KUBOTA DIESEL 3.

6L
ENGINE
H4.0FT5, H4.0FT6, H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) [R005, S005,
U005];H6.0-7.0FT (H135-155FT) [K006, L006];H6.0FT,
H7.0FT, H7.0FTS6, H7.0FTS9, H8.0FTS6 (H135FT,
H155FT, H155FTS, H170FTS) [N006];H6.0FT, H7.0FT,
H7.0FTS9, H8.0FTS6 (H135FT, H155FT, H155FTS,
H170FTS) [P006]

PART NO. 4053146 0600 SRM 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 HYSTER ® APPROVED parts when making repairs. Replacement parts must meet or
exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and when
working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:

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

CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange 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.............................................................................................................................................8
Install................................................................................................................................................................ 9
Rocker Arm Assembly.......................................................................................................................................10
Remove............................................................................................................................................................ 10
Disassemble.................................................................................................................................................... 12
Clean and Inspect...........................................................................................................................................12
Push Rods.....................................................................................................................................................12
Rocker Arm Assembly..................................................................................................................................12
Assemble......................................................................................................................................................... 13
Install.............................................................................................................................................................. 13
Valve Clearance Adjustments.......................................................................................................................... 13
Cylinder Head Assembly.................................................................................................................................. 14
Remove............................................................................................................................................................ 14
Disassemble.................................................................................................................................................... 22
Valves and Valve Springs, Remove.............................................................................................................22
Valve Guides, Remove................................................................................................................................. 24
Clean and Inspect...........................................................................................................................................24
Cylinder Head.............................................................................................................................................. 25
Valve Guides................................................................................................................................................ 25
Valves........................................................................................................................................................... 25
Valve Sink.................................................................................................................................................... 26
Valve Seat.....................................................................................................................................................26
Valve Springs............................................................................................................................................... 26
Assemble......................................................................................................................................................... 27
Valve Guides, Install................................................................................................................................... 27
Valves and Valve Springs, Install...............................................................................................................28
Install.............................................................................................................................................................. 28
Timing Gear Case and Timing Gears Repair.....................................................................................................32
Timing Gear Case Cover...................................................................................................................................32
Remove............................................................................................................................................................ 32
Clean and Inspect...........................................................................................................................................32
Install.............................................................................................................................................................. 33
Timing Gears.....................................................................................................................................................33
Crankshaft Gear.............................................................................................................................................34
Remove......................................................................................................................................................... 34
Install............................................................................................................................................................34
Idler Gear........................................................................................................................................................34
Remove......................................................................................................................................................... 34
Inspect.......................................................................................................................................................... 35
Install............................................................................................................................................................35
Camshaft Gear................................................................................................................................................35
Remove......................................................................................................................................................... 35
Install............................................................................................................................................................36

©2021 HYSTER COMPANY i

Table of Contents

TABLE OF CONTENTS (Continued)

Timing Gear Case............................................................................................................................................. 36
Remove............................................................................................................................................................ 36
Clean and Inspect...........................................................................................................................................37
Install.............................................................................................................................................................. 37
Drive Train, Camshaft, and Cylinder Block Repair.......................................................................................... 38
Remove...............................................................................................................................................................38
Disassemble.......................................................................................................................................................38
Pistons and Connecting Rods.........................................................................................................................38
Crankshaft...................................................................................................................................................... 39
Camshaft.........................................................................................................................................................41
Clean and Inspect..............................................................................................................................................42
Cylinder Block................................................................................................................................................ 43
Honing and Boring.......................................................................................................................................45
Cylinder Correction (Oversize)....................................................................................................................46
Pistons.............................................................................................................................................................46
Piston Pin........................................................................................................................................................47
Connecting Rod...............................................................................................................................................47
Tappets............................................................................................................................................................47
Crankshaft...................................................................................................................................................... 48
Camshaft.........................................................................................................................................................50
Camshaft Bushing..........................................................................................................................................51
Assemble............................................................................................................................................................51
Camshaft.........................................................................................................................................................51
Crankshaft...................................................................................................................................................... 51
Pistons and Connecting Rods.........................................................................................................................51
Install.................................................................................................................................................................53
Lubrication System Repair................................................................................................................................. 55
Engine Oil and Oil Filter Change.................................................................................................................... 55
Oil Pan............................................................................................................................................................... 56
Remove............................................................................................................................................................ 56
Install.............................................................................................................................................................. 57
Oil Suction Tube................................................................................................................................................57
Remove............................................................................................................................................................ 57
Clean............................................................................................................................................................... 58
Install.............................................................................................................................................................. 58
Oil Pump............................................................................................................................................................58
Remove............................................................................................................................................................ 58
Clean and Inspect...........................................................................................................................................59
Outer Rotor Outside Clearance...................................................................................................................59
Outer Rotor to Inner Rotor Tip Clearance..................................................................................................59
Outer Rotor Side Clearance.........................................................................................................................60
Rotor Shaft Clearance..................................................................................................................................60
Install.............................................................................................................................................................. 60
Fuel System Repair............................................................................................................................................. 62
Fuel Injectors.....................................................................................................................................................62
Remove............................................................................................................................................................ 62
Inspect.............................................................................................................................................................62
Clean............................................................................................................................................................... 62
Replace............................................................................................................................................................ 62
Install.............................................................................................................................................................. 62
Electronic Throttle System...............................................................................................................................63
Remove............................................................................................................................................................ 63

ii
 Table of Contents

TABLE OF CONTENTS (Continued)

Throttle Position Sensor Proceedures After September 2018 H135FT, H155FT,H6.0FT, H7.0FT (L006),
H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9, H8.0FTS6 (H135FT, H155FT, H155FTS, H170FTS) (N006),
H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6 (H135FT, H155FT, H155FTS, H170FTS) (P006), and H80FT,
H90FT, H100FT, H110FT, H120FT, H4.0FT5, H4.0FT6, H4.5FTS5, H4.5FT6, H5.0FT, H5.5FT (U005)..
66
Bearing Replacement..................................................................................................................................... 67
Install.............................................................................................................................................................. 67
Adjustment......................................................................................................................................................68
Fuel Injection Pump..........................................................................................................................................68
Remove............................................................................................................................................................ 68
Disassemble.................................................................................................................................................... 73
Clean and Inspect...........................................................................................................................................74
Assemble......................................................................................................................................................... 74
Install.............................................................................................................................................................. 75
Cooling System Repair........................................................................................................................................ 77
Serpentine Belt..................................................................................................................................................77
Remove............................................................................................................................................................ 77
Inspect.............................................................................................................................................................77
Install.............................................................................................................................................................. 77
Serpentine Belt, Adjustment......................................................................................................................... 77
Water Pump.......................................................................................................................................................78
Remove............................................................................................................................................................ 78
Install.............................................................................................................................................................. 80
Thermostat........................................................................................................................................................ 81
Remove............................................................................................................................................................ 81
Inspect.............................................................................................................................................................82
Install.............................................................................................................................................................. 82
Flywheel and Flywheel Housing.........................................................................................................................84
Flywheel.............................................................................................................................................................84
Remove............................................................................................................................................................ 84
Install.............................................................................................................................................................. 84
Flywheel Housing..............................................................................................................................................84
Remove............................................................................................................................................................ 84
Install.............................................................................................................................................................. 84
Electrical Equipment Repair...............................................................................................................................85
Alternator.......................................................................................................................................................... 85
Remove............................................................................................................................................................ 85
Install.............................................................................................................................................................. 86
Starter................................................................................................................................................................87
Remove............................................................................................................................................................ 87
Install.............................................................................................................................................................. 87
Engine Specifications.......................................................................................................................................... 88
Engine Data.......................................................................................................................................................88
Engine Tuning...................................................................................................................................................89
Cylinder Head................................................................................................................................................... 89
Intake/Exhaust Valve and Guide..................................................................................................................... 90
Valve Spring...................................................................................................................................................... 90
Rocker Arm and Shaft...................................................................................................................................... 90
Push Rod............................................................................................................................................................90
Gear Train and Camshaft.................................................................................................................................91
Camshaft.........................................................................................................................................................91
Idle Gear Shaft and Bushing......................................................................................................................... 91

iii
Table of Contents

TABLE OF CONTENTS (Continued)

Backlash of Each Gear................................................................................................................................... 91
Cylinder Block................................................................................................................................................... 91
Crankshaft.........................................................................................................................................................91
Piston................................................................................................................................................................. 92
Piston Ring........................................................................................................................................................ 92
Connecting Rod................................................................................................................................................. 92
Rod Small End................................................................................................................................................ 92
Tappet............................................................................................................................................................. 93
Oil Pump............................................................................................................................................................93
Engine Oil Pressure....................................................................................................................................... 93
Outer Rotor Outside Clearance..................................................................................................................... 93
Outer Rotor Side Clearance........................................................................................................................... 93
Inner Rotor to Cover.......................................................................................................................................93
Standard Torque Specifications..........................................................................................................................94
Standard Torque Chart.....................................................................................................................................94
Special Torque Specifications..............................................................................................................................95
Special Tools.........................................................................................................................................................97

iv
0600 SRM 1579 General

General
This section has the repair instructions for the Location of Labels
Kubota 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
Major Engine Component Identification shown in Figure 2. The emissions exempt label is
Figure 1 shows where the major engine components shown in 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 SRM 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 SRM 1579 Engine Removal and Installation

Engine Removal and Installation

The procedures to remove and install engine are not Frame 0100SRM1948 for lift truck models
included in this section. For procedures refer to H6.0-7.0FT (H135-155FT) (L006)
•
Frame 0100SRM1243 for lift truck models • H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
• H4.0FT5, H4.0FT6, H4.5FTS5, H4.5FT6, H8.0FTS6 (H135FT, H155FT, H155FTS,
H5.0FT, H5.5FT (H80-120FT) (R005, S005) H170FTS) (N006)
Frame 0100SRM1581 for lift truck models • H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6
(H135FT, H155FT, H155FTS, H170FTS)
• H6.0-7.0FT (H135-155FT) (K006) (P006)
Frame 0100SRM1891 for lift truck models
• H4.0FT5, H4.0FT6, H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (U005)

3
Cylinder Head Assembly Repair 0600 SRM 1579

Cylinder Head Assembly Repair

VALVE COVERS AND FUEL INJECTORS • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (R005)
Remove • H6.0-7.0FT (H135-155FT) (K006)
1. Disconnect negative battery cable at battery. See Figure 6 for lift truck model
NOTE: Mark connectors/wires during removal to • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
aid in installation. H5.0-5.5FT (H80-120FT) (S005, U005)

2. Unclip engine wiring harness and move to side See Figure 7 for lift truck model
for better access. • H6.0-7.0FT (H135-155FT) (L006)
See Figure 5 for lift truck models • H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
H8.0FTS6 (H135FT, H155FT, H155FTS,
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H170FTS) (N006)
H5.0-5.5FT (H80-120FT) (R005)
• H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6
• H6.0-7.0FT (H135-155FT) (K006) (H135FT, H155FT, H155FTS, H170FTS)
See Figure 6 for lift truck model (P006)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; 5. Remove clamp and breather tube from valve
H5.0-5.5FT (H80120FT) (S005, U005) cover.
See Figure 7 for lift truck model
See Figure 5 for lift truck models
• H6.0-7.0FT (H135-155FT) (L006, N006)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
• H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6 H5.0-5.5FT (H80-120FT) (R005)
(H135FT, H155FT, H155FTS, H170FTS) • H6.0-7.0FT (H135-155FT) (K006)
(P006)
See Figure 6 for lift truck model
3. Disconnect wiring connector from glow plug
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
strip. H5.0-5.5FT (H80-120FT) (S005, U005)
See Figure 5 for lift truck models See Figure 7 for lift truck model
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, • H6.0-7.0FT (H135-155FT) (L006)
H5.0-5.5FT (H80-120FT) (R005)
• H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
• H6.0-7.0FT (H135-155FT) (K006) H8.0FTS6 (H135FT, H155FT, H155FTS,
See Figure 6 for lift truck model H170FTS) (N006)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; • H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6
H5.0-5.5FT (H80-120FT) (S005,U005) (H135FT, H155FT, H155FTS, H170FTS)
(P006)
See Figure 7 for lift truck model
• H6.0-7.0FT (H135-155FT) (L006) 6. Remove turbo outlet hose from turbocharger
and air inlet elbows.
• H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
H8.0FTS6 (H135FT, H155FT, H155FTS, See Figure 5 for lift truck models
H170FTS) (N006) • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
• H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6 H5.0-5.5FT (H80-120FT) (R005)
(H135FT, H155FT, H155FTS, H170FTS) • H6.0-7.0FT (H135-155FT) (K006)
(P006)
See Figure 6 for lift truck model
4. Loosen two clamps at air filter and
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
turbocharger for air intake hose. Remove air H5.0-5.5FT (H80-120FT) (S005, U005)
intake hose.
See Figure 7 for lift truck model
See Figure 5 for lift truck models
• H6.0-7.0FT (H135-155FT) (L006)

4
0600 SRM 1579 Cylinder Head Assembly Repair

• H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,

H8.0FTS6 (H135FT, H155FT, H155FTS,
H170FTS) (N006)
• H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6
(H135FT, H155FT, H155FTS, H170FTS)
(P006)

1. ENGINE WIRING HARNESS

2. CLAMP
3. AIR FILTER
4. TURBOCHARGER
1. ENGINE WIRING HARNESS 5. AIR INTAKE HOSE
2. CLAMP 6. BREATHER TUBE
3. AIR FILTER 7. TURBOCHARGER OUTLET HOUSE
4. TURBOCHARGER 8. GLOW PLUG STRIP CONNECTOR
5. AIR INTAKE HOSE
6. BREATHER TUBE Figure 6. Breather Tube and Hoses for Lift Truck
7. TURBOCHARGER OUTLET HOUSE Model H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
8. GLOW PLUG STRIP CONNECTOR H5.0-5.5FT (H80-120FT) (S005, U005)
Figure 5. Breather Tube and Hoses for Lift Truck
Models and H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (R005) H6.0-7.0FT
(H135-155FT) (K006)

5
Cylinder Head Assembly Repair 0600 SRM 1579

Legend for Figure 7.

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

7. Remove ten bolts, valve cover and gasket from

cylinder head. Discard gasket. See Figure 8.

Figure 7. Breather Tube and Hoses for Lift Truck

Models H6.0-7.0FT (H135-155FT) (L006) and
H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9, H8.0FTS6
(H135FT, H155FT, H155FTS, H170FTS) (N006),
H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6 (H135FT,
H155FT, H155FTS, H170FTS) (P006)

6
0600 SRM 1579 Cylinder Head Assembly Repair

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 11. Loosen four fuel lines at fuel injection pump.
strip from glow plugs. See Figure 9. See Figure 9.

NOTE: Note position and location of fuel line 12. Remove four fuel lines, four nuts, and overflow
clamps 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.

7
Cylinder Head Assembly Repair 0600 SRM 1579

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 Clean and Inspect
base 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.

8
0600 SRM 1579 Cylinder Head Assembly Repair

7. Install four clamps and two pan head screws

onto fuel injector lines as noted during removal.
WARNING
See Figure 8.
Compressed air can move particles so that they
cause injury to the user or to other personnel. 8. Using four flange nuts, install glow plug strip
Make sure that the path of the compressed air is onto glow plugs. See Figure 9.
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes. 9. Lightly grease new valve cover gasket.

10. Place new valve cover gasket into groove of

CAUTION valve cover.
Use caution not to scratch the gasket mating
surfaces when cleaning the valve cover and 11. Install valve cover and ten bolts onto cylinder
cylinder head. head. Tighten bolts to
9.8 to 11.2 N•m (86.7 to 99 lbf in). See
Carefully remove all gasket residue from valve Figure 8.
cover and cylinder head.
12. Install outlet hose from turbocharger and air
Clean valve cover in cleaning solvent. Dry valve inlet elbows.
cover with compressed air. Inspect for wear, cracks,
and any other damage. If necessary, replace valve See Figure 5 for lift truck models
cover. • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
Inspect all O-rings, plugs and grommets for wear, H5.0-5.5FT (H80-120FT) (R005)
cracks, and any other damage. Replace where • H6.0-7.0FT (H135-155FT) (K006)
necessary. See Figure 6 for lift truck model
Inspect valve cover breather and breather cover for • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
cracks, wear, and any other damage (see Figure 8). H5.0-5.5FT (H80-120FT) (S005, U005)
if necessary see Parts Manual for replacement
parts. See Figure 7 for lift truck model
• H6.0-7.0FT (H135-155FT) (L006)
Install • H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
1. Install four glow plugs into cylinder head. H8.0FTS6 (H135FT, H155FT, H155FTS,
Tighten to 20 to 24 N•m (15 to 18 lbf ft). See H170FTS) (N006)
Figure 9. • H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6
(H135FT, H155FT, H155FTS, H170FTS)
2. Install four new gaskets and four new base (P006)
seals onto four fuel injectors. Install four fuel
injectors into cylinder head. Tighten to 13. Install breather tube and clamp to valve cover.
49 to 68 N•m (37 to 50 lbf ft). See Figure 9. See Figure 5 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
3. Install overflow pipe assembly and four nuts
H5.0-5.5FT (H80-120FT) (R005)
onto fuel injectors. Tighten nuts to
20 to 24 N•m (15 to 18 lbf ft). See Figure 9. • H6.0-7.0FT (H135-155FT) (K006)
See Figure 6 for lift truck model
4. Install four fuel lines onto fuel injectors.
Tighten to 23 to 36 N•m (17 to 26 lbf ft). See • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80-120FT) (S005, U005)
Figure 9.
See Figure 7 for lift truck model
5. Install four fuel lines onto fuel injection pump. H6.0-7.0FT (H135-155FT) (L006)
•
Tighten to 23 to 36 N•m (17 to 26 lbf ft). See
Figure 9. • H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
H8.0FTS6 (H135FT, H155FT, H155FTS,
6. Using two hose clamps, connect fuel overflow H170FTS) (N006)
hoses to overflow pipe assembly. See Figure 9.

9
Cylinder Head Assembly Repair 0600 SRM 1579

• H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6 • H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6

(H135FT, H155FT, H155FTS, H170FTS) (H135FT, H155FT, H155FTS, H170FTS)
(P006) (P006)

14. Install air intake hose assembly and tighten 16. Install engine wiring harness and attach clips
clamps at air filter and turbocharger. as noted during removal.
See Figure 5 for lift truck models See Figure 5 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (R005) H5.0-5.5FT (H80-120FT) (R005)
• H6.0-7.0FT (H135-155FT) (K006) • H6.0-7.0FT (H135-155FT) (K006)
See Figure 6 for lift truck model See Figure 6 for lift truck model
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80-120FT) (S005, U005) H5.0-5.5FT (H80-120FT) (S005, U005)
See Figure 7 for lift truck model See Figure 7 for lift truck model
• H6.0-7.0FT (H135-155FT) (L006) • H6.0-7.0FT (H135-155FT) (L006)
• H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9, • H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
H8.0FTS6 (H135FT, H155FT, H155FTS, H8.0FTS6 (H135FT, H155FT, H155FTS,
H170FTS) (N006) H170FTS) (N006)
• H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6 • H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6
(H135FT, H155FT, H155FTS, H170FTS) (H135FT, H155FT, H155FTS, H170FTS)
(P006) (P006)

15. Connect wiring connector to glow plug strip as 17. Connect negative battery cable at battery.
noted during removal.
See Figure 5 for lift truck models ROCKER ARM ASSEMBLY
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, Remove
H5.0-5.5FT (H80-120FT) (R005)
1. Remove valve cover, fuel injectors, and glow
• H6.0-7.0FT (H135-155FT) (K006) plugs. See Valve Covers and Fuel Injectors,
See Figure 6 for lift truck model Remove.

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; 2. Remove four flange bolts holding rocker arm
H5.0-5.5FT (H80-120FT) (S005, U005) brackets to cylinder head. See Figure 10.
See Figure 7 for lift truck model
• H6.0-7.0FT (H135-155FT) (L006)
• H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
H8.0FTS6 (H135FT, H155FT, H155FTS,
H170FTS) (N006)

10
0600 SRM 1579 Cylinder Head Assembly Repair

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

Figure 10. Rocker Arm Assembly

3. Lift rocker arm shaft assembly from cylinder 4. Remove push rods from cylinder head.
head. See Figure 10.

NOTE: Mark push rods so they can be reinstalled in

original location during reassembly.

11
Cylinder Head Assembly Repair 0600 SRM 1579

Disassemble
1. Remove c-clips and washers from each end of
rocker arm shafts. Discard washers. See
Figure 10.

NOTE: Mark rocker arms so they can be reinstalled

in original location during reassembly.
NOTE: The rocker arm shaft fits tightly in rocker
arm support brackets. Clamp support bracket in a
padded vise and twist and pull rocker arm shaft to
remove shaft.
2. Slide rocker arm shaft out of rocker arm
brackets, springs, and rocker arms. See
Figure 10.

3. If necessary, remove adjusting screw and lock Figure 11. Push Rod Inspection
nut from rocker arms. See Figure 10.
Rocker Arm Assembly
Clean and Inspect Rocker Arm and Support Bracket Inside
Diameter: Use a test indicator and micrometer to
determine if inside diameter of all rocker arm
WARNING support brackets and rocker arms are within limits.
Cleaning solvents can be flammable and toxic and Refer to Engine Specifications for service limit. See
can cause skin irritation. When using cleaning Figure 12.
solvents, always follow the recommendations of
the manufacturer.

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.

Clean all parts in cleaning solvent. Dry parts with

compressed air. Inspect for wear, cracks, and any
other damage. Replace all parts as needed.

Push Rods Figure 12. Rocker Arm Inside Diameter

1. Place push rods on a flat inspection block. Shaft Outside Diameter: Use a micrometer to
measure rocker arm shaft outside diameter. Refer to
2. Roll push rods until a gap can be observed Engine Specifications for service limit. See
between a portion of push rod and surface of Figure 13.
inspection block.

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

Engine Specifications for service limit. See
Figure 11.

12
0600 SRM 1579 Cylinder Head Assembly Repair

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.

VALVE CLEARANCE ADJUSTMENTS

NOTE: Make measurements and adjustments while
engine is cold.
Figure 13. Rocker Arm Shaft Outside Diameter 1. Remove valve cover. See Valve Covers and Fuel
Injectors, Install.
Assemble
NOTE: The rocker arm shaft fits tightly in rocker NOTE: The number one piston position is on the fan
arm support brackets. Clamp rocker arm shaft in a end of engine, opposite side of the flywheel, and
padded vise and twist and push support brackets ignition order is 1-3-4-2 at 180 degree intervals.
onto rocker arm shaft. 2. Rotate crankshaft clockwise, as seen from
1. Lubricate rocker arm shaft. Slide rocker arm radiator side, to bring number one piston to top
support brackets, springs, and rocker arms dead center (TDC) (See Fuel Injection Pump for
onto shaft, as noted during removal. TDC procedure). See Table 1 for reference to
help determine which valves will be available
2. Position rocker arm assembly on a flat surface. for adjustment with number one piston at TDC.
Install washers and c-clips onto ends of rocker
arm shaft. See Figure 10. Table 1. Available Valves for Adjustment
Adjustable Cylinder Intake Exhaust
3. If removed, install valve adjusting screws and
Location Of Piston
lock nuts. See Figure 10.
When No. 1 1 * *
Install piston is at 2 *
compressio
NOTE: When installing push rod, mount it securely n top dead 3 *
in groove located in bottom of lifter. center 4
1. Install push rods.
When No. 1 1
2. Place rocker arm assembly in position on piston is at 2 *
cylinder head. overlap
position 3 *
3. Install and hand tighten rocker arm shaft 4 * *
retaining flange nuts. See Figure 10.
3. Insert a feeler gauge between rocker arm and
4. Align push rods with their respective rocker valve cap. See Figure 14. Record measured
arms, as noted during removal. valve 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 SRM 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.
1. VALVE ADJUSTING SCREW
2. VALVE LOCK NUT CYLINDER HEAD ASSEMBLY
Remove
Figure 14. Valve Clearance Measurement
1. Disconnect negative battery cable at battery.
4. If adjustment is needed, loosen valve adjusting
screw lock nut and valve adjusting screw on NOTE: Place a suitable container with a capacity of
rocker arm (see Figure 14) and check valve for at least 12.0 liter (13 qt) under radiator and lower
any inclination of valve cap, entrance of dirt, or radiator hose.
wear. See Figure 15. 2. Remove lower radiator hose and radiator cap.
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
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (R005)
• H6.0-7.0FT (H135-155FT) (K006)
See Figure 17 for lift truck model
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
A. NORMAL H5.0-5.5FT (H80-120FT) (S005, U005)
B. ABNORMAL
See Figure 18 for lift truck model
1. VALVE CAP • H6.0-7.0FT (H135-155FT) (L006)
Figure 15. Valve Cap Check • H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
H8.0FTS6 (H135FT, H155FT, H155FTS,
NOTE: There is a tendency for clearance to H170FTS) (N006)
decrease slightly when lock nut is tightened. It is • H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6
suggested that you make clearance adjustment (H135FT, H155FT, H155FTS, H170FTS)
slightly on loose side before tightening lock nut. (P006)
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.).

14
0600 SRM 1579 Cylinder Head Assembly Repair

1. HOSE CLAMP
2. RETAINING CLAMP
3. AIR INTAKE HOSE

Figure 16. Air Intake Hoses for Lift Truck Models 1. HOSE CLAMP
2. RETAINING CLAMP
H6.0-7.0FT (H135-155FT) (K006) 3. AIR INTAKE HOSE

Figure 18. Air Intake Hoses for Lift Truck Models

H6.0-7.0FT (H135-155FT) (L006) and H6.0FT,
H7.0FT, H7.0FTS6, H7.0FTS9, H8.0FTS6 (H135FT,
H155FT, H155FTS, H170FTS) (N006), H6.0FT,
H7.0FT, H7.0FTS9, H8.0FTS6 (H135FT, H155FT,
H155FTS, H170FTS) (P006)

NOTE: Tag wiring connectors and wiring harness

before removal to aid during installation.
4. Tag and disconnect connectors for engine
wiring harness. Move harness aside for better
access.

5. Loosen adjustment bolt for alternator and

release tension on serpentine belt. Remove
serpentine belt. See Figure 19.

1. HOSE CLAMP
2. RETAINING CLAMP
3. AIR INTAKE HOSE

Figure 17. Air Intake Hoses for Lift Truck Model

H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80-120FT) (S005, U005)

15
Cylinder Head Assembly Repair 0600 SRM 1579

1. IDLER ASSEMBLY
2. BOLT
3. PULLEY
4. SPACER
5. COLLAR
6. WATER FLANGE
1. ADJUSTMENT BOLT 7. WATER PUMP
2. ADJUSTER BRACKET
3. RETAINING NUT
4. MOUNTING BOLT Figure 20. Engine Pulleys
5. WASHER
6. MOUNTING BRACKET 8. Remove eight bolts, collar, spacer, and two fan
7. ALTERNATOR pulleys from water pump and water flange. See
Figure 20.
Figure 19. Alternator Mounting and Adjustment
9. Tag and disconnect fuel hoses from fuel filter.
6. Remove three mounting bolts, three retaining
nuts, mounting bracket and alternator from lift 10. Remove two capscrews holding fuel filter
truck. See Figure 19. housing assembly to intake manifold. Remove
fuel filter assembly. See Figure 21.
7. Remove three bolts and idler assembly from
water pump assembly. See Figure 20.

16
0600 SRM 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. CAPSCREW
2. FUEL FILTER ASSEMBLY
3. INTAKE MANIFOLD

Figure 21. Fuel Filter Assembly

11. Remove boost compensator hose and fuel

overflow return hose from fuel injection pump.
See Figure 22.

12. Disconnect lubricating pipe from block just 1. CLAMP

2. HOSE
below injection pump. See Figure 22. 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. BOOST COMPENSATOR HOSE

2. FUEL OVERFLOW RETURN HOSE
3. LUBRICATING PIPE

Figure 22. Fuel Lines

17
Cylinder Head Assembly Repair 0600 SRM 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. WATER FLANGE ASSEMBLY

2. CLAMP
3. BYPASS HOSE
4. BOLT
5. GASKET
6. CYLINDER HEAD

Figure 24. Water Flange 1. INTAKE MANIFOLD ASSEMBLY

2. FLANGE BOLT
21. Remove two bolts, clamp and lifting eye bracket 3. GASKET
from cylinder head. See Figure 25. 4. CYLINDER HEAD

Figure 26. Intake Manifold

NOTE: Have container that will hold at least

13.5 liter (14 gal).
24. Remove oil pan drain plug and drain engine oil
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.

1. LIFTING EYE BRACKET

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

Figure 25. Lifting Eye Bracket

18
0600 SRM 1579 Cylinder Head Assembly Repair

1. DIPSTICK
2. CAPSCREW
3. DIPSTICK TUBE
4. O-RING
5. GUIDE
6. ENGINE BLOCK
7. EXHAUST MANIFOLD 1. BANJO BOLT
2. WASHER SET
3. OIL SUPPLY LINE
Figure 27. Engine Oil Dipstick 4. CAPSCREW
5. CLAMP
27. Remove two banjo bolts, two washer sets and 6. DRAIN TUBE
turbocharger oil supply line. Discard washer 7. HOSE
sets. See Figure 28. 8. GASKET

28. Remove two capscrews, two clamps, oil drain Figure 28. Turbocharger Oil Lines
tube, hose and gasket from turbocharger and
block. Discard gasket. See Figure 28. 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 SRM 1579

1. OIL FILTER
2. CLAMP
3. HOSE
4. OIL COOLER JOINT
5. OIL COOLER
6. O-RING
7. ENGINE BLOCK 1. TURBOCHARGER
2. FLANGE NUT
Figure 29. Oil Cooler 3. FLANGE BOLT
4. GASKET
32. Remove six flange nuts, two flange bolts, 5. EXHAUST MANIFOLD
gasket and turbocharger from exhaust 6. STUD
manifold. Discard gasket. See Figure 30.
Figure 30. Turbocharger

20
0600 SRM 1579 Cylinder Head Assembly Repair

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
freezes, oil can work its way back through the
Closed Crankcase Ventilation (CCV) system into
the air inlet that is in front of the turbocharger.
If oil is found in any of the following checks, it is
likely that the CCV system has frozen:
Check the CCV tubes, hoses, and air feed
adapter for signs of oil.
Remove the breather filter from the canister 1. FLANGE BOLT
for inspection. If ice or debris is found, the 2. FLANGE NUT
breather should be replaced. 3. EXHAUST MANIFOLD
4. GASKET
Verify the engine oil viscosity. 5. CYLINDER HEAD
If oil is found in the CCV tubes, hoses, air
feed adapter, or ice accumulation is present Figure 31. Exhaust Manifold
in the breather, confirm that oil has not
reached the turbocharger. 35. Remove rocker arm assembly. See Rocker Arm
Frozen CCV systems that have allowed oil to reach Assembly, Remove.
the turbocharger will require the CCV and exhaust
36. Remove eighteen cylinder head bolts in
systems to be cleaned. Excessive amounts of oil
sequence shown, from one to eighteen. See
that pass into the after-treatment systmem can
Figure 32.
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. A. TIMING GEAR CASE END
B. FLYWHEEL END
34. Remove six flange nuts, gasket and exhaust
manifold from cylinder head. Discard gasket. Figure 32. Head Bolt Pattern
See Figure 31.
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.

21
Cylinder Head Assembly Repair 0600 SRM 1579

Disassemble
Valves and Valve Springs, Remove
1. Remove four valve arms, four valve arm pads
and four valve arm shafts from cylinder head.
See Figure 35.

2. Using a valve spring compressor tool, compress

valve springs.

3. Remove valve keepers and valve cap from end

A. TIMING GEAR CASE END of valve. See Figure 35.
B. FLYWHEEL END

1. HEAD GASKET

Figure 33. Head Gasket

37. Remove cylinder head and gasket from engine

block. Discard gasket.

38. Remove eight lifters from crankcase. See

Figure 34.

1. LIFTERS
2. CRANKCASE

Figure 34. Lifters

22
0600 SRM 1579 Cylinder Head Assembly Repair

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
5. Remove spring retainer, valve spring, and removed.
valve stem seal.

23
Cylinder Head Assembly Repair 0600 SRM 1579

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

in 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

24
0600 SRM 1579 Cylinder Head Assembly Repair

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

Repair or replace as needed.
Visually inspect valve guides for distortions,
Carefully remove all gasket residue from intake scoring, or other damage.
manifold and cylinder head. Inspect intake manifold
for scratches, cracks, or any other damage. Repair Use a test indicator and micrometer to measure
or replace as needed. inside 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 Valves
scratches, cracks, or any other damage. Repair or
replace as needed. Valve Stem Diameter: Use a micrometer to
measure valve stem diameter. Measure valve stem
Thoroughly clean all components using a near combustion end and near opposite end. Refer
nonmetallic brush and cleaning solvent. Dry parts to Engine Specifications for service limit. See
with compressed air. Each part must be free of Figure 38.
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 side up) on work bench.
A. MEASUREMENT POINTS
2. Use a straight edge and feeler gauge to Figure 38. Valve Stem Diameter Measurement
measure amount of cylinder head distortion. Points
Refer to Engine Specifications for service limit.
See Figure 37. Valve Stem Straightness: Place valve stem on a
flat 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 fractures are found. Figure 39. Valve Stem Straightness Check

25
Cylinder Head Assembly Repair 0600 SRM 1579

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
Figure 40. Valve Sink Measurement standard limits. 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
Valve Seat check each spring for squareness. Refer to Engine
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.

26
0600 SRM 1579 Cylinder Head Assembly Repair

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 7.010 to
installing valve guides, clean new valve guide Intake 7.025 mm
and valve 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.)

27
Cylinder Head Assembly Repair 0600 SRM 1579

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
2. VALVE STEM SEAL
3. VALVE GUIDE Figure 35.
4. CYLINDER HEAD
6. Using valve compressor tool, compress valve
Figure 46. Valve Stem Seal Installation spring.

4. Measure distance from cylinder head to valve 7. Install valve keepers and slowly release tension
stem seal. Refer to Engine Specifications for in valve spring.
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.

28
0600 SRM 1579 Cylinder Head Assembly Repair

3. Measure the piston head's protrusion or Use Table 3 to select an applicable cylinder
recession from crankcase cylinder face in four head 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 9. Install push rods and rocker arm assembly. See
head bolts to 98 to 107 N•m (72 to 80 lbf ft). Rocker Arm Assembly, Install.
See 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.

29
Cylinder Head Assembly Repair 0600 SRM 1579

13. Install new O-ring, oil cooler and oil cooler joint 30. Install valve cover, fuel injectors and related
to engine block. Tighten oil cooler joint to parts. See Valve Covers and Fuel Injectors,
40 to 44 N•m (29 to 32 lbf ft). See Figure 29. Install.

14. Install hose and two clamps to oil cooler and 31. Connect lubricating pipe to engine block just
engine block. See Figure 29. below injection pump. See Figure 22.

15. Install new oil filter onto oil cooler. See 32. Install fuel overflow return hose and boost
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 33. Using two capscrews, install fuel filter housing
turbocharger and 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
19. Install capscrew to dipstick tube and exhaust water 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 38. Put serpentine belt on pulley's. Using a pry
to cylinder head. See Figure 25. bar, pull alternator into position and put
tension onto serpentine belt. Tighten alternator
22. Install lifting eye bracket, clamp and two bolts adjustment bolt. See Figure 19.
to 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,
24. Install water pump. See Cooling System Repair and two hose clamps onto air cleaner and
section in this manual. turbocharger. See Figure 16.

25. Install coolant by pass hose and two clamps 41. Install lower radiator hose.
onto 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 Hyster dealer.
27. Install hose and two clamps onto oil cooler and 42. Fill cooling system with coolant. For correct
oil cooler pipe. See Figure 23. coolant amount and type refer to
28. Install hose and two clamps onto water pump Periodic Maintenance 8000SRM1558 for lift
and oil cooler pipe. See Figure 23. truck models
• H4.0FT5, H4.0FT6, H4.5FTS5, H4.5FT6,
29. Install fuel injection pump. See Fuel System H5.0FT, H5.5FT (H80-120FT) (R005)
Repair section for procedures.

30
0600 SRM 1579 Cylinder Head Assembly Repair

Periodic Maintenance 8000SRM1583 for lift

46. Start engine and check for leaks.
truck models
• H6.0FT, H7.0FT (H135FT,H155FT) (K006) 47. Change engine oil and oil filter. See
Lubrication System Repair, Engine Oil and Oil
Periodic Maintenance 8000SRM1604 for lift
Filter Change.
truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (S005) WARNING
Periodic Maintenance 8000SRM1902 for lift DO NOT remove the radiator cap from the radiator
truck models when the engine is hot. When the radiator cap is
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; removed, pressure will release from the coolant
•
H5.0-5.5FT (H80-120FT) (U005) system. If the coolant system is hot, the steam and
boiling coolant can cause severe burns.
Periodic Maintenance 8000SRM1957 for lift
truck model
• H6.0-7.0FT (H135-155FT) (L006) WARNING
• H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9, The radiator or other parts of the cooling system
H8.0FTS6 (H135FT, H155FT, H155FTS, may be hot or under pressure and can cause
H170FTS) (N006) serious injury. Wait 30 minutes for the radiator and
Periodic Maintenance 8000SRM2401 for the engine to cool before performing maintenance to
following lift truck models the cooling system. After 30 minutes, do a touch
test by touching the radiator with your hand. If the
• H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6
radiator is still hot to the touch, wait another 30
(H135FT, H155FT, H155FTS, H170FTS)
(P006) minutes before attempting any maintenance to the
cooling system.
43. Install radiator cap.

44. Fill engine oil. See Lubrication System Repair, CAUTION

Engine Oil and Oil Filter Change. Additives may damage the cooling system. Before
using additives, contact your local Hyster dealer.
45. Connect negative battery cable.
48. Stop engine. If coolant is hot, allow engine time
to cool. Check coolant level and fill as required
WARNING between ADD and FULL marks on coolant
During engine operation, be careful not to touch reservoir.
the fan, pulleys, or drive belts. Contact with these
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.

31
Timing Gear Case and Timing Gears Repair 0600 SRM 1579

Timing Gear Case and Timing Gears Repair

TIMING GEAR CASE COVER
Remove
1. Remove engine.
See Frame 0100SRM1243 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (R005, S005)
See Frame 0100SRM1581 for lift truck models
• H6.0-7.0FT (H135-155FT) (K006)
See Frame 0100SRM1891 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80-120FT) (U005)
See Frame 0100SRM1948 for lift truck models
1. TIMING GEAR CASE COVER
• H6.0-7.0FT (H135-155FT) (L006) 2. BOLT
• H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9, 3. TIMING GEAR CASE PLATE
H8.0FTS6 (H135FT, H155FT, H155FTS, 4. FRONT OIL SEAL
H170FTS) (N006) 5. ENGINE BLOCK
• H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6 Figure 49. Timing Gear Case Cover
(H135FT, H155FT, H155FTS, H170FTS)
(P006) 6. Remove timing gear case cover.
2. Remove coolant fan, serpentine belt, and water 7. Remove front oil seal from timing gear case
pump. See Cooling System Repair. cover. See Figure 49.
3. Remove bolt and washer retaining crankshaft
pulley.
Clean and Inspect

4. Using a gear puller, remove crankshaft pulley.

WARNING
5. Remove bolts retaining timing gear case cover Cleaning solvents can be flammable and toxic and
and plate to engine block. See Figure 49. can cause skin irritation. When using cleaning
solvents, always follow the recommendations of
the manufacturer.

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.

Clean all old sealant from timing gear case cover

and timing gear case. Clean timing gear case cover
in cleaning solvent. Dry timing gear case cover with
compressed air. Inspect for wear, cracks, and any
other damage. If necessary, replace timing gear case
cover.

32
0600 SRM 1579 Timing Gear Case and Timing Gears Repair

Install See Frame 0100SRM1948 for lift truck models

1. Apply a continuous bead of Three Bond Liquid • H6.0-7.0FT (H135-155FT) (L006)
Gasket (Hyster P/N 1599478 ) to outside • H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
diameter of a new front oil seal. H8.0FTS6 (H135FT, H155FT, H155FTS,
H170FTS) (N006)
2. Using a special tool, install new front oil seal • H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6
into timing gear case cover. Apply lithium (H135FT, H155FT, H155FTS, H170FTS)
grease to lip of front oil seal. See Figure 50. (P006)

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

amount and type refer to
Periodic Maintenance 8000SRM1558 for lift
truck models
• H4.0FT5, H4.0FT6, H4.5FTS5, H4.5FT6,
H5.0FT, H5.5FT (H80-120FT) (R005)
Periodic Maintenance 8000SRM1583 for lift
truck models
• H6.0-7.0FT (H135-155FT) (K006)
Periodic Maintenance 8000SRM1604 for lift
truck models

Figure 50. Front Oil Seal Installation • H4.0FT5, H4.0FT6, H4.5FTS5, H4.5FT6,
H5.0FT, H5.5FT (H80-120FT) (S005)
3. Apply a continuous bead of Three Bond Liquid Periodic Maintenance 8000SRM1902 for lift
Gasket (Hyster P/N 1599478 ) to mating truck models
surface of timing gear case cover and timing
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
gear case plate. H5.0-5.5FT (H80-120FT) (U005)
4. Place timing gear case cover and plate in Periodic Maintenance 8000SRM1957 for lift
position on engine block and install retaining truck models
bolts. Tighten bolts to • H6.0-7.0FT (H135-155FT) (L006)
24 to 27 N•m (18 to 20 lbf ft).
• H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
H8.0FTS6 (H135FT, H155FT, H155FTS,
5. Install crankshaft pulley and bolt to crankshaft
H170FTS) (N006)
pulley. Tighten bolt to
255 to 274 N•m (188 to 202 lbf ft). Periodic Maintenance 8000SRM2401 for the
following lift truck models
6. Install water pump, serpentine belt, and • H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6
coolant fan. See Cooling System Repair. (H135FT, H155FT, H155FTS, H170FTS)
(P006)
7. Install engine.
See Frame 0100SRM1243 for lift truck models 9. Start engine and check for leaks.

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, TIMING GEARS

H5.0-5.5FT (H80-120FT) (R005, S005)
NOTE: For removal of fuel injection pump drive
See Frame 0100SRM1581 for lift truck models
gear, refer to Fuel System Repair.
• H6.0-7.0FT (H135-155FT) (K006)
Before removing any of timing gears, rotate
See Frame 0100SRM1891 for lift truck models crankshaft to align alignment marks on gears as
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; follows (see Figure 51):
H5.0-5.5FT (H80-120FT) (U005) • Align mark "A" on camshaft gear with mark
"A" on idler gear 1.

33
Timing Gear Case and Timing Gears Repair 0600 SRM 1579

• Align mark "B" on crankshaft gear with mark

"B" on idler gear 1.
• Align mark "C" on idler gear 1 with mark "C"
on idler gear 2.

1. OIL PUMP DRIVE GEAR

2. CRANKSHAFT GEAR
3. CRANKSHAFT
4. KEY

Figure 52. Crankshaft Gear

NOTE: TIMING GEARS FOR LIFT TRUCK MODELS
H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT
(H80-120FT) (R005) AND H6.0-7.0FT (H135-155FT) Install
(K006) SHOWN. H4.0FT5/FT6; H4.5FTS5, H4.5FT6; 1. Install key into crankshaft.
H5.0-5.5FT (H80-120FT) (S005, U005), H6.0-7.0FT
(H135-155FT) (L006), AND H6.0FT, H7.0FT, 2. Align alignment mark "B" on crankshaft gear
H7.0FTS6, H7.0FTS9, H8.0FTS6 (H135FT, H155FT, with alignment mark "B" on idler gear 1 and
H155FTS, H170FTS) (N006), H6.0FT, H7.0FT, install crankshaft gear onto crankshaft.
H7.0FTS9, H8.0FTS6 (H135FT, H155FT, H155FTS,
H170FTS) (P006) ARE SIMILAR. 3. Verify that all alignment marks are properly
aligned. Figure 51.
1. CAMSHAFT GEAR
2. CRANKSHAFT GEAR 4. Install timing gear case cover. See Timing Gear
3. IDLER GEAR 1 Case Cover, Install.
4. OIL PUMP GEAR
5. IDLER GEAR 2
Idler Gear
Figure 51. Timing Gear Alignment Remove
Crankshaft Gear NOTE: There are two idler gears on this engine
(idler gear 1 and idler gear 2). The repair procedure
Remove is same for both.
1. Remove timing gear case cover. See Timing
Gear Case Cover, Remove. 1. Remove timing gear case cover. See Timing
Gear Case Cover, Remove.
2. Verify that gears are properly aligned with
alignment marks. See Figure 51. 2. Verify that gears are properly aligned with
alignment marks. See Figure 51.
3. Remove oil pump drive gear. See Figure 52.
3. Remove bolts from idler gear shaft. See
NOTE: If using a gear puller to remove crankshaft Figure 53.
gear, be careful not to damage threads in end of
crankshaft. 4. Remove idler gear shaft, alignment pin, idler
gear, idler gear collar, and bushing.
4. Remove crankshaft gear. See Figure 52.

5. Remove key from crankshaft.

34
0600 SRM 1579 Timing Gear Case and Timing Gears Repair

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
1. Measure outside diameter of idler gear shaft. Gear 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

35
Timing Gear Case and Timing Gears Repair 0600 SRM 1579

TIMING GEAR CASE

Remove
1. Remove engine.
See Frame 0100SRM1243 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (R005, S005)
See Frame 0100SRM1581 for lift truck models
• H6.0-7.0FT (H135-155FT) (K006)
See Frame 0100SRM1891 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80-120FT) (U005)
See Frame 0100SRM1948 for lift truck models
• H6.0-7.0FT (H135-155FT) (L006)
• H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
H8.0FTS6 (H135FT, H155FT, H155FTS,
1. ENGINE BLOCK
2. CAMSHAFT GEAR H170FTS) (N006)
3. PULSE GEAR • H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6
4. CAPSCREW (H135FT, H155FT, H155FTS, H170FTS)
5. BOLT (P006)
6. RETAINER
7. KEY 2. Remove timing gear case cover. See Timing
8. CAMSHAFT
Gear Case Cover, Remove.
Figure 55. Camshaft Gear
3. Remove fuel injection pump. See Fuel System
Repair.
Install
1. Install key into camshaft. 4. Remove timing gears. See Timing Gears.

2. Align alignment mark "A" on camshaft gear 5. Remove three bolts holding gear case plate to
with alignment mark "A" on idler gear and cylinder block. Remove gear case plate. See
install camshaft gear onto camshaft. Figure 56.

3. Install pulse gear and four capscrews onto 6. Remove two O-rings from cylinder block and
camshaft gear. Tighten capscrews to discard.
4.7 to 5.6 N•m (42 to 50 lbf in).

4. Install timing gear case cover. See Timing Gear

Case Cover, Install.

36
0600 SRM 1579 Timing Gear Case and Timing Gears Repair

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 H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (R005) .
2. Apply a continuous bead of Three Bond Liquid
Gasket (Hyster P/N 1599478 ) 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

Case Cover, Install.
A. THREE BOLTS HOLDING GEAR CASE PLATE
TO CYLINDER BLOCK
6. Install fuel injection pump. See Fuel System
1. TIMING GEAR CASE PLATE Repair.
2. BOLT
3. O-RINGS 7. Install engine.
4. CYLINDER BLOCK
See Frame 0100SRM1243 for lift truck models
Figure 56. Timing Gear Case • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (R005, S005)
Clean and Inspect See Frame 0100SRM1581 for lift truck models
• H6.0-7.0FT (H135-155FT) (K006)
WARNING See Frame 0100SRM1891 for lift truck models
Cleaning solvents can be flammable and toxic and
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
can cause skin irritation. When using cleaning
H5.0-5.5FT (H80-120FT) (U005)
solvents, always follow the recommendations of
the manufacturer. See Frame 0100SRM1948 for lift truck models
• H6.0-7.0FT (H135-155FT) (L006)
• H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
WARNING H8.0FTS6 (H135FT, H155FT, H155FTS,
Compressed air can move particles so that they H170FTS) (N006)
cause injury to the user or to other personnel. • H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6
Make sure that the path of the compressed air is (H135FT, H155FT, H155FTS, H170FTS)
away from all personnel. Wear protective goggles (P006)
or a face shield to prevent injury to the eyes.
8. Change engine oil and oil filter. See
Clean all old sealant from timing gear case cover Lubrication System Repair, Engine Oil and Oil
and timing gear case. Clean timing gear case cover Filter Change.
and gear case in cleaning solvent. Dry timing gear
case cover and gear case with compressed air. 9. Start engine and check for leaks.

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

Drive Train, Camshaft, and Cylinder Block Repair

REMOVE 8. Remove oil suction tube. See Lubrication
System Repair.
1. Remove engine.
See Frame 0100SRM1243 for lift truck models 9. Remove timing gear case cover. See Timing
Gear Case and Timing Gears Repair.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80-120FT) (S005, U005)
10. Remove oil pump. See Lubrication System
See Frame 0100SRM1891 for lift truck models Repair.
• H4.0FT5, H4.0FT6, H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (U005) NOTE: DO NOT remove camshaft gear at this time.

See Frame 0100SRM1581 for lift truck models 11. Remove crankshaft gear and idler gear. See
Timing Gear Case and Timing Gears Repair.
• H6.0-7.0FT (H135-155FT) (K006)
See Frame 0100SRM1948 for lift truck models DISASSEMBLE
• H6.0-7.0FT (H135-155FT) (L006) Pistons and Connecting Rods
• H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9, NOTE: It is necessary to rotate crankshaft to access
H8.0FTS6 (H135FT, H155FT, H155FTS,
some of connecting rod assemblies at bottom dead
H170FTS) (N006)
center position.
• H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6
(H135FT, H155FT, H155FTS, H170FTS) 1. Using a feeler gauge, measure connecting rod
(P006) thrust clearance. See Figure 57. Refer to
Engine Specifications for standard limit. If
Remove starter. See Electrical Equipment
measurement is out of specification, either
Repair.
crankshaft or connecting rod must be replaced.
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

2. Remove two bolts from one of connecting rod

caps. See Figure 58.

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

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
7. Remove piston rings from piston. rear 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.

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

Description Factory Allowable

Specification Limit Dimension Minimum Maximum
Side Clearance 0.15 to 0.31 mm 0.50 mm Oversize 0.2 mm 0.4 mm
of Crankshaft (0.0059 to (0.020 in.) Journal (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 (0.11 to
0.12 in.) radius 0.12 in.) 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.

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

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.

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

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
Repair.
interfering 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.

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

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

Figure 65. Cylinder Measurement Points number one is calculated as follows:
Select least value of values X, Y and Z
4. Perform calculations as follows: record that value as S. Complete
calculation as follows:
a. Measure inside diameter of cylinder number
V-S = W
one, near top of cylinder (a) and in (d)
direction. Record that measurement as data W is difference between V and S
f. measurements. This value represents
cylindricity of cylinder.
b. Measure inside diameter of cylinder number
one, near top of cylinder (a) and in (e) 5. Repeat cylindricity and roundness
direction. Record that measurement as data measurements and calculations for remaining
g. cylinders.

c. Measure inside diameter of cylinder number 6. Compare worksheet findings with

one, near center of cylinder (b) and in (d) specifications listed in Table 5.
direction. Record that measurement as data
h. 7. Consider boring and honing, cylinder
correction, or replacing cylinder block if
measurements fall outside specifications.

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

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 = __________

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

Honing and Boring d. Insert rotating honing tool into cylinder and
move it down through entire length of
Pistons must move freely in cylinders while cylinder in a five-second motion. See
maintaining adequate compression and oil sealing. Figure 67.
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.
Factory Specification Allowable Limit

100.500 to 100.522 mm 100.650 mm

(3.95670 to 3.95755 in.) (3.96260 in.)
Figure 66. Cylinder Honing Angle
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
must be honed.

2. Honing: Slight cylinder imperfections might be

corrected by honing.
Figure 67. Cylinder Honing
a. Insert appropriate honing tool into chuck of
an electric drill. e. Without stopping honing tool, pull it up
through entire length of cylinder in a five-
b. Saturate cylinder wall with solvent using a second motion.
50% diesel fuel and 50% engine oil mixture.
f. Maintain up-and-down motion for thirty to
c. Rotate honing tool at 300 to 1200 rpm. forty seconds.

CAUTION WARNING
DO NOT allow the honing tool to operate in one Compressed air can move particles so that they
position for any length of time. Damage to the cause injury to the user or to other personnel.
cylinder wall will occur. Keep the tool in constant Make sure that the path of the compressed air is
up-and-down motion. away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.
NOTE: Tilt honing tool at a 30 to 40 degree angle
during honing operation, to leave a cross hatch
mark on cylinder wall. See Figure 66.

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

g. When honing is completed, wash cylinder Pistons

block with hot water and soap. Use brushes
to clean all passages and crevices. Rinse with 1. Using a micrometer, measure piston diameter
hot water and blow dry with compressed air. at skirt. Refer to Engine Specifications for
Apply clean engine oil to all steel surfaces to service limit. See Figure 69.
prevent rusting.

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 Figure 69. Piston Skirt Measurement

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

A. WIDTH
B. THICKNESS

Figure 70. Piston and Piston Ring Side Clearance

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

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.

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.

1. CYLINDER GAUGE
Piston Pin 2. CONNECTING ROD SMALL END
Measure outside diameter of piston pin and inside Figure 72. Connecting Rod Small End
diameter of wrist pin bushing. Calculate clearance
between piston pin and wrist pin bushing. Refer to 2. Measure crank-pin and connecting rod bearing
Engine Specifications for service limit. See halves. Place connecting rod bearing halves
Figure 71. 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.

Tappets
1. Check tappet contact surfaces with camshaft
and push rods. Slight surface defects can be
corrected using an oilstone. See Figure 73.
NOTE: MEASURE AT POSITIONS A, B, AND C IN
DIRECTIONS A AND B.

Figure 71. Piston Pin Outside Diameter

Connecting Rod
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

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

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 Figure 75. Crankshaft Bend Measurement
to 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

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

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
fractures are found. of 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 Connectin Crank Pin Bearing

g Rod
Large End Class Center
Diameter Wall
Thickness
56.010 to 1.496 to
Description Factory Allowable 56.020 mm 1.501 mm
Blue L
Specification Limit (2.2052 to (0.05890 to
2.2055 in.) 0.05909 in.)
52.977 to N/A
52.990 mm 56.00 to 1.491 to
Crank Pin O.D. Without 56.01 mm 1.496 mm
(2.0857 to S
2.0862 in.) Color (2.2048 to (0.05870 to
2.2051 in.) 0.05889 in.)
Oil Clearance 0.018 to 0.20 mm
Between Crank 0.051 mm (0.0079 in.) Figure 78. Crankshaft Pin Bearing Identification
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.

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

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 (0.11 to
0.12 in.) radius 0.12 in.) 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.) A. CAM HEIGHT
relief.
Figure 81. Intake/Exhaust Cam Height
Figure 79. Crank Pin Journal Measurement Measurement

Camshaft 3. Measure gear end bearing surface,

intermediate position bearing surface, and
1. Measure trueness of camshaft. flywheel end bearing surface diameters. See
Figure 82. Determine oil clearance. The oil
a. Place camshaft on V-blocks positioned at end
clearance is calculated by subtracting
journals. See Figure 80.
measured camshaft bearing surface diameter
b. Place a dial indicator on gear side bearing from camshaft bushing inside diameter. Refer
surface and zero gauge. to Engine Specifications for service limit.

c. Rotate camshaft and observe runout. Refer

to Engine Specifications for service limit.

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

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
2. INTERMEDIATE POSITION BEARING SURFACE 3. Lubricate bearing cap bolts and install bolts.
3. GEAR END BEARING SURFACE
4. Install a new oil seal in rear oil seal housing.
Figure 82. Camshaft Bearing Surface
Measurements 5. Apply a continuous bead of Three Bond Liquid
Gasket (Hyster P/N 1599478 ) to mating
Camshaft Bushing surface of rear oil seal housing.
If camshaft bushing is damaged, replace bushing 6. Align rear oil seal housing with two dowel pins
using appropriate service tool. on cylinder block and install rear oil seal
housing. Install retaining bolts.
ASSEMBLE
Camshaft Pistons and Connecting Rods
1. Verify that all parts are clean. Lightly lubricate 1. Select parts needed to assemble piston and
all parts with clean engine oil. connecting rod for Number 1 cylinder.

2. Install timing gear case. See Timing Gear Case 2. Lubricate and insert wrist pin bushing into
and Timing Gears Repair. small end of connecting rod. See Figure 58.

NOTE: Rotate cylinder block into a position in 3. Install one snap ring into piston.
which it allows gravity to keep tappets in place and
out of way of camshaft lobes for when camshaft is 4. Position connecting rod into piston under skirt.
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.

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

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
15. FUEL SUPPLY PUMP DIRECTION 1. TOP COMPRESSION RING
2. SECOND COMPRESSION RING
Figure 83. Piston and Connecting Rod 3. OIL RING
Identification Marks 4. PISTON

5. Lubricate and install piston wrist pin through Figure 85. Piston Rings
piston and wrist pin bushing.
c. Stagger piston ring joints at 120 degree
6. Install second snap ring. intervals. DO NOT position top compression
ring joint in line with piston wrist pin. The
7. Using piston ring pliers, install piston rings. coil expander joint must be opposite oil ring
joint. See Figure 86.
a. Install each piston ring on piston with
punched manufacture's mark facing upward.
See Figure 84.

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

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.

1. TOP COMPRESSION RING 10. Install flywheel and flywheel housing. See
2. SECOND COMPRESSION RING Flywheel and Flywheel Housing.
3. OIL RING
4. JOINTS 11. Install starter. See Electrical Equipment
Repair.
Figure 86. Piston Rings Staggering
12. Install engine.
8. Perform Step 1 through Step 7 for assembly of
remaining pistons. See Frame 0100SRM1243 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
9. Lubricate Number 1 piston and piston rings H5.0-5.5FT (H80-120FT) (R005, S005)
with clean engine oil. See Frame 0100SRM1581 for lift truck models
10. Using special tool, piston ring compressor, • H6.0-7.0FT (H135-155FT) (K006)
compress piston rings on Number 1 piston. See Frame 0100SRM1891 for lift truck models
11. Carefully install piston into Number 1 cylinder. • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
Be sure matched mark on connecting rod and H5.0-5.5FT (H80-120FT) (U005)
connecting rod cap is facing towards fuel supply See Frame 0100SRM1948 for lift truck models
pump side. See Figure 83.
• H6.0-7.0FT (H135-155FT) (L006)
12. Install connecting rod bearing halves and • H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
connecting rod cap. Install connecting rod bolts H8.0FTS6 (H135FT, H155FT, H155FTS,
and tighten to 79 to 83 N•m (58 to 61 lbf ft). H170FTS) (N006)
See Figure 83. • H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6
(H135FT, H155FT, H155FTS, H170FTS)
13. Perform Step 9 through Step 12 to install (P006)
remaining pistons in their respective cylinders.

53
Drive Train, Camshaft, and Cylinder Block Repair 0600 SRM 1579

13. If not previously removed, remove and discard See Periodic Maintenance 8000SRM1583 for
engine oil filter. Apply clean oil to gasket of lift truck models
new filter. Install new filter. Turn filter until H6.0F-7.0FT (H135-155FT) (K006)
•
gasket touches, then tighten ½ to 3/4 turn with
your hand. See Periodic Maintenance 8000SRM1957 for
lift truck models
14. Fill engine oil to correct level. • H6.0-7.0FT (H135-155FT) (L006)
See Periodic Maintenance 8000SRM1558 for Periodic Maintenance 8000SRM2196
lift truck model
H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H8.0FTS6 (H135FT, H155FT, H155FTS,
H5.0-5.5FT (H80-120FT) (R005) H170FTS) (N006)
See Periodic Maintenance 8000SRM1604 for Periodic Maintenance 8000SRM2401 for the
lift truck model following lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; • H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6
H5.0-5.5FT (H80-120FT) (S005) (H135FT, H155FT, H155FTS, H170FTS)
See Periodic Maintenance 8000SRM1902 (P006)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; 15. Start engine and check for leaks.
H5.0-5.5FT (H80-120FT) (U005)

54
0600 SRM 1579 Lubrication System Repair

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 8000SRM1558 for lift
Figure 87. Oil Pan truck models
2. Remove engine oil filter. See Figure 88. • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (R005)
Periodic Maintenance 8000SRM1583 for lift
truck models
• H6.0-7.0FT (H135-155FT) (K006)
Periodic Maintenance 8000SRM1604 for lift
truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (S005)
Periodic Maintenance 8000SRM1902 for lift
truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (U005)
See Periodic Maintenance 8000SRM1957 for
lift truck models

55
Lubrication System Repair 0600 SRM 1579

• H6.0-7.0FT (H135-155FT) (L006) • H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,

H8.0FTS6 (H135FT, H155FT, H155FTS,
Periodic Maintenance 8000SRM2196 H170FTS) (N006)
• H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9, Periodic Maintenance 8000SRM2401 for the
H8.0FTS6 (H135FT, H155FT, H155FTS,
following lift truck models
H170FTS) (N006)
• H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6
Periodic Maintenance 8000SRM2401 for the
(H135FT, H155FT, H155FTS, H170FTS)
following lift truck models (P006)
• H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6
(H135FT, H155FT, H155FTS, H170FTS) 2. Remove underbody shield.
(P006)
See Frame 0100SRM1243 for lift truck models
6. Start engine. Check area around oil filter for • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
leaks. H5.0-5.5FT (H80-120FT) (R005, S005)
See Frame 0100SRM1581 for lift truck models
OIL PAN
• H6.0-7.0FT (H135-155FT) (K006)
Remove See Frame 0100SRM1891 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
WARNING H5.0-5.5FT (H80-120FT) (U005)
When putting the lift truck on blocks, make sure See Frame 0100SRM1948 for lift truck models
the surface is solid, even, and level. Any blocks
used to support the lift truck must be solid, one- • H6.0-7.0FT (H135-155FT) (L006)
piece units. See Periodic Maintenance 8000SRM2196

1. Put lift truck on blocks so that you have access • H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
under lift truck. Refer to Operating Manual H8.0FTS6 (H135FT, H155FT, H155FTS,
H170FTS) (N006)
or section
Periodic Maintenance 8000SRM2401 for the
Periodic Maintenance 8000SRM1558 for lift
following lift truck models
truck models
• H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
(H135FT, H155FT, H155FTS, H170FTS)
H5.0-5.5FT (H80-120FT) (R005)
(P006)
Periodic Maintenance 8000SRM1583 for lift
truck models NOTE: Place a container with a capacity of at least
13.2 liter (3.5 gal) under oil pan drain plug.
• H6.0-7.0FT (H135-155FT) (K006)
3. Remove oil pan drain plug and drain engine oil
Periodic Maintenance 8000SRM1604 for lift
into a suitable container. See Figure 88.
truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, 4. Remove oil filter.
H5.0-5.5FT (H80-120FT) (S005)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; 5. Remove twenty bolts holding oil pan to
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (S005) crankcase. See Figure 87.
Periodic Maintenance 8000SRM1902 for lift 6. Remove four flange bolts holding oil pan to
truck models crankcase. See Figure 87.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (U005) 7. Remove oil pan.
See Periodic Maintenance 8000SRM1957 for
lift truck models
CAUTION
• H6.0-7.0FT (H135-155FT) (L006)
Use care not to damage the mating surfaces when
See Periodic Maintenance 8000SRM2196 removing old gaskets and sealant residues.

56
0600 SRM 1579 Lubrication System Repair

8. Carefully remove old sealant residue from Periodic Maintenance 8000SRM1583 for lift
mating surfaces of oil pan and cylinder block. truck models
• H6.0-7.0FT (H135-155FT) (K006)
9. Thoroughly clean outside and inside surfaces of
oil pan. Periodic Maintenance 8000SRM1604 for lift
truck models
Install • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
1. Apply a continuous bead of Three Bond Liquid H5.0-5.5FT (H80-120FT) (S005)
Gasket (Hyster P/N 1599478 ) around sealing Periodic Maintenance 8000SRM1902 for lift
surface of oil pan. truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
2. Place oil pan in position and install retaining
H5.0-5.5FT (H80-120FT) (U005)
bolts. Refer to Standard Torque Specifications.
See Periodic Maintenance 8000SRM1957 for
3. Apply clean oil to gasket of new filter. Install lift truck models
new filter. Turn filter until gasket touches, • H6.0-7.0FT (H135-155FT) (L006)
then tighten ½ to 3/4 turn with your hand.
See Periodic Maintenance 8000SRM2196
4. Install oil pan drain plug. • H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
H8.0FTS6 (H135FT, H155FT, H155FTS,
5. Install underbody shield. H170FTS) (N006)
See Frame 0100SRM1243 for lift truck models Periodic Maintenance 8000SRM2401 for the
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, following lift truck models
H5.0-5.5FT (H80-120FT) (R005, S005) • H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6
See Frame 0100SRM1581 for lift truck models (H135FT, H155FT, H155FTS, H170FTS)
(P006)
• H6.0-7.0FT (H135-155FT) (K006)
See Frame 0100SRM1891 for lift truck models 8. Start engine and check for leaks.

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; OIL SUCTION TUBE

H5.0-5.5FT (H80-120FT) (U005)
See Frame 0100SRM1948 for lift truck models Remove
• H6.0-7.0FT (H135-155FT) (L006) 1. Remove oil pan. See Oil Pan, Remove
See Periodic Maintenance 8000SRM2196 2. Remove two bolts holding oil suction tube. See
• H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9, Figure 89.
H8.0FTS6 (H135FT, H155FT, H155FTS,
H170FTS) (N006) 3. Remove oil suction tube.
Periodic Maintenance 8000SRM2401 for the
4. Remove O-ring from oil suction tube and
following lift truck models
discard.
• H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6
(H135FT, H155FT, H155FTS, H170FTS)
(P006)

6. Remove lift truck from blocks.

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

amount and type refer to
Periodic Maintenance 8000SRM1558 for lift
truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (R005)

57
Lubrication System Repair 0600 SRM 1579

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
Remove
1. Remove engine.
See Frame 0100SRM1243 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
1. BOLT
2. OIL SUCTION TUBE H5.0-5.5FT (H80-120FT) (R005, S005)
3. O-RING See Frame 0100SRM1581 for lift truck models
4. CRANKCASE
• H6.0-7.0FT (H135-155FT) (K006)
Figure 89. Oil Suction Tube See Frame 0100SRM1891 for lift truck models

Clean • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;

H5.0-5.5FT (H80-120FT) (U005)
See Frame 0100SRM1948 for lift truck models
WARNING • H6.0-7.0FT (H135-155FT) (L006)
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning • H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
H8.0FTS6 (H135FT, H155FT, H155FTS,
solvents, always follow the recommendations of
H170FTS) (N006)
the manufacturer.
• H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6
(H135FT, H155FT, H155FTS, H170FTS)
(P006)
WARNING
Compressed air can move particles so that they 2. Remove coolant fan, serpentine belt, and water
cause injury to the user or to other personnel. pump. See Cooling System Repair.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles 3. Remove bolt and washer holding crankshaft
or a face shield to prevent injury to the eyes. pulley.

NOTE: The oil suction tube and screen are to be 4. Using a gear puller, remove crankshaft pulley.
serviced as an assembly. DO NOT attempt to repair
wire mesh portion of tube and screen assembly. 5. Remove timing gear case cover. See Timing
Gear Case and Timing Gears Repair.
Clean oil suction tube in cleaning solvent. Dry oil
suction tube with compressed air. Inspect for wear 6. Remove eight capscrews holding oil pump
and damage. If necessary, replace oil suction tube. assembly and remove oil pump assembly from
timing gear case housing. See Figure 90.

58
0600 SRM 1579 Lubrication System Repair

Outer Rotor Outside Clearance

Insert a feeler gauge between outer rotor and timing
gear case oil pump cavity and measure clearance.
Refer to section Engine Specifications for clearance
limits. See Figure 91.

1. CAPSCREW
2. OIL PUMP COVER
3. OIL PUMP ROTOR
4. GEAR CASE HOUSING

Figure 90. Oil Pump Assembly 1. OUTER ROTOR

2. FEELER GAUGE
7. Remove outer rotor from timing gear case 3. OIL PUMP CAVITY
housing. See Figure 90.
Figure 91. Outer Rotor Outside Clearance Check
Clean and Inspect
Outer Rotor to Inner Rotor Tip Clearance
Insert a feeler gauge between top of an inner rotor
WARNING tooth and top of an outer rotor tooth and measure
Cleaning solvents can be flammable and toxic and clearance. Refer to section Engine Specifications for
can cause skin irritation. When using cleaning clearance limits. See Figure 92.
solvents, always follow the recommendations of
the manufacturer.

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 1. FEELER GAUGE
to the engine. 2. INNER ROTOR
3. OUTER ROTOR
Clean all parts in cleaning solvent. Dry parts with
compressed air. Inspect for wear and damage. If Figure 92. Outer Rotor to Inner Rotor Tip
necessary, replace oil pump assembly. Clearance Check

59
Lubrication System Repair 0600 SRM 1579

Outer Rotor Side Clearance Install

Using a depth micrometer, measure depression of 1. Lubricate outer rotor and pump bore in gear
outer rotor across pump cavity to determine side case with clean engine oil.
clearance. Refer to section Engine Specifications for
clearance limits. See Figure 93. NOTE: The punch mark end of outer rotor must
face away from gear case housing.
2. Install outer rotor in gear case housing. Verify
that punch mark end of outer rotor faces away
from gear case housing. See Figure 95.

1. DEPTH MICROMETER
2. PUMP CAVITY 1. PUNCH MARK
3. OUTER ROTOR 2. OUTER ROTOR
3. TIMING GEAR CASE
Figure 93. Outer Rotor Side Clearance Check
Figure 95. Outer Rotor
Rotor Shaft Clearance
3. Position oil pump assembly in gear case
Measure outside diameter of rotor shaft and bore housing. Install bolts to retain oil pump. Refer
diameter in gear case housing to determine rotor to Standard Torque Specifications. See
shaft clearance. Refer to section Engine Figure 95.
Specifications for clearance limits. See Figure 94.
4. Install timing gear case cover. See Timing Gear
Case and Timing Gears Repair.

1. ROTOR SHAFT
2. GEAR CASE HOUSING

Figure 94. Rotor Shaft Clearance Check

60
0600 SRM 1579 Lubrication System Repair

5. Install crankshaft pulley, washer, and bolt to • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;

retain crankshaft pulley. Tighten bolt to H5.0-5.5FT (H80-120FT) (U005)
255 to 274 N•m (188 to 202 lbf ft). See Frame 0100SRM1948 for lift truck models
6. Install water pump, serpentine belt, and • H6.0-7.0FT (H135-155FT) (L006)
coolant fan. See Cooling System Repair. • H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
H8.0FTS6 (H135FT, H155FT, H155FTS,
7. Install engine. H170FTS) (N006)
See Frame 0100SRM1243 for lift truck models • H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6
(H135FT, H155FT, H155FTS, H170FTS)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, (P006)
H5.0-5.5FT (H80-120FT) (R005, S005)
See Frame 0100SRM1581 for lift truck models 8. Change engine oil and oil filter. See Engine Oil
and Oil Filter Change.
• H6.0-7.0FT (H135-155FT) (K006)
See Frame 0100SRM1891 for lift truck models 9. Start engine and check for leaks.

61
Fuel System Repair 0600 SRM 1579

Fuel System Repair

FUEL INJECTORS • Remove fuel injector from cylinder head.
• Push a screw driver into hole located in
Remove middle 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
1. Remove fuel injector lines and fuel injectors. will also come out with seal at this time. See
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 Valve Covers and Fuel Injectors section for
free from obstruction. procedure.

Replace
If it becomes to necessary to replace a fuel injector,
follow procedure outlined below:

62
0600 SRM 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

H135FT, H155FT,H6.0FT, H7.0FT (L006), H6.0FT,
H7.0FT, H7.0FTS6, H7.0FTS9, H8.0FTS6 (H135FT,
H155FT, H155FTS, H170FTS) (N006), H6.0FT,
H7.0FT, H7.0FTS9, H8.0FTS6 (H135FT, H155FT,
H155FTS, H170FTS) (P006), and H80FT, H90FT,
H100FT, H110FT, H120FT, H4.0FT5, H4.0FT6,
H4.5FTS5, H4.5FT6, H5.0FT, H5.5FT (U005)

NOTE: The TPS mounting screws are non-magnetic

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

63
Fuel System Repair 0600 SRM 1579

2. Remove two Torx-head capscrews, two lock 3. Remove two Allen-head capscrews from TPS
washers, and throttle position sensor (TPS) mounting bracket and fuel shut off solenoid.
from TPS mounting bracket and TPS plate. See 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
the steps found in Throttle Position Sensor plate. See Figure 99.
Proceedures After September 2018 H135FT,
H155FT,H6.0FT, H7.0FT (L006), H6.0FT, H7.0FT, 5. Pull rubber boot from collar and rotate throttle
H7.0FTS6, H7.0FTS9, H8.0FTS6 (H135FT, lever plate to full open position. See Figure 100.
H155FT, H155FTS, H170FTS) (N006), H6.0FT,
H7.0FT, H7.0FTS9, H8.0FTS6 (H135FT, H155FT,
H155FTS, H170FTS) (P006), and H80FT, H90FT,
H100FT, H110FT, H120FT, H4.0FT5, H4.0FT6,
H4.5FTS5, H4.5FT6, H5.0FT, H5.5FT (U005) for
trucks assembled after September 2018.

64
0600 SRM 1579 Fuel System Repair

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.

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
1. THROTTLE ROD 6. LINKAGE
2. RUBBER BOOT 7. BELLCRANK WELDMENT
3. LOCK WASHER 8. STUD
4. CAPSCREW
5. INLINE BALL SOCKET Figure 101. Linkage Arrangement
6. INSERT
7. ACTUATOR ENGINE MOUNT BRACKET 9. Remove nut, washer, and capscrew securing
8. COLLAR linkage to throttle lever plate and speed control
9. ACTUATOR NUT
10. ACTUATOR ROD lever. See Figure 101.
11. ALLEN HEAD CAPSCREW
12. ACTUATOR 10. Remove shoulder bolt, washer, shim, and nut
from crank bracket and bellcrank weldment.
Figure 100. Electronic Throttle Actuator Set bellcrank weldment aside. See Figure 101.

6. Unscrew inline ball joint from actuator rod. See 11. If required, pull throttle lever plate from speed
Figure 100. control lever on fuel injection pump. See
Figure 99.

65
Fuel System Repair 0600 SRM 1579

12. If required, remove three capscrews and Throttle Position Sensor Proceedures
actuator engine mount bracket from engine. After September 2018 H135FT,
See Figure 102.
H155FT,H6.0FT, H7.0FT (L006), H6.0FT,
H7.0FT, H7.0FTS6, H7.0FTS9, H8.0FTS6
(H135FT, H155FT, H155FTS, H170FTS)
(N006), H6.0FT, H7.0FT, H7.0FTS9,
H8.0FTS6 (H135FT, H155FT, H155FTS,
H170FTS) (P006), and H80FT, H90FT,
H100FT, H110FT, H120FT, H4.0FT5,
H4.0FT6, H4.5FTS5, H4.5FT6, H5.0FT,
H5.5FT (U005)
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, navigate display console menus to
read Throttle Position Sensor Voltage
under No-run Data Display menu. With
accelerator released and throttle lever against
1. CAPSCREW low idle stop, Throttle Position Sensor must be
2. ACTUATOR ENGINE MOUNT BRACKET within 1.0-1.1 volts.
3. RUBBER BOOT
3. Maunually rotate throttle lever (not accelerator
Figure 102. Actuator Engine Mount Bracket To
pedal) to full throttle position. This will
Engine
immediately set a fault code for the Throttle
13. If required, remove four Allen head capscrews Position Exceeds Command. Fault code
and actuator from actuator engine mount must be cleared after performing this
bracket. See Figure 100. 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.

66
0600 SRM 1579 Fuel System Repair

1. NUT
2. SHIM
3. INBOARD BEARING
4. BELLCRANK WELDMENT
5. OUTBOARD BEARING
6. WASHER
7. SHOULDER BOLT
8. CRANK BRACKET

Figure 104. Bellcrank Weldment To Crank Bracket

Assembly

3. Clean dirt and debris from sealed bearings.

4. Inspect bearings and shoulder bolt for wear or

damage. Replace shoulder bolt and bearings (as
a set) if worn or damaged.

1. E-THROTTLE CRANK BRACKET 5. Install bearings into bellcrank weldment. Be

2. SET SCREW sure to fully seat bearing in bellcrank
3. BELLCRANK weldment.
Figure 103. E-Throttle Crank Bracket Install
Bearing Replacement 1. If removed, install actuator, four capscrews,
washers, and nuts into actuator engine mount
1. Place bellcrank weldment in a soft jawed vice. bracket. See Figure 100.
2. Using a brass punch and hammer, drive sealed 2. If removed, install acutator engine mount
bearings (#3 and #5, Figure 104) from the bracket on engine using three capscrews. See
bellcrank weldment. Figure 102.

3. If removed, install throttle lever plate on speed

control lever of fuel injection pump. See
Figure 99.

67
Fuel System Repair 0600 SRM 1579

4. Assemble shoulder bolt through washer, 15. Perform adjustment procedures. See section
bearings, bellcrank weldment, and shim. Adjustment.
Install assembly onto crank bracket (with shim
facing toward engine) and secure into position 16. Tighten Torx-head screws (installed in Step 13)
with nut. Tighten shoulder bolt to to 2.25 N•m (20 lbf in).
25.6 N•m (226.6 lbf in). See Figure 104.
Adjustment
5. Install linkage and nut onto set screw in
bellcrank weldment. DO NOT tighten nut. See
Figure 101. CAUTION
DO NOT attempt to adjust the low or high idle
6. Install capscrew, washer, nut, and linkage onto speed limit screws. This may impair the safety and
throttle lever plate. Tighten capscrew to performance of the lift truck and shorten it’s
10.5 N•m (92.9 lbf in). See Figure 101. engine life. If the idle speed limit screws require
adjustment, see your authorized Kubota industrial
7. Tighten nut on stud in bellcrank weldment to engine dealer or distributor.
10.5 N•m (92.9 lbf in).
1. Rotate throttle lever plate manually to verify if
8. Rotate throttle lever plate into full open lever is in full contact with low and high idle
position to install capscrew, ball joint rod end, stop screws.
washer, and nut. Tighten nut to
7.9 N•m (70 lbf in). 2. With the engine at idle, adjust the ball joint rod
end on the actuator rod up or down to align
9. Rotate throttle lever into full closed position hole in ball joint rod end with hole in bellcrank
and install throttle rod with inline ball joint weldment. Once holes are aligned install
onto actuator rod. Fully seat inline ball joint on capscrew, washer, and nut. Tighten capscrew to
actuator rod. Tighten inline ball joint to 7.9 N•m (70 lbf in). See Figure 99.
7.9 N•m (70 lbf in). See Figure 100.
3. With truck power ON and engine OFF,
10. Connect rubber boot to collar on actuator navigate display consule menus to read throttle
engine mount bracket. See Figure 100. position sensor "A" voltage under no-run data
diplay menu. PC Service Tool may also be used.
11. If removed, install TPS rotor on throttle lever With the accelerator released and the throttle
plate. See Figure 100. lever against low idle stop, throttle sensor "A"
voltage must be with in 1.0 - 1.1 volts.
12. Install TPS mounting bracket and two Allen-
head capscrews on fuel injection pump at fuel 4. Manually rotate throttle lever to full open
shut off solenoid. Tighten Allen-head capscrews position. Adjust actuator rod upstop set screw
to 10.5 N•m (92.9 lbf in). See Figure 100. to permit full speed control lever stroke.
Tighten nut on ball joint rod to
NOTE: The TPS mounting screws are non-magnetic 25.6 N•m (226.6 lbf in). See Figure 99.
stainless steel to avoid interference with sensor
magnet and must be reused if TPS is replaced. FUEL INJECTION PUMP
NOTE: When installing TPS, rotate throttle lever Remove
plate to match TPS rotor to TPS.
1. Disconnect electrical connector from solenoid
13. Install TPS, two Torx-head screws, two lock
on top of fuel injection pump. See Figure 105.
washers, and TPS plate on TPS mounting
bracket using. See Figure 99.

14. Connect electrical connectors as tagged during

removal. Remove tags as electrical connections
are made. See Figure 97.

68
0600 SRM 1579 Fuel System Repair

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 6. Remove fuel injection lines from fuel injection
move to side. See Figure 105. pump assembly and fuel injectors. See Valve
Covers and Fuel Injectors.
3. Remove two capscrews, flange bolt and engine
harness bracket from intake manifold. See 7. Disconnect lubricating pipe from engine block
Figure 105. just below fuel injection pump assembly. See
Figure 105.
4. Remove clamp and fuel supply hose from fuel
lift pump. Plug hose so debris DOES NOT enter 8. Remove serpentine belt and fan assembly. See
fuel line. See Figure 105. Cooling System Repair section for procedure.

5. Remove fuel return hose from overflow pipe 9. Remove six flange bolts, injection pump gear
and bleeder valve. Cap overflow pipe and cover, and gasket from front of timing gear case
bleeder valve so debris DOES NOT enter fuel cover. Discard gasket. See Figure 106.
system. See Figure 105.

69
Fuel System Repair 0600 SRM 1579

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 10. Put piston of number 4 cylinder at top dead
TDC, rotate flywheel counterclockwise and align TC center (TDC). See Figure 107.
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.

70
0600 SRM 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 1. PLUG
and idler gear to get timing correct. 2. WASHER
11. To aid in reassembly, mark one tooth on idler Figure 109. Fuel Injection Pump Plugs
gear with a dot of white paint. See Figure 108.

71
Fuel System Repair 0600 SRM 1579

NOTE: Use 17. Remove two flange nuts from bracket at back of
8 mm x 1.25 mm x 45 mm fuel injection pump assembly. See Figure 111.
(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

1. SOCKET SETSCREW 18. Remove two flange bolts and bracket from
engine block and back of fuel injection pump
Figure 110. Fuel Injection Pump Camshaft Lock assembly. See Figure 111.
Screw

15. Insert socket setscrew into lower port in side of CAUTION

fuel injection pump assembly housing. This
As mounting nuts are removed the fuel injection
screw will act as a fuel injection pump
pump assembly will need to be supported during
camshaft lock screw. See Figure 110.
removal. Failure to do so could result in injury or
damage to component if it is dropped.
NOTE: The fuel injection pump shaft is tapered
with a woodruff key. Once you have applied some 19. Remove three flange nuts holding fuel injection
pressure with a puller, a slight tap with a hammer pump assembly to back of timing case housing.
on center puller bolt will help pop gear from shaft. See Figure 111.
16. Using a two-bolt gear puller, remove fuel
injection pump drive gear from fuel injection 20. Remove fuel injection pump assembly, woodruff
pump shaft. key, and O-ring. Discard O-ring. See
Figure 106.

72
0600 SRM 1579 Fuel System Repair

Disassemble
NOTE: It is not necessary to remove fuel injection
pump assembly from lift truck to perform
Disassemble 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.

NOTE: SOME ASSEMBLY COMPONENTS RE-

MOVED FOR CLARITY.

1. BOOST ACTUATOR
2. O-RING
3. FUEL INJECTION PUMP ASSEMBLY

Figure 113. Boost Actuator

4. Remove inspection port cover from fuel

injection pump assembly housing. See
Figure 114.

NOTE: SOME ASSEMBLY COMPONENTS RE-

MOVED FOR CLARITY.

1. SOCKET HEAD BOLT

2. FUEL SHUT DOWN SOLENOID
3. FUEL INJECTION PUMP ASSEMBLY

Figure 112. Fuel Shut Down Solenoid

3. Remove boost actuator and O-ring from fuel

injection pump assembly. Discard O-ring. See
Figure 113.
1. INSPECTION PORT COVER

Figure 114. Inspection Port Cover

73
Fuel System Repair 0600 SRM 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.

74
0600 SRM 1579 Fuel System Repair

4. Slide governor connecting rod onto rack pin of 3. Install bracket and two flange bolts to engine
fuel injection pump. See Figure 116. block and back of fuel injection pump assembly.
See Figure 111.
5. Insert governor connecting rod JIG (Hyster P/N
4621033 ) into fuel shut down solenoid 4. Install two flange nuts to bracket on back of
mounting hole on fuel injection pump assembly. fuel injection pump assembly. See Figure 111.

6. Install governor connecting rod lock nut onto 5. Install fuel injection pump drive gear using
rack pin. DO NOT tighten at this time. See alignment marks on fuel injection pump gear
Figure 115. and idler gear. See Figure 108.

7. While holding down governor connecting rod 6. Install locknut onto shaft of fuel injection
JIG (Hyster P/N 4621033 ), tighten lock nut for pump. Tighten locknut to
governor connecting rod. Tighten lock nut to 74 to 83 N•m (55 to 61 lbf ft).
2.8 to 4.0 N•m (24.7 to 35 lbf in). See
Figure 115. 7. Install new cover gasket, injection pump gear
cover, and six flange bolts into timing gear case
8. Remove governor connecting rod JIG from shut cover. Tighten bolts to
down solenoid mounting hole. 24 to 27 N•m (18 to 20 lbf ft).

9. Install start spring onto rack pin of fuel 8. Install fan assembly and serpentine belt. See
injection pump. See Figure 115. Cooling System Repair for procedure.

10. Install inspection port cover to side of fuel 9. Connect lubricating pipe to engine block just
injection pump housing. See Figure 114. below fuel injection pump assembly. See
Figure 105.
11. Install new O-ring and boost actuator onto fuel
injection pump assembly. Tighten actuator to 10. Remove two socket setscrews from 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 11. Install two washers and two plugs into side of
head bolts onto fuel injection pump assembly. fuel injection pump housing. See Figure 109.
See Figure 112.

13. If fuel injection lift pump assembly was not CAUTION

removed from lift truck, install fuel injection DO NOT bend any of the fuel lines when installing
lines and hoses. See Valve Covers and Fuel them.
Injectors for procedure.
12. Install fuel injector lines, fuel injectors, and
Install valve covers. See Valve Covers and Fuel
1. Install new O-ring, woodruff key, and injection Injectors section.
pump onto rear of timing gear case. See
13. Remove caps from overflow pipe and bleeder
Figure 106.
valve. Install fuel return hose to overflow pipe
2. Install three flange nuts onto three studs and bleeder valve. See Figure 105.
holding injection pump in place. Tighten nuts
to 18 to 20 N•m (13 to 15 lbf ft). See
Figure 111.

75
Fuel System Repair 0600 SRM 1579

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

18. Prime fuel system using procedure outlined

below:

76
0600 SRM 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 0700SRM1123
wait another 30 minutes before attempting to
check or fix any part of the cooling system. • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (R005, S005)
1. Turn ignition switch to OFF position. • H6.0-7.0FT (H135-155FT) (K006)

Remove fan assembly. See Cooling System 0700SRM1895 for lift

2.
truck models
See Cooling System 0700SRM1123
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80-120FT) (U005)
H5.0-5.5FT (H80-120FT) (R005, S005)
See Cooling System 0700SRM1950 for lift
• H6.0-7.0FT (H135-155FT) (K006) truck models
See Cooling System 0700SRM1895 for lift • H6.0-7.0FT (H135-155FT) (L006)
truck models
• H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H8.0FTS6 (H135FT, H155FT, H155FTS,
H5.0-5.5FT (H80-120FT) (U005) H170FTS) (N006)
See Cooling System 0700SRM1950 for lift • H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6
truck models (H135FT, H155FT, H155FTS, H170FTS)
(P006)
• H6.0-7.0FT (H135-155FT) (L006)
• H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9, Serpentine Belt, Adjustment
H8.0FTS6 (H135FT, H155FT, H155FTS,
H170FTS) (N006) NOTE: The serpentine belt is to be checked at
position A or B shown in Figure 118.
• H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6
(H135FT, H155FT, H155FTS, H170FTS) 1. Using a belt tension gauge, adjust belt tension
(P006) to 500 to 550 N (112 to 124 lbf).

3. Loosen alternator set bolt and pivot alternator

toward engine.

4. Remove serpentine belt from pulleys.

77
Cooling System Repair 0600 SRM 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 The radiator or other parts of the cooling system
set bolt and move alternator with a pry bar to may be hot or under pressure and can cause
tighten 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

78
0600 SRM 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 0700SRM1123 3. PULLEY
4. SPACER
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, 5. COLLAR
H5.0-5.5FT (H80-120FT) (R005, S005) 6. WATER FLANGE
7. WATER PUMP
• H6.0-7.0FT (H135-155FT) (K006)
See Cooling System 0700SRM1895 for lift Figure 121. Water Pump Pulley
truck models
10. Pivot alternator away from engine.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (U005) 11. Disconnect electrical connector for coolant
See Cooling System 0700SRM1950 for lift temperature sensor.
truck models
12. If necessary, remove coolant temperature
• H6.0-7.0FT (H135-155FT) (L006)
sensor.
• H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
H8.0FTS6 (H135FT, H155FT, H155FTS, 13. Disconnect coolant hoses from water pump. See
H170FTS) (N006) Cylinder Head Assembly Repair section for
• H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6 procedure.
(H135FT, H155FT, H155FTS, H170FTS)
(P006) 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.

79
Cooling System Repair 0600 SRM 1579

• H6.0-7.0FT (H135-155FT) (K006)

See Cooling System 0700SRM1895 for lift
truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (U005)
See Cooling System 0700SRM1950 for lift
truck models
• H6.0-7.0FT (H135-155FT) (L006)
• H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
H8.0FTS6 (H135FT, H155FT, H155FTS,
H170FTS) (N006)
• H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6
(H135FT, H155FT, H155FTS, H170FTS)
(P006)
1. BOLT 4. WATER PUMP
2. WATER PUMP HOUSING 11. Connect lower radiator hose.
3. GASKET 5. O-RING
6. ENGINE BLOCK
12. Install coolant drain plug in engine block. See
Figure 122. Water Pump Figure 120.

Install
CAUTION
1. Install new gasket, water pump, and two bolts Additives may damage the cooling system. Before
to water pump housing. See Figure 122. using additives, contact your local Hyster dealer.
2. Install new O-ring, water pump assembly, and 13. Fill cooling system with coolant. For correct
four bolts to engine block. See Figure 122. coolant amount and type refer to
3. Connect coolant hoses to water pump. See Periodic Maintenance 8000SRM1558 for lift
Cylinder Head Assembly Repair for procedure. truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
4. If removed, install coolant temperature sensor H5.0-5.5FT (H80-120FT) (R005)
and tighten to 16 to 23 N•m (12 to 17 lbf ft).
Periodic Maintenance 8000SRM1583 for lift
5. Connect electrical connector for coolant truck models
temperature sensor. • H6.0-7.0FT (H135-155FT) (K006)

6. Install plate with tension pulley and three Periodic Maintenance 8000SRM1604 for lift
capscrews. See Figure 121. truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
7. Install water pump pulley and four capscrews. H5.0-5.5FT (H80-120FT) (S005)
See Figure 121. Periodic Maintenance 8000SRM1902 for lift
truck models
8. Install fan pulley.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
9. Install serpentine belt. See Serpentine Belt, H5.0-5.5FT (H80-120FT) (U005)
Install. See Periodic Maintenance 8000SRM1957 for
lift truck models
10. Install fan assembly.
• H6.0-7.0FT (H135-155FT) (L006)
See Cooling System 0700SRM1123
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (R005, S005)

80
0600 SRM 1579 Cooling System Repair

See Periodic Maintenance 8000SRM2196

• H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9, CAUTION
H8.0FTS6 (H135FT, H155FT, H155FTS, Additives may damage the cooling system. Before
H170FTS) (N006) using additives, contact your local Hyster dealer.
Periodic Maintenance 8000SRM2401 for the
following lift truck models 17. Stop engine. If coolant is hot, allow engine time
to cool. Check coolant level and fill as required
• H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6 between ADD and FULL marks on coolant
(H135FT, H155FT, H155FTS, H170FTS) reservoir.
(P006)

14. Install radiator cap. THERMOSTAT

Remove
15. Connect negative battery cable.

WARNING
WARNING The radiator or other parts of the cooling system
During engine operation, be careful not to touch may be hot or under pressure and can cause
the fan, pulleys, or drive belts. Contact with these serious injury. Wait 30 minutes for the radiator and
parts can cause serious injury. 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
WARNING radiator is still hot to the touch, wait another 30
The radiator or other parts of the cooling system minutes before attempting any maintenance to the
may be hot or under pressure and can cause cooling system.
serious injury.

16. Start engine and check cooling system for CAUTION

leaks. DO NOT operate the engine without a thermostat.
The engine and cooling system can be damaged.

WARNING
DO NOT remove the radiator cap from the radiator CAUTION
when the engine is hot. When the radiator cap is Disposal of lubricants must meet local
removed, pressure will release from the coolant environmental regulations.
system. If the coolant system is hot, the steam and
boiling coolant can cause severe burns. 1. Drain cooling system to level of thermostat.

2. Disconnect coolant hose from thermostat cover.

WARNING
3. Remove three bolts holding thermostat cover.
The radiator or other parts of the cooling system Remove thermostat cover and gasket. Discard
may be hot or under pressure and can cause gasket. See Figure 123.
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.

81
Cooling System Repair 0600 SRM 1579

1. THERMOMETER
2. THERMOSTAT

Figure 124. Thermostat Check

2. Slowly increase temperature of water.

3. The thermostat is operating correctly if it starts

1. BOLT
2. THERMOSTAT COVER to open at temperature value stamped on
3. GASKET flange of thermostat and fully opens as
4. THERMOSTAT temperature of 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.
Inspect Install 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 Hyster dealer.

4. Fill cooling system with coolant. For correct

coolant amount and type refer to
Periodic Maintenance 8000SRM1558 for lift
truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (R005)
Periodic Maintenance 8000SRM1583 for lift
truck models

82
0600 SRM 1579 Cooling System Repair

• H6.0-7.0FT (H135-155FT) (K006)

5. Start engine and check cooling system for
Periodic Maintenance 8000SRM1604 for lift leaks.
truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (S005) WARNING
DO NOT remove the radiator cap from the radiator
Periodic Maintenance 8000SRM1902 for lift
when the engine is hot. When the radiator cap is
truck models
removed, pressure will release from the coolant
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, system. If the coolant system is hot, the steam and
H5.0-5.5FT (H80-120FT) (U005) boiling coolant can cause severe burns.
See Periodic Maintenance 8000SRM1957 for
lift truck models
• H6.0-7.0FT (H135-155FT) (L006) WARNING
The radiator or other parts of the cooling system
See Periodic Maintenance 8000SRM2196 may be hot or under pressure and can cause
• H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9, serious injury. Wait 30 minutes for the radiator and
H8.0FTS6 (H135FT, H155FT, H155FTS, engine to cool before performing maintenance to
H170FTS) (N006) the cooling system. After 30 minutes, do a touch
Periodic Maintenance 8000SRM2401 for the test by touching the radiator with your hand. If the
following lift truck models radiator is still hot to the touch, wait another 30
minutes before attempting any maintenance to the
• H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6 cooling system.
(H135FT, H155FT, H155FTS, H170FTS)
(P006)

CAUTION
WARNING Additives may damage the cooling system. Before
During engine operation, be careful not to touch using additives, contact your local Hyster dealer.
the fan, pulleys, or drive belts. Contact with these
6. Stop engine. If coolant is hot, allow engine time
parts can cause serious injury.
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.

83
Flywheel and Flywheel Housing 0600 SRM 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 0100SRM1243 for lift truck models
2. Install engine.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (R005, S005) See Frame 0100SRM1243 for lift truck model
See Frame 0100SRM1581 for lift truck models • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (R005, S005)
• H6.0-7.0FT (H135-155FT) (K006)
See Frame 0100SRM1891 for lift truck models See Frame 0100SRM1581 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; • H6.0-7.0FT (H135-155FT) (K006)
H5.0-5.5FT (H80-120FT) (U005)
See Frame 0100SRM1891 for lift truck models
See Frame 0100SRM1948 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
• H6.0-7.0FT (H135-155FT) (L006) H5.0-5.5FT (H80-120FT) (U005)
• H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9, See Frame 0100SRM1948 for lift truck models
H8.0FTS6 (H135FT, H155FT, H155FTS,
H170FTS) (N006) • H6.0-7.0FT (H135-155FT) (L006)
• H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6 • H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
(H135FT, H155FT, H155FTS, H170FTS) H8.0FTS6 (H135FT, H155FT, H155FTS,
(P006) H170FTS) (N006)
• H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6
2. Remove seven bolts holding flywheel to (H135FT, H155FT, H155FTS, H170FTS)
crankshaft flange and remove flywheel. See (P006)
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

84
0600 SRM 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 2200SRM1142 for lift truck 2. Disconnect battery positive cable at positive
models terminal.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
3. Put labels on wires prior to disconnecting to aid
H5.0-5.5FT (H80-120FT) (R005, S005)
in correct installation.
• H6.0-7.0FT (H135-155FT) (K006)
See Electrical System 2200SRM1901 for lift truck 4. Disconnect wires from alternator.
models
5. Loosen set bolt on alternator and tilt alternator
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; towards engine.
H5.0-5.5FT (H80-120FT) (U005)
See Electrical System 2200SRM1954 for lift truck 6. Remove serpentine belt from alternator pulley.
models
7. Remove set bolt from alternator. See
• H6.0-7.0FT (H135-155FT) (L006) Figure 126.
• H6.0FT, H7.0FT, H7.0FTS6, H7.0FTS9,
H8.0FTS6 (H135FT, H155FT, H155FTS,
H170FTS) (N006)
• H6.0FT, H7.0FT, H7.0FTS9, H8.0FTS6
(H135FT, H155FT, H155FTS, H170FTS)
(P006)

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.

85
Electrical Equipment Repair 0600 SRM 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 8. Connect battery negative cable at negative
bracket in position and install bolt to retain terminal.
bracket to water 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 10. Verify that charge indicator is ON while engine
tighten. is operating. If charge indicator is not ON,
repair problem before operating engine.
3. Install set bolt for alternator and adjustment
bracket but do not tighten.

4. Connect electrical wires to alternator.

86
0600 SRM 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
cables on the terminals. Figure 128.

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

1. FLYWHEEL HOUSING 3. Connect battery positive cable at positive

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

87
Engine Specifications 0600 SRM 1579

Engine Specifications
ENGINE DATA

Table 7. V3600-T-E3B Engine

Engine Model 1J408-32000 (Hyster P/N 4615470 )
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.

88
0600 SRM 1579 Engine Specifications

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)
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°

89
Engine Specifications 0600 SRM 1579

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

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.)

90
0600 SRM 1579 Engine Specifications

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.)

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.)

91
Engine Specifications 0600 SRM 1579

Inspection Item Standard Limit

Crank Journal Selective Journal Outside 74.977 to 74.990 mm (2.9519 to
Pairing Diameter 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.)

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 0.20 mm (0.0079 in.)
to 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 0.15 mm (0.0059 in.)
to 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.)

92
0600 SRM 1579 Engine Specifications

Inspection Item Standard Limit

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
0.0024 in.) (0.003 in.)

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.)

93
Standard Torque Specifications 0600 SRM 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 M12 × 1.75 mm 78.0 to 90.0 N•m (58 to
and lock nuts. 66 lbf ft)
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.

94
0600 SRM 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 Electronic Throttle Inline Ball Joint
Nut 7.9 N•m (70 lbf in)
74 to 83 N•m (55 to 61 lbf ft)

95
Special Torque Specifications 0600 SRM 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)

96
0600 SRM 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 (0.461 to (0.256 to
Guide) 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

97
Special Tools 0600 SRM 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

98
0600 SRM 1579 Special Tools

No. Tool Name Applicable Model and Tool Size Illustration

8 Crankshaft A Rmax = 12.5 S
Sleeve Press B 94.5 to 95.0 dia. mm (3.72 to 3.74 dia. in.)
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

99
Special Tools 0600 SRM 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

100
0600 SRM 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 Hyster P/N 1607212 83 to 95 mm ( in.)
of Cylinder
Walls) 4TNE98 Hyster P/N 1599906 89 to 101 mm ( in.)

101
Special Tools 0600 SRM 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.
Hyster P/N C Chamfer 2.0 mm (0.08 in.)
4621033 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 Hyster P/N 1607213
(for The Piston Insertion Tool is Applicable for
Inserting 60 to 125 mm (2.362 to 4.921 in.)
Piston) Diameter Pistons

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

102
0600 SRM 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.

103
Special Tools 0600 SRM 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.

104
0600 SRM 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
Clamp Type object.
18 Circuit Tester For measuring resistance, voltage, and
continuity of electrical circuits.

19 Compression Gauge Kit For measuring compression pressure. Use

Hyster P/N 4621032 for compression test
adaptor.

105
 TECHNICAL PUBLICATIONS

0600 SRM 1579 6/21 (11/19)(10/18)(6/18)(12/15)(9/15)