Yale B974 Service Manual Download Page 1

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GLP20LX, GLP25LX, GDP20LX, GDP25LX (B974)

SERVICE MANUAL CONTENTS

SECTION

PART

NUMBER

YRM

NUMBER

REV

DATE

FRAME............................................................................................................................

550109110

0100 YRM 1766

12/14

YANMAR DIESEL ENGINES..........................................................................................

524240453

0600 YRM 1205

12/14

PSI 2.4L ENGINE............................................................................................................

550108890

0600 YRM 1755

12/14

COOLING SYSTEM........................................................................................................

550109111

0700 YRM 1767

12/14

FUEL SYSTEM PSI 2.4L................................................................................................

550108892

0900 YRM 1757

12/14

SINGLE SPEED PS CHAIN DRIVE PTO........................................................................

550108495

1300 YRM 1740

12/14

DRIVE AXLE AND DIFFERENTIAL ASSEMBLY REPAIR............................................

550109112

1400 YRM 1768

12/14

STEERING AXLE REPAIR.............................................................................................

550109113

1600 YRM 1769

12/14

BRAKE SYSTEM............................................................................................................

550108498

1800 YRM 1743

12/14

HYDRAULIC CLEANLINESS PROCEDURES...............................................................

550073240

1900 YRM 1620

12/14

HYDRAULIC GEAR PUMPS..........................................................................................

550108499

1900 YRM 1744

12/14

MAIN CONTROL VALVE................................................................................................

550108500

2000 YRM 1745

12/14

CYLINDER REPAIR (MAST S/N A698 AND A699).......................................................

550109114

2100 YRM 1770

12/14

WIRE HARNESS REPAIR..............................................................................................

524223769

2200 YRM 1128

12/14

ELECTRICAL SYSTEM..................................................................................................

550109115

2200 YRM 1771

12/14

ENGINE ELECTRICAL SYSTEM, PSI 2.4L ENGINE.....................................................

550109116

2200 YRM 1772

12/14

MAST REPAIR (S/N A698 AND A699)...........................................................................

550109117

4000 YRM 1773

12/14

METRIC AND INCH (SAE) FASTENERS.......................................................................

524150797

8000 YRM 0231

10/13

PERIODIC MAINTENANCE............................................................................................

550109197

8000 YRM 1774

12/14

CAPACITIES AND SPECIFICATIONS...........................................................................

550109119

8000 YRM 1775

12/14

DIAGRAMS AND SCHEMATICS....................................................................................

550109120

8000 YRM 1776

12/14

DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................

550022929

9000 YRM 1434

12/14

PART NO. 550109188 (12/14)

Summary of Contents for B974

Page 1: ...ULIC CLEANLINESS PROCEDURES 550073240 1900 YRM 1620 12 14 HYDRAULIC GEAR PUMPS 550108499 1900 YRM 1744 12 14 MAIN CONTROL VALVE 550108500 2000 YRM 1745 12 14 CYLINDER REPAIR MAST S N A698 AND A699 550109114 2100 YRM 1770 12 14 WIRE HARNESS REPAIR 524223769 2200 YRM 1128 12 14 ELECTRICAL SYSTEM 550109115 2200 YRM 1771 12 14 ENGINE ELECTRICAL SYSTEM PSI 2 4L ENGINE 550109116 2200 YRM 1772 12 14 MAST...

Page 2: ...e surface must be solid even and level when the lift truck is put on blocks Make sure that any blocks used to support the lift truck are solid one piece units See the Operating Manual or the Periodic Maintenance 8000YRM1774 This section contains the description of the frame see Figure 1 and Figure 2 and connected parts Procedures for removing and installing the counterweight hood overhead guard en...

Page 3: ...1 COWL PLATE 2 FENDER 3 FRAME 4 HOOD MOUNT 5 COUNTERWIEGHT SUPPORT 6 FUEL TANK 7 HYDRAULIC TANK Figure 2 Frame Dual Fuel or Diesel General 0100 YRM 1766 2 ...

Page 4: ... System PSI 2 4L 0900YRM1757 for procedures 4 Raise the hood latch on the left front corner of the hood to unlatch and lift up the hood See Fig ure 3 5 Remove the floor mat and floor plate See Fig ure 4 6 Remove the two capscrews holding the left and right rear side covers to the frame Remove the rear side covers from the frame See Figure 4 1 HOOD LATCH 2 SEAT 3 HOOD Figure 3 Hood Latch 0100 YRM 1...

Page 5: ...Figure 4 Side Cover Floor Plate and Cowl Components Hood Seat and Side Covers Replacement 0100 YRM 1766 4 ...

Page 6: ...ER 8 RIGHT FRONT SIDE COVER 9 LEFT STEP PANEL 10 RIGHT STEP PANEL 11 LEFT STEP PLATE 12 RIGHT STEP PLATE 13 LEFT REAR SIDE COVER 14 RIGHT REAR SIDE COVER 15 FLOOR MAT 16 FLOOR PLATE 17 RADIATOR COVER 18 SEALS 19 CAPSCREW 20 CLIP NUT 21 INSERT 22 PLATE ASSEMBLY SEAL 23 LEFT COWL PLATE 24 RIGHT COWL PLATE 0100 YRM 1766 Hood Seat and Side Covers Replacement 5 ...

Page 7: ...See Figure 5 10 Remove the five Allen Head screws see Fig ure 5 securing the dash to top of cowl 11 Pull kick panel up from bottom and out to remove kick panel from seal plate and clips on dash panel 12 Remove dash panel from cowl See Figure 6 13 Remove three capscrews holding the seal plate Remove seal plate See Figure 6 NOTE TOP VIEW OF DASH PANEL SHOWN A INDICATES TO PULL UP TO UNLATCH 1 ALLEN ...

Page 8: ...N HEAD SCREWS 2 COWL 3 DASH PANEL 4 KICK PANEL 5 KICK PANEL NOTCHES 6 SEAL PLATE 7 CAPSCREWS 8 CLIPS Figure 6 Dash Panel Kick Panel and Seal Plate Removal 0100 YRM 1766 Hood Seat and Side Covers Replacement 7 ...

Page 9: ... See Figure 8 Remove the four capscrews and nuts holding the seat to the hood Lift the seat off the hood See Figure 8 Close hood 16 Remove the nuts from ball studs on gas springs Remove gas springs from the hood See Figure 9 17 Remove the hinge capscrews and nuts located in the rear of the hood See Figure 9 18 Lift the hood from the truck A NON SUSPENSION SEAT B FULL SUSPENSION SEAT 1 CAPSCREWS 2 ...

Page 10: ...HE SAME 1 CAPSCREW 2 NUT 3 HOLE FOR CHASSIS HARNESS 4 HOOD LINER A HOOD HINGE ARRANGEMENT B GAS SPRING ARRANGEMENT LEFT SIDE SHOWN 1 NUT 2 CAPSCREW 3 HOOD HINGE MOUNT 4 HOOD HINGE ARM 5 HOOD 6 BALL STUD 7 GAS SPRING MOUNTING BRACKET 8 HOOD MOUNT 9 GAS SPRING Figure 9 Gas Spring and Hood Removal 0100 YRM 1766 Hood Seat and Side Covers Replacement 9 ...

Page 11: ...d latch properly and that the stop screw contacts the frame A properly closed hood MUST click twice on the hood latch If the hood latch does not close properly loosen the capscrews on the back of the center pin and adjust the center pin up or down as required for correct alignment See Figure 11 5 Push down until hood just touches rubber bumper Make sure latch striker is still in center of hood lat...

Page 12: ... and secure dash panel to cowl using five Allen Head screws Tighten Al len Head screws to 3 5 N m 31 lbf in See Fig ure 5 12 Align notches on kick panel to clips on dash panel and push kick panel into place on seal plate See Figure 6 13 Raise steering column to highest position and in stall upper steering column cover by aligning the two latches and pushing down until latched See Figure 5 14 Using...

Page 13: ...k of tires to prevent lift truck from moving CAUTION Disconnect the negative battery cable on internal combustion trucks Disconnect the battery before removing any covers 2 Attach a tag on the battery connector or negative battery cable stating DO NOT CONNECT BAT TERY Move the steering column to the most FORWARD position CAUTION If a puller tool is used to remove steering wheel from steering colum...

Page 14: ...ng column and four isolators from cowl standoffs See Figure 14 Disassemble NOTE Remove and discard snap rings if installed 1 Remove two pins and gas spring from housing See Figure 15 2 Remove two pivot bolts two bushings two nuts and bracket from housing 3 Remove split pin and lower shaft from upper shaft 4 Remove connector from connector bracket Re move connector bracket fastener four screws and ...

Page 15: ... the horn contact slip rings with a small amount of conductive grease Yale P N 582014302 See Figure 15 2 Install fastener connector bracket and connector two horn contacts and four screws 3 Assemble lower shaft and upper shaft secure with spit pin 4 Install two pivot bolts two bushings two nuts and bracket onto housing 5 Install gas spring and two pins on housing Install NOTE Lubricate spline end ...

Page 16: ...R 3 JOINT 4 NUT 5 WASHER 6 SCREW 7 UPPER SHAFT 8 HOUSING 9 PIN 10 LOWER SHAFT 11 GAS SPRING 12 BOLT 13 BUSHING 14 CONNECTOR 15 FASTENER 16 HORN CONTACT Figure 15 Steering Column Assembly 0100 YRM 1766 Steering Column 15 ...

Page 17: ...LPG tank Loosen the fitting on the supply hose from the LPG tank where it enters the filter unit Permit the pressure in the fuel system to de crease slowly Fuel leaving the fitting removes heat Use a cloth to protect your hands from the cold fitting NOTE The counterweight is held in position on the frame by two hooks that are part of the frame One M24 3 110 capscrew holds the counterweight to the ...

Page 18: ...terweight and frame See Figure 16 and Figure 17 Tighten capscrew to 555 N m 409 lbf ft 1 SEAL 2 COUNTERWEIGHT 3 TOW PIN 4 CAPSCREW 5 WASHER 6 FRAME Figure 16 Counterweight Installation 4 Install tow pin onto counterweight NOTE Perform Step 5 for lift trucks equipped with LPG 5 Use the procedures in Fuel System PSI 2 4L 0900YRM1757 to install the LPG tank and bracket after the counterweight has bee...

Page 19: ...f the lift the overhead guard is off balance lower immediately and move the hoist to a more centered point No welding or drilling on legs of overhead guard is permitted as per previous WARNING 1 Connect a lifting device to overhead guard NOTE Note routing of electrical wires prior to discon necting Tag electrical connectors during removal to aid in installation 2 Disconnect wires between frame and...

Page 20: ... See Figure 19 4 Remove two capscrews two wheel nuts right bracket and left bracket from front corner of over head guard See Figure 19 NOTE Note position of rain top on overhead guard before removal 5 Remove rain top from overhead guard See Fig ure 19 Clean and Inspect 1 Clean all remaining sealer residue from rain top and overhead guard surfaces 2 Inspect rain top and brackets for cracks Replace ...

Page 21: ...TOP 2 CAPSCREW 3 WHEEL NUT 4 LOCKNUT 5 WASHER 6 LEFT BRACKET 7 RIGHT BRACKET 8 CENTER BRACKET 9 BUSHING 10 SEALER 11 OVERHEAD GUARD Figure 19 Overhead Guard Rain Top Overhead Guard Replacement 0100 YRM 1766 20 ...

Page 22: ...l out of the retractor assembly the internal latch may be locked Pull firmly on the seat belt and hold for a mo ment to remove slack from the belt in the re tractor Release the seat belt Seat belt will re tract and the internal latch will unlock If the seat belt cannot be pulled from the retractor assembly or the belt will not retract replace the seat belt assembly With the hood closed and in the ...

Page 23: ... of gravity mast drive axle engine and transmission and counterweight When the lift truck is put on blocks put additional blocks in the following positions to maintain stability Before removing the mast and drive axle put blocks under the counterweight so the lift truck cannot fall backward Before removing the counterweight put blocks under the mast assembly so the lift truck cannot fall forward T...

Page 24: ...toff valve on the LPG tank and run engine until all fuel is gone and engine stops 2 For removal of the LPG Tank see service manual Fuel System PSI 2 4L 0900YRM1757 for the pro cedures 3 Remove overhead guard See section Overhead Guard Replacement for procedures 4 Remove the floor mat and floor plate NOTE PART OF THE FRAME NOT SHOWN FOR CLARITY 1 TRANSMISSION ISOLATOR ASSEMBLY 2 TRANSMISSION MOUNTI...

Page 25: ...Figure 22 PSI Engine and Transmission Remove Engine Replacement 0100 YRM 1766 24 ...

Page 26: ...Open the drain plug or disconnect the bottom ra diator hose to drain coolant from radiator and en gine See Figure 22 7 Remove the hood and seat combination and rear side covers See section Hood Seat and Side Covers Replacement for procedures 8 Disconnect the ground strap from the frame and remove the power distribution module PDM from the battery tray See Figure 23 9 Remove battery and battery tra...

Page 27: ... a block under the transmission housing to support the transmission 18 Remove four capscrews from torque converter housing and flywheel housing on transmission side See Figure 26 19 Remove six capscrews from flywheel housing and torque converter housing on flywheel housing side WARNING The engine is heavy Make sure that any lifting de vice has enough capacity to lift the engine The engine can weig...

Page 28: ...CTOR 4 TRANSDUCER CONNECTOR 5 TRANSMISSION SENSOR PLUG 6 SOLENOID VALVE CONNECTOR 7 ENGINE WIRING HARNESS Figure 24 Transmission Electrical Connectors 1 ACCESS PORT 2 ENGINE MOUNTING BRACKET AND HARD WARE Figure 25 PSI Engine Removal Access Port 0100 YRM 1766 Engine Replacement 27 ...

Page 29: ...EYEBOLT BRACKET 2 TORQUE CONVERTER HOUSING 3 FLYWHEEL HOUSING 4 CAPSCREW 5 TRANSMISSION ASSEMBLY 6 ENGINE ASSEMBLY Figure 26 PSI Flywheel and Torque Converter Housings Engine Replacement 0100 YRM 1766 28 ...

Page 30: ...LOCK NUT Figure 27 PSI Engine and Frame 1 CAPSCREW 2 WASHER 3 SNUBBING WASHER 4 ISOLATOR 5 LOCKNUT 6 CROSSMEMBER OPTIONAL 7 LEFT ENGINE MOUNT 8 RIGHT ENGINE MOUNT Figure 28 PSI Engine Mounts 0100 YRM 1766 Engine Replacement 29 ...

Page 31: ... radiator Remove radiator cap CAUTION Disposal of lubricants and fluids must meed local environmental regulations 4 Open drain plug or disconnect bottom radiator hose to drain coolant from radiator and engine See Figure 30 5 Remove hood and seat combination and rear side covers See section Hood Seat and Side Covers Replacement for procedures 6 Disconnect ground strap from frame Remove three flange...

Page 32: ...50LX B974 SHOWN 1 TRANSMISSION ISOLATOR 2 TRANSMISSION MOUNTING BRACKET 3 ENGINE ISOLATOR 4 ENGINE MOUNTING BRACKET 5 FRAME 6 ENGINE WIRING HARNESS 7 CHASSIS WIRING HARNESS Figure 29 Yanmar Diesel Engine and Transmission Mounting Arrangement 0100 YRM 1766 Engine Replacement 31 ...

Page 33: ...Figure 30 Yanmar 2 6L Diesel Engine and Transmission Removal Engine Replacement 0100 YRM 1766 32 ...

Page 34: ...COOLER LINES 16 ELECTRONIC CONTROL MODULE ECM AND BRACKET 17 FAN 18 FAN PULLEY AND FAN SPACER 19 BOTTOM RADIATOR HOSE 20 FUEL LINE 21 HYDRAULIC SUPPLY HOSE 1 BATTERY LOCKDOWN BAR 2 CAP 3 FLANGE NUT 4 LOCKWASHER 5 BATTERY 6 BATTERY TRAY 7 CAPSCREW 8 PDM 9 GROUND STRAP 10 FRAME Figure 31 Power Distribution Module and Battery Tray 1 TEMPERATURE SENSOR CONNECTOR 2 TRANSMISSION HOUSING 3 PROPORTIONAL V...

Page 35: ...using side See Fig ure 34 WARNING The engine is heavy Make sure that any lifting de vice has enough capacity to lift the engine The engine can weigh approximately 194 kg 428 lb 17 Remove flange locknuts washers snubbing washers capscrews and isolators from the en gine mounts Remove engine adapter to transmis sion bolts if equipped See Figure 35 CAUTION When separating the engine away from the tran...

Page 36: ...USING 2 EYEBOLT BRACKET 3 HEX HEAD CAPSCREW 4 FLYWHEEL HOUSING 5 LOCKWASHER 6 FLANGE BOLT 7 TRANSMISSION ASSEMBLY 8 ENGINE ASSEMBLY Figure 34 Yanmar Flywheel and Torque Converter Housings 0100 YRM 1766 Engine Replacement 35 ...

Page 37: ...six capscrews in torque converter housing and flywheel housing from flywheel housing side Tighten capscrews to 38 N m 28 lbf ft See Fig ure 26 7 Install exhaust pipe to exhaust manifold See Fuel System PSI 2 4L 0900YRM1757 8 Connect engine wiring harness connectors to pro portional valve connectors transducer connec tors solenoid valve connector temperature sen sor connector and transmission See F...

Page 38: ...ine and install four bolts attached flywheel to torque converter See Figure 33 Tighten bolts to 55 N m 41 lbf ft 5 Install six hex head capscrews and six lockwash ers on flywheel housing and torque converter housing on torque converter housing side See Figure 34 Tighten capscrews to 38 N m 28 lbf ft 6 Install four flange bolts on flywheel housing and torque converter housing on transmission side S...

Page 39: ... truck cannot fall backward Before removing the counterweight put blocks under the mast assembly so the lift truck cannot fall forward The surface must be solid even and level when the lift truck is put on blocks Make sure that any blocks used to support the lift truck are solid one piece units See the Operating Manual or Periodic Maintenance 8000YRM1774 WARNING The transmission is heavy Make sure...

Page 40: ...YDRAULIC GEAR PUMP INLET PORT 6 HYDRAULIC GEAR OUTLET PUMP 7 HYDRAULIC GEAR PUMP Figure 36 Hydraulic Hose Aluminum Transmission Housing NOTE DRIVE AXLE NOT SHOWN FOR CLARITY 1 MOUNTING BRACKET 2 CAPSCREW 3 WASHER 4 SNUBBING WASHER 5 ISOLATOR Figure 37 Rear Mount Transmission 0100 YRM 1766 Transmission Replacement 39 ...

Page 41: ...new stat o seal on yoke See Figure 38 4 Install spacer yoke and flange head capscrew on back of transmission housing See Figure 38 Tighten capscrew to 77 N m 57 lbf ft 5 Install isolators snubbing washers washer and capscrew on mounting bracket at the rear of the transmission See Figure 37 Tighten capscrew to 225 to 250 N m 166 to 184 lbf ft 6 Connect hydraulic hose to hydraulic gear pump outlet p...

Page 42: ...sion between the bellcrank and cowl plate is 5 1 mm 0 20 0 04 in See Figure 40 3 If dimension is not correct adjust ball ends on push rod so that a minimum of 6 mm 0 24 in of threaded rod screws into each ball end After ad justing push rod tighten jam nuts to 8 to 15 N m 71 to 133 lbf in 4 Connect throttle cable to bellcrank and engine See Figure 40 5 With throttle pedal in full up position adjust...

Page 43: ...40 Throttle Pedal and Cable Adjustment Yanmar Diesel Engine Cooling System DESCRIPTION The cooling system is used to cool the engine and keep it at the correct operating temperature The cool ing system is comprised of the following main compo nents Radiator Fan and belt Fan shroud Coolant hoses and lines Coolant reservoir For the procedures to repair clean inspect and in stall the radiator and coo...

Page 44: ...d place in container Cover head to prevent any foreign material from getting into the hydraulic tank See Figure 41 4 After filter element has drained discard filter ele ment and O ring 5 Remove and discard quad ring from filter housing See Figure 41 CLEAN AND INSPECT 1 Clean housing and cover plate as necessary 2 Inspect filter housing especially sealing surfaces for damage Replace if damaged 3 In...

Page 45: ...s of the tank In spect the welds for cracks and leakage Check for wet areas accumulation of dirt and loose or missing paint caused by leakage Areas of the tank that are not easily seen can be checked with an inspection mirror and a light that is approved for locations with flamma ble vapors Clean WARNING When cleaning the tank do not use solutions that make dangerous gases at normal temperatures o...

Page 46: ...on the inside of the tank are flushed with the solution Drain the tank 4 Put steam into the tank until the tank does not have odors and the metal is hot Steam vapors must come from all the openings 5 Flush the inside of the tank with boiling water Make sure all the loose material is removed from the inside of the tank 6 Make an inspection of the inside of the tank If it is not clean repeat Step 4 ...

Page 47: ...below the lower flammable limit repeat the cleaning procedures ADDITIONAL PREPARATIONS FOR REPAIR If nitrogen gas or carbon dioxide gas is available pre pare the tank for welding using these gases See the manual Safe Practices for Welding and Cutting Con tainers That Have Held Combustibles by the Ameri can Welding Society F4 1 1999 If these gases are not available another method using water can be...

Page 48: ...al are shown in and Figure 44 See the Parts Manual for a complete listing of all labels used on these lift trucks and their part numbers See Figure 43 for lift truck models below with PSI en gine GLC050LX B967 GLP20 25LX GLP050LX B974 See Figure 44 for lift truck models below with Yanmar Diesel engine GDP20 25LX GDP050LX B974 If a new label must be installed use the following pro cedure to install...

Page 49: ...Figure 43 Warning and Safety Labels for Lift Trucks with PSI Engine Label Replacement 0100 YRM 1766 48 ...

Page 50: ... UL LABEL 10 NAMEPLATE 11 NO ONE ON OR UNDER FORKS 12 LOCKING GAS SPRING 13 LIFT AND TILT LABEL 14 FLAMMABLE LP GAS 15 LPG TANK WARNING 16 AIR FILTER INSTALL CAUTION 17 FAN WARNING 18 BORON FREE LABEL 19 ANTIFREEZE LABEL 20 TRANSMISSION LABEL EXAMPLE ONLY 21 SPLIT WHEEL WARNING OPTIONAL FOR GLP GDP20 25LX 22 STABILITY SYSTEM LABEL US TRUCKS ONLY 0100 YRM 1766 Label Replacement 49 ...

Page 51: ...Figure 44 Warning and Safety Labels for Lift Trucks with Yanmar Diesel Engine Label Replacement 0100 YRM 1766 50 ...

Page 52: ...NING 9 TIP OVER WARNING 10 LIFT AND TILT LABEL 11 NOTICE TO USER LABEL 12 NAMEPLATE 13 PINCH POINT WARNING 14 NO ONE ON OR UNDER FORKS 15 NO RIDERS 16 LOCKING GAS SPRING 17 TRANSMISSION LABEL EXAMPLE ONLY 18 FAN WARNING 19 BORON FREE LABEL 20 ANTIFREEZE LABEL 21 SPLIT WHEEL WARNING OPTIONAL FOR GLP GDP20 25LX 22 STABILITY SYSTEM LABEL U S TRUCKS ONLY 0100 YRM 1766 Label Replacement 51 ...

Page 53: ...in lift truck GLP GDP20 35VX GP GLP GDP040 070VX B875 C875 4TNE92 NMHA 1688253 2 6L engine 2008 Yale Part No 580090035 used in lift truck models GLP GDP16 18VX GLP GDP20SVX GP GLP GDP030 035VX GP GLP GDP040SVX C810 and GLP GDP20 25LX GLP GDP050LX A974 4TNE94L BSNMH 3 0L engine Yale Part No 582023116 used in lift truck GLP GDP20 35VX B875 C875 ENGINE IDENTIFICATION Major Engine Component Identifica...

Page 54: ...s shown in Figure 2 The typical location of the engine nameplate is shown in Figure 2 The engine nameplate is shown in Figure 3 1 ENGINE NAMEPLATE 2 EMISSION CONTROL INFORMATION LABEL Figure 2 Typical Location of Engine Labels Figure 3 Engine Nameplate Typical General 0600 YRM 1205 2 ...

Page 55: ...X GP GLP GDP030VX GP GLP GDP035VX GP GLP GDP040SVX C810 GLP GDP20 35VX GP GLP GDP040 070VX B875 See section Frame 0100YRM1423 for lift truck mod els GLP GDP20 25LX GLP GDP050LX A974 See section Frame 0100YRM1672 for lift truck mod els GLP GDP20 35VX GP GLP GDP040 070VX C875 Cylinder Head Assembly Repair Refer to Figure 4 for the cylinder head components 0600 YRM 1205 Engine Removal and Installatio...

Page 56: ...Figure 4 Cylinder Head Components Cylinder Head Assembly Repair 0600 YRM 1205 4 ...

Page 57: ...VE SPRING 13 VALVE STEM SEAL 14 VALVE GUIDE 15 INTAKE VALVE 16 EXHAUST VALVE 17 CYLINDER HEAD GASKET 18 CYLINDER HEAD 19 GLOW PLUG 20 GLOW PLUG COVER 21 PUSH ROD 22 SUPPORT BRACKET BOLT 23 ROCKER ARM SHAFT SPRING 24 SUPPORT BRACKET STUD 25 SUPPORT BRACKET 26 ROCKER ARM 27 ROCKER ARM SHAFT RETAINING RING 28 VALVE ADJUSTING SCREW LOCK NUT 29 VALVE ADJUSTING SCREW 30 SUPPORT BRACKET NUT 0600 YRM 1205...

Page 58: ... Plugs Install 1 Install the glow plugs into the cylinder head 2 Connect the glow plug harness to the glow plugs 3 Install the glow plug covers on each glow plug 4 Connect the negative battery cable VALVE COVER Remove 1 Remove the valve cover nuts See Figure 6 2 Inspect the O rings on each valve cover nut Re place as needed 3 Remove the valve cover 4 Remove the valve cover gasket and discard 1 VAL...

Page 59: ...ed on the valve cover nuts 5 Install and tighten the valve cover nuts Refer to Standard Torque Specifications ROCKER ARM ASSEMBLY Remove 1 Remove the valve cover See Valve CoverRe move 2 Remove the bolt and locking nuts that retain the rocker arm assembly support brackets to the cyl inder head See Figure 7 3 Lift the rocker arm shaft assembly from the cylin der head NOTE Mark the push rods so they...

Page 60: ...ROCKER ARM SHAFT 5 ROCKER ARM SHAFT RETAINING RING 6 SUPPORT BRACKET STUD 7 SUPPORT BRACKET 8 ROCKER ARM SHAFT SPRING 9 ROCKER ARM 10 SUPPORT BRACKET BOLT 11 ROCKER ARM SHAFT RETAINING SCREW 12 CYLINDER HEAD Figure 7 Rocker Arm Assembly Cylinder Head Assembly Repair 0600 YRM 1205 8 ...

Page 61: ...k 2 Roll the push rods until a gap can be observed between a portion of the push rod and the surface of the inspection block 3 Use a feeler gauge to measure the gap Refer to the Engine Specifications for the service limit See Figure 8 Figure 8 Push Rod Inspection Rocker Arm Assembly Rocker Arm and Support Bracket Inside Diameter Use a test indicator and micrometer to determine if the inside diamet...

Page 62: ...e is cold NOTE The cylinder to be adjusted first does not have to be the number one cylinder Select and adjust the cylinder where the piston is the nearest to top dead center TDC after rotating and make the adjust ment for the other cylinders in the order of the ignition by turning the crankshaft 180 degrees each time 1 Remove the valve cover See Valve CoverRe move NOTE The number one piston posit...

Page 63: ...ert a 0 2 mm 0 008 in feeler gauge between the rocker arm and valve cap and adjust the clearance so there is a slight drag on the feeler gauge when sliding it between the rocker arm and valve cap Tighten the valve adjusting screw lock nut and recheck the clearance The valve clear ance should be between 0 15 to 0 25 mm 0 006 to 0 010 in 6 Apply clean engine oil to the contact surface be tween the a...

Page 64: ...ee Fuel System Repair 7 If equipped remove the pull actuator and mount ing bracket See Fuel System Repair 8 Disconnect the electrical connector for the fuel fil ter sensor 9 Tag and disconnect the fuel hoses from the fuel filter 10 Remove the bolts retaining the fuel filter housing assembly to the intake manifold and remove the fuel filter housing assembly See Figure 14 1 BOLTS 2 INTAKE MANIFOLD 3...

Page 65: ...he intake manifold to the cylinder head and remove the intake manifold and gasket Discard gasket See Figure 15 1 GASKET 2 INTAKE MANIFOLD 3 BOLT 4 CYLINDER HEAD Figure 15 Intake Manifold 0600 YRM 1205 Cylinder Head Assembly Repair 13 ...

Page 66: ...ipe from the exhaust manifold 13 Remove the bolts retaining the exhaust manifold to the cylinder head and remove the exhaust manifold and gasket Discard gasket See Fig ure 16 1 CYLINDER HEAD 2 BOLT 3 EXHAUST MANIFOLD 4 GASKET Figure 16 Exhaust Manifold Cylinder Head Assembly Repair 0600 YRM 1205 14 ...

Page 67: ... B FAN SIDE Figure 17 Cylinder Head Bolt Loosening Sequence 17 Remove the cylinder head bolts See Figure 18 18 Lift the cylinder head away from the cylinder block Place the cylinder head on a work bench to prevent damage to the combustion chamber 19 Remove the cylinder head gasket and discard 1 BOLT 2 CYLINDER HEAD 3 GASKET Figure 18 Cylinder Head and Gasket 0600 YRM 1205 Cylinder Head Assembly Re...

Page 68: ... Remove the spring retainer valve spring and valve stem seal 5 Repeat this procedure until all intake and exhaust valve springs and valve stem seals are removed NOTE If existing valves are going to be reinstalled in the cylinder head mark the valves so they can be in stalled in their original location 6 Turn the cylinder head so the exhaust port side faces down Remove the intake and exhaust valves...

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