface. Roll valve until a gap can be observed
between a portion of valve stem and flat surface. Use
a feeler gauge to measure gap. Refer to Engine
Specifications for service limit. See Figure 39.

Figure 37. Cylinder Head Distortion Check

3. Use Magnaflux method and inspect cylinder head

for cracks. Replace cylinder head if evidence of Figure 39. Valve Stem Straightness Check
fractures are found.

24
0600 YRM 1579 Cylinder Head Assembly Repair

Valve Sink
Insert valves into their proper places in cylinder head
and press them down until they are fully seated. Using
a depth micrometer, measure difference between
cylinder head surface and combustion surface of each
exhaust and intake valve. Refer to Engine
Specifications for service limit. See Figure 40 and
Figure 41.

1. VALVE SEAT

Figure 42. Valve Seat

Roughness or burrs will cause poor seating of a valve.

Visually inspect seating of each valve and determine if
lapping or grinding is needed. Grinding is needed if
cylinder head's seat width exceeds standard limits.
Figure 40. Valve Sink Measurement Refer to Engine Specifications for service limit.
Lap valve seat and cylinder head with a mixture of
valve compound and engine oil.
If valve requires grinding, lap valve after grinding. Be
sure to thoroughly wash parts to remove all grinding
powder or compound.

Valve Springs
Inspect valve springs. If damage or corrosion is seen,
or if measurements exceed specified limits, replace
springs.
Fractures: Check for fractures on inside and outside
portions of springs. If valve spring is fractured, replace
spring.
Corrosion: Check for corrosion of spring material
caused by oxidation.
Figure 41. Valve Sink Squareness: Use a flat surface and a square to check
each spring for squareness. Refer to Engine
Valve Seat Specifications for service limit. See Figure 43.

Always check clearance between valve and valve

guide before correcting valve seat. See Figure 42. If
clearance exceeds limit, replace valve or valve guide
to bring clearance within limit.

25
Cylinder Head Assembly Repair 0600 YRM 1579

Figure 43. Spring Squareness Check

Free Length: Use a caliper to measure length of

spring. Refer to Engine Specifications for service limit.
See Figure 44.

A. REMOVAL
B. INSTALLATION

1. VALVE GUIDE INSTALLATION TOOL

2. CYLINDER HEAD
3. VALVE GUIDE

Figure 45. Valve Guide Installation

Figure 44. Spring Free Length Check
3. Accurately size I.D. of valve guide to specified
Assemble dimension. See Table 2.
Valve Guides, Install Table 2. Valve Guide Specification
1. The valve guides are installed into cylinder head
with an extremely tight press fit. Before installing 7.010 to
valve guides, clean new valve guide and valve Intake 7.025 mm
guide bore and apply oil to them. Valve Valve (0.2760 to
Factory 0.2765 in.)
Guide
Specificati
2. Press fit new valve guide with valve guide Inside 7.010 to
on
replacing tool. See Figure 45. Diameter Exhaust 7.025 mm
Valve (0.2760 to
0.2765 in.)

26
0600 YRM 1579 Cylinder Head Assembly Repair

Valves and Valve Springs, Install

1. Place cylinder head assembly on exhaust port
side.

2. Place all valves in their proper positions, as

marked when disassembled, in cylinder head.

3. Apply clean engine oil to lip of valve stem seal.

Using valve stem seal installation tool, insert a
new valve stem seal on each of valves. See
Figure 46.

1. VALVE STEM SEAL

2. VALVE GUIDE
3. VALVE GUIDE PROTECTION
4. VALVE STEM SEAL PROTECTION
5. CLEARANCE

Figure 47. Valve Stem Seal Clearance

5. Place cylinder head on work bench with

combustion chamber facing down. Install valve
1. VALVE STEM SEAL INSTALLATION TOOL springs and valve spring retainers. See Figure 35.
2. VALVE STEM SEAL
3. VALVE GUIDE
4. CYLINDER HEAD 6. Using valve compressor tool, compress valve
spring.
Figure 46. Valve Stem Seal Installation
7. Install valve keepers and slowly release tension in
4. Measure distance from cylinder head to valve valve spring.
stem seal. Refer to Engine Specifications for
clearance specifications. See Figure 47. 8. Install valve cap.

9. Repeat these procedures until all intake and

exhaust valves are installed.

10. Install four valve shafts, four pads, and four valve
arms. See Figure 35.

Install
1. Lightly oil outside of lifters. Install eight lifters into
crankcase.

2. Carefully clean combustion surface of cylinder

head and top surface of cylinder block.

27
Cylinder Head Assembly Repair 0600 YRM 1579

3. Measure the piston head's protrusion or Use Table 3 to select an applicable cylinder head
recession from crankcase cylinder face in four gasket.
spots per each piston, using a dial gauge, and get
the average of measurements.

Table 3. Selecting A Cylinder Head Gasket

Notch of Cylinder Thickness of Cylinder Head Gasket Kubota Code Piston Head's
Head Gasket Before Tightening After Tightening Number Protrusion or
(Noted At Recession from
Removal) Crankcase Cylinder
Face
2 notches (a) 0.90 mm (0.035 in.) 0.80 mm (0.031 in.) 1G514-03310 -0.070 to +0.490 mm
(-0.00275 to
+0.00192 in.)
1 notch (b) 1.00 mm (0.039 in.) 0.90 mm (0.035 in.) 1G514-03600 +0.050 to +0.149 mm
(+0.00197 to
+0.00586 in.)
Without notch ©) 1.05 mm (0.041 in.) 0.95 mm (0.037 in.) 1G514-03610 +0.050 to +0.200 mm
(+0.00591 to
+0.00787 in.)

4. Place a new cylinder head gasket, as identified in

Table 3, on cylinder block.

5. Place a new cylinder head gasket, as noted

during removal, on engine block.

6. Position cylinder head on cylinder head gasket

and engine block.

7. Lightly oil threads of cylinder head bolts.

8. Install cylinder head bolts in sequence shown A. TIMING GEAR CASE END
B. FLYWHEEL END
(from 1 to 18), using a two stage process: .
On first pass (1 to 18), tighten cylinder head Figure 48. Cylinder Head Torque Sequence
bolts 50 N•m (37 lbf ft). See Figure 48
On second pass (1 to 18), tighten cylinder head 9. Install push rods and rocker arm assembly. See
bolts to 98 to 107 N•m (72 to 80 lbf ft). See Rocker Arm Assembly, Install.
Figure 48.
10. Using six flange nuts, install new exhaust
manifold gasket and exhaust manifold onto
cylinder head. See Figure 31.

11. Install two flange bolts to exhaust manifold and

cylinder head. See Figure 31.

12. Install new gasket, turbocharger, two flange bolts

and six flange nuts onto top of exhaust manifold.
See Figure 30.

28
0600 YRM 1579 Cylinder Head Assembly Repair

13. Install new O-ring, oil cooler and oil cooler joint to 30. Install valve cover, fuel injectors and related parts.
engine block. Tighten oil cooler joint to See Valve Covers and Fuel Injectors, Install.
40 to 44 N•m (29 to 32 lbf ft). See Figure 29.
31. Connect lubricating pipe to engine block just
14. Install hose and two clamps to oil cooler and below injection pump. See Figure 22.
engine block. See Figure 29.
32. Install fuel overflow return hose and boost
15. Install new oil filter onto oil cooler. See Figure 29. compensator hose onto fuel injection pump. See
Figure 22.
16. Install oil drain tube, new gasket, two capscrews,
two clamps, and hose onto turbocharger and 33. Using two capscrews, install fuel filter housing
block. See Figure 28. assembly to intake manifold. See Figure 21.

17. Install turbocharger oil supply line, two washer 34. Connect fuel hoses to fuel filter as noted during
sets and two banjo bolts onto turbocharger. See removal.
Figure 28.
35. Install two fan pulleys, spacer, collar, and eight
18. Install dipstick tube guide, new O-ring, dipstick bolts onto water pump and water flange. See
tube, and dipstick into engine block. See Figure 20.
Figure 27.
36. Install idler assembly and three bolts onto water
19. Install capscrew to dipstick tube and exhaust pump assembly. See Figure 20.
manifold. See Figure 27.
37. Install alternator, mounting bracket, three
20. Install intake manifold, new gasket and eight retaining nuts, and three mounting bolts onto
flange bolts to cylinder head. See Figure 26. engine. See Figure 19.

21. Install lifting eye bracket, flange nut and bolt to 38. Put serpentine belt on pulley's. Using a pry bar,
cylinder head. See Figure 25. pull alternator into position and put tension onto
serpentine belt. Tighten alternator adjustment
22. Install lifting eye bracket, clamp and two bolts to bolt. See Figure 19.
cylinder head. See Figure 25.
39. Attach wiring harness to connectors as noted
23. Install new gasket, water flange assembly and during removal.
four bolts to cylinder head. See Figure 24.
40. Install air intake hoses, two retaining clamps, and
24. Install water pump. See Cooling System Repair two hose clamps onto air cleaner and
section in this manual. turbocharger. See Figure 16.

25. Install coolant by pass hose and two clamps onto 41. Install lower radiator hose.
water pump and water flange assembly. See
Figure 24.
CAUTION
26. Using a bolt, install oil cooler pipe into engine Additives may damage the cooling system. Before
block. See Figure 23. using additives, contact your local Yale dealer.
27. Install hose and two clamps onto oil cooler and oil 42. Fill cooling system with coolant. For correct
cooler pipe. See Figure 23. coolant amount and type refer to
28. Install hose and two clamps onto water pump and Periodic Maintenance 8000YRM1558 for lift
oil cooler pipe. See Figure 23. truck models
• GDP 40VX5, 40VX6, 45VX6, 45SVX5, 50VX,
29. Install fuel injection pump. See Fuel System 55VX (GDP 080-120VX) (H813)
Repair section for procedures.

29
Cylinder Head Assembly Repair 0600 YRM 1579

Periodic Maintenance 8000YRM1583 for lift

46. Start engine and check for leaks.
truck models
• GDP60VX, GDP70VX (GDP135VX, 47. Change engine oil and oil filter. See Lubrication
GDP155VX) (E878) System Repair, Engine Oil and Oil Filter Change.
Periodic Maintenance 8000YRM1604 for lift
truck models
WARNING
• GDP40VX5/VX6; GDP45SVX5, GDP45VX6;
DO NOT remove the radiator cap from the radiator
GDP50-55VX (GDP080, 090, 100, 110, 120VX)
(J813) when the engine is hot. When the radiator cap is
removed, pressure will release from the coolant
Periodic Maintenance 8000YRM1902 for lift system. If the coolant system is hot, the steam and
truck models boiling coolant can cause severe burns.
• GDP40VX5/VX6; GDP45SVX5, GDP45VX6;
GDP50-55VX (GDP080-120VX) (K813)
Periodic Maintenance 8000YRM1957 for lift WARNING
truck model The radiator or other parts of the cooling system
may be hot or under pressure and can cause
• GDP60-70VX (GDP135-155VX) (F878)
serious injury. Wait 30 minutes for the radiator and
• GDP60VX, GDP70VX, GP70VXS6 engine to cool before performing maintenance to
(GDP135VX. GDP155VX, GP155VXS) (G878) the cooling system. After 30 minutes, do a touch
• GP60VX, GP70VX, GP70SVX, GP70SVX9, test by touching the radiator with your hand. If the
GP80SVX (GP135VX, GP155VX, GP155SVX, radiator is still hot to the touch, wait another 30
GP170SVX) (H878) minutes before attempting any maintenance to the
cooling system.
43. Install radiator cap.

44. Fill engine oil. See Lubrication System Repair,

Engine Oil and Oil Filter Change. CAUTION
Additives may damage the cooling system. Before
45. Connect negative battery cable. using additives, contact your local Yale dealer.

48. Stop engine. If coolant is hot, allow engine time to

WARNING cool. Check coolant level and fill as required
During engine operation, be careful not to touch between ADD and FULL marks on coolant
the fan, pulleys, or drive belts. Contact with these reservoir.
parts can cause serious injury.

WARNING
The radiator or other parts of the cooling system
may be hot or under pressure and can cause
serious injury.

30
0600 YRM 1579 Timing Gear Case and Timing Gears Repair

Timing Gear Case and Timing Gears Repair

TIMING GEAR CASE COVER Legend for Figure 49.

Remove 1. TIMING GEAR CASE COVER

2. BOLT
1. Remove engine. 3. TIMING GEAR CASE PLATE
See Frame 0100YRM1243 for lift truck models 4. FRONT OIL SEAL
5. ENGINE BLOCK
• GDP40VX5/VX6; GDP45SVX5,GDP45VX6,
GDP50-55VX (GDP080-120VX) (H813, J813) 6. Remove timing gear case cover.
See Frame 0100YRM1581 for lift truck models
7. Remove front oil seal from timing gear case
• GDP60-70VX (GDP135-155VX) (E878) cover. See Figure 49.
See Frame 0100YRM1891 for lift truck models
• GDP40VX5/VX6; GDP45SVX5, GDP45VX6;
Clean and Inspect
GDP50-55VX (GDP080-120VX) (K813)
See Frame 0100YRM1948 for lift truck models WARNING
• GDP60-70VX (GDP135-155VX) (F878) Cleaning solvents can be flammable and toxic and
GDP60VX, GDP70VX, GP70VXS6 can cause skin irritation. When using cleaning
•
(GDP135VX. GDP155VX, GP155VXS) (G878) solvents, always follow the recommendations of
the manufacturer.
• GP60VX, GP70VX, GP70SVX, GP70SVX9,
GP80SVX (GP135VX, GP155VX, GP155SVX,
GP170SVX) (H878)
WARNING
2. Remove coolant fan, serpentine belt, and water Compressed air can move particles so that they
pump. See Cooling System Repair. cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
3. Remove bolt and washer retaining crankshaft away from all personnel. Wear protective goggles
pulley. or a face shield to prevent injury to the eyes.
4. Using a gear puller, remove crankshaft pulley. Clean all old sealant from timing gear case cover and
timing gear case. Clean timing gear case cover in
5. Remove bolts retaining timing gear case cover cleaning solvent. Dry timing gear case cover with
and plate to engine block. See Figure 49. compressed air. Inspect for wear, cracks, and any
other damage. If necessary, replace timing gear case
cover.

Install
1. Apply a continuous bead of Three Bond Liquid
Gasket (Yale P/N 580062478 ) to outside
diameter of a new front oil seal.

2. Using a special tool, install new front oil seal into

timing gear case cover. Apply lithium grease to lip
of front oil seal. See Figure 50.

Figure 49. Timing Gear Case Cover

31
Timing Gear Case and Timing Gears Repair 0600 YRM 1579

8. Fill engine oil to correct level. For correct oil

amount and type refer to
Periodic Maintenance 8000YRM1558 for lift
truck models
• GDP40VX5, GDP40VX6, GDP45VX6,
GDP45SVX5, GDP50-55VX (GDP 080-120VX)
(H813)
Periodic Maintenance 8000YRM1583 for lift
truck models
• GDP60-70VX (GDP135-155VX) (E878)
Periodic Maintenance 8000YRM1604 for lift
truck models
Figure 50. Front Oil Seal Installation GDP40VX5, GDP40VX6, GDP45VX6,
•
GDP45SVX5, GDP50-55VX (GDP 080-120VX)
3. Apply a continuous bead of Three Bond Liquid (J813)
Gasket (Yale P/N 580062478 ) to mating surface
of timing gear case cover and timing gear case Periodic Maintenance 8000YRM1902 for lift
plate. truck models
• GDP40VX5/VX6; GDP45SVX5, GDP45VX6;
4. Place timing gear case cover and plate in position GDP50-55VX (GDP080-120VX) (K813)
on engine block and install retaining bolts.
Periodic Maintenance 8000YRM1957 for lift
Tighten bolts to 24 to 27 N•m (18 to 20 lbf ft).
truck models
5. Install crankshaft pulley and bolt to crankshaft • GDP60-70VX (GDP135-155VX) (F878)
pulley. Tighten bolt to • GDP60VX, GDP70VX, GP70VXS6
255 to 274 N•m (188 to 202 lbf ft). (GDP135VX. GDP155VX, GP155VXS) (G878)
• GP60VX, GP70VX, GP70SVX, GP70SVX9,
6. Install water pump, serpentine belt, and coolant GP80SVX (GP135VX, GP155VX, GP155SVX,
fan. See Cooling System Repair. GP170SVX) (H878)
7. Install engine. 9. Start engine and check for leaks.
See Frame 0100YRM1243 for lift truck models
GDP40VX5/VX6; GDP45SVX5,GDP45VX6,
TIMING GEARS
•
GDP50-55VX (GDP080-120VX) (H813, J813) NOTE: For removal of fuel injection pump drive gear,
See Frame 0100YRM1581 for lift truck models refer to Fuel System Repair.

• GDP60-70VX (GDP135-155VX) (E878) Before removing any of timing gears, rotate crankshaft
to align alignment marks on gears as follows (see
See Frame 0100YRM1891 for lift truck models Figure 51):
• GDP40VX5/VX6; GDP45SVX5, GDP45VX6; • Align mark "A" on camshaft gear with mark "A"
GDP50-55VX (GDP080-120VX) (K813) on idler gear 1.
See Frame 0100YRM1948 for lift truck models • Align mark "B" on crankshaft gear with mark "B"
• GDP60-70VX (GDP135-155VX) (F878) on idler gear 1.
• Align mark "C" on idler gear 1 with mark "C" on
• GDP60VX, GDP70VX, GP70VXS6
idler gear 2.
(GDP135VX. GDP155VX, GP155VXS) (G878)
• GP60VX, GP70VX, GP70SVX, GP70SVX9,
GP80SVX (GP135VX, GP155VX, GP155SVX,
GP170SVX) (H878)

32
0600 YRM 1579 Timing Gear Case and Timing Gears Repair

NOTE: TIMING GEARS FOR LIFT TRUCK MODELS 1. OIL PUMP DRIVE GEAR
GDP40VX5/VX6; GDP45SVX5,GDP45VX6, 2. CRANKSHAFT GEAR
3. CRANKSHAFT
GDP50-55VX (GDP080-120VX) (H813) AND 4. KEY
GDP60-70VX (GDP135-155VX) (E878) SHOWN.
GDP40VX5/VX6; GDP45SVX5, GDP45VX6; Figure 52. Crankshaft Gear
GDP50-55VX (GDP080-120VX) (J813, K813),
GDP60-70VX (GDP135-155VX) (F878), AND Install
GDP60VX, GDP70VX, GP70VXS6 (GDP135VX.
GDP155VX, GP155VXS) (G878), GP60VX, GP70VX, 1. Install key into crankshaft.
GP70SVX, GP70SVX9, GP80SVX (GP135VX,
GP155VX, GP155SVX, GP170SVX) (H878) ARE 2. Align alignment mark "B" on crankshaft gear with
SIMILAR. alignment mark "B" on idler gear 1 and install
crankshaft gear onto crankshaft.
1. CAMSHAFT GEAR
2. CRANKSHAFT GEAR 3. Verify that all alignment marks are properly
3. IDLER GEAR 1 aligned. Figure 51.
4. OIL PUMP GEAR
5. IDLER GEAR 2 4. Install timing gear case cover. See Timing Gear
Case Cover, Install.
Figure 51. Timing Gear Alignment
Idler Gear
Crankshaft Gear
Remove
Remove
NOTE: There are two idler gears on this engine (idler
1. Remove timing gear case cover. See Timing Gear gear 1 and idler gear 2). The repair procedure is same
Case Cover, Remove. for both.
2. Verify that gears are properly aligned with 1. Remove timing gear case cover. See Timing Gear
alignment marks. See Figure 51. Case Cover, Remove.
3. Remove oil pump drive gear. See Figure 52. 2. Verify that gears are properly aligned with
alignment marks. See Figure 51.
NOTE: If using a gear puller to remove crankshaft
gear, be careful not to damage threads in end of 3. Remove bolts from idler gear shaft. See
crankshaft. Figure 53.
4. Remove crankshaft gear. See Figure 52.
4. Remove idler gear shaft, alignment pin, idler gear,
5. Remove key from crankshaft. idler gear collar, and bushing.

33
Timing Gear Case and Timing Gears Repair 0600 YRM 1579

Install
1. Lubricate idler gear bushing and idler gear shaft
with clean engine oil.

NOTE: Make sure oil hole in bushing is facing toward

top of engine.
2. Align alignment mark "C" on idler gear 1 with
alignment mark "C" on idler gear 2 and alignment
mark "A" on idler gear 1 with alignment mark "A"
on camshaft gear. Install idler gear, bushing, and
idler gear shaft.

3. Verify that all alignment marks are properly

1. ENGINE BLOCK aligned. See Figure 51.
2. IDLER GEAR 1
3. IDLER GEAR 2 4. Install idler gear retaining bolts.
4. IDLER GEAR COLLAR
5. BUSHING
6. ALIGNMENT PIN 5. Install timing gear case cover. See Timing Gear
7. IDLER GEAR SHAFT Case Cover, Install.
8. BOLT
Camshaft Gear
Figure 53. Idler Gear
Remove
Inspect 1. Remove timing gear case cover. See Timing Gear
1. Measure outside diameter of idler gear shaft. Case Cover, Remove.
Refer to Engine Specifications for service limit.
See Figure 54. 2. Verify that gears are properly aligned with
alignment marks. See Figure 51.
2. Measure inside diameter of idler gear. Refer to
Engine Specifications for service limit. See 3. Remove four capscrews and pulsar gear from
Figure 54. camshaft gear. See Figure 55.

4. Using a gear puller, remove camshaft gear. See

Figure 55.

5. Remove key from camshaft.

1. OUTSIDE DIAMETER
2. IDLER GEAR SHAFT
3. INSIDE DIAMETER
4. IDLER GEAR

Figure 54. Idler Gear and Shaft Measurement

34
0600 YRM 1579 Timing Gear Case and Timing Gears Repair

TIMING GEAR CASE

Remove
1. Remove engine.
See Frame 0100YRM1243 for lift truck models
• GDP40VX5/VX6, GDP45SVX5, GDP45VX6,
GDP50-55VX (GDP080-120VX) (H813, J813)
See Frame 0100YRM1581 for lift truck models
• GDP60-70VX (GDP135-155VX) (E878)
See Frame 0100YRM1891 for lift truck models
• GDP40VX5/VX6; GDP45SVX5, GDP45VX6;
GDP50-55VX (GDP080-120VX) (K813)
See Frame 0100YRM1948 for lift truck models
• GDP60-70VX (GDP135-155VX) (F878)
• GDP60VX, GDP70VX, GP70VXS6
(GDP135VX. GDP155VX, GP155VXS) (G878)
1. ENGINE BLOCK
2. CAMSHAFT GEAR • GP60VX, GP70VX, GP70SVX, GP70SVX9,
3. PULSE GEAR GP80SVX (GP135VX, GP155VX, GP155SVX,
4. CAPSCREW GP170SVX) (H878)
5. BOLT
6. RETAINER 2. Remove timing gear case cover. See Timing Gear
7. KEY
8. CAMSHAFT Case Cover, Remove.

Figure 55. Camshaft Gear 3. Remove fuel injection pump. See Fuel System
Repair.
Install
4. Remove timing gears. See Timing Gears.
1. Install key into camshaft.
5. Remove three bolts holding gear case plate to
2. Align alignment mark "A" on camshaft gear with cylinder block. Remove gear case plate. See
alignment mark "A" on idler gear and install Figure 56.
camshaft gear onto camshaft.
6. Remove two O-rings from cylinder block and
3. Install pulse gear and four capscrews onto discard.
camshaft gear. Tighten capscrews to
4.7 to 5.6 N•m (42 to 50 lbf in).

4. Install timing gear case cover. See Timing Gear

Case Cover, Install.

35
Timing Gear Case and Timing Gears Repair 0600 YRM 1579

cover and gear case with compressed air. Inspect for

wear, cracks, and any other damage. Replace
components as necessary.

Install
1. Install two new O-rings in cylinder block.

NOTE: Perform Step 2 and Step 3 for lift truck models

GDP40VX5/VX6; GDP45SVX5,GDP45VX6,
GDP50-55VX (GDP080-120VX) (H813) .
2. Apply a continuous bead of Three Bond Liquid
Gasket (Yale P/N 580062478 ) to mating surface
of timing gear case plate.

3. Position gear case plate on cylinder block and

install retaining bolts. Tighten to
24 to 27 N•m (18 to 20 lbf ft).

4. Install timing gears. See Timing Gears.

5. Install timing gear case cover. See Timing Gear

A. THREE BOLTS HOLDING GEAR CASE PLATE
TO CYLINDER BLOCK Case Cover, Install.

1. TIMING GEAR CASE PLATE 6. Install fuel injection pump. See Fuel System
2. BOLT Repair.
3. O-RINGS
4. CYLINDER BLOCK 7. Install engine.

Figure 56. Timing Gear Case See Frame 0100YRM1243 for lift truck models
• GDP40VX5/VX6; GDP45SVX5,GDP45VX6,
Clean and Inspect GDP50-55VX (GDP080-120VX) (H813, J813)
See Frame 0100YRM1581 for lift truck models
WARNING • GDP60-70VX (GDP135-155VX) (E878)
Cleaning solvents can be flammable and toxic and See Frame 0100YRM1891 for lift truck models
can cause skin irritation. When using cleaning
• GDP40VX5/VX6; GDP45SVX5, GDP45VX6;
solvents, always follow the recommendations of
GDP50-55VX (GDP080-120VX) (K813)
the manufacturer.
See Frame 0100YRM1948 for lift truck models
• GDP60-70VX (GDP135-155VX) (F878)
WARNING • GDP60VX, GDP70VX, GP70VXS6
Compressed air can move particles so that they (GDP135VX. GDP155VX, GP155VXS) (G878)
cause injury to the user or to other personnel. • GP60VX, GP70VX, GP70SVX, GP70SVX9,
Make sure that the path of the compressed air is GP80SVX (GP135VX, GP155VX, GP155SVX,
away from all personnel. Wear protective goggles GP170SVX) (H878)
or a face shield to prevent injury to the eyes.
8. Change engine oil and oil filter. See Lubrication
Clean all old sealant from timing gear case cover and System Repair, Engine Oil and Oil Filter Change.
timing gear case. Clean timing gear case cover and
gear case in cleaning solvent. Dry timing gear case 9. Start engine and check for leaks.

36
0600 YRM 1579 Drive Train, Camshaft, and Cylinder Block Repair

Drive Train, Camshaft, and Cylinder Block Repair

REMOVE 10. Remove oil pump. See Lubrication System
Repair.
1. Remove engine.
See Frame 0100YRM1243 for lift truck models NOTE: DO NOT remove camshaft gear at this time.
• GDP40VX5/VX6; GDP45SVX5, GDP45VX6; 11. Remove crankshaft gear and idler gear. See
GDP50-55VX (GDP080-120VX) (J813, K813) Timing Gear Case and Timing Gears Repair.
See Frame 0100YRM1891 for lift truck models
DISASSEMBLE
• GDP40VX5/VX6; GDP45SVX5, GDP45VX6;
GDP50-55VX (GDP080-120VX) (K813) Pistons and Connecting Rods
See Frame 0100YRM1581 for lift truck models NOTE: It is necessary to rotate crankshaft to access
• GDP60-70VX (GDP135-155VX) (E878) some of connecting rod assemblies at bottom dead
center position.
See Frame 0100YRM1948 for lift truck models
1. Using a feeler gauge, measure connecting rod
• GDP60-70VX (GDP135-155VX) (F878) thrust clearance. See Figure 57. Refer to Engine
• GDP60VX, GDP70VX, GP70VXS6 Specifications for standard limit. If measurement
(GDP135VX. GDP155VX, GP155VXS) (G878) is out of specification, either crankshaft or
• GP60VX, GP70VX, GP70SVX, GP70SVX9, connecting rod must be replaced.
GP80SVX (GP135VX, GP155VX, GP155SVX,
GP170SVX) (H878)
Remove starter. See Electrical Equipment Repair.

2. Remove flywheel and flywheel housing. See

Flywheel and Flywheel Housing.

3. Remove alternator. See Electrical Equipment

Repair.

4. Remove water pump. See Cooling System

Repair.

5. Remove fuel injection pump. See Fuel System

Repair.

6. Remove cylinder head. See Cylinder Head

Assembly Repair.

7. Remove oil pan. See Lubrication System Repair.

Figure 57. Connecting Rod Thrust Clearance
8. Remove oil suction tube. See Lubrication System
Repair. 2. Remove two bolts from one of connecting rod
caps. See Figure 58.
9. Remove timing gear case cover. See Timing Gear
Case and Timing Gears Repair.

37
Drive Train, Camshaft, and Cylinder Block Repair 0600 YRM 1579

Crankshaft
1. Remove eight bolts holding rear oil seal assembly
to engine block. Remove rear oil seal assembly.
See Figure 59.

1. PISTON RINGS 6. CONNECTING ROD

2. PISTON 7. CONNECTING ROD
3. WRIST PIN CAP
4. SNAP RING 8. BEARING HALVES
5. WRIST PIN 9. BOLT
BUSHING
1. BOLT
Figure 58. Piston and Connecting Rod 2. REAR MAIN SEAL HOUSING
3. REAR MAIN SEAL
4. CYLINDER BLOCK
3. Remove connecting rod cap.
Figure 59. Rear Main Seal
4. Remove bearing halves.
2. Remove rear main seal.
5. Tap piston through cylinder and remove piston
assembly with connecting rod. 3. Measure crankshaft side gap using following
method:
6. Mark connecting rod cap and connecting rod and
place assembly on a bench. a. Set a dial indicator with it's point on end of
crankshaft. Move crankshaft to front and rear
7. Remove piston rings from piston. to measure side clearance. See Figure 60.
8. Remove snap rings retaining wrist pin.

9. Remove wrist pin.

10. Remove piston from connecting rod.

11. Remove wrist pin bushing from connecting rod.

12. Repeat Step 2 through Step 11 for remaining

pistons and piston rods.

38
0600 YRM 1579 Drive Train, Camshaft, and Cylinder Block Repair

Description Factory Allowable Limit

Specification Dimension Minimum Maximum
Side Clearance 0.15 to 0.31 mm 0.50 mm Oversize Journal 0.2 mm 0.4 mm
of Crankshaft (0.0059 to (0.020 in.) (0.008 in.) (0.016 in.)
0.012 in.)
Dimension A 169.10 to 169.2 to
169.15 mm 169.25 mm
Figure 60. Crankshaft Side Gap Measurement With (6.6575 to (6.6615 to
Dial Indicator 6.6594 in.) 6.6633 in.)
b. If measurement is more than allowable limit, Dimension B 29.20 to 29.40 to
replace thrust bearings. If same dimension 29.25 mm 29.45 mm
bearing is not applicable because of journal (1.150 to (1.158 to
wear, replace it with an oversize one. See 1.151 in.) 1.159 in.)
Figure 61. Dimension C 2.8 to 3.2 mm 2.8 to 3.2 mm
(0.11 to 0.12 in.) (0.11 to 0.12 in.)
radius radius

Figure 61. Crankshaft Measurement With Oversize

Journal

NOTE: Be sure to note markings on main bearing

caps, or mark them yourself, so they can be reinstalled
in same location as they were removed.
NOTE: The arrows on main bearing caps point to
flywheel end of engine.
4. Remove bolts holding main bearing caps.
Remove main bearing caps. See Figure 62.

39
Drive Train, Camshaft, and Cylinder Block Repair 0600 YRM 1579

1. BOLT 4. BEARING HALVES

2. MAIN BEARING CAP 5. THRUST BEARING
3. CYLINDER BLOCK 6. CRANKSHAFT

Figure 62. Crankshaft

5. Remove bearing halves and thrust bearings. See

Figure 62.

6. Remove crankshaft from cylinder block.

Camshaft
1. Using a feeler gauge, measure camshaft side
gap. Refer to Engine Specifications for service
limit. See Figure 63.

1. THRUST METAL
2. CAMSHAFT
3. SIDE GAP
4. CAMSHAFT PULLEY

Figure 63. Camshaft Side Gap

2. Using a gear puller, remove camshaft gear. See

Figure 64.

40
0600 YRM 1579 Drive Train, Camshaft, and Cylinder Block Repair

3. Remove key from camshaft. 6. Slowly pull camshaft out of cylinder block.

4. Remove two bolts holding thrust plate and NOTE: Be sure to mark tappets so they can be
remove thrust plate. installed in same location as they were removed.
7. Remove tappets.
NOTE: If engine is not installed on an engine stand,
position engine with mounting flange (flywheel end)
8. Remove three flange bolts and timing gear case
facing down. Rotate camshaft a few turns to bump
plate. See Timing Gear Case and Timing Gears
tappets out of way to prevent tappets from interfering
Repair.
with removal of camshaft.
5. With engine installed on an engine stand, rotate
engine so gravity causes the tappets to drop
away from camshaft lobes.

A. THREE BOLTS HOLDING GEAR CASE PLATE TO CYLINDER BLOCK

1. CYLINDER BLOCK 7. CAPSCREW

2. O-RING 8. PULSAR GEAR
3. CAMSHAFT 9. CAMSHAFT GEAR
4. BOLT 10. TIMING CASE PLATE
5. THRUST PLATE 11. FLANGE BOLT
6. KEY

Figure 64. Camshaft

CLEAN AND INSPECT

WARNING
Compressed air can move particles so that they
WARNING cause injury to the user or to other personnel.
Cleaning solvents can be flammable and toxic and Make sure that the path of the compressed air is
can cause skin irritation. When using cleaning away from all personnel. Wear protective goggles
solvents, always follow the recommendations of or a face shield to prevent injury to the eyes.
the manufacturer.

41
Drive Train, Camshaft, and Cylinder Block Repair 0600 YRM 1579

Clean all old sealant from all parts. Clean all parts in e. Measure inside diameter of cylinder number
cleaning solvent. Dry parts with compressed air. Each one, near bottom of cylinder (c) and in (d)
part must be free of carbon, metal filings, old sealant, direction. Record that measurement as data j.
and other debris. Inspect for wear, cracks, and any
other damage. Replace components as necessary. f. Measure inside diameter of cylinder number
one, near bottom of cylinder (c) and in (e)
Cylinder Block direction. Record that measurement as data k.
1. Verify that oil holes are clear and unobstructed. g. Roundness: Roundness for cylinder number
Clear any oil holes as needed. one is calculated as follows:
2. Check for discoloration or evidence of cracks. If f-g = X
evidence of a fracture is found, use color check h-I = Y
method or Magnaflux method to determine if j-k = Z
cylinder block is fractured.
X is difference between f and g measurements
3. Inspect cylinder roundness and cylindricity for at top of cylinder.
evidence of distortions. Collect and record Y is difference between h and I measurements
measurements. See Figure 65 and Table 4. at center/middle of cylinder.
Z is difference between j and k measurements
at bottom of cylinder.
Select greatest of values X, Y and Z, then
record it as V. This value represents
roundness of cylinder.

h. Cylindricity: Cylindricity for cylinder number

one is calculated as follows:
Select least value of values X, Y and Z
record that value as S. Complete
calculation as follows:
V-S = W

Figure 65. Cylinder Measurement Points W is difference between V and S

measurements. This value represents
4. Perform calculations as follows: cylindricity of cylinder.

a. Measure inside diameter of cylinder number 5. Repeat cylindricity and roundness measurements
one, near top of cylinder (a) and in (d) and calculations for remaining cylinders.
direction. Record that measurement as data f.
6. Compare worksheet findings with specifications
b. Measure inside diameter of cylinder number listed in Table 5.
one, near top of cylinder (a) and in (e)
direction. Record that measurement as data g. 7. Consider boring and honing, cylinder correction,
or replacing cylinder block if measurements fall
c. Measure inside diameter of cylinder number outside specifications.
one, near center of cylinder (b) and in (d)
direction. Record that measurement as data h.

d. Measure inside diameter of cylinder number

one, near center of cylinder (b) and in (e)
direction. Record that measurement as data I.

42
0600 YRM 1579 Drive Train, Camshaft, and Cylinder Block Repair

Table 4. 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
Top Dimension (d) Dimension (e) f-g = X X, Y and Z = V
(a) f = __________ g = __________ X = __________ Roundness
V = __________
Least of
Cylinder #2 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
Top Dimension (d) Dimension (e) f-g = X X, Y and Z = V
(a) f = __________ g = __________ X = __________ Roundness
V = __________
Least of
Cylinder #3 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
Top Dimension (d) Dimension (e) f-g = X X, Y and Z = V
(a) f = __________ g = __________ X = __________ Roundness
V = __________
Least of
Cylinder #4 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 = __________

43
Drive Train, Camshaft, and Cylinder Block Repair 0600 YRM 1579

Honing and Boring

Pistons must move freely in cylinders while
maintaining adequate compression and oil sealing. If
cylinder walls are scuffed, scored, out of round, or
have poor cylindricity, boring or boring and honing
might correct cylinder problems. Re-boring is
necessary if bore dimensions fall outside specified
limits. See Table 5. Honing must follow any re-boring
operations. Slight imperfections can be corrected by
honing alone.

Table 5. Cylinder Bore Specification

Cylinder Bore I.D.
Figure 66. Cylinder Honing Angle
Factory Specification Allowable Limit

100.500 to 100.522 mm 100.650 mm

(3.95670 to 3.95755 in.) (3.96260 in.)

1. Boring: Significant cylinder damage might be

corrected by re-boring.
• Boring out a cylinder block can only be done in
a properly equipped machine shop.
• After re-boring, existing pistons must be
replaced with oversized pistons.
• After re-boring a cylinder block, each cylinder Figure 67. Cylinder Honing
must be honed.
e. Without stopping honing tool, pull it up through
2. Honing: Slight cylinder imperfections might be entire length of cylinder in a five-second
corrected by honing. motion.
a. Insert appropriate honing tool into chuck of an f. Maintain up-and-down motion for thirty to forty
electric drill. seconds.
b. Saturate cylinder wall with solvent using a 50%
diesel fuel and 50% engine oil mixture. WARNING
c. Rotate honing tool at 300 to 1200 rpm. Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
CAUTION away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.
DO NOT allow the honing tool to operate in one
position for any length of time. Damage to the g. When honing is completed, wash cylinder
cylinder wall will occur. Keep the tool in constant block with hot water and soap. Use brushes to
up-and-down motion. clean all passages and crevices. Rinse with
hot water and blow dry with compressed air.
NOTE: Tilt honing tool at a 30 to 40 degree angle
Apply clean engine oil to all steel surfaces to
during honing operation, to leave a cross hatch mark
prevent rusting.
on cylinder wall. See Figure 66.
d. Insert rotating honing tool into cylinder and
move it down through entire length of cylinder
in a five-second motion. See Figure 67.

44
0600 YRM 1579 Drive Train, Camshaft, and Cylinder Block Repair

Cylinder Correction (Oversize)

1. If cylinder wear is more than allowable limit, bore
and hone to specified dimension. See Honing and
Boring for procedures.

NOTE: If maximum I.D. or difference for oversize

cylinder is more than allowable limit, replace cylinder
block.
2. Replace piston and piston rings with oversized
components. See Table 6 and Figure 68 for
oversized cylinder specifications.

Table 6. Oversized Cylinder Specifications

Oversize Factory 100.500 to Figure 69. Piston Skirt Measurement
Cylinder I.D. Specification 100.522 mm
(3.95670 to 2. Measure piston ring and piston ring groove for
3.95755 in.) cylinder number one.
Maximum Wear Allowable Limit 100.650 mm
(3.96260 in.) a. Using a micrometer, measure thickness of top
compression ring. Refer to Engine
Finishing Hone to 1.2 to 3.0 microns Specifications for service limit.
(0.000048 to 0.00011 in.) Rz
b. Place a properly-sized, top compression ring in
groove as shown in Figure 70. Use a feeler
gauge to measure gap between ring and
piston. Refer to Engine Specifications for
service limit.

1. CYLINDER I.D. (BEFORE CORRECTION)

2. CYLINDER I.D. (OVERSIZE)

Figure 68. Oversize Piston

Pistons A. WIDTH
1. Using a micrometer, measure piston diameter at B. THICKNESS
skirt. Refer to Engine Specifications for service
Figure 70. Piston and Piston Ring Side Clearance
limit. See Figure 69.
c. Add top compression ring groove width and top
compression ring side clearance together to
determine top ring groove width. Refer to
Engine Specifications for service limit.

45
Drive Train, Camshaft, and Cylinder Block Repair 0600 YRM 1579

d. Replace piston if values fall outside

specification.

e. Using a feeler gauge, measure end gap

clearance of top compression ring. Refer to
Engine Specifications for service limit.

f. Measure rings and ring grooves for second

compression ring and oil ring using same
method used to measure top compression ring
and groove dimensions.

3. Repeat Step 2 for each piston.

Piston Pin
Measure outside diameter of piston pin and inside
diameter of wrist pin bushing. Calculate clearance
between piston pin and wrist pin bushing. Refer to
1. CYLINDER GAUGE
Engine Specifications for service limit. See Figure 71. 2. CONNECTING ROD SMALL END

Figure 72. Connecting Rod Small End

2. Measure crank-pin and connecting rod bearing

halves. Place connecting rod bearing halves into
connecting rod and connecting rod cap. Install
end of connecting rod to connecting rod cap.
Install bolts and tighten to
54 to 59 N•m (40 to 43 lbf ft).

3. Measure inside diameter. Refer to Engine

Specifications for service limit.
NOTE: MEASURE AT POSITIONS A, B, AND C IN
DIRECTIONS A AND B. Tappets
Figure 71. Piston Pin Outside Diameter 1. Check tappet contact surfaces with camshaft and
push rods. Slight surface defects can be
Connecting Rod corrected using an oilstone. See Figure 73.
1. Measure inside diameter of connecting rod small
end. Refer to Engine Specifications for service
limit. See Figure 72.

1. ABNORMAL CONTACT SURFACE

2. NORMAL CONTACT SURFACE

Figure 73. Tappet Contact Surface

46
0600 YRM 1579 Drive Train, Camshaft, and Cylinder Block Repair

2. Measure outside diameter of tappet stem. Refer

to Engine Specifications for service limit. See
Figure 74.

Figure 74. Tappet Stem Measurement

Crankshaft
1. Measure trueness of crankshaft.
A. BEND
a. Place crankshaft on V-blocks at end journals. B. DEFLECTION
See Figure 75.
1. DIAL GAUGE
b. Place a dial indicator on a main bearing 2. CRANKSHAFT
surface and zero gauge. 3. V-BLOCK

c. Rotate crankshaft and observe runout. Refer to Figure 75. Crankshaft Bend Measurement
Engine Specifications for service limit.
2. Inspect crankshaft for fractures.
d. Repeat this procedure for remaining bearing
surfaces. a. Using color check method, inspect crankshaft
for cracks. Replace crankshaft if evidence of
fractures are found. See Figure 76.

Figure 76. Crankshaft Fracture Check

47
Drive Train, Camshaft, and Cylinder Block Repair 0600 YRM 1579

b. If color check method is not available, use b. If oil clearance is more than allowable limit,
Magnaflux method. Inspect crankshaft for replace pin bearing. See Figure 78. If same
cracks. Replace crankshaft if evidence of dimension bearing is not applicable because of
fractures are found. crank pin wear, replace it with undersize one.
Refer to Figure 79.
3. Measure oil clearance between crank-pin and
crank pin bearing.

NOTE: DO NOT put Plastigage into crank pin hole.

NOTE: When tightening connecting rod screws, DO
NOT move crankshaft.
a. Clean crank pin and crank bearing. Put a strip
of plastigage on center of crank pin. Install
connecting rod cap. Tighten connecting rod
cap screws to specified torque. Remove
connecting rod cap again. Measure width that
becomes flat with scale to get oil clearance.
See Figure 77.

1. ID COLOR
2. CRANK PIN BEARING
3. CENTER WALL THICKNESS

ID Color Connecting Crank Pin Bearing

Rod
Large End Class Center Wall
Diameter Thickness
56.010 to 1.496 to
56.020 mm 1.501 mm
Blue L
Description Factory Allowable Limit (2.2052 to (0.05890 to
Specification 2.2055 in.) 0.05909 in.)

52.977 to N/A 56.00 to 1.491 to

52.990 mm Without 56.01 mm 1.496 mm
Crank Pin O.D. S
(2.0857 to Color (2.2048 to (0.05870 to
2.0862 in.) 2.2051 in.) 0.05889 in.)

Oil Clearance 0.018 to 0.20 mm Figure 78. Crankshaft Pin Bearing Identification
Between Crank 0.051 mm (0.0079 in.)
Pin and Crank (0.00071 to
Pin Bearing 0.0020 in.)

Figure 77. Crank Pin Oil Clearance

NOTE: When replacing crank pin bearing with a

standard service part, make sure crank pin bearing
and connecting rod are marked with same ID color.

48
0600 YRM 1579 Drive Train, Camshaft, and Cylinder Block Repair

Dimension Minimum Maximum Figure 80. Camshaft Runout Check

0.2 mm 0.4 mm
Undersize 2. Measure intake/exhaust cam height. Refer to
(0.008 in.) (0.016 in.)
Engine Specifications for service limit. See
2.8 to 3.2 mm 2.8 to 3.2 mm Figure 81.
Dimension A (0.11 to 0.12 in.) (0.11 to 0.12 in.)
radius radius
1.0 to 1.5 mm 1.0 to 1.5 mm
*Dimension B (0.040 to (0.040 to
0.059 in.) relief 0.059 in.) relief
52.777 to 52.577 to
52.790 mm 52.590 mm
Dimension C
(2.0779 to (2.0700 to
2.0783 in.) dia. 2.0704 in.) dia.
The crank pin must be fine-finished to higher to
Rmax=0.8S. *Holes to be de-burred and edges
rounded with 10 to 1.5 mm (0.040 to 0.059 in.) relief. A. CAM HEIGHT

Figure 79. Crank Pin Journal Measurement Figure 81. Intake/Exhaust Cam Height
Measurement
Camshaft
3. Measure gear end bearing surface, intermediate
1. Measure trueness of camshaft. position bearing surface, and flywheel end
bearing surface diameters. See Figure 82.
a. Place camshaft on V-blocks positioned at end
Determine oil clearance. The oil clearance is
journals. See Figure 80.
calculated by subtracting measured camshaft
b. Place a dial indicator on gear side bearing bearing surface diameter from camshaft bushing
surface and zero gauge. inside diameter. Refer to Engine Specifications for
service limit.
c. Rotate camshaft and observe runout. Refer to
Engine Specifications for service limit.

49
Drive Train, Camshaft, and Cylinder Block Repair 0600 YRM 1579

Crankshaft
1. Place crankshaft in position in cylinder block.

NOTE: The numbers and arrows on main bearing

caps are for proper positioning. The caps are
numbered 1, 2, 3, and 4 with number 1 cap at flywheel
end of cylinder block. The arrows on bearing caps
should point towards flywheel end of cylinder block.
2. Position bearing halves, thrust bearings, and
bearing caps on crankshaft. See Figure 62.

1. FLYWHEEL END BEARING SURFACE 3. Lubricate bearing cap bolts and install bolts.
2. INTERMEDIATE POSITION BEARING SURFACE
3. GEAR END BEARING SURFACE 4. Install a new oil seal in rear oil seal housing.

Figure 82. Camshaft Bearing Surface 5. Apply a continuous bead of Three Bond Liquid
Measurements Gasket (Yale P/N 580062478 ) to mating surface
of rear oil seal housing.
Camshaft Bushing
6. Align rear oil seal housing with two dowel pins on
If camshaft bushing is damaged, replace bushing cylinder block and install rear oil seal housing.
using appropriate service tool. Install retaining bolts.
ASSEMBLE Pistons and Connecting Rods
Camshaft 1. Select parts needed to assemble piston and
1. Verify that all parts are clean. Lightly lubricate all connecting rod for Number 1 cylinder.
parts with clean engine oil.
2. Lubricate and insert wrist pin bushing into small
2. Install timing gear case. See Timing Gear Case end of connecting rod. See Figure 58.
and Timing Gears Repair.
3. Install one snap ring into piston.
NOTE: Rotate cylinder block into a position in which it
allows gravity to keep tappets in place and out of way 4. Position connecting rod into piston under skirt.
of camshaft lobes for when camshaft is installed. The match marks on connecting rod and
connecting rod cap, must be in line of piston
3. Install tappets into cylinder block in same identification number on top of piston. See
locations as they were removed. Figure 83.
4. Slowly insert camshaft through front of engine.

5. Place camshaft thrust plate in position and install

retaining bolts. See Figure 63.

6. Install key on camshaft.

7. Install camshaft gear.

50
0600 YRM 1579 Drive Train, Camshaft, and Cylinder Block Repair

Figure 84. Piston Ring Mark

b. Install top compression ring, second

compression ring, and oil ring. See Figure 85.

A. TOP OF PISTON (LOOKING DOWN)

1. PISTON RINGS
2. PISTON
3. WRIST PIN
4. SNAP RING
5. WRIST PIN BEARING
6. CONNECTING ROD
7. CONNECTING ROD BEARING
8. CONNECTING ROD CAP
9. CONNECTING ROB BOLTS
10. MATCH MARKS
11. TOP RING GAP
12. OIL RING GAP
13. SECOND RING GAP
14. PISTON WRIST PIN HOLE 1. TOP COMPRESSION RING
15. FUEL SUPPLY PUMP DIRECTION 2. SECOND COMPRESSION RING
3. OIL RING
Figure 83. Piston and Connecting Rod 4. PISTON
Identification Marks
Figure 85. Piston Rings
5. Lubricate and install piston wrist pin through
c. Stagger piston ring joints at 120 degree
piston and wrist pin bushing.
intervals. DO NOT position top compression
6. Install second snap ring. ring joint in line with piston wrist pin. The coil
expander joint must be opposite oil ring joint.
7. Using piston ring pliers, install piston rings. See Figure 86.

a. Install each piston ring on piston with punched

manufacture's mark facing upward. See
Figure 84.

51
Drive Train, Camshaft, and Cylinder Block Repair 0600 YRM 1579

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

Case and Timing Gears Repair.

4. Install oil suction tube. See Lubrication System

Repair.

5. Install oil pan. See Lubrication System Repair.

6. Install cylinder head. See Cylinder Head

Assembly Repair.

7. Install fuel injection pump. See Fuel System

Repair.

8. Install water pump. See Cooling System Repair.

9. Install alternator. See Electrical Equipment

Repair.

10. Install flywheel and flywheel housing. See

Flywheel and Flywheel Housing.
1. TOP COMPRESSION RING
2. SECOND COMPRESSION RING 11. Install starter. See Electrical Equipment Repair.
3. OIL RING
4. JOINTS 12. Install engine.
See Frame 0100YRM1243 for lift truck models
Figure 86. Piston Rings Staggering
• GDP40VX5/VX6; GDP45SVX5,GDP45VX6,
8. Perform Step 1 through Step 7 for assembly of GDP50-55VX (GDP080-120VX) (H813, J813)
remaining pistons. See Frame 0100YRM1581 for lift truck models
9. Lubricate Number 1 piston and piston rings with • GDP60-70VX (GDP135-155VX) (E878)
clean engine oil. See Frame 0100YRM1891 for lift truck models

10. Using special tool, piston ring compressor, • GDP40VX5/VX6; GDP45SVX5, GDP45VX6;
compress piston rings on Number 1 piston. GDP50-55VX (GDP080-120VX) (K813)
See Frame 0100YRM1948 for lift truck models
11. Carefully install piston into Number 1 cylinder. Be
• GDP60-70VX (GDP135-155VX) (F878)
sure matched mark on connecting rod and
connecting rod cap is facing towards fuel supply • GDP60VX, GDP70VX, GP70VXS6
pump side. See Figure 83. (GDP135VX. GDP155VX, GP155VXS) (G878)
• GP60VX, GP70VX, GP70SVX, GP70SVX9,
12. Install connecting rod bearing halves and GP80SVX (GP135VX, GP155VX, GP155SVX,
connecting rod cap. Install connecting rod bolts GP170SVX) (H878)
and tighten to 79 to 83 N•m (58 to 61 lbf ft). See
Figure 83.

13. Perform Step 9 through Step 12 to install

remaining pistons in their respective cylinders.

52
0600 YRM 1579 Drive Train, Camshaft, and Cylinder Block Repair

13. If not previously removed, remove and discard See Periodic Maintenance 8000YRM1902
engine oil filter. Apply clean oil to gasket of new GDP40VX5/VX6; GDP45SVX5, GDP45VX6;
•
filter. Install new filter. Turn filter until gasket GDP50-55VX (GDP080-120VX) (K813)
touches, then tighten ½ to 3/4 turn with your
hand. See Periodic Maintenance 8000YRM1583 for lift
truck models
14. Fill engine oil to correct level. • GDP60-70VX (GDP135-155VX) (E878)
See Periodic Maintenance 8000YRM1558 for lift See Periodic Maintenance 8000YRM1957 for lift
truck model truck models
• GDP40VX5/VX6; GDP45SVX5, GDP45VX6; • GDP60-70VX (GDP135-155VX) (F878)
GDP50-55VX (GDP080-120VX) (J813)
Periodic Maintenance 8000YRM2196
See Periodic Maintenance 8000YRM1604 for lift
truck model GDP60VX, GDP70VX, GP70VXS6
(GDP135VX. GDP155VX, GP155VXS) (G878)
• GDP40VX5/VX6; GDP45SVX5, GDP45VX6;
GDP50-55VX (GDP080-120VX) (J813) 15. Start engine and check for leaks.

53
Lubrication System Repair 0600 YRM 1579

Lubrication System Repair

ENGINE OIL AND OIL FILTER CHANGE
NOTE: Place a container with a capacity of at least
13.2 liter (3.5 gal) under oil pan drain plug.
1. Remove oil pan drain plug and drain engine oil
into a suitable container. See Figure 87.

1. OIL FILTER
2. ADAPTER BOLT
3. OIL COOLER
4. CRANK CASE

Figure 88. Oil Filter

3. Install oil pan drain plug.

4. Apply clean oil to gasket of new filter. Install new

filter. Turn filter until gasket touches, then tighten
½ to 3/4 turn with your hand.
1. DRAIN PLUG 4. BOLT
2. GASKET 5. FLANGE BOLT 5. Fill engine oil to correct level. For correct oil
3. OIL PAN 6. CRANK CASE amount and type refer to
Periodic Maintenance 8000YRM1558 for lift
Figure 87. Oil Pan truck models
2. Remove engine oil filter. See Figure 88. • GDP40VX5/VX6; GDP45SVX5, GDP45VX6,
GDP50-55VX (GDP080-120VX) (H813)
Periodic Maintenance 8000YRM1583 for lift
truck models
• GDP60-70VX (GDP135-155VX) (E878)
Periodic Maintenance 8000YRM1604 for lift
truck models
• GDP40VX5/VX6; GDP45SVX5, GDP45VX6,
GDP50-55VX (GDP080-120VX) (J813)
Periodic Maintenance 8000YRM1902 for lift
truck models
• GDP40VX5/VX6; GDP45SVX5, GDP45VX6,
GDP50-55VX (GDP080-120VX) (K813)

54
0600 YRM 1579 Lubrication System Repair

See Periodic Maintenance 8000YRM1957 for lift See Periodic Maintenance 8000YRM2196
truck models GDP60VX, GDP70VX, GP70VXS6
•
• GDP60-70VX (GDP135-155VX) (F878) (GDP135VX. GDP155VX, GP155VXS) (G878)
Periodic Maintenance 8000YRM2196 • GP60VX, GP70VX, GP70SVX, GP70SVX9,
GP80SVX (GP135VX, GP155VX, GP155SVX,
• GDP60VX, GDP70VX, GP70VXS6 GP170SVX) (H878)
(GDP135VX. GDP155VX, GP155VXS) (G878)
• GP60VX, GP70VX, GP70SVX, GP70SVX9, 2. Remove underbody shield.
GP80SVX (GP135VX, GP155VX, GP155SVX, See Frame 0100YRM1243 for lift truck models
GP170SVX) (H878)
• GDP40VX5/VX6; GDP45SVX5, GDP45VX6;
6. Start engine. Check area around oil filter for GDP50-55VX (GDP080-120VX) (H813, J813)
leaks. See Frame 0100YRM1581 for lift truck models

OIL PAN • GDP60-70VX (GDP135-155VX) (E878)

See Frame 0100YRM1891 for lift truck models
Remove
• GDP40VX5/VX6; GDP45SVX5, GDP45VX6;
GDP50-55VX (GDP080-120VX) (K813)
WARNING See Frame 0100YRM1948 for lift truck models
When putting the lift truck on blocks, make sure
the surface is solid, even, and level. Any blocks • GDP60-70VX (GDP135-155VX) (F878)
used to support the lift truck must be solid, one- See Periodic Maintenance 8000YRM2196
piece units.
• GDP60VX, GDP70VX, GP70VXS6
1. Put lift truck on blocks so that you have access (GDP135VX. GDP155VX, GP155VXS) (G878)
under lift truck. Refer to Operating Manual or • GP60VX, GP70VX, GP70SVX, GP70SVX9,
section GP80SVX (GP135VX, GP155VX, GP155SVX,
GP170SVX) (H878)
Periodic Maintenance 8000YRM1558 for lift
truck models NOTE: Place a container with a capacity of at least
• GDP40VX5/VX6; GDP45SVX5, GDP45VX6, 13.2 liter (3.5 gal) under oil pan drain plug.
GDP50-55VX (GDP080-120VX) (H813) 3. Remove oil pan drain plug and drain engine oil
Periodic Maintenance 8000YRM1583 for lift into a suitable container. See Figure 88.
truck models
4. Remove oil filter.
• GDP60-70VX (GDP135-155VX) (E878)
Periodic Maintenance 8000YRM1604 for lift 5. Remove twenty bolts holding oil pan to
truck models crankcase. See Figure 87.
• GDP40VX5/VX6; GDP45SVX5, GDP45VX6, 6. Remove four flange bolts holding oil pan to
GDP50-55VX (GDP080-120VX) (J813)
crankcase. See Figure 87.
• GDP40VX5/VX6; GDP45SVX5, GDP45VX6;
GDP50-55VX (GDP080, 090, 100, 110, 120VX) 7. Remove oil pan.
(J813)
Periodic Maintenance 8000YRM1902 for lift
truck models CAUTION
• GDP40VX5/VX6; GDP45SVX5, GDP45VX6, Use care not to damage the mating surfaces when
GDP50-55VX (GDP080-120VX) (K813) removing old gaskets and sealant residues.
See Periodic Maintenance 8000YRM1957 for lift 8. Carefully remove old sealant residue from mating
truck models surfaces of oil pan and cylinder block.
• GDP60-70VX (GDP135-155VX) (F878)
9. Thoroughly clean outside and inside surfaces of
oil pan.

55
Lubrication System Repair 0600 YRM 1579

Install Periodic Maintenance 8000YRM1902 for lift

truck models
1. Apply a continuous bead of Three Bond Liquid
Gasket (Yale P/N 580062478 ) around sealing • GDP40VX5/VX6; GDP45SVX5, GDP45VX6;
surface of oil pan. GDP50-55VX (GDP080-120VX) (K813)
See Periodic Maintenance 8000YRM1957 for lift
2. Place oil pan in position and install retaining bolts. truck models
Refer to Standard Torque Specifications.
• GDP60-70VX (GDP135-155VX) (F878)
3. Apply clean oil to gasket of new filter. Install new See Periodic Maintenance 8000YRM2196
filter. Turn filter until gasket touches, then tighten
• GDP60VX, GDP70VX, GP70VXS6
½ to 3/4 turn with your hand. (GDP135VX. GDP155VX, GP155VXS) (G878)
4. Install oil pan drain plug. • GP60VX, GP70VX, GP70SVX, GP70SVX9,
GP80SVX (GP135VX, GP155VX, GP155SVX,
5. Install underbody shield. GP170SVX) (H878)

See Frame 0100YRM1243 for lift truck models 8. Start engine and check for leaks.
• GDP40VX5/VX6; GDP45SVX5,GDP45VX6,
GDP50-55VX (GDP080-120VX) (H813, J813) OIL SUCTION TUBE
See Frame 0100YRM1581 for lift truck models Remove
• GDP60-70VX (GDP135-155VX) (E878) 1. Remove oil pan. See Oil Pan, Remove
See Frame 0100YRM1891 for lift truck models
2. Remove two bolts holding oil suction tube. See
• GDP40VX5/VX6; GDP45SVX5, GDP45VX6; Figure 89.
GDP50-55VX (GDP080-120VX) (K813)
See Frame 0100YRM1948 for lift truck models 3. Remove oil suction tube.
• GDP60-70VX (GDP135-155VX) (F878) 4. Remove O-ring from oil suction tube and discard.
See Periodic Maintenance 8000YRM2196
• GDP60VX, GDP70VX, GP70VXS6
(GDP135VX. GDP155VX, GP155VXS) (G878)
• GP60VX, GP70VX, GP70SVX, GP70SVX9,
GP80SVX (GP135VX, GP155VX, GP155SVX,
GP170SVX) (H878)

6. Remove lift truck from blocks.

7. Fill engine oil to correct level. For correct oil

amount and type refer to
Periodic Maintenance 8000YRM1558 for lift
truck models
• GDP40VX5/VX6; GDP45SVX5,GDP45VX6,
GDP50-55VX (GDP080-120VX) (H813)
Periodic Maintenance 8000YRM1583 for lift
truck models 1. BOLT
• GDP60-70VX (GDP135-155VX) (E878) 2. OIL SUCTION TUBE
3. O-RING
Periodic Maintenance 8000YRM1604 for lift 4. CRANKCASE
truck models
Figure 89. Oil Suction Tube
• GDP40VX5/VX6; GDP45SVX5, GDP45VX6;
GDP50-55VX (GDP080-120VX) (J813)

56
0600 YRM 1579 Lubrication System Repair

Clean • GDP60VX, GDP70VX, GP70VXS6

(GDP135VX. GDP155VX, GP155VXS) (G878)
• GP60VX, GP70VX, GP70SVX, GP70SVX9,
WARNING GP80SVX (GP135VX, GP155VX, GP155SVX,
Cleaning solvents can be flammable and toxic and GP170SVX) (H878)
can cause skin irritation. When using cleaning
solvents, always follow the recommendations of 2. Remove coolant fan, serpentine belt, and water
the manufacturer. pump. See Cooling System Repair.

3. Remove bolt and washer holding crankshaft

pulley.
WARNING
Compressed air can move particles so that they 4. Using a gear puller, remove crankshaft pulley.
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is 5. Remove timing gear case cover. See Timing Gear
away from all personnel. Wear protective goggles Case and Timing Gears Repair.
or a face shield to prevent injury to the eyes.
6. Remove eight capscrews holding oil pump
NOTE: The oil suction tube and screen are to be assembly and remove oil pump assembly from
serviced as an assembly. DO NOT attempt to repair timing gear case housing. See Figure 90.
wire mesh portion of tube and screen assembly.
Clean oil suction tube in cleaning solvent. Dry 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 oil suction tube.

2. Position oil suction tube in cylinder block.

3. Install two bolts to retain oil suction tube. Refer to

Standard Torque Specifications.

4. Install oil pan. See Oil Pan, Install.

OIL PUMP
1. CAPSCREW
Remove 2. OIL PUMP COVER
3. OIL PUMP ROTOR
1. Remove engine. 4. GEAR CASE HOUSING
See Frame 0100YRM1243 for lift truck models
Figure 90. Oil Pump Assembly
• GDP40VX5/VX6; GDP45SVX5,GDP45VX6,
GDP50-55VX (GDP080-120VX) (H813, J813) 7. Remove outer rotor from timing gear case
See Frame 0100YRM1581 for lift truck models housing. See Figure 90.

• GDP60-70VX (GDP135-155VX) (E878) Clean and Inspect

See Frame 0100YRM1891 for lift truck models
• GDP40VX5/VX6; GDP45SVX5, GDP45VX6; WARNING
GDP50-55VX (GDP080-120VX) (K813)
Cleaning solvents can be flammable and toxic and
See Frame 0100YRM1948 for lift truck models can cause skin irritation. When using cleaning
• GDP60-70VX (GDP135-155VX) (F878) solvents, always follow the recommendations of
the manufacturer.

57
Lubrication System Repair 0600 YRM 1579

WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.

CAUTION
If any oil pump component clearance exceeds its
limit, the oil pump must be replaced as an
assembly. Failure to replace the complete pump
assembly could result in pump failure and damage
to the engine.
1. FEELER GAUGE
Clean all parts in cleaning solvent. Dry parts with 2. INNER ROTOR
compressed air. Inspect for wear and damage. If 3. OUTER ROTOR
necessary, replace oil pump assembly.
Figure 92. Outer Rotor to Inner Rotor Tip
Outer Rotor Outside Clearance Clearance Check

Insert a feeler gauge between outer rotor and timing Outer Rotor Side Clearance
gear case oil pump cavity and measure clearance.
Refer to section Engine Specifications for clearance Using a depth micrometer, measure depression of
limits. See Figure 91. outer rotor across pump cavity to determine side
clearance. Refer to section Engine Specifications for
clearance limits. See Figure 93.

1. OUTER ROTOR
2. FEELER GAUGE
3. OIL PUMP CAVITY

Figure 91. Outer Rotor Outside Clearance Check

Outer Rotor to Inner Rotor Tip Clearance 1. DEPTH MICROMETER

2. PUMP CAVITY
Insert a feeler gauge between top of an inner rotor 3. OUTER ROTOR
tooth and top of an outer rotor tooth and measure
clearance. Refer to section Engine Specifications for Figure 93. Outer Rotor Side Clearance Check
clearance limits. See Figure 92.

58
0600 YRM 1579 Lubrication System Repair

Rotor Shaft Clearance 3. Position oil pump assembly in gear case housing.
Install bolts to retain oil pump. Refer to Standard
Measure outside diameter of rotor shaft and bore Torque Specifications. See Figure 95.
diameter in gear case housing to determine rotor shaft
clearance. Refer to section Engine Specifications for 4. Install timing gear case cover. See Timing Gear
clearance limits. See Figure 94. Case and Timing Gears Repair.

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

crankshaft pulley. Tighten bolt to
255 to 274 N•m (188 to 202 lbf ft).

6. Install water pump, serpentine belt, and coolant

fan. See Cooling System Repair.

7. Install engine.
See Frame 0100YRM1243 for lift truck models
• GDP40VX5/VX6; GDP45SVX5,GDP45VX6,
GDP50-55VX (GDP080-120VX) (H813, J813)
See Frame 0100YRM1581 for lift truck models
1. ROTOR SHAFT
2. GEAR CASE HOUSING • GDP60-70VX (GDP135-155VX) (E878)
See Frame 0100YRM1891 for lift truck models
Figure 94. Rotor Shaft Clearance Check
• GDP40VX5/VX6; GDP45SVX5, GDP45VX6;
Install GDP50-55VX (GDP080-120VX) (K813)
See Frame 0100YRM1948 for lift truck models
1. Lubricate outer rotor and pump bore in gear case
with clean engine oil. • GDP60-70VX (GDP135-155VX) (F878)
• GDP60VX, GDP70VX, GP70VXS6
NOTE: The punch mark end of outer rotor must face (GDP135VX. GDP155VX, GP155VXS) (G878)
away from gear case housing. GP60VX, GP70VX, GP70SVX, GP70SVX9,
•
2. Install outer rotor in gear case housing. Verify that GP80SVX (GP135VX, GP155VX, GP155SVX,
punch mark end of outer rotor faces away from GP170SVX) (H878)
gear case housing. See Figure 95.
8. Change engine oil and oil filter. See Engine Oil
and Oil Filter Change.

9. Start engine and check for leaks.

1. PUNCH MARK
2. OUTER ROTOR
3. TIMING GEAR CASE

Figure 95. Outer Rotor

59
Fuel System Repair 0600 YRM 1579

Fuel System Repair

FUEL INJECTORS • Remove fuel injector from cylinder head.
• Push a screw driver into hole located in middle
Remove of seal. See Figure 96.
NOTE: Note position of each fuel injector prior to • Turn screw driver three or four times in each
removal. direction to help secure screw driver in seal.
See Figure 96.
NOTE: Store fuel injectors and fuel injector lines so
they DO NOT get any dirt or debris in them. • While turning screw driver, slowly pull up seal
out of cylinder head. The injector gasket will
1. Remove fuel injector lines and fuel injectors. See also come out with seal at this time. See
Valve Covers and Fuel Injectors. Figure 96.
• If seal falls off screw driver before it is
successfully removed, repeat this procedure.
CAUTION
Remove the fuel lines as an assembly whenever
possible. Disassembling the fuel lines from the
retainers or bending any of the fuel lines will make
it difficult to reinstall the fuel lines.

2. Remove fuel lines. See Valve Covers and Fuel

Injectors.

Inspect
Visually inspect fuel injectors and nozzle holes for
carbon deposits or damage. Clean and replace as
necessary.
1. FUEL INJECTOR
Clean 2. INJECTOR GASKET
3. INJECTOR SEAL
4. SCREW DRIVER
CAUTION
DO NOT use a wire brush or similar tool to clean Figure 96. Kubota Diesel Fuel Injector
the nozzle hole. It will damage the hole.
Install
1. Install fuel lines. See Valve Covers and Fuel
CAUTION Injectors for procedure.
DO NOT disassemble the injector to clean it.
2. Install fuel injectors and fuel injector lines. See
1. Clean exterior of nozzle so that nozzle hole is free Valve Covers and Fuel Injectors section for
from obstruction. procedure.
Replace
If it becomes to necessary to replace a fuel injector,
follow procedure outlined below:

60
0600 YRM 1579 Fuel System Repair

ELECTRONIC THROTTLE SYSTEM

Remove
NOTE: Tag electrical connectors during removal to aid
in installation.
1. Disconnect engine harness electrical connectors
from throttle position sensor (TPS) and actuator.
See Figure 97 or Figure 98.

1. THROTTLE POSITION SENSOR

2. ACTUATOR ELECTRICAL CONNECTOR

Figure 97. TPS and Actuator Connections Before

September 2018

1. TPS MOUNT
2. SEALED BEARING
3. ROD END BALL JOINT
4. THROTTLE POSITION SENSOR (TPS)

Figure 98. TPS Connections After September 2018

GDP60-70VX (GDP135-155VX) (F878), GDP60VX,
GDP70VX, GP70VXS6 (GDP135VX. GDP155VX,
GP155VXS) (G878), GP60VX, GP70VX, GP70SVX,
GP70SVX9, GP80SVX (GP135VX, GP155VX,
GP155SVX, GP170SVX) (H878) and GP080VX,
GP090VX, GP100VX, GP100VX, GP120VX
(GDP40VX5, GDP40VX6, GDP45VX6, GDP45SVX5,
GDP50VX, GDP55VX) (K813)

NOTE: The TPS mounting screws are non-magnetic

stainless steel to avoid interference with sensor
magnet and must be reused if TPS is replaced.

61
Fuel System Repair 0600 YRM 1579

2. Remove two Torx-head capscrews, two lock 3. Remove two Allen-head capscrews from TPS
washers, and throttle position sensor (TPS) from mounting bracket and fuel shut off solenoid. See
TPS mounting bracket and TPS plate. See Figure 99.
Figure 99.

1. ALLEN HEAD CAPSCREW 13. SHOULDER BOLT

2. TPS MOUNTING BRACKET 14. CAPSCREW
3. THROTTLE POSITION SENSOR (TPS) 15. BALL JOINT ROD END
4. LOCK WASHER 16. ROD
5. TORX-HEAD CAPSCREWS 17. BELLCRANK WELDMENT
6. TPS PLATE 18. LINKAGE
7. TPS ROTOR 19. THROTTLE LEVER PLATE
8. UPSTOP SET SCREW 20. FUEL SHUTOFF SOLENOID
9. NUT 21. CRANK BRACKET
10. SHIM 22. SPEED CONTROL LEVER
11. BEARING 23. STUD
12. WASHER

Figure 99. TPS Assembly

NOTE: After the TPS is assembled, ensure to follow 4. If required, pull TPS rotor from throttle lever plate.
the steps found in Throttle Position Sensor See Figure 99.
Proceedures After September 2018 GDP60-70VX
(GDP135-155VX) (F878), GDP60VX, GDP70VX, 5. Pull rubber boot from collar and rotate throttle
GP70VXS6 (GDP135VX. GDP155VX, GP155VXS) lever plate to full open position. See Figure 100.
(G878), GP60VX, GP70VX, GP70SVX, GP70SVX9,
GP80SVX (GP135VX, GP155VX, GP155SVX,
GP170SVX) (H878) and GP080VX, GP090VX,
GP100VX, GP100VX, GP120VX (GDP40VX5,
GDP40VX6, GDP45VX6, GDP45SVX5, GDP50VX,
GDP55VX) (K813) for trucks assembled after
September 2018.

62
0600 YRM 1579 Fuel System Repair

8. Remove nut from stud securing linkage to

bellcrank weldment. See Figure 101.

NOTE: SPEED CONTROL LEVER REMOVED

FROM FUEL PUMP TO SHOW ASSEMBLY. SPEED
CONTROL LEVER IS FIXED TO FUEL PUMP.

1. SPEED CONTROL LEVER

2. THROTTLE LEVER PLATE
3. NUT
4. WASHER
5. CAPSCREW
6. LINKAGE
7. BELLCRANK WELDMENT
8. STUD

Figure 101. Linkage Arrangement

1. THROTTLE ROD 9. Remove nut, washer, and capscrew securing

2. RUBBER BOOT linkage to throttle lever plate and speed control
3. LOCK WASHER
4. CAPSCREW lever. See Figure 101.
5. INLINE BALL SOCKET
6. INSERT 10. Remove shoulder bolt, washer, shim, and nut
7. ACTUATOR ENGINE MOUNT BRACKET from crank bracket and bellcrank weldment. Set
8. COLLAR bellcrank weldment aside. See Figure 101.
9. ACTUATOR NUT
10. ACTUATOR ROD
11. ALLEN HEAD CAPSCREW 11. If required, pull throttle lever plate from speed
12. ACTUATOR control lever on fuel injection pump. See
Figure 99.
Figure 100. Electronic Throttle Actuator
12. If required, remove three capscrews and actuator
6. Unscrew inline ball joint from actuator rod. See engine mount bracket from engine. See
Figure 100. Figure 102.

7. Remove capscrew, washer, and nut from ball joint

rod end and bellcrank weldment. Remove rod and
ball joint rod end from lift truck. See Figure 99.

63
Fuel System Repair 0600 YRM 1579

3. Maunually rotate throttle lever (not accelerator

pedal) to full throttle position. This will
immediately set a fault code for the Throttle
Position Exceeds Command. Fault code must
be cleared after performing this procedure. With
throttle lever against high idle stop, Throttle
Position must be within 3.0-3.7 volts. Adjust
Sealed Bearing (see Figure 98 ) to provide a stop
for E-Throttle Crank at full throttle (see
Figure 103).

4. Turn truck power OFF, wait 5 seconds, turn truck

power ON. Navigate display conslole menus to
clear VSM fault codes.

1. CAPSCREW
2. ACTUATOR ENGINE MOUNT BRACKET
3. RUBBER BOOT

Figure 102. Actuator Engine Mount Bracket To

Engine

13. If required, remove four Allen head capscrews

and actuator from actuator engine mount bracket.
See Figure 100.

Throttle Position Sensor Proceedures

After September 2018 GDP60-70VX
(GDP135-155VX) (F878), GDP60VX,
GDP70VX, GP70VXS6 (GDP135VX.
GDP155VX, GP155VXS) (G878), GP60VX,
GP70VX, GP70SVX, GP70SVX9, GP80SVX
(GP135VX, GP155VX, GP155SVX,
GP170SVX) (H878) and GP080VX,
GP090VX, GP100VX, GP100VX, GP120VX
(GDP40VX5, GDP40VX6, GDP45VX6,
GDP45SVX5, GDP50VX, GDP55VX) (K813)
1. After assembling, rotate throttle lever manually to
ensure lever is in full contact with low and high
idle stop screws

2. With truck power ON and engine NOT running, 1. E-THROTTLE CRANK BRACKET
2. SET SCREW
navigate display console menus to read Throttle 3. BELLCRANK
Position Sensor Voltage under No-run Data
Display menu. With accelerator released and Figure 103. E-Throttle Crank Bracket
throttle lever against low idle stop, Throttle
Position Sensor must be within 1.0-1.1 volts.

64
0600 YRM 1579 Fuel System Repair

Bearing Replacement 4. Assemble shoulder bolt through washer,

bearings, bellcrank weldment, and shim. Install
1. Place bellcrank weldment in a soft jawed vice. assembly onto crank bracket (with shim facing
toward engine) and secure into position with nut.
2. Using a brass punch and hammer, drive sealed
Tighten shoulder bolt to 25.6 N•m (226.6 lbf in).
bearings (#3 and #5, Figure 104) from the
See Figure 104.
bellcrank weldment.
5. Install linkage and nut onto set screw in bellcrank
weldment. DO NOT tighten nut. See Figure 101.

6. Install capscrew, washer, nut, and linkage onto

throttle lever plate. Tighten capscrew to
10.5 N•m (92.9 lbf in). See Figure 101.

7. Tighten nut on stud in bellcrank weldment to

10.5 N•m (92.9 lbf in).

8. Rotate throttle lever plate into full open position to

install capscrew, ball joint rod end, washer, and
nut. Tighten nut to 7.9 N•m (70 lbf in).

9. Rotate throttle lever into full closed position and

install throttle rod with inline ball joint onto
1. NUT
2. SHIM actuator rod. Fully seat inline ball joint on actuator
3. INBOARD BEARING rod. Tighten inline ball joint to 7.9 N•m (70 lbf in).
4. BELLCRANK WELDMENT See Figure 100.
5. OUTBOARD BEARING
6. WASHER 10. Connect rubber boot to collar on actuator engine
7. SHOULDER BOLT
8. CRANK BRACKET mount bracket. See Figure 100.

Figure 104. Bellcrank Weldment To Crank Bracket 11. If removed, install TPS rotor on throttle lever
Assembly plate. See Figure 100.

3. Clean dirt and debris from sealed bearings. 12. Install TPS mounting bracket and two Allen-head
capscrews on fuel injection pump at fuel shut off
4. Inspect bearings and shoulder bolt for wear or solenoid. Tighten Allen-head capscrews to
damage. Replace shoulder bolt and bearings (as 10.5 N•m (92.9 lbf in). See Figure 100.
a set) if worn or damaged.
NOTE: The TPS mounting screws are non-magnetic
5. Install bearings into bellcrank weldment. Be sure stainless steel to avoid interference with sensor
to fully seat bearing in bellcrank weldment. magnet and must be reused if TPS is replaced.
NOTE: When installing TPS, rotate throttle lever plate
Install to match TPS rotor to TPS.
1. If removed, install actuator, four capscrews, 13. Install TPS, two Torx-head screws, two lock
washers, and nuts into actuator engine mount washers, and TPS plate on TPS mounting
bracket. See Figure 100. bracket using. See Figure 99.

2. If removed, install acutator engine mount bracket 14. Connect electrical connectors as tagged during
on engine using three capscrews. See removal. Remove tags as electrical connections
Figure 102. are made. See Figure 97.

3. If removed, install throttle lever plate on speed 15. Perform adjustment procedures. See section
control lever of fuel injection pump. See Adjustment.
Figure 99.

65
Fuel System Repair 0600 YRM 1579

16. Tighten Torx-head screws (installed in Step 13) to weldment. Once holes are aligned install
2.25 N•m (20 lbf in). capscrew, washer, and nut. Tighten capscrew to
7.9 N•m (70 lbf in). See Figure 99.
Adjustment
3. With truck power ON and engine OFF, navigate
display consule menus to read throttle position
CAUTION sensor "A" voltage under no-run data diplay
DO NOT attempt to adjust the low or high idle menu. PC Service Tool may also be used. With
speed limit screws. This may impair the safety and the accelerator released and the throttle lever
performance of the lift truck and shorten it’s against low idle stop, throttle sensor "A" voltage
engine life. If the idle speed limit screws require must be with in 1.0 - 1.1 volts.
adjustment, see your authorized Kubota industrial
engine dealer or distributor. 4. Manually rotate throttle lever to full open position.
Adjust actuator rod upstop set screw to permit full
1. Rotate throttle lever plate manually to verify if speed control lever stroke. Tighten nut on ball
lever is in full contact with low and high idle stop joint rod to 25.6 N•m (226.6 lbf in). See Figure 99.
screws.

2. With the engine at idle, adjust the ball joint rod

end on the actuator rod up or down to align hole
in ball joint rod end with hole in bellcrank

66
0600 YRM 1579 Fuel System Repair

FUEL INJECTION PUMP

Remove
1. Disconnect electrical connector from solenoid on
top of fuel injection pump. See Figure 105.

1. ELECTRICAL CONNECTOR 7. FUEL SUPPLY HOSE

2. ELECTRICAL HARNESS 8. FUEL LIFT PUMP
3. BRACKET 9. FUEL RETURN HOSE
4. CAPSCREW 10. BLEEDER VALVE
5. FLANGE BOLT 11. LUBRICATING PIPE
6. CLAMP 12. FUEL INJECTION PUMP ASSEMBLY

Figure 105. Fuel System Components

2. Unclip electrical harness from bracket and move 5. Remove fuel return hose from overflow pipe and
to side. See Figure 105. bleeder valve. Cap overflow pipe and bleeder
valve so debris DOES NOT enter fuel system.
3. Remove two capscrews, flange bolt and engine See Figure 105.
harness bracket from intake manifold. See
Figure 105. 6. Remove fuel injection lines from fuel injection
pump assembly and fuel injectors. See Valve
4. Remove clamp and fuel supply hose from fuel lift Covers and Fuel Injectors.
pump. Plug hose so debris DOES NOT enter fuel
line. See Figure 105. 7. Disconnect lubricating pipe from engine block just
below fuel injection pump assembly. See
Figure 105.

67
Fuel System Repair 0600 YRM 1579

8. Remove serpentine belt and fan assembly. See 9. Remove six flange bolts, injection pump gear
Cooling System Repair section for procedure. cover, and gasket from front of timing gear case
cover. Discard gasket. See Figure 106.

1. FUEL INJECTION PUMP 7. GEAR

2. STUD 8. LOCKNUT
3. NUT 9. TIMING GEAR CASE
4. INJECTION PUMP BASE 10. COVER GASKET
5. BASE GASKET 11. INJECTION PUMP GEAR COVER
6. FLANGE BOLT 12. KEY

Figure 106. Fuel Injection Pump

NOTE: When positioning piston of 4th cylinder to

TDC, rotate flywheel counterclockwise and align TC
mark on flywheel with top of inspection port on
flywheel housing (see Figure 107). If fuel injection
pump gear timing mark meshes with idler gear, then
piston of 4th cylinder is TDC. If they do not mesh,
rotate flywheel counterclockwise one revolution.
10. Put piston of number 4 cylinder at top dead center
(TDC). See Figure 107.

68
0600 YRM 1579 Fuel System Repair

1. FUEL INJECTION PUMP DRIVE GEAR

2. FUEL INJECTION PUMP GEAR MOUNTING NUT
3. TIMING MARK
4. IDLER GEAR
5. ALIGNMENT MARK

Figure 108. Fuel Pump Drive Gear Timing

Alignment

12. While holding flywheel from turning with a

flywheel stopper tool, remove fuel injection pump
drive gear locknut. See Figure 106.

13. Remove two plugs and two washers from side of

fuel injection pump housing. See Figure 109.

1. TDC MARK
2. SERVICE HOLE
3. INSPECTION PORT

Figure 107. Kubota 3.6L TDC Mark

A. REMOVE PLUGS HERE
NOTE: This alignment mark is extremely useful during
assembly of fuel injection pump drive gear and idler 1. PLUG
gear to get timing correct. 2. WASHER
11. To aid in reassembly, mark one tooth on idler gear Figure 109. Fuel Injection Pump Plugs
with a dot of white paint. See Figure 108.

69
Fuel System Repair 0600 YRM 1579

NOTE: Use
8 mm x 1.25 mm x 45 mm
(0.315 in x 0.05 in x 1.77 in.) socket setscrew for fuel
injection pump camshaft lock screw.
14. Insert socket setscrew into upper port in side of
fuel injection pump assembly housing. This screw
will act as a fuel injection pump camshaft lock
screw. See Figure 110.

1. FLANGE NUT
2. FLANGE BOLT
3. BRACKET

Figure 111. Fuel Injection Pump Assembly

Mounting

18. Remove two flange bolts and bracket from engine

block and back of fuel injection pump assembly.
See Figure 111.
1. SOCKET SETSCREW

Figure 110. Fuel Injection Pump Camshaft Lock CAUTION

Screw
As mounting nuts are removed the fuel injection
pump assembly will need to be supported during
15. Insert socket setscrew into lower port in side of
removal. Failure to do so could result in injury or
fuel injection pump assembly housing. This screw
damage to component if it is dropped.
will act as a fuel injection pump camshaft lock
screw. See Figure 110. 19. Remove three flange nuts holding fuel injection
pump assembly to back of timing case housing.
NOTE: The fuel injection pump shaft is tapered with a
See Figure 111.
woodruff key. Once you have applied some pressure
with a puller, a slight tap with a hammer on center 20. Remove fuel injection pump assembly, woodruff
puller bolt will help pop gear from shaft. key, and O-ring. Discard O-ring. See Figure 106.
16. Using a two-bolt gear puller, remove fuel injection
pump drive gear from fuel injection pump shaft. Disassemble
NOTE: It is not necessary to remove fuel injection
17. Remove two flange nuts from bracket at back of
pump assembly from lift truck to perform Disassemble
fuel injection pump assembly. See Figure 111.
procedure.

1. If fuel injection lift pump assembly has not been

removed from lift truck, remove fuel injection lines
and hoses. See Valve Covers and Fuel Injectors
for procedure.

2. Remove two socket head bolts and fuel shutdown

solenoid from fuel injection pump assembly. See
Figure 112.

70
0600 YRM 1579 Fuel System Repair

NOTE: SOME ASSEMBLY COMPONENTS RE- NOTE: SOME ASSEMBLY COMPONENTS RE-
MOVED FOR CLARITY. MOVED FOR CLARITY.

1. SOCKET HEAD BOLT 1. BOOST ACTUATOR

2. FUEL SHUT DOWN SOLENOID 2. O-RING
3. FUEL INJECTION PUMP ASSEMBLY 3. FUEL INJECTION PUMP ASSEMBLY

Figure 112. Fuel Shut Down Solenoid Figure 113. Boost Actuator

3. Remove boost actuator and O-ring from fuel 4. Remove inspection port cover from fuel injection
injection pump assembly. Discard O-ring. See pump assembly housing. See Figure 114.
Figure 113.

1. INSPECTION PORT COVER

Figure 114. Inspection Port Cover

71
Fuel System Repair 0600 YRM 1579

5. Unhook start spring from rack pin on fuel injection

pump. See Figure 115.

1. START SPRING
2. RACK PIN
3. LOCK NUT
4. GOVERNOR ROD

Figure 115. Governor Connector Rod Components

6. Remove lock nut from rack pin. See Figure 115.

7. Remove governor connector rod from rack pin of

fuel injection pump. See Figure 116. 1. FLANGE NUT
2. FLANGE BOLT
3. FUEL INJECTION PUMP
4. GASKET
5. FUEL INJECTION PUMP ASSEMBLY

Figure 117. Fuel Injection Pump

9. Remove fuel injection pump and gasket from fuel

injection pump assembly. Discard gasket. See
Figure 117.

Clean and Inspect

Clean all old sealant from timing gear case cover and
fuel injection pump drive gear cover. Inspect all parts
for damage. Replace as needed.
1. GOVERNOR CONNECTOR ROD

Figure 116. Governor Connector Rod Assemble

1. Install gasket and fuel injection pump onto fuel
8. Remove four flange nuts and two flange bolts injection pump assembly. See Figure 117.
from fuel injection pump assembly. See
Figure 117. 2. Install two flange bolts onto fuel injection pump
assembly. Tighten bolts to
24 to 27 N•m (18 to 20 lbf ft). See Figure 117.

3. Install four flange nuts onto fuel injection pump

assembly. Tighten nuts to
18 to 20 N•m (13 to 15 lbf ft). See Figure 117.

72
0600 YRM 1579 Fuel System Repair

4. Slide governor connecting rod onto rack pin of 4. Install two flange nuts to bracket on back of fuel
fuel injection pump. See Figure 116. injection pump assembly. See Figure 111.

5. Insert governor connecting rod JIG (Yale P/N 5. Install fuel injection pump drive gear using
582023341 ) into fuel shut down solenoid alignment marks on fuel injection pump gear and
mounting hole on fuel injection pump assembly. idler gear. See Figure 108.

6. Install governor connecting rod lock nut onto rack 6. Install locknut onto shaft of fuel injection pump.
pin. DO NOT tighten at this time. See Figure 115. Tighten locknut to 74 to 83 N•m (55 to 61 lbf ft).

7. While holding down governor connecting rod JIG 7. Install new cover gasket, injection pump gear
(Yale P/N 582023341 ), tighten lock nut for cover, and six flange bolts into timing gear case
governor connecting rod. Tighten lock nut to cover. Tighten bolts to
2.8 to 4.0 N•m (24.7 to 35 lbf in). See Figure 115. 24 to 27 N•m (18 to 20 lbf ft).

8. Remove governor connecting rod JIG from shut 8. Install fan assembly and serpentine belt. See
down solenoid mounting hole. Cooling System Repair for procedure.

9. Install start spring onto rack pin of fuel injection 9. Connect lubricating pipe to engine block just
pump. See Figure 115. below fuel injection pump assembly. See
Figure 105.
10. Install inspection port cover to side of fuel
injection pump housing. See Figure 114. 10. Remove two socket setscrews from side of fuel
injection pump housing. See Figure 109.
11. Install new O-ring and boost actuator onto fuel
injection pump assembly. Tighten actuator to 11. Install two washers and two plugs into side of fuel
40 to 45 N•m (29 to 33 lbf ft). See Figure 113. injection pump housing. See Figure 109.

12. Install fuel shut down solenoid and two socket

head bolts onto fuel injection pump assembly. CAUTION
See Figure 112. DO NOT bend any of the fuel lines when installing
them.
13. If fuel injection lift pump assembly was not
removed from lift truck, install fuel injection lines 12. Install fuel injector lines, fuel injectors, and valve
and hoses. See Valve Covers and Fuel Injectors covers. See Valve Covers and Fuel Injectors
for procedure. section.

Install 13. Remove caps from overflow pipe and bleeder

1. Install new O-ring, woodruff key, and injection valve. Install fuel return hose to overflow pipe and
pump onto rear of timing gear case. See bleeder valve. See Figure 105.
Figure 106.
14. Remove plug from fuel supply hose. Install fuel
2. Install three flange nuts onto three studs holding supply hose and clamp to fuel lift pump. See
injection pump in place. Tighten nuts to Figure 105.
18 to 20 N•m (13 to 15 lbf ft). See Figure 111.

3. Install bracket and two flange bolts to engine

block and back of fuel injection pump assembly.
See Figure 111.

73
Fuel System Repair 0600 YRM 1579

15. Install engine harness bracket, flange bolt and • Open bleeder valve located on fuel injection
two capscrews onto intake manifold. See pump. See Figure 105.
Figure 105. • Pump fuel into fuel system using hand primer
pump on fuel filter.
16. Attach electrical harness and clips to engine • Continue pumping until fuel is present at
harness bracket. See Figure 105. bleeder valve.
• Close bleeder valve.
17. Connect electrical connector to solenoid on top of
fuel injection pump. See Figure 105.
19. Turn ignition to ON position and start engine
18. Prime fuel system using procedure outlined normally.
below:
20. Check fuel lines and hoses for leaks.

74
0600 YRM 1579 Cooling System Repair

Cooling System Repair

SERPENTINE BELT Inspect
Remove Inspect serpentine belt for cracks, oil, wear, and
damage. If any of these conditions exist, replace
serpentine belt.
WARNING
During engine operation, be careful not to touch Install
the fan, pulleys, or drive belts. Contact with these
parts can cause serious injury. 1. Place serpentine belt over pulleys.

2. Adjust tension of serpentine belt as shown in

section Serpentine Belt, Adjustment.
WARNING
The radiator or other parts of the cooling system 3. Tighten set bolt for alternator to
may be hot or under pressure and can cause 25.5 N•m (18.8 lbf ft).
serious injury. Wait 30 minutes for the radiator to
cool. Do a touch test by touching the radiator with 4. Install fan assembly.
your hand. If the radiator is still hot to the touch, See Cooling System 0700YRM1123
wait another 30 minutes before attempting to
check or fix any part of the cooling system. • GDP40VX5/VX6; GDP45SVX5,GDP45VX6,
GDP50-55VX (GDP080-120VX) (H813, J813)
1. Turn ignition switch to OFF position. • GDP60-70VX (GDP135-155VX) (E878)

2. Remove fan assembly. See Cooling System 0700YRM1895 for lift truck
models
See Cooling System 0700YRM1123
• GDP40VX5/VX6; GDP45SVX5,GDP45VX6,
• GDP40VX5/VX6; GDP45SVX5,GDP45VX6, GDP50-55VX (GDP080-120VX) (K813)
GDP50-55VX (GDP080-120VX) (H813, J813)
See Cooling System 0700YRM1950 for lift truck
• GDP60-70VX (GDP135-155VX) (E878) models
See Cooling System 0700YRM1895 for lift truck • GDP60-70VX (GDP135-155VX) (F878)
models
• GDP60VX, GDP70VX, GP70VXS6
• GDP40VX5/VX6; GDP45SVX5,GDP45VX6, (GDP135VX. GDP155VX, GP155VXS) (G878)
GDP50-55VX (GDP080-120VX) (K813) GP60VX, GP70VX, GP70SVX, GP70SVX9,
•
See Cooling System 0700YRM1950 for lift truck GP80SVX (GP135VX, GP155VX, GP155SVX,
models GP170SVX) (H878)
• GDP60-70VX (GDP135-155VX) (F878)
Serpentine Belt, Adjustment
• GDP60VX, GDP70VX, GP70VXS6
(GDP135VX. GDP155VX, GP155VXS) (G878) NOTE: The serpentine belt is to be checked at
position A or B shown in Figure 118.
• GP60VX, GP70VX, GP70SVX, GP70SVX9,
GP80SVX (GP135VX, GP155VX, GP155SVX, 1. Using a belt tension gauge, adjust belt tension to
GP170SVX) (H878) 500 to 550 N (112 to 124 lbf).

3. Loosen alternator set bolt and pivot alternator

toward engine.

4. Remove serpentine belt from pulleys.

75
Cooling System Repair 0600 YRM 1579

3. When tension is correct, tighten set bolt to

25.5 N•m (18.8 lbf ft). Check belt tension again to
verify tension is still correct.

4. Repeat Step 1 through Step 3 if necessary.

WATER PUMP
Remove
1. Turn ignition switch to OFF position.

2. Disconnect negative battery cable at battery.

WARNING
DO NOT remove the radiator cap from the radiator
when the engine is hot. When the radiator cap is
removed, pressure will release from the coolant
system. If the coolant system is hot, the steam and
A. TENSION CHECK POSITION boiling coolant can cause severe burns.
B. TENSION CHECK POSITION

Figure 118. Serpentine Tension Check Points

WARNING
2. If adjustment is necessary, loosen alternator set The radiator or other parts of the cooling system
bolt and move alternator with a pry bar to tighten may be hot or under pressure and can cause
serpentine belt. See Figure 119. serious injury. Wait 30 minutes for the radiator and
engine to cool before performing maintenance to
the cooling system. After 30 minutes, do a touch
test by touching the radiator with your hand. If the
radiator is still hot to the touch, wait another 30
minutes before attempting any maintenance to the
cooling system.

CAUTION
Disposal of lubricants must meet local
environmental regulations.

3. Remove radiator cap.

4. Loosen lower radiator hose and drain coolant

from coolant system into a suitable container.

5. Remove coolant drain plug and drain coolant from

engine block. See Figure 120.

1. SET BOLT
2. ALTERNATOR
3. PRY BAR

Figure 119. Serpentine Belt Adjustment

76
0600 YRM 1579 Cooling System Repair

1. COOLANT DRAIN PLUG

Figure 120. Engine Block Coolant Drain Plug

1. IDLER ASSEMBLY
6. Remove fan assembly. 2. BOLT
See Cooling System 0700YRM1123 3. PULLEY
4. SPACER
• GDP40VX5/VX6; GDP45SVX5,GDP45VX6, 5. COLLAR
GDP50-55VX (GDP080-120VX) (H813, J813) 6. WATER FLANGE
7. WATER PUMP
• GDP60-70VX (GDP135-155VX) (E878)
See Cooling System 0700YRM1895 for lift truck Figure 121. Water Pump Pulley
models
10. Pivot alternator away from engine.
• GDP40VX5/VX6; GDP45SVX5,GDP45VX6,
GDP50-55VX (GDP080-120VX) (K813) 11. Disconnect electrical connector for coolant
See Cooling System 0700YRM1950 for lift truck temperature sensor.
models
12. If necessary, remove coolant temperature sensor.
• GDP60-70VX (GDP135-155VX) (F878)
• GDP60VX, GDP70VX, GP70VXS6 13. Disconnect coolant hoses from water pump. See
(GDP135VX. GDP155VX, GP155VXS) (G878) Cylinder Head Assembly Repair section for
• GP60VX, GP70VX, GP70SVX, GP70SVX9, procedure.
GP80SVX (GP135VX, GP155VX, GP155SVX,
GP170SVX) (H878) 14. Remove four water pump bolts and water pump.
See Figure 122.
7. Remove serpentine belt. See Serpentine Belt,
Remove. 15. Remove two bolts, gasket, and water pump from
water pump housing. Discard gasket. See
8. Remove three bolts and idler assembly from Figure 122.
water pump assembly. See Figure 121.
16. Remove and discard O-ring. See Figure 122.
9. Remove eight bolts, collar, spacer, and two fan
pulleys from water pump and water flange. See
Figure 121.

77
Cooling System Repair 0600 YRM 1579

• GDP60-70VX (GDP135-155VX) (E878)

See Cooling System 0700YRM1895 for lift truck
models
• GDP40VX5/VX6; GDP45SVX5,GDP45VX6,
GDP50-55VX (GDP080-120VX) (K813)
See Cooling System 0700YRM1950 for lift truck
models
• GDP60-70VX (GDP135-155VX) (F878)
• GDP60VX, GDP70VX, GP70VXS6
(GDP135VX. GDP155VX, GP155VXS) (G878)
• GP60VX, GP70VX, GP70SVX, GP70SVX9,
GP80SVX (GP135VX, GP155VX, GP155SVX,
GP170SVX) (H878)

1. BOLT 4. WATER PUMP 11. Connect lower radiator hose.

2. WATER PUMP HOUSING
3. GASKET 5. O-RING 12. Install coolant drain plug in engine block. See
6. ENGINE BLOCK
Figure 120.
Figure 122. Water Pump

Install CAUTION
Additives may damage the cooling system. Before
1. Install new gasket, water pump, and two bolts to
using additives, contact your local Yale dealer.
water pump housing. See Figure 122.
13. Fill cooling system with coolant. For correct
2. Install new O-ring, water pump assembly, and coolant amount and type refer to
four bolts to engine block. See Figure 122.
Periodic Maintenance 8000YRM1558 for lift
3. Connect coolant hoses to water pump. See truck models
Cylinder Head Assembly Repair for procedure. • GDP40VX5/VX6; GDP45SVX5,GDP45VX6,
GDP50-55VX (GDP080-120VX) (H813)
4. If removed, install coolant temperature sensor
and tighten to 16 to 23 N•m (12 to 17 lbf ft). Periodic Maintenance 8000YRM1583 for lift
truck models
5. Connect electrical connector for coolant • GDP60-70VX (GDP135-155VX) (E878)
temperature sensor.
Periodic Maintenance 8000YRM1604 for lift
6. Install plate with tension pulley and three truck models
capscrews. See Figure 121. • GDP40VX5/VX6; GDP45SVX5,GDP45VX6,
GDP50-55VX (GDP080-120VX) (J813)
7. Install water pump pulley and four capscrews.
Periodic Maintenance 8000YRM1902 for lift
See Figure 121.
truck models
8. Install fan pulley. • GDP40VX5/VX6; GDP45SVX5,GDP45VX6,
GDP50-55VX (GDP080-120VX) (K813)
9. Install serpentine belt. See Serpentine Belt, See Periodic Maintenance 8000YRM1957 for lift
Install. truck models
10. Install fan assembly. • GDP60-70VX (GDP135-155VX) (F878)
See Cooling System 0700YRM1123 See Periodic Maintenance 8000YRM2196
• GDP40VX5/VX6; GDP45SVX5,GDP45VX6, • GDP60VX, GDP70VX, GP70VXS6
GDP50-55VX (GDP080-120VX) (H813, J813) (GDP135VX. GDP155VX, GP155VXS) (G878)

78
0600 YRM 1579 Cooling System Repair

• GP60VX, GP70VX, GP70SVX, GP70SVX9,

GP80SVX (GP135VX, GP155VX, GP155SVX,
GP170SVX) (H878) CAUTION
Additives may damage the cooling system. Before
14. Install radiator cap. using additives, contact your local Yale dealer.

15. Connect negative battery cable. 17. Stop engine. If coolant is hot, allow engine time to
cool. Check coolant level and fill as required
between ADD and FULL marks on coolant
WARNING reservoir.
During engine operation, be careful not to touch
the fan, pulleys, or drive belts. Contact with these THERMOSTAT
parts can cause serious injury. Remove

WARNING WARNING
The radiator or other parts of the cooling system The radiator or other parts of the cooling system
may be hot or under pressure and can cause may be hot or under pressure and can cause
serious injury. serious injury. Wait 30 minutes for the radiator and
engine to cool before performing maintenance to
16. Start engine and check cooling system for leaks. the cooling system. After 30 minutes, do a touch
test by touching the radiator with your hand. If the
radiator is still hot to the touch, wait another 30
WARNING minutes before attempting any maintenance to the
cooling system.
DO NOT remove the radiator cap from the radiator
when the engine is hot. When the radiator cap is
removed, pressure will release from the coolant
system. If the coolant system is hot, the steam and CAUTION
boiling coolant can cause severe burns. DO NOT operate the engine without a thermostat.
The engine and cooling system can be damaged.

WARNING
The radiator or other parts of the cooling system CAUTION
may be hot or under pressure and can cause Disposal of lubricants must meet local
serious injury. Wait 30 minutes for the radiator and environmental regulations.
engine to cool before performing maintenance to
the cooling system. After 30 minutes, do a touch 1. Drain cooling system to level of thermostat.
test by touching the radiator with your hand. If the
2. Disconnect coolant hose from thermostat cover.
radiator is still hot to the touch, wait another 30
minutes before attempting any maintenance to the
3. Remove three bolts holding thermostat cover.
cooling system.
Remove thermostat cover and gasket. Discard
gasket. See Figure 123.

79
Cooling System Repair 0600 YRM 1579

1. THERMOMETER
2. THERMOSTAT

Figure 124. Thermostat Check

2. Slowly increase temperature of water.

3. The thermostat is operating correctly if it starts to

1. BOLT
2. THERMOSTAT COVER open at temperature value stamped on flange of
3. GASKET thermostat and fully opens as temperature of
4. THERMOSTAT water is increased.
5. WATER FLANGE
Install
Figure 123. Thermostat
1. Install thermostat into water flange. See
4. Remove thermostat from water flange. See Figure 123.
Figure 123.
2. Install thermostat cover and a new gasket. Install
Inspect bolts to hold thermostat cover. Tighten bolts to
23 to 28 N•m (17 to 21 lbf ft).
1. Place thermostat and an accurate thermometer in
warm water. See Figure 124. 3. Connect coolant hose to thermostat cover. See
Figure 123.

CAUTION
Additives may damage the cooling system. Before
using additives, contact your local Yale dealer.

4. Fill cooling system with coolant. For correct

coolant amount and type refer to
Periodic Maintenance 8000YRM1558 for lift
truck models
• GDP40VX5/VX6; GDP45SVX5,GDP45VX6,
GDP50-55VX (GDP080-120VX) (H813)

80
0600 YRM 1579 Cooling System Repair

Periodic Maintenance 8000YRM1586 for lift

5. Start engine and check cooling system for leaks.
truck models
• GDP60-70VX (GDP135-155VX) (E878)
Periodic Maintenance 8000YRM1604 for lift WARNING
truck models DO NOT remove the radiator cap from the radiator
when the engine is hot. When the radiator cap is
• GDP40VX5/VX6; GDP45SVX5,GDP45VX6, removed, pressure will release from the coolant
GDP50-55VX (GDP080-120VX) (J813)
system. If the coolant system is hot, the steam and
Periodic Maintenance 8000YRM1902 for lift boiling coolant can cause severe burns.
truck models
• GDP40VX5/VX6; GDP45SVX5,GDP45VX6,
GDP50-55VX (GDP080-120VX) (K813) WARNING
See Periodic Maintenance 8000YRM1957 for lift The radiator or other parts of the cooling system
truck models may be hot or under pressure and can cause
serious injury. Wait 30 minutes for the radiator and
• GDP60-70VX (GDP135-155VX) (F878,)
engine to cool before performing maintenance to
See Periodic Maintenance 8000YRM2196 the cooling system. After 30 minutes, do a touch
GDP60VX, GDP70VX, GP70VXS6 test by touching the radiator with your hand. If the
•
(GDP135VX. GDP155VX, GP155VXS) (G878) radiator is still hot to the touch, wait another 30
minutes before attempting any maintenance to the
• GP60VX, GP70VX, GP70SVX, GP70SVX9,
cooling system.
GP80SVX (GP135VX, GP155VX, GP155SVX,
GP170SVX) (H878)

CAUTION
WARNING Additives may damage the cooling system. Before
During engine operation, be careful not to touch using additives, contact your local Yale dealer.
the fan, pulleys, or drive belts. Contact with these
parts can cause serious injury. 6. Stop engine. If coolant is hot, allow engine time to
cool. Check coolant level and fill as required
between ADD and FULL marks on coolant
reservoir.
WARNING
The radiator or other parts of the cooling system
may be hot or under pressure and can cause
serious injury.

81
Flywheel and Flywheel Housing 0600 YRM 1579

Flywheel and Flywheel Housing

FLYWHEEL Install
Remove 1. Place flywheel in position on crankshaft flange
and install seven bolts. Tighten bolts to
1. Remove engine. See section 98 to 107 N•m (72 to 80 lbf ft).
See Frame 0100YRM1243 for lift truck models
2. Install engine.
• GDP40VX5/VX6; GDP45SVX5,GDP45VX6,
GDP50-55VX (GDP080-120VX) (H813, J813) See Frame 0100YRM1243 for lift truck model
See Frame 0100YRM1581 for lift truck models • GDP40VX5/VX6; GDP45SVX5,GDP45VX6,
GDP50-55VX (GDP080-120VX) (H813, J813)
• GDP60-70VX (GDP135-155VX) (E878)
See Frame 0100YRM1891 for lift truck models See Frame 0100YRM1581 for lift truck models
• GDP40VX5/VX6; GDP45SVX5, GDP45VX6; • GDP60-70VX (GDP135-155VX) (E878)
GDP50-55VX (GDP080-120VX) (K813)
See Frame 0100YRM1891 for lift truck models
See Frame 0100YRM1948 for lift truck models
• GDP40VX5/VX6; GDP45SVX5, GDP45VX6;
• GDP60-70VX (GDP135-155VX) (F878) GDP50-55VX (GDP080-120VX) (K813)
• GDP60VX, GDP70VX, GP70VXS6 See Frame 0100YRM1948 for lift truck models
(GDP135VX. GDP155VX, GP155VXS) (G878)
• GDP60-70VX (GDP135-155VX) (F878)
• GP60VX, GP70VX, GP70SVX, GP70SVX9,
GP80SVX (GP135VX, GP155VX, GP155SVX, • GDP60VX, GDP70VX, GP70VXS6
GP170SVX) (H878) (GDP135VX. GDP155VX, GP155VXS) (G878)
• GP60VX, GP70VX, GP70SVX, GP70SVX9,
2. Remove seven bolts holding flywheel to GP80SVX (GP135VX, GP155VX, GP155SVX,
crankshaft flange and remove flywheel. See GP170SVX) (H878)
Figure 125.
FLYWHEEL HOUSING
Remove
1. Remove flywheel. See Flywheel, Remove.

2. Remove ten bolts holding flywheel housing to

cylinder block. See Figure 125.

3. Remove flywheel housing.

Install
1. Place flywheel housing in position on cylinder
block and install bolts. Tighten bolts to
78 to 90 N•m (58 to 66 lbf ft).

1. FLYWHEEL HOUSING 2. Install flywheel. See Flywheel, Install.

2. FLYWHEEL
3. BOLT
4. CRANKSHAFT
5. ENGINE BLOCK

Figure 125. Flywheel and Housing

82
0600 YRM 1579 Electrical Equipment Repair

Electrical Equipment Repair

NOTE: This section covers repair procedures for
1. Disconnect battery negative cable at negative
major electrical components only, if engine specific
terminal.
sensors or switches need to be serviced
See Electrical System 2200YRM1142 for lift truck 2. Disconnect battery positive cable at positive
models terminal.
• GDP40VX5/VX6; GDP45SVX5,GDP45VX6,
3. Put labels on wires prior to disconnecting to aid in
GDP50-55VX (GDP080-120VX) (H813, J813)
correct installation.
• GDP60-70VX (GDP135-155VX) (E878)
See Electrical System 2200YRM1901 for lift truck 4. Disconnect wires from alternator.
models
5. Loosen set bolt on alternator and tilt alternator
• GDP40VX5/VX6; GDP45SVX5, GDP45VX6; towards engine.
GDP50-55VX (GDP080-120VX) (K813)
See Electrical System 2200YRM1954 for lift truck 6. Remove serpentine belt from alternator pulley.
models
7. Remove set bolt from alternator. See Figure 126.
• GDP60-70VX (GDP135-155VX) (F878)
• GDP60VX, GDP70VX, GP70VXS6
(GDP135VX. GDP155VX, GP155VXS) (G878)
• GP60VX, GP70VX, GP70SVX, GP70SVX9,
GP80SVX (GP135VX, GP155VX, GP155SVX,
GP170SVX) (H878)

ALTERNATOR
Remove

WARNING
Always disconnect the cables at the battery before
you make repairs to the engine. Disconnect the
cable at the negative terminal first. Install a tag on
the battery terminals so that no one connects the
cables on the terminals.

83
Electrical Equipment Repair 0600 YRM 1579

1. WATER FLANGE 6. TIMING GEAR CASE

2. SET BOLT 7. WELDED NUT
3. ALTERNATOR ADJUSTMENT BRACKET 8. ALTERNATOR MOUNTING BRACKET
4. ALTERNATOR 9. WASHER
5. BOLT 10. SERPENTINE BELT

Figure 126. Alternator

8. If necessary, remove bolt holding alternator 5. Install serpentine belt and adjust to proper
adjustment bracket to water flange and remove tension. See Cooling System Repair, Serpentine
bracket. Belt, Adjustment.

9. Remove bolt holding alternator to alternator 6. Tighten set bolt to 25.5 N•m (18.8 lbf ft).
mounting bracket. Remove alternator.
7. Connect battery positive cable at positive
Install terminal.
1. If removed, place alternator adjustment bracket in 8. Connect battery negative cable at negative
position and install bolt to retain bracket to water terminal.
flange.
9. Start engine and listen for any unusual sounds
2. Position alternator on alternator mounting from alternator.
bracket. Install bolt holding alternator to alternator
mounting bracket, but do not tighten. 10. Verify that charge indicator is ON while engine is
operating. If charge indicator is not ON, repair
3. Install set bolt for alternator and adjustment problem before operating engine.
bracket but do not tighten.

4. Connect electrical wires to alternator.

84
0600 YRM 1579 Electrical Equipment Repair

STARTER Install
Remove 1. Place starter in position in flywheel housing.
Install two M10 bolts on starter and flywheel
housing.
WARNING
Always disconnect the cables at the battery before 2. Connect wires and cables as labeled in removal.
you make repairs to the engine. Disconnect the Tighten M8 nut, B terminal, to
cable at the negative terminal first. Install a tag on 7.9 to 9.8 N•m (70 to 87 lbf in). Be sure to place
the battery terminals so that no one connects the cover over M4 screw connection. See Figure 128.
cables on the terminals.

1. Disconnect battery negative cable at negative

terminal.

2. Disconnect battery positive cable at positive

terminal.

3. Put labels on wires and cables prior to

disconnecting to aid in correct installation.

4. Disconnect wires and cables from starter.

5. Hold starter so it won't fall. Remove two M10

bolts and starter from flywheel housing. See
Figure 127.

NOTE: ILLUSTRATION USED FOR REFERENCE

ONLY.

1. M8 NUT
2. COVER
3. M4 SCREW
4. STARTER

Figure 128. Starter Connections

3. Connect battery positive cable at positive

1. FLYWHEEL HOUSING terminal.
2. M10 BOLT
3. STARTER 4. Connect battery negative cable at negative
terminal.
Figure 127. Starter

85
Engine Specifications 0600 YRM 1579

Engine Specifications
ENGINE DATA

Table 7. V3600-T-E3B Engine

Engine Model 1J408-32000 (Yale P/N 582016815 )
Type Vertical Inline Diesel Engine
Combustion System Spherical Type (E-TVCS)
Aspiration Turbo Charged
No. of Cylinders 4
Ignition Order 1-3-4-2
Bore × Stroke 98 × 120 mm (3.86 × 4.72 in.)
Displacement 3.620 liter (220.9 cu in.)
Max. Rated Output (Net) rpm 2200
(min-1)
hp SAE 76.5
kW 57.2
PS 46.2
High Idle Speed (Bare Engine) 2400 ± 50 rpm
Low Idle Speed (Bare Engine) 850 ± 50 rpm
Engine Weight (Dry)* 275 kg (606 lb)
Direction of Rotation Counter-counterclockwise Viewed From Flywheel Side
Cooling System Liquid-Cooled With Radiator
Lubricating System Forced Lubrication With Trochoid Pump
Starting System Electric Starting Starter Motor: DC12V, 3.0 kW (4.0 hp)
Alternator: DC12V, 80A
Recommended Battery Capacity: 12V, 1050 to 1200 CCA (Cold Cranking
Amps)
Dimensions (L × W × H)* 632 × 498 × 711 mm (24.9 × 19.6 × 28.0 in.)
Engine Oil Pan Capacity 13.2 liter (13.9 qt)
Engine Coolant Capacity 4.9 liter (1.3 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.

ENGINE TUNING

Inspection Item Standard Limit

Valve Gap Intake/Exhaust (Engine Cold) 0.23 to 0.27 mm (0.009 to
0.011 in.)
Compression Pressure at 250 rpm 3.92 MPa (569 psi) 2.99 MPa (434 psi)

86
0600 YRM 1579 Engine Specifications

Inspection Item Standard Limit

Lubricating Oil Pressure At rated output 0.20 to 0.39 MPa (29 to 57 psi)
When Idling 0.05 MPa or greater
(7.3 psi)
Thermostat Valve Opening Temperature Full Opening Lift
Temperature
74.5 to 78.5°C (166.1 to 90°C (194°F)
173.3°F)

CYLINDER HEAD

Inspection Item Standard Limit

Combustion Surface Distortion (Flatness) 0.05 mm (0.0020 in.)
Valve Sink Intake -0.2 to 0.0 mm (-0.007 to 0.4 mm (0.02 in.)
0.00 in.)
Exhaust -0.050 to 0.15 mm 0.4 mm (0.02 in.)
(-0.0019 to 0.0059 in.)
Valve Seat Angle Intake 60°
Exhaust 45°

INTAKE/EXHAUST VALVE AND GUIDE

Inspection Item Standard Limit

Intake Valve Guide Inside Diameter 7.030 to 7.045 mm (0.2768 to
0.2773 in.)
Valve Stem Outside Diameter 6.960 to 6.975 mm (0.2741 to
0.2746 in.)
Oil Clearance 0.055 to 0.085 mm (0.0022 to 0.10 mm (0.004 in.)
0.0033 in.)
Exhaust Valve Guide Inside Diameter 8.015 to 8.030 mm (0.3156 to
0.3161 in.)
Valve Stem Outside Diameter 7.960 to 7.975 mm (0.3134 to
0.3439 in.)
Oil Clearance 0.040 to 0.070 mm (0.0016 to 0.10 mm (0.004 in.)
0.0027 in.)

87
Engine Specifications 0600 YRM 1579

VALVE SPRING

Inspection Item Standard Limit

Free Length 35.1 to 35.6 mm (1.39 to 34.6 mm (1.36 in.)
1.40 in.)
Inclination 1.0 mm (0.039 in.)

ROCKER ARM AND SHAFT

Inspection Item Standard Limit

Arm Shaft Hole Diameter 16.0 to 16.018 mm
(0.62993 to 0.63062 in.)
Shaft Outside Diameter 15.973 to 15.984 mm
(0.62886 to 0.62929 in.)
Clearance 0.0016 to 0.045 mm 0.15 mm (0.0059 in.)
(0.00063 to 0.0017 in.)

PUSH ROD

Inspection Item Standard Limit

Push Rod Bend 0.25 mm (0.0098 in.)

GEAR TRAIN AND CAMSHAFT

Camshaft

Inspection Item Standard Limit

Camshaft Oil Clearance 0.070 to 0.22 mm (0.0028 to 0.30 mm
0.0086 in.) (0.0118 in.)
Cam Height Intake 37.64 mm (1.482 in.) 37.14 mm
(1.462 in.)
Exhaust 38.96 mm (1.534 in.) 38.46 mm
(1.514 in.)

Idle Gear Shaft and Bushing

Inspection Item Standard Limit

Shaft Outside Diameter 44.959 to 44.975 mm
(1.7701 to 1.7706 in.)
Bushing Inside Diameter 45.025 to 45.050 mm 46.075 mm (1.8140 in.)
(1.7727 to 1.7736 in.)
Clearance 0.050 to 0.091 mm 0.10 mm (0.0039 in.)
(0.0019 to 0.0030 in.)

88
0600 YRM 1579 Engine Specifications

Backlash of Each Gear

Inspection Item Standard Limit

Crank Gear and Cam Gear 0.049 to 0.193 mm 0.22 mm (0.0087 in.)
(0.0031 to 0.0055 in.)
Idler Gear and Fuel Injection Pump Gear 0.0300 to 0.165 mm 0.22 mm (0.0087 in.)
(0.00119 to 0.00649 in.)

CYLINDER BLOCK

Inspection Item Standard Limit

Cylinder Inside Diameter 98.00 to 98.022 mm (3.8583 to 98.150 mm
3.8591 in.) (3.8642 in.)

CRANKSHAFT

Inspection Item Standard Limit

Bending (1/2 the dial gauge reading) 0.02 mm
(0.0008 in.)
Connecting Rod Journals Pin Outside Diameter 52.977 to 52.990 mm (2.0857 to
2.0862 in.)
Clearance 0.018 to 0.062 mm (0.00071 to 0.20 mm
0.0024 in.) (0.0079 in.)
Crank Journal Selective Journal Outside Diameter 74.977 to 74.990 mm (2.9519 to
Pairing 2.9528 in.)
Clearance 0.018 to 0.062 mm (0.00071 to 0.20 mm
0.0024 in.) (0.0079 in.)

PISTON

Inspection Item Standard Limit

Piston Pin Hole Inside Diameter 30.006 to 30.013 mm (1.1814 to 30.05 mm
1.1816 in.) (1.183 in.)
Pin Outside Diameter 30.006 to 30.011 mm (1.1807 to
1.1811 in.)
Clearance 0.020 to 0.040 mm (0.0079 to 0.15 mm
0.0015 in.) (0.0059 in.)

89
Engine Specifications 0600 YRM 1579

PISTON RING

Inspection Item Standard Limit

Top Ring Side Clearance 0.05 to 0.09 mm (0.002 to 0.15 mm (0.0059 in.)
0.003 in.)
End Clearance 0.30 to 0.450 mm (0.012 to 1.25 mm (0.0492 in.)
0.017 in.)
Second Ring Side Clearance 0.093 to 0.120 mm (0.00367 to 0.20 mm (0.0079 in.)
0.00472 in.)
End Clearance 0.30 to 0.45 mm (0.012 to 1.25 mm (0.0492 in.)
0.017 in.)
Oil Ring Side Clearance 0.020 to 0.060 mm (0.00079 to 0.15 mm (0.0059 in.)
0.0023 in.)
End Clearance 0.250 to 0.450 mm (0.0099 to 1.25 mm (0.0492 in.)
0.017 in.)

CONNECTING ROD

Inspection Item Standard Limit

Thrust Clearance 0.05 mm
(0.002 in.)

Rod Small End

Inspection Item Standard Limit

Bushing Outside Diameter 30.031 to 30.046 mm (1.1824 to
1.1829 in.)
Pin Outside Diameter 30.006 to 30.011 mm (1.1814 to
1.1815 in.)
Clearance 0.020 to 0.040 mm (0.00079 to 0.15 mm
0.0015 in.) (0.0059 in.)

Tappet

Inspection Item Standard Limit

Tappet Hole (Block) Inside Diameter 24.000 to 24.021 mm (0.94489 to
0.94570 in.)
Tappet Stem Outside Diameter 23.959 to 23.980 mm (0.94327 to
0.94409 in.)
Clearance 0.020 to 0.062 mm (0.00079 to 0.07 mm (0.003 in.)
0.0024 in.)

90
0600 YRM 1579 Engine Specifications

OIL PUMP
Engine Oil Pressure

Model Number at Rated Engine rpm at Low Idle Speed

All models 0.20 to 0.39 MPa (29 to 56.56 psi) 0.05 MPa (7 psi) or greater

Outer Rotor Outside Clearance

Model Standard Limit

All models 0.100 to 0.184 mm (0.0039 to 0.3 mm (0.01 in.)
0.0062 in.)

Outer Rotor Side Clearance

Model Standard Limit

All models 0.040 to 0.16 mm (0.0016 to 0.3 mm (0.01 in.)
0.0062 in.)

Inner Rotor to Cover

Model Standard Limit

All models 0.025 to 0.075 mm (0.00099 to 0.225 mm (0.00886 in.)
0.0029 in.)

91
Standard Torque Specifications 0600 YRM 1579

Standard Torque Specifications

STANDARD TORQUE CHART

Nominal Thread
Item × Pitch Tightening Torque
Diameter
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
the Tightening Torque when the M8 × 1.25 mm 24 to 27 N•m (18 to 20 lbf ft)
tightening part is aluminum. M10 × 1.5 mm 49 to 55 N•m (37 to 41 lbf ft)
Use 60% of the value of the
Tightening Torque for 4T bolts and M12 × 1.75 mm 78.0 to 90.0 N•m (58 to 66 lbf ft)
lock nuts. M14 × 1.5 mm 127.5 to 147.1 N•m (94 to
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.

92
0600 YRM 1579 Special Torque Specifications

Special Torque Specifications

Alternator Pulley Nut Fuel Injection Pump Mounting Nut
58.4 to 78.9 N•m (43.1 to 58.2 lbf ft) 18 to 20 N•m (13 to 15 lbf ft)

Bearing Cap Set Bolt Fuel Injection Pump Mounting Screw

138 to 147 N•m (102 to 108 lbf ft) 24 to 27 N•m (18 to 20 lbf ft)

Boost Actuator Fuel Overflow Pipe Retaining Nut

40 to 45 N•m (29 to 33 lbf ft) 20 to 24 N•m (15 to 18 lbf ft)

Camshaft Setscrew Glow Plug

24 to 27 N•m (18 to 20 lbf in) 20 to 24 N•m (15 to 18 lbf ft)

Connecting Rod Bolt Governor Connecting Rod Lock Nut

79 to 83 N•m (58 to 61 lbf ft) 2.8 to 4.0 N•m (24.7 to 35.0 lbf in)

Crankshaft Pulley Bolt Idler Gear Mounting Screw

255 to 274 N•m (188 to 202 lbf ft) 24 to 27 N•m (18 to 20 lbf ft)

Cylinder Head Bolt Oil Pressure Switch Screw

98.1 to 107 N•m (72.4 to 79.5 lbf ft) 15 to 19 N•m (11 to 14 lbf ft)

Cylinder Head Cover Screw, Upper Overflow Pipe Joint Screw

10 to 11 N•m (61 to 99 lbf in) 9.8 to 11.2 N•m (86.7 to 99.1 lbf in)

Cylinder Head Cover Screw, Lower Rocker Arm Bracket Nut

7 to 11 N•m (87 to 99 lbf in) 49 to 55 N•m (37 to 41 lbf ft)

Engine Oil Pump Cover Screw Starter Solenoid Nut (B Terminal)

7.9 to 9.3 N•m (70 to 82 lbf in) 9.8 to 11 N•m (87 to 97 lbf in)

Engine Oil Cooler Joint Bolt Timing Gear Case Cover Mounting Screw
40 to 44 N•m (29 to 32 lbf ft) 24 to 27 N•m (18 to 20 lbf ft)

Flywheel Bolts Timing Gear Case Plate Mounting Screw

98.1 to 107 N•m (72.4 to 79.5 lbf ft) 24 to 27 N•m (18 to 20 lbf ft)

Flywheel Housing Bolts Thermostat Cover Bolts

78 to 90 N•m (58 to 66 lbf ft) 23 to 28 N•m (17 to 21 lbf ft)

Fuel Injector Electronic Throttle Shoulder Bolt

49 to 68 N•m (37 to 50 lbf ft) 25.6 N•m (226.6 lbf in)

Fuel Injector Nut Electronic Throttle Linkage Capscrew

18 to 20 N•m (13 to 15 lbf in) 10.5 N•m (92.9 lbf in)

Fuel Pump Gear Cover Mounting Screw Electronic Throttle Bellcrank Weldment Stud Nut
24 to 27 N•m (18 to 20 lbf ft) 10.5 N•m (92.9 lbf in)

Fuel Injection Pump Assembly Mounting Nut Electronic Throttle Lever Plate Capscrew
18 to 20 N•m (13 to 15 lbf ft) 7.9 N•m (70 lbf in)

Fuel Injection Pump Assembly Gear Mounting Nut Electronic Throttle Inline Ball Joint
74 to 83 N•m (55 to 61 lbf ft) 7.9 N•m (70 lbf in)

93
Special Torque Specifications 0600 YRM 1579

Electronic Throttle Fuel Shut Off Solenoid Allen- Electronic Throttle Ball Joint Rod Nut
head Capscrews 25.6 N•m (226.6 lbf in)
10.5 N•m (92.9 lbf in)

Throttle Position Sensor Torx-head Screws

2.25 N•m (20 lbf in)

94
0600 YRM 1579 Special Tools

Special Tools

No. Tool Name Applicable Model and Tool Size Illustration

1 Valve Guide L1 L2 L3 d1 d2 d3
Tool (for
Extracting/ 225 mm 70 mm 45 mm 20 mm 11.7 to 6.50 to
Inserting (8.86 in.) (2.8 in.) (1.8 in.) (0.79 in.) 11.9 mm 6.60 mm
Valve Guide) (0.461 to (0.256 to
0.468 in.) 0.259 in.)

Locally Manufactured
2 Small End A 157 mm (6.16 in.)
Bushing B 14.5 mm (0.571 in.)
Replacemen
t Tool (Press C 120 mm (4.72 in.)
Out) D 30.0 dia. mm (1.18 dia. in.)
E 32.95 dia. mm (1.297 dia. in.)
F 20 mm (0.79 in.)
a 6.3 microns (250 micro inches)
b 6.3 microns (250 micro inches)
C1 Chamfer 1.0 mm (0.039 in.)
C2 Chamfer 2.0 mm (0.079 in.)
Locally Manufactured
3 Small End A 157 mm (6.16 in.)
Bushing B 14.5 mm (0.571 in.)
Replacemen
t Tool (Press C 120 mm (4.72 in.)
In) D 30 dia. mm (1.18 dia. in.)
E 42 dia. mm (1.6535 dia. in.)
F 20 mm (0.79 in.)
a 6.3 microns (250 micro inches)
b 6.3 microns (250 micro inches)
C1 Chamfer 1.0 mm (0.039 in.)
C2 Chamfer 2.0 mm (0.079 in.)
Locally Manufactured

95
Special Tools 0600 YRM 1579

No. Tool Name Applicable Model and Tool Size Illustration

5 Idler Gear A 196 mm (7.72 in.)
Bushing B 3.75 mm (1.48 in.)
Replacemen
t Tool C 150 mm (5.91 in.)
D 44.95 dia. mm (1.770 dia. in.)
E 48.075 to 48.100 dia. mm (1.8928 to 1.8937 dia. in.)
F 20 mm (0.79 in.)
a 6.3 microns (250 micro inches)
b 6.3 microns (250 micro inches)
C1 Chamfer 1.0 mm (0.039 in.)
C2 Chamfer 2.0 mm (0.079 in.)
Locally Manufactured
6 Filter
Wrench (for
Removal/
Available Locally
Installation
of Engine Oil
Filter)
7 Gear Case A 148.8 mm (5.858 in.)
Oil Seal B 50 mm (2.0 in.)
Press Fit
Tool C 18.8 mm (0.740 in.)
D 13.7 to 13.9 mm (0.540 to 0.547 in.)
E 11 mm (0.43 in.)
F 18 dia. mm (0.71 dia. in.)
G 38 dia. mm (1.5 dia. in.)
H 45 dia. mm (1.8 dia. in.)
I 57.90 to 58.10 dia. mm ( 2.280 to 2.287 dia. in.)
J 79.5 dia. mm (3.13 dia. in.)
K 87 dia. mm (3.4 dia. in.)
L 12 mm (0.47 in.)
M 40 mm (1.6 in.)
N 120 mm (4.72 in.)
Locally Manufactured

96
0600 YRM 1579 Special Tools

No. Tool Name Applicable Model and Tool Size Illustration

8 Crankshaft A Rmax = 12.5 S
Sleeve B 94.5 to 95.0 dia. mm (3.72 to 3.74 dia. in.)
Press Tool
C 40 dia. mm (1.6 dia. in.)
D 30 dia. mm (1.2 dia. in.)
E 12 mm (0.47 in.)
F 7.90 to 8.10 mm (0.311 to 0.318 in.)
G 20 mm (0.79 in.)
H 130 dia. mm (5.12 dia. in.)
I 99.40 to 99.60 dia. mm (3.914 to 3.921 dia. in.)
J 95.05 to 95.20 dia. mm (3.743 to 3.748 dia. in.)
K 3 dia. mm (0.1 dia. in.)
L 15 mm (0.59 in.)
M 10 mm (0.39 in.)
N 90 mm (3.5 in.)
O 115 mm (4.53 in.)
P 16.9 to 17.1 mm ( 0.666 to 0.673 in.)
C1 Chamfer 1.0 mm (0.039 in.)
C3 Chamfer 3.0 mm (0.12 in.)
C5 Chamfer 5.0 mm (0.20 in.)
C0.2 Chamfer 0.2 mm (0.008 in.)
C0.3 Chamfer 0.3 mm (0.01 in.)
Locally Manufactured

97
Special Tools 0600 YRM 1579

No. Tool Name Applicable Model and Tool Size Illustration

9 Injector A 10 dia. mm (0.39 dia. in.)
Pump Gear B M16 × Pitch 1.5
Puller
C 19 mm (0.75 in.)
D 0.5 radius mm (0.02 radius. in.)
E 0.87 rad (50°)
F 10 mm (0.39 in.)
G 20 mm (0.79 in.)
H 5 mm (0.2 in.)
I 95 mm (3.7 in.)
J 125 mm (4.92 in.)
K 5 mm (0.2 in.)
L M16 × Pitch 1.5
M 30 mm (1.2 in.)
N 9.5 mm (0.37 in.)
O 11 mm (0.43 in.)
P 9.5 mm (0.37 in.)
Q 5.5 radius mm (0.22 radius in.)
R 3.0 mm (0.12 in.)
S 20 mm (0.79 in.)
T 20 mm (0.79 in.)
U 80 mm (3.1 in.)
W 12 mm (0.47 in.)
C2 Chamfer 2.0 mm (0.079 in.)
Locally Manufactured
10 Flywheel A 140 mm (5.51 in.)
Stopper Tool B 80 mm (3.1 in.)
C 49.3 mm (1.94 in.)
D 49.3 mm (1.94 in.)
E 23.8 mm (0.937 in.)
F 23.8 mm (0.937 in.)
G 11 dia. mm (0.43 dia. in.)
H 56.5 mm (2.22 in.)
I 56.5 mm (2.22 in.)
J 8 mm (0.3 in.)
Locally Manufactured

98
0600 YRM 1579 Special Tools

No. Tool Name Applicable Model and Tool Size Illustration

11 Crankcase 1 A 115 mm (4.53 in.)
and 2 B 56 mm (2.2 in.)
Aligning Tool
C 17 mm (0.67 in.)
D 20 mm (0.79 in.)
E 14 dia. mm (0.55 dia. in.)
F 11 dia. mm (0.43 dia. in.)
G 14 dia. mm (0.55 dia. in.)
H 17.5 mm (0.689 in.)
I 17.5 mm (0.689 in.)
J 35 mm (1.4 in.)
K 19 mm (0.75 in.)
Locally Manufactured
12 Flex-Hone
(for Model Part Number Cylinder Bore
Preparation
4TNE92 Yale P/N 580064718 83 to 95 mm ( in.)
of Cylinder
Walls) 4TNE98 Yale P/N 580062800 89 to 101 mm ( in.)

99
Special Tools 0600 YRM 1579

No. Tool Name Applicable Model and Tool Size Illustration

13 Governor A 1 radius mm (0.04 radius in.)
Connector B Chamfer 0.2 mm (0.008 in.)
Rod JIG.
Yale P/N C Chamfer 2.0 mm (0.08 in.)
582023341 D 35 dia. mm (1.4 dia. in.)
E Chamfer 1.0 mm (0.04 in.)
F Chamfer 0.1 mm (0.004 in.)
G 1.0 radius mm (0.04 radius in.)
H Chamfer 0.2 mm (0.008 in.)
I 8 radius mm (0.3 radius in.)
J 1 radius mm (0.04 radius in.)
K 1 radius mm (0.04 radius in.)
L Chamfer 0.2 mm (0.008 in.)
M Chamfer 0.2 mm (0.008 in.)
N 29 mm (1.1 in.)
O 6 mm (0.2 in.)
P 10.7 mm (0.421 in.)
Q 35 mm (1.4 in.)
R 99.3 mm (3.91 in.)
S 45.65 to 45.75 mm (1.798 to 1.801 in.)
T 145 mm (5.71 in.)
U 16.15 to 16.35 mm (0.6359 to 0.6437 in.)
V 3 mm (0.1 in.)
W 10.0 mm (0.39 in.)
X 8 mm (0.3 in.)
1 Material: S45C-D
Permanent Magnet: 8 dia. mm (0.3 dia. in.) Thickness:
2
3 mm (0.1 in.)
Locally Manufactured
14 Piston Ring
Compressor Yale P/N 580064719
(for Inserting The Piston Insertion Tool is Applicable for
Piston) 60 to 125 mm (2.362 to 4.921 in.)
Diameter Pistons

15 Piston Ring
Replacer (for
Removal/
Available Locally
Installation
of Piston
Ring)

100
0600 YRM 1579 Special Tools

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

crankshaft, pistons, piston pins, etc.

5 Cylinder Gauge For measuring the inside diameters of

cylinder 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.

101
Special Tools 0600 YRM 1579

No. Instrument Name Application Illustration

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.

16 Digital Thermometer For measuring temperature.

102
0600 YRM 1579 Special Tools

No. Instrument Name Application Illustration

17 Tachometer Contact Type For measuring revolution by contacting the
revolving shaft.

Photoelectric For measuring revolution by sensing the

Type reflecting mark on the outer periphery of the
revolving shaft.

Fuel High This measures the revolution regardless of

Pressure Pipe the center of periphery of the revolving object.
Clamp Type
18 Circuit Tester For measuring resistance, voltage, and
continuity of electrical circuits.

19 Compression Gauge Kit For measuring compression pressure. Use

Yale P/N 582023340 for compression test
adaptor.

103
0600 YRM 1579 6/21 (11/19)(10/18)(6/18)(12/15)(10/15)