Kubota Diesel 3.8L Engines With Diesel Particulate Filter (DPF)
Kubota Diesel 3.8L Engines With Diesel Particulate Filter (DPF)
Kubota Diesel 3.8L Engines With Diesel Particulate Filter (DPF)
com
SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow in-
structions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or ex-
ceed 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 flamma-
ble. 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.
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Table of Contents
TABLE OF CONTENTS
General .....................................................................................................................................................................1
Engine Identification .......................................................................................................................................... 1
Major Engine Component Identification ....................................................................................................... 1
Location of Labels ...........................................................................................................................................1
Crankcase Description ........................................................................................................................................3
Precautions Before Beginning Repair ................................................................................................................4
Engine Removal and Installation ...........................................................................................................................4
Cylinder Head Assembly Repair ............................................................................................................................ 5
Valve Covers and Fuel Injectors ........................................................................................................................ 5
Remove ............................................................................................................................................................ 5
Clean and Inspect ........................................................................................................................................... 8
Install .............................................................................................................................................................. 8
Rocker Arm Assembly .........................................................................................................................................9
Remove ............................................................................................................................................................ 9
Disassemble .................................................................................................................................................. 10
Clean and Inspect ......................................................................................................................................... 10
Push Rods ................................................................................................................................................. 10
Rocker Arm Assembly .............................................................................................................................. 10
Assemble ....................................................................................................................................................... 11
Install ............................................................................................................................................................ 11
Valve Clearance Adjustments .......................................................................................................................... 11
Cylinder Head Assembly .................................................................................................................................. 13
Remove .......................................................................................................................................................... 13
Disassemble .................................................................................................................................................. 21
Valves and Valve Springs, Remove ......................................................................................................... 21
Valve Guides, Remove ..............................................................................................................................22
Clean and Inspect ......................................................................................................................................... 23
Cylinder Head ...........................................................................................................................................23
Valve Guides .............................................................................................................................................24
Valves ........................................................................................................................................................24
Valve Sink .................................................................................................................................................24
Valve Seat ................................................................................................................................................. 25
Valve Springs ............................................................................................................................................25
Assemble ....................................................................................................................................................... 26
Valve Guides, Install ................................................................................................................................26
Valves and Valve Springs, Install ........................................................................................................... 27
Install ............................................................................................................................................................ 28
Timing Gear Case and Timing Gears Repair ...................................................................................................... 30
Timing Gear Case Cover ...................................................................................................................................30
Remove .......................................................................................................................................................... 30
Clean and Inspect ......................................................................................................................................... 32
Install ............................................................................................................................................................ 32
Timing Gears .....................................................................................................................................................33
Crankshaft Gear ........................................................................................................................................... 33
Remove ......................................................................................................................................................33
Install ........................................................................................................................................................33
Idler Gear ...................................................................................................................................................... 34
Remove ......................................................................................................................................................34
Inspect .......................................................................................................................................................35
Install ........................................................................................................................................................35
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0600 SRM 1590 General
General
This section has the repair instructions for the Location of Labels
Kubota 3.8L diesel engines.
The typical location of the emission control
ENGINE IDENTIFICATION information label is shown in Figure 2.
Major Engine Component Identification The typical location of the engine nameplate is
shown in Figure 2. The engine nameplate is shown
Figure 1 shows where the major engine components in Figure 3.
are located.
1
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General 0600 SRM 1590
2
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0600 SRM 1590 General
CRANKCASE DESCRIPTION
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General 0600 SRM 1590
Frame 0100SRM1243 for lift truck models Frame 0100SRM1891 for lift truck models
• H4.0FT5, H4.0FT6, H4.5FTS5, H4.5FT6, • H4.0FT5, H4.0FT6, H4.5FTS5, H4.5FT6,
H5.0FT, H5.5FT (H80-120FT) (S005) H5.0-5.5FT (H80-120FT) (U005)
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0600 SRM 1590 Cylinder Head Assembly Repair
Remove
1. Disconnect the negative battery cable at the
battery.
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Cylinder Head Assembly Repair 0600 SRM 1590
NOTE: Note position and location of fuel line 11. Remove ten lower valve cover bolts, lower valve
clamps during removal to aid in installation. cover and gasket from cylinder head. Discard
gasket. See Figure 8.
9. Remove three pan head screws and six clamps
from fuel injector lines. See Figure 8. 12. Remove four banjo bolts and eight washers
holding fuel overflow pipe to four injectors. Dis-
card washers. See Figure 8.
CAUTION
DO NOT loosen the fuel injection lines when the 13. Remove four flange nuts holding injector
fuel is under high pressure (within five minutes of clamps to fuel injectors. See Figure 8.
stopping the engine).
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0600 SRM 1590 Cylinder Head Assembly Repair
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Cylinder Head Assembly Repair 0600 SRM 1590
CAUTION 13. Place new valve cover gasket into groove of up-
per valve cover.
Use caution not to scratch the gasket mating sur-
faces when cleaning the valve cover and cylinder 14. Install upper valve cover and thirteen cap-
head. screws onto lower valve cover. Torque to 10 to
11 N•m (89 to 97 lbf in). See Figure 7.
Carefully remove all gasket residue from the valve
cover and cylinder head. 15. Connect wiring connector to fuel injector har-
ness on upper cylinder head cover.
Clean the valve cover in cleaning solvent. Dry the
valve cover with compressed air. Inspect for wear, 16. Install EGR tube to back of EGR valve and
cracks, and any other damage. If necessary, replace EGR cooler. See Figure 6.
valve cover.
17. Install turbo air outlet hose to turbo charger
and air inlet elbow. See Figure 6.
Inspect all O-rings and grommets for wear, cracks,
and any other damage. Replace where necessary. 18. Connect breather tubes to turbo air inlet pipe
and upper cylinder head cover. See Figure 6.
Install
19. Connect breather tube to bottom of crankcase
1. Install four O-rings and four new base gaskets breather filter and lower block.
onto four fuel injectors. Install four fuel injec-
tors into cylinder head. See Figure 8. 20. Connect negative battery cable at battery.
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0600 SRM 1590 Cylinder Head Assembly Repair
ROCKER ARM ASSEMBLY 3. Lift the rocker arm shaft assembly from the cyl-
inder head.
Remove
NOTE: Mark the push rods so they can be reinstal-
1. Remove valve cover and fuel injectors. See led in original location during reassembly.
Valve Covers and Fuel Injectors, Remove.
4. Remove the push rods from the cylinder head.
2. Remove four flange nuts holding rocker arm
brackets to cylinder head. See Figure 9.
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Cylinder Head Assembly Repair 0600 SRM 1590
Disassemble
1. Remove rocker arm shaft c-clips and washers
from each end of the rocker arm shafts. Discard
washers. See Figure 9.
3. Slide the rocker arm shaft out of the rocker arm Figure 10. Push Rod Inspection
brackets, springs, and rocker arms.
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.
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0600 SRM 1590 Cylinder Head Assembly Repair
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Cylinder Head Assembly Repair 0600 SRM 1590
A. NORMAL B. ABNORMAL
1. VALVE CAP
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0600 SRM 1590 Cylinder Head Assembly Repair
Remove
1. HOSE CLAMP
1. Disconnect the negative battery cable at the 2. RETAINING CLAMP
battery. 3. AIR INTAKE HOSE
4. AIR FLOW SENSOR CONNECTOR
NOTE: Place a suitable container with a capacity
of at least 12.0 liter (13 qt) under the radiator and Figure 15. Air Intake Hoses
lower radiator hose.
2. Remove the lower radiator hose and radiator NOTE: Tag wiring connectors and wiring harness
cap. Allow cooling system to drain. before removal to aid during installation.
3. Disconnect electrical connectors from air flow 5. Tag and disconnect connectors for engine wir-
sensor. ing harness. Move harness aside for better ac-
cess.
4. Remove two hose clamps, two retaining clamps
and air intake hoses from air cleaner and turbo 6. Loosen adjustment bolt for the alternator and
charger. See Figure 15. release tension on serpentine belt. Remove ser-
pentine belt. See Figure 16.
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0600 SRM 1590 Cylinder Head Assembly Repair
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Cylinder Head Assembly Repair 0600 SRM 1590
1. CLAMP 5. BOLT
2. HOSE 6. WATER PUMP ASSEMBLY
3. WATER PIPE 7. EGR COOLER
4. O-RING
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Cylinder Head Assembly Repair 0600 SRM 1590
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0600 SRM 1590 Cylinder Head Assembly Repair
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Cylinder Head Assembly Repair 0600 SRM 1590
1. HEAT SHIELD
2. FLANGE BOLT
3. FLANGE NUT
4. EXHAUST MANIFOLD
5. GASKET
6. CYLINDER HEAD
1. TURBOCHARGER
2. FLANGE NUT
3. STUD
4. GASKET
5. EXHAUST MANIFOLD
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0600 SRM 1590 Cylinder Head Assembly Repair
33. Remove rocker arm assembly. See Rocker Arm 35. Remove cylinder head and gasket from engine
AssemblyRemove. block. Discard gasket.
34. Remove eighteen cylinder head bolts in se- 36. Remove eight lifters from crankcase. See Fig-
quence shown, from eighteen to one. See Fig- ure 30.
ure 28.
Disassemble
A. TIMING GEAR CASE END 3. Remove the valve keepers and the valve cap
B. FLYWHEEL END from the end of the valve. See Figure 31.
1. HEAD GASKET
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Cylinder Head Assembly Repair 0600 SRM 1590
Press out used valve guide using the valve guide re-
placing tool. See Figure 32.
1. PAD
2. VALVE BRIDGE ARM
3. VALVE SHAFT
4. VALVE KEEPERS
5. VALVE SPRING RETAINER
6. VALVE SPRING
7. VALVE STEM SEAL
8. VALVE GUIDE
9. INTAKE VALVE
10. EXHAUST VALVE
11. CYLINDER HEAD
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0600 SRM 1590 Cylinder Head Assembly Repair
Clean and Inspect Carefully remove all gasket residue from the intake
manifold and cylinder head. Inspect the intake
manifold for scratches, cracks, or any other dam-
WARNING age. Repair or replace as needed.
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning Carefully remove all gasket residue from the cylin-
solvents, always follow the recommendations of der head and cylinder block. Inspect the cylinder
the manufacturer. head for scratches, cracks, or any other damage.
Repair or replace as needed.
WARNING
Thoroughly clean all components using a nonmetal-
Compressed air can move particles so that they lic brush and cleaning solvent. Dry the parts with
cause injury to the user or to other personnel. compressed air. Each part must be free of carbon,
Make sure that the path of the compressed air is metal filings, and other debris.
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes. Visually inspect the parts. Replace any parts that
are obviously discolored, heavily pitted, or other-
CAUTION wise damaged. Replace parts that do not meet the
specified limit.
Any part which is found defective as a result of in-
spection or any part whose measured value does
not satisfy the standard or limit must be replaced. Cylinder Head
1. Place the cylinder head flat and inverted (com-
CAUTION bustion side up) on the work bench.
Any part determined to not meet the service 2. Use a straight edge and feeler gauge to meas-
standard or limit before the next service, as deter- ure the amount of cylinder head distortion. Re-
mined from the state of current rate of wear, fer to the Engine Specifications for the service
should be replaced even though the part currently limit. See Figure 33.
meets the service standard limit.
CAUTION
Use caution not to scratch the gasket mating sur-
faces when cleaning the exhaust manifold and
cylinder head.
CAUTION
Use caution not to scratch the gasket mating sur-
faces when cleaning the intake manifold and cyl-
inder head.
CAUTION
Use caution not to scratch the gasket mating sur-
faces when cleaning the cylinder head and cylin- Figure 33. Cylinder Head Distortion Check
der block.
Carefully remove all gasket residue from the ex- 3. Use the Magnaflux method and inspect the cyl-
haust manifold and cylinder head. Inspect the ex- inder head for cracks. Replace the cylinder
haust manifold for scratches, cracks, or any other head if evidence of fractures are found.
damage. Repair or replace as needed.
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Cylinder Head Assembly Repair 0600 SRM 1590
Valve Guides
Valves
Valve Sink
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0600 SRM 1590 Cylinder Head Assembly Repair
Valve Springs
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Cylinder Head Assembly Repair 0600 SRM 1590
Assemble
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0600 SRM 1590 Cylinder Head Assembly Repair
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Cylinder Head Assembly Repair 0600 SRM 1590
6. Using the valve compressor tool, compress the 8. Install two new washers, banjo bolt and fuel re-
valve spring. turn line onto back of fuel pump. See Figure 27.
7. Install the valve keepers and slowly release the 9. Install new washer set, banjo bolt and fuel re-
tension in the valve spring. turn line onto back of cylinder head. See Fig-
ure 27.
8. Install the valve cap.
10. Install new gasket, exhaust manifold, four
9. Repeat these procedures until all the intake flange bolts and four flange nuts onto cylinder
and exhaust valves are installed. head. See Figure 26.
10. Install eight valve shafts, eight pads, and eight
valve bridge arms. See Figure 31.
Install
NOTE: See one of the following sections, Standard
Torque Specifications and Special Torque Specifica-
tions for torque values to use during the installa-
tion process.
3. Place a new cylinder head gasket, as noted dur- 11. Install heat shield and two flange bolts to ex-
ing removal, on the cylinder block. haust manifold. See Figure 26.
4. Position the cylinder head on the cylinder head 12. Install new gasket, turbocharger, two lower
gasket and cylinder block. flange nuts and two upper flange nuts onto ex-
haust manifold. See Figure 25.
5. Lightly oil the threads of the cylinder head
bolts. 13. Install new gasket, EGR pipe and two flange
bolts onto EGR pipe flange. See Figure 24.
6. Install the cylinder head bolts and tighten the
cylinder head bolts, 1 to 18, using a two stage 14. Install new gasket, EGR pipe flange and two
process: flange bolts onto EGR cooler. See Figure 24.
a. On first pass (1 to 18), tighten cylinder 15. Install new gasket, EGR cooler flange, and two
head bolts to 50 N•m (37 lbf ft). See Fig- flange bolts onto EGR cooler. See Figure 24.
ure 44.
b. On second pass (1 to 18), tighten cylinder 16. Install EGR cooler assembly, new gasket, and
head bolts to 98 to 107 N•m (72 to two flange bolts onto exhaust manifold. See
80 lbf ft). See Figure 44. Figure 24.
7. Install the push rods and rocker arm assembly. 17. Install hose and two clamps to EGR cooler and
See Rocker Arm Assembly, Install. engine block. See Figure 24.
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0600 SRM 1590 Cylinder Head Assembly Repair
18. Install oil drain tube, new gasket, two cap- 33. Install alternator, mounting bracket, three re-
screws, two clamps, and hose onto turbocharger taining nuts, and three mounting bolts onto en-
and block. See Figure 23. gine. See Figure 16.
19. Install turbocharger oil supply line, two washer 34. Put serpentine belt on pulley's. Using a pry bar,
sets and two banjo bolts onto turbocharger. See pull alternator into position and put tension
Figure 23. onto serpentine belt. Tighten alternator adjust-
ment bolt. See Figure 16.
20. Install intake manifold, new gasket and nine
bolts to cylinder head. See Figure 22. 35. Attach wiring harness to connectors as noted
during removal.
21. Install common fuel rail and two flange bolts
onto side of intake manifold. Torque nuts to 24 36. Install air intake hoses, retaining clamp, and
to 27 N•m (18 to 20 lbf ft). See Figure 21. two hose clamps onto air cleaner and turbo-
charger. See Figure 15.
22. Install fuel supply line to fuel pump and end of
fuel rail. See Figure 20. 37. Connect electrical connector to air flow sensor.
See Figure 15.
23. Install two fuel lines to fuel rail and fuel pump.
See Figure 20. 38. Install lower radiator hose.
32. Install idler assembly and three bolts onto the 42. Start the engine and check for leaks.
water pump assembly. See Figure 17.
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Cylinder Head Assembly Repair 0600 SRM 1590
43. Change the engine oil and oil filter. See Lubri- the cooling system. After 30 minutes, do a touch
cation System Repair. 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
WARNING cooling system.
DO NOT remove the radiator cap from the radiator
when the engine is hot. When the radiator cap is
removed, pressure will release from the coolant CAUTION
system. If the coolant system is hot, the steam Additives may damage the cooling system. Before
and boiling coolant can cause severe burns. using additives, contact your local Hyster dealer.
See Frame 0100SRM1581 for lift truck models 4. Using a gear puller, remove the crankshaft pul-
ley.
• H6.0-7.0FT (H135-155FT) (K006)
• H8.0-9.0FT, H8.0FT9 (H170-190FT, 5. Remove the bolts holding the timing gear case
H175FT36) (B299) cover to engine block. See Figure 45.
See Frame 0100SRM1316 for lift truck models 6. Remove the timing gear case cover and O-rings
from engine block. Discard O-rings. See Fig-
• S6.0-7.0FT (S135-155FT) (G024)
ure 45.
See Frame 0100SRM1243 for lift truck models
7. Remove the front oil seal from the timing gear
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; case cover. See Figure 45.
H5.0-5.5FT (H80-120FT) (S005)
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0600 SRM 1590 Timing Gear Case and Timing Gears Repair
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Timing Gear Case and Timing Gears Repair 0600 SRM 1590
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0600 SRM 1590 Timing Gear Case and Timing Gears Repair
Periodic Maintenance 8000SRM1604 for lift 2. Verify that the gears are properly aligned with
truck models the alignment marks. See Figure 47.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
3. Remove oil pump drive gear. See Figure 48.
H5.0-5.5FT (H80-120FT) (S005)
NOTE: If using a gear puller to remove the crank-
Periodic Maintenance 8000SRM1902 for lift
shaft gear, be careful not to damage the threads in
truck models
the end of the crankshaft.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80-120FT) (U005) 4. Remove the crankshaft gear. See Figure 48.
10. Start the engine and check for leaks. 5. Remove the key from the crankshaft.
TIMING GEARS
NOTE: For removal of the fuel injection pump
drive gear, refer to the section Fuel System Repair.
Install
1. Install the key into the crankshaft.
Remove
1. Remove the timing gear case cover. See Timing
Gear Case Cover, Remove.
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Timing Gear Case and Timing Gears Repair 0600 SRM 1590
Idler Gear 3. Remove the bolts from the idler gear shaft. See
Figure 49.
Remove
4. Remove the idler gear shaft, alignment pin, id-
1. Remove the timing gear case cover. See Timing ler gear, idler gear collar, and bushing.
Gear Case Cover, Remove.
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0600 SRM 1590 Timing Gear Case and Timing Gears Repair
Remove
1. Remove the timing gear case cover. See Timing
Gear Case Cover, Remove.
NOTE: Make sure the oil hole in the bushing is fac- 3. Install pulse gear and four capscrews onto cam-
ing toward the top of the engine. shaft gear. Tighten capscrews to 4.7 to
5.6 N•m (42 to 50 lbf in).
2. Align the alignment mark "C" on the idler gear
1 with the alignment mark "C" on idler gear 2 4. Install the timing gear case cover. See Timing
and the alignment mark "A" on idler gear 1 Gear Case Cover, Install.
with the alignment mark "A" on the camshaft
gear. Install the idler gear, bushing, and idler
gear shaft.
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Drive Train, Camshaft, and Cylinder Block Repair 0600 SRM 1590
9. Remove the oil suction tube. See Lubrication Figure 51. Connecting Rod Thrust Clearance
System Repair.
10. Remove the timing gear case cover. See Timing 2. Remove the two bolts from one of the connect-
Gear Case and Timing Gears Repair. ing rod caps. See Figure 52.
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0600 SRM 1590 Drive Train, Camshaft, and Cylinder Block Repair
Crankshaft
1. Remove eight bolts holding the rear oil seal as-
sembly to the engine block. Remove the rear oil
seal assembly. See Figure 53.
1. PISTON RINGS
2. PISTON
3. WRIST PIN
4. SNAP RING
5. WRIST PIN BUSHING
6. CONNECTING ROD
7. CONNECTING ROD CAP
8. BEARING HALVES
9. BOLT
7. Remove piston rings from the piston. 3. Measure the crankshaft side gap using the fol-
lowing method:
8. Remove the snap rings retaining the wrist pin.
a. Set a dial indicator with it's point on the end
9. Remove the wrist pin. of the crankshaft. Move the crankshaft to the
front and rear to measure side clearance. See
10. Remove the piston from the connecting rod. Figure 54.
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Drive Train, Camshaft, and Cylinder Block Repair 0600 SRM 1590
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0600 SRM 1590 Drive Train, Camshaft, and Cylinder Block Repair
Camshaft
1. Using a feeler gauge, measure the camshaft
side gap. Refer to Engine Specifications for the
service limit. See Figure 57.
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Drive Train, Camshaft, and Cylinder Block Repair 0600 SRM 1590
NOTE: If the engine is not installed on an engine NOTE: Be sure to mark the tappets so they can be
stand, position the engine with the mounting flange installed in the same location as they were re-
(flywheel end) facing down. Rotate the camshaft a moved.
few turns to bump the tappets out of the way to
prevent the tappets from interfering with the re- 7. Remove the tappets.
moval of the camshaft.
8. Remove three flange bolts and the timing gear
5. With the engine installed on an engine stand, case plate. See Timing Gear Case and Timing
rotate the engine so the gravity causes the tap- Gears Repair.
pets to drop away from the camshaft lobes.
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0600 SRM 1590 Drive Train, Camshaft, and Cylinder Block Repair
1. Verify that oil holes are clear and unobstructed. f. Measure the inside diameter of cylinder
Clear any oil holes as needed. number one, near the bottom of the cylinder
(c) and in the (e) direction. Record that
2. Check for discoloration or evidence of cracks. If measurement as data k.
evidence of a fracture is found, use the color
check method or the Magnaflux method to de- g. Roundness: Roundness for cylinder number
termine if the cylinder block is fractured. one is calculated as follows:
f-g = X
3. Inspect the cylinder roundness and cylindricity
for evidence of distortions. Collect and record h-i = Y
the measurements. See Figure 59 and Table 3. j-k = Z
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Drive Train, Camshaft, and Cylinder Block Repair 0600 SRM 1590
h. Cylindricity: Cylindricity for cylinder num- 5. Repeat the cylindricity and roundness measure-
ber one is calculated as follows: ments and calculations for the remaining cylin-
Select the least value of values X, Y ders.
and Z record that value as S. Com-
6. Compare the worksheet findings with the speci-
plete the calculation as follows: fications listed in Table 4.
V-S = W
7. Consider honing, re-boring, cylinder correction,
W is the difference between the V and S meas- or replacing the cylinder block if the measure-
urements. This value represents the cylindric- ments fall outside the specifications.
ity of the cylinder.
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
Cylinder #3 V = __________
Least of
Center Dimension (d) Dimension (e) h-i = Y
X, Y and Z = S
(b) h = __________ i = __________ Y = __________
S = __________
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0600 SRM 1590 Drive Train, Camshaft, and Cylinder Block Repair
Cylinder
Measurements Calculated Values
Number
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 = __________
Table 4. Cylinder Bore Specification c. Rotate the honing tool at 300 to 1200 rpm.
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Drive Train, Camshaft, and Cylinder Block Repair 0600 SRM 1590
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. 1. CYLINDER I.D. (BEFORE CORRECTION)
2. CYLINDER I.D. (OVERSIZE)
g. When the honing is completed, wash the cyl-
inder block with hot water and soap. Use Figure 62. Oversize Piston
brushes to clean all passages and crevices.
Rinse with hot water and blow dry with com-
pressed air. Apply clean engine oil to all steel
surfaces to prevent rusting.
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0600 SRM 1590 Drive Train, Camshaft, and Cylinder Block Repair
Connecting Rod
1. Measure the inside diameter of the connecting
rod small end. Refer to the Engine Specifica-
tions for the service limit. See Figure 66.
A. WIDTH B. THICKNESS
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Drive Train, Camshaft, and Cylinder Block Repair 0600 SRM 1590
1. CYLINDER GAUGE
2. CONNECTING ROD SMALL END
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0600 SRM 1590 Drive Train, Camshaft, and Cylinder Block Repair
A. BEND B. DEFLECTION
1. DIAL GAUGE 3. V-BLOCK
2. CRANKSHAFT
Figure 70. Crankshaft Fracture Check Figure 71. Crank Pin Oil Clearance
b. If the color check method is not available, NOTE: When replacing the crank pin bearing with
use the Magnaflux method. Inspect the a standard service part, make sure the crank pin
crankshaft for cracks. Replace the crankshaft bearing and connecting rod are marked with the
if evidence of fractures are found. same ID color.
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Drive Train, Camshaft, and Cylinder Block Repair 0600 SRM 1590
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0600 SRM 1590 Drive Train, Camshaft, and Cylinder Block Repair
Camshaft Bushing
ASSEMBLE
Camshaft
1. Verify that all parts are clean. Lightly lubricate
all parts with clean engine oil.
Figure 75. Intake/Exhaust Cam Height
Measurement
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Drive Train, Camshaft, and Cylinder Block Repair 0600 SRM 1590
2. Install the timing gear case. See Timing Gear 2. Lubricate and insert the wrist pin bushing into
Case and Timing Gears Repair. the small end of the connecting rod. See Fig-
ure 52.
NOTE: Rotate the cylinder block into a position in
which it allows gravity to keep the tappets in place 3. Install one snap ring into the piston.
and out of the way of the camshaft lobes for when
the camshaft is installed. 4. Position the connecting rod into the piston un-
der the skirt. The match marks on the connect-
3. Install the tappets into the cylinder block in the ing rod must be opposite of the piston identifi-
same locations as they were removed. cation mark on the top of the piston. See Fig-
ure 77.
4. Slowly insert the camshaft through the front of
the engine.
Crankshaft
1. Place the crankshaft in position in the cylinder
block.
5. Apply a continuous bead of Three Bond Liquid Figure 77. Piston and Connecting Rod
Gasket (Hyster P/N 1599478) to the mating Identification Marks
surface of the rear oil seal housing.
6. Align the rear oil seal housing with the two 5. Lubricate and install the piston wrist pin
dowel pins on the cylinder block and install the through the piston and wrist pin bushing.
rear oil seal housing. Install the retaining bolts.
6. Install the second snap ring.
Pistons and Connecting Rods
7. Using piston ring pliers, install the piston
1. Select the parts needed to assemble the piston rings.
and connecting rod for the Number 1 cylinder.
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0600 SRM 1590 Drive Train, Camshaft, and Cylinder Block Repair
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Drive Train, Camshaft, and Cylinder Block Repair 0600 SRM 1590
12. Install the connecting rod bearing halves and See Frame 0100SRM1891 for lift truck models
connecting rod cap. Install the connecting rod • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
bolts and tighten to 79 to 83 N•m (58 to H5.0-5.5FT (H80-120FT) (U005)
61 lbf ft).
13. If not previously removed, remove and discard
13. Perform Step 9 through Step 12 to install the engine oil filter. Apply clean oil to gasket of
remaining pistons in their respective cylinders. new filter. Install new filter. Turn filter until
gasket touches, then tighten 1/2 to 3/4 turn
INSTALL with your hand.
1. Install the crankshaft gear and idler gear. See 14. Fill the engine oil to the correct level. For cor-
Timing Gear Case and Timing Gears Repair. rect amount of oil and type refer to
2. Install the oil pump. See Lubrication System Periodic Maintenance 8000SRM1583 for lift
Repair. truck models
3. Install the timing gear case cover. See Timing • H6.0-7.0FT (H135-155FT) (K006)
Gear Case and Timing Gears Repair.
Periodic Maintenance 8000SRM1586 for lift
4. Install the oil suction tube. See Lubrication truck model
System Repair. • H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299)
5. Install the oil pan. See Lubrication System Re-
pair. Periodic Maintenance 8000SRM1606 for lift
truck models
6. Install the cylinder head. See Cylinder Head
Assembly Repair. • S6.0-7.0FT (S135-155FT) (G024)
7. Install the fuel injection pump. See Fuel Sys- Periodic Maintenance 8000SRM1604 for lift
tem Repair. truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
8. Install the water pump. See Cooling System Re-
H5.0-5.5FT (H80-120FT) (S005)
pair.
Periodic Maintenance 8000SRM1902 for lift
9. Install the alternator. See Electrical Equipment
truck models
Repair.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
10. Install the flywheel and flywheel housing. See H5.0-5.5FT (H80-120FT) (U005)
Flywheel and Flywheel Housing.
15. Start the engine and check for leaks.
11. Install the starter. See Electrical Equipment
Repair. Angular Deviation Procedure - Kubota 3.8L
Diesel Engine
12. Install the engine.
NOTE: This procedure ONLY needs to be per-
See Frame 0100SRM1581 for lift truck models
formed if the crankshaft has been replaced.
• H6.0-7.0FT (H135-155FT) (K006)
• H8.0-9.0FT, H8.0FT9 (H170-190FT, NOTE: The angular deviation procedure is used to
H175FT36) (B299) measure the angular difference between crankshaft
top dead center (TDC) and the detected TDC by the
See Frame 0100SRM1316 for lift truck models crankshaft position sensor.
• S6.0-7.0FT (S135-155FT) (G024) 1. Remove cylinder head cover, number four injec-
tor and rocker arm. See Cylinder Head Assem-
See Frame 0100SRM1243 for lift truck models
bly Repair for procedures.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80-120FT) (S005)
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0600 SRM 1590 Drive Train, Camshaft, and Cylinder Block Repair
5. Set a dial gauge on tip of valve. See Figure 81. 1. REFERENCE LINE
2. FLYWHEEL HOUSING
NOTE: When measuring the highest position of the 3. FLYWHEEL
exhaust valve tip, DO NOT rotate the flywheel
Figure 83. Complete TDC Reference Line
clockwise. If you go past the highest point of the
valve, back the flywheel up slightly and measure
the highest point of the exhaust valve.
8. Connect engine harness and ignition switch.
6. Turn flywheel counterclockwise and measure
9. Connect battery.
position where tip of exhaust valve is at its
highest. See Figure 81. 10. Attach a tester to output terminal and ground
terminal of crankshaft position sensor. See Fig-
NOTE: The reference line indicates the TDC of the
ure 84 and Figure 85.
crankshaft.
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Drive Train, Camshaft, and Cylinder Block Repair 0600 SRM 1590
WARNING
When turning the ignition switch to the ON posi-
tion, DO NOT start the lift truck. Injury may occur.
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0600 SRM 1590 Drive Train, Camshaft, and Cylinder Block Repair
NOTE: The position where the needle of the tester 16. Measure the interval between crankshaft TDC
changes momentarily from 0 to 5 V is the TDC as and crankshaft position sensor TDC (see Fig-
detected by the crankshaft position sensor. ure 88). This measurement will be used to cal-
culate any necessary fuel injection timing cor-
14. Slowly turn flywheel counterclockwise and stop rection.
the flywheel at the point where the needle of
the tester changes momentarily from 0 to 5V.
This should be the fourteenth tooth from miss-
ing teeth opening on pulsar gear. This point is
when the crankshaft position sensor detects
TDC. See Figure 86.
1. INTERVAL
Figure 87. Crankshaft Position Sensor TDC 19. Remove O-ring from exhaust valve.
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Lubrication System Repair 0600 SRM 1590
4. Apply clean oil to gasket of new filter. Install Periodic Maintenance 8000SRM1902 for lift
new filter. Turn filter until gasket touches, truck models
then tighten 1/2 to 3/4 turn with your hand. • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80-120FT) (U005)
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0600 SRM 1590 Lubrication System Repair
6. Start engine. Check area around oil filter for See Frame 0100SRM1316 for lift truck models
leaks. • S6.0-7.0FT (S135-155FT) (G024)
OIL PAN See Frame 0100SRM1243 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
Remove H5.0-5.5FT (H80-120FT) (S005)
Periodic Maintenance 8000SRM1586 for lift 6. Remove four flange bolts holding the oil pan to
truck model the crankcase. See Figure 89.
• H8.0FT, H8.0FT9, H9.0FT (H170FT, 7. Remove the oil pan.
H175FT36, H190FT) (B299)
Periodic Maintenance 8000SRM1604 for lift 8. Carefully remove old sealant residue from the
truck models mating surfaces of the oil pan and cylinder
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; block.
H5.0-5.5FT (H80-120FT) (S005)
9. Thoroughly clean the outside and inside surfa-
Periodic Maintenance 8000SRM1902 for lift ces of the oil pan.
truck models
Install
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80-120FT) (U005) 1. Apply a continuous bead of Three Bond Liquid
Gasket (Hyster P/N 1599478) around the seal-
2. Remove the underbody shield.
ing surface of the oil pan.
See Frame 0100SRM1581 for lift truck models
2. Place the oil pan in position and install the re-
• H6.0-7.0FT (H135-155FT) (K006) taining bolts. Refer to Standard Torque Specifi-
• H8.0-9.0FT, H8.0FT9 (H170-190FT, cations.
H175FT36) (B299)
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Lubrication System Repair 0600 SRM 1590
2. Remove the two bolts holding the oil suction Clean the oil suction tube in cleaning solvent. Dry
tube. See Figure 91. the oil suction tube with compressed air. Inspect for
wear and damage. If necessary, replace oil suction
3. Remove the oil suction tube. tube.
4. Remove O-ring from the oil suction tube and
discard.
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0600 SRM 1590 Lubrication System Repair
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Lubrication System Repair 0600 SRM 1590
CAUTION
If any oil pump component clearance exceeds its
limit, the oil pump must be replaced as an assem-
bly. Failure to replace the complete pump assem-
bly could result in pump failure and damage to the
engine.
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0600 SRM 1590 Lubrication System Repair
1. DEPTH MICROMETER
2. PUMP CAVITY
3. OUTER ROTOR 1. PUNCH MARK
2. OUTER ROTOR
Figure 95. Outer Rotor Side Clearance Check 3. TIMING GEAR CASE
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Lubrication System Repair 0600 SRM 1590
See Frame 0100SRM1243 for lift truck models 8. Change engine oil and oil filter. See Engine Oil
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; and Oil Filter Change.
H5.0-5.5FT (H80-120FT) (S005)
9. Start engine and check for leaks.
See Frame 0100SRM1891 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80-120FT) (U005)
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0600 SRM 1590 Fuel System Repair
Replace
Install
1. Install high pressure fuel lines. See Cylinder FUEL INJECTION PUMP
Head Assembly Repair for procedure.
Remove
2. Install fuel injectors, valve covers, and fuel in-
jector lines. See Valve Covers and Fuel Injec-
tors section for procedure. CAUTION
DO NOT loosen the fuel injection lines when the
Test fuel is under high pressure (within five minutes of
stopping the engine).
1. Test the fuel system for proper operation using
PC service tool. See Diagnostic Trouble- 1. Remove banjo bolt, fuel supply line, and two
shooting Manual 9000SRM1112 for test and washers from back of injection pump. Discard
procedures. washers and plug line to help prevent debris
from entering line. See Figure 99.
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Fuel System Repair 0600 SRM 1590
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0600 SRM 1590 Fuel System Repair
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Fuel System Repair 0600 SRM 1590
Clean and Inspect 8. Install fuel filter assembly and high pressure
fuel lines. See Cylinder Head Assembly Repair.
Clean all old sealant from the timing gear case
cover and the fuel injection pump drive gear cover.
Inspect all parts for damage. Replace as needed.
CAUTION
DO NOT bend any of the fuel lines when installing
Install them.
1. Using alignment pins to locate proper position, 9. Install fuel injector lines, fuel injectors, and
install new base gasket, injection pump base, valve covers. See Valve Covers and Fuel Injec-
and three flange bolts into rear of timing gear tors section.
case. See Figure 99. 10. Connect electrical connectors for the fuel tem-
2. Install new O-ring, woodruff key, and injection perature sensor and fuel pump solenoid.
pump onto rear of timing gear case. See Fig- 11. Connect fuel supply and return lines to fuel
ure 99. rail.
3. Install two nuts onto two studs holding injec- 12. Remove plug from fuel line. Install two wash-
tion pump in place. Torque to 24 to 27 N•m (18 ers, overflow pipe return line, and banjo bolt to
to 20 lbf ft). side of injection pump. See Figure 99.
4. Install injection pump drive gear using align- 13. Remove plug from fuel line. Install two wash-
ment marks on the fuel injection pump gear ers, fuel supply line, and banjo bolt to back of
and idler gear. See Figure 101. injection pump. See Figure 99.
5. Install locknut onto shaft of fuel injection 14. Turn ignition to ON position to cycle fuel pump.
pump. Torque to 59 to 68 N•m (44 to 50 lbf ft).
15. Check fuel lines and hoses for leaks.
6. Install new cover gasket, injection pump gear
cover, and six flange bolts into timing gear case 16. After removing or replacing the fuel injection
cover. Torque to 24 to 27 N•m (18 to 20 lbf ft). pump it will be necessary to reset the operating
parameters for fuel injection pump. See Diag-
7. Install the fan assembly and serpentine belt. nostic Troubleshooting Manual
See Cooling System Repair for procedure. 9000SRM1112 for procedure.
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0600 SRM 1590 Cooling System Repair
Inspect
Install
1. Place serpentine belt over pulleys.
A. TENSION CHECK POSITION
2. Adjust tension of serpentine belt as shown in B. TENSION CHECK POSITION
section Adjust.
Figure 102. Serpentine Tension Check Points
3. Tighten set bolt for alternator to
25.5 N•m (18.8 lbf ft).
2. If adjustment is necessary, loosen alternator
4. Install fan assembly.
set bolt and move alternator with a pry bar to
See Cooling System 0700SRM1123 for lift tighten serpentine belt. See Figure 103.
truck models
• H6.0-7.0FT (H135-155FT) (K006)
• H8.0-9.0FT, H8.0FT9 (H170-190FT,
H175FT36) (B299)
• S6.0-7.0FT (S135-155FT) (G024)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80-120FT) (S005)
Adjust
NOTE: The serpentine belt is to be checked at posi-
tion A or B shown in Figure 102.
1. Using a belt tension gauge, adjust belt tension 1. SET BOLT 3. PRY BAR
to 500 to 550 N (112 to 124 lbf). 2. ALTERNATOR
Figure 103. Serpentine Belt Adjustment
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Cooling System Repair 0600 SRM 1590
3. When tension is correct, tighten set bolt to 5. Remove coolant drain plug and drain coolant
25.5 N•m (18.8 lbf ft). Check belt tension again from engine block. See Figure 104.
to verify tension is still correct.
WATER PUMP
Remove
1. Turn ignition switch to OFF position.
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 boiling coolant can cause severe burns. 1. COOLANT DRAIN PLUG
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0600 SRM 1590 Cooling System Repair
7. Remove serpentine belt. See Serpentine Belt, 11. If necessary, remove coolant temperature sen-
Remove. sor.
8. Remove fan pulley. 12. Disconnect coolant hoses from water pump. See
Cylinder Head Assembly Repair section for pro-
9. Pivot alternator away from engine. cedure.
10. Disconnect electrical connector for coolant tem- 13. Remove four water pump bolts and water pump
perature sensor. from water pump/timing gear housing. See Fig-
ure 105.
1. BOLT 3. GASKET
2. WATER PUMP
Figure 105. Water Pump
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Cooling System Repair 0600 SRM 1590
Install 10. Fill cooling system with coolant. For the correct
coolant amount and type refer to
1. Install new gasket, water pump, and four bolts
to water pump/timing gear housing. See Fig- Periodic Maintenance 8000SRM1583 for lift
ure 105. truck model
• H6.0FT, H7.0FT (H135FT, H155FT)
2. Connect coolant hoses to water pump. See Cyl-
(K006)
inder Head Assembly Repair for procedure.
Periodic Maintenance 8000SRM1586 for lift
3. If removed, install coolant temperature sensor
truck model
and tighten to 16 to 23 N•m (12 to 17 lbf ft).
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
4. Connect electrical connector for coolant temper- H175FT36, H190FT) (B299)
ature sensor.
Periodic Maintenance 8000SRM1606 for lift
5. Install the fan pulley. truck models
6. Install serpentine belt. See Serpentine Belt, In- • S6.0-7.0FT (S135-155FT) (G024)
stall. Periodic Maintenance 8000SRM1604 for lift
7. Install fan assembly. truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
See Cooling System 0700SRM1123 for lift H5.0-5.5FT (H80-120FT) (S005)
truck models
• H6.0-7.0FT (H135-155FT) (K006) Periodic Maintenance 8000SRM1902 for lift
truck models
• H8.0-9.0FT, H8.0FT9 (H170-190FT,
H175FT36) (B299) • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80-120FT) (U005)
• S6.0-7.0FT (S135-155FT) (G024)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; 11. Install radiator cap.
H5.0-5.5FT (H80-120FT) (S005)
12. Connect negative battery cable.
See Cooling System 0700SRM1895 for lift
truck models WARNING
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; During engine operation, be careful not to touch
H5.0-5.5FT (H80-120FT) (U005) the fan, pulleys, or drive belts. Contact with these
parts can cause serious injury.
8. Connect lower radiator hose.
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0600 SRM 1590 Cooling System Repair
WARNING CAUTION
DO NOT remove the radiator cap from the radiator DO NOT operate the engine without a thermostat.
when the engine is hot. When the radiator cap is The engine and cooling system can be damaged.
removed, pressure will release from the coolant
system. If the coolant system is hot, the steam
and boiling coolant can cause severe burns. CAUTION
Disposal of lubricants must meet local environ-
mental regulations.
WARNING
The radiator or other parts of the cooling system 1. Drain cooling system to level of thermostat.
may be hot or under pressure and can cause seri-
ous injury. Wait 30 minutes for the radiator and 2. Disconnect coolant hose from thermostat cover.
engine to cool before performing maintenance to 3. Remove three bolts holding thermostat cover.
the cooling system. After 30 minutes, do a touch Remove thermostat cover and gasket. Discard
test by touching the radiator with your hand. If the gasket. See Figure 106.
radiator is still hot to the touch, wait another 30
minutes before attempting any maintenance to the
cooling system.
CAUTION
Additives may damage the cooling system. Before
using additives, contact your local Hyster dealer.
THERMOSTAT
Remove
WARNING
The radiator or other parts of the cooling system
may be hot or under pressure and can cause seri-
ous 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 1. BOLT
minutes before attempting any maintenance to the 2. THERMOSTAT COVER
3. GASKET
cooling system. 4. THERMOSTAT
5. WATER FLANGE
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Cooling System Repair 0600 SRM 1590
1. Place thermostat and an accurate thermometer 2. Install thermostat cover and a new gasket. In-
in warm water. See Figure 107. stall bolts to hold thermostat cover. Tighten
bolts to 23 to 28 N•m (17 to 21 lbf ft).
CAUTION
Additives may damage the cooling system. Before
using additives, contact your local Hyster dealer.
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0600 SRM 1590 Cooling System Repair
WARNING CAUTION
The radiator or other parts of the cooling system Additives may damage the cooling system. Before
may be hot or under pressure and can cause seri- using additives, contact your local Hyster dealer.
ous injury. 6. Stop engine. If coolant is hot, allow engine time
5. Start engine and check cooling system for to cool. Check coolant level and fill as required
leaks. between the ADD and FULL marks on coolant
reservoir.
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Flywheel and Flywheel Housing 0600 SRM 1590
1. Remove the engine. See Frame 0100SRM1891 for lift truck models
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0600 SRM 1590 Flywheel and Flywheel Housing
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Electrical Equipment Repair 0600 SRM 1590
3. Put labels on wires prior to disconnecting to aid 6. Remove the serpentine belt from the alternator
in correct installation. pulley.
4. Disconnect wires from alternator. 7. Remove the set bolt from the alternator. See
Figure 109.
5. Loosen the set bolt on the alternator and tilt
the alternator towards the engine.
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0600 SRM 1590 Electrical Equipment Repair
8. If necessary, remove the bolt holding the alter- 1. Disconnect battery negative cable at negative
nator adjustment bracket to the water flange terminal.
and remove the bracket.
2. Disconnect the battery positive cable at positive
9. Remove the bolt holding the alternator to the terminal.
alternator mounting bracket. Remove the alter-
nator. 3. Put labels on wires and cables prior to discon-
necting to aid in correct installation.
Install 4. Disconnect wires and cables from starter.
1. If removed, place the alternator adjustment 5. Hold starter so it won't fall. Remove the two
bracket in position and install the bolt to retain M12 bolts and starter from flywheel housing.
the bracket to the water flange. See Figure 110.
2. Position the alternator on the alternator
mounting bracket. Install the bolt holding the
alternator to the alternator mounting bracket,
but do not tighten.
9. Start the engine and listen for any unusual Figure 110. Starter
sounds from the alternator.
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Electrical Equipment Repair 0600 SRM 1590
1. M8 NUT 3. M4 SCREW
2. COVER 4. STARTER
Engine Specifications
ENGINE DATA
Table 6. V3800-CR-TIE4C Engine for Lift Truck Model H6.0FT, H7.0FT (H135FT, H155FT) (K006)
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0600 SRM 1590 Engine Specifications
Table 6. V3800-CR-TIE4C Engine for Lift Truck Model H6.0FT, H7.0FT (H135FT, H155FT) (K006) (Contin-
ued)
Table 7. V3800-CR-TIE4C Engine for Lift Truck Model H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
H190FT) (B299)
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Engine Specifications 0600 SRM 1590
Table 7. V3800-CR-TIE4C Engine for Lift Truck Model H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
H190FT) (B299) (Continued)
Table 8. V3800-CR-TIE4C Engine for Lift Truck Model S6.0-7.0FT (S135-155FT) (G024)
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Table 8. V3800-CR-TIE4C Engine for Lift Truck Model S6.0-7.0FT (S135-155FT) (G024) (Continued)
Table 9. V3800-CR-TIE4C Engine for Lift Truck Model H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80-120FT) (S005, U005)
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Engine Specifications 0600 SRM 1590
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 3.09 to 3.28 MPa 2.41 MPa
(448 to 476 psi) (350 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
75°C 90°C (194°F)
(167°F)
CYLINDER HEAD
Inspection Item Standard Limit
Combustion Surface Distortion (Flatness) 0.05 mm (0.0020 in.)
Valve Sink Intake 0.6 to 0.8 mm 1.2 mm
(0.024 to 0.031 in.) (0.047 in.)
Exhaust 0.85 to 1.05 mm 1.2 mm
(0.0335 to 0.0413 in.) (0.047 in.)
Valve Seat Angle Intake 60°
Exhaust 45°
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0600 SRM 1590 Engine Specifications
VALVE SPRING
Inspection Item Standard Limit
Free Length 35.1 to 35.6 mm 34.6 mm
(1.39 to 1.40 in.) (1.36 in.)
Inclination 1.0 mm
(0.039 in.)
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Engine Specifications 0600 SRM 1590
PUSH ROD
Inspection Item Standard Limit
Push Rod Bend 0.25 mm
(0.0098 in.)
Camshaft
CYLINDER BLOCK
Inspection Item Standard Limit
Cylinder Inside Diameter 100.000 to 100.022 mm 100.150 mm
(3.93701 to 3.93787 in.) (3.9429 in.)
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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 0.20 mm
(0.00071 to 0.0024 in.) (0.0079 in.)
Crank Journal Selective Journal Outside Diame- 74.977 to 74.990 mm
Pairing ter (2.9519 to 2.9528 in.)
Clearance 0.018 to 0.062 mm 0.20 mm
(0.00071 to 0.0024 in.) (0.0079 in.)
PISTON
Inspection Item Standard Limit
Piston Pin Hole Inside Diameter 30.006 to 30.013 mm 30.05 mm
(1.1814 to 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 1.25 mm
(0.00079 to 0.0015 in.) (0.0059 in.)
PISTON RING
Inspection Item Standard Limit
Top Ring Side Clearance 0.05 to 0.09 mm 0.15 mm
(0.002 to 0.003 in.) (0.0059 in.)
End Clearance 0.30 to 0.450 mm 1.25 mm
(0.012 to 0.017 in.) (0.0492 in.)
Second Ring Side Clearance 0.093 to 0.120 mm 0.20 mm
(0.00367 to 0.00472 in.) (0.0079 in.)
End Clearance 0.30 to 0.45 mm 1.25 mm
(0.012 to 0.017 in.) (0.0492 in.)
Oil Ring Side Clearance 0.020 to 0.060 mm 0.15 mm
(0.00079 to 0.0023 in.) (0.0059 in.)
End Clearance 0.250 to 0.450 mm 1.25 mm
(0.0099 to 0.017 in.) (0.0492 in.)
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CONNECTING ROD
Inspection Item Standard Limit
Thrust Clearance 0.05 mm
(0.002 in.)
Tappet
OIL PUMP
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Special Torque Specifications 0600 SRM 1590
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)
Fuel Pump Gear Cover Mounting Screw Electronic Throttle Bellcrank Weldment Stud
24 to 27 N•m (18 to 20 lbf ft) Nut
10.5 N•m (92.9 lbf in)
Fuel Injection Pump Assembly Mounting Nut
18 to 20 N•m (13 to 15 lbf ft) Electronic Throttle Lever Plate Capscrew
7.9 N•m (70 lbf in)
Fuel Injection Pump Assembly Gear Mount-
ing Nut Electronic Throttle Inline Ball Joint
74 to 83 N•m (55 to 61 lbf ft) 7.9 N•m (70 lbf in)
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Electronic Throttle Fuel Shut Off Solenoid Al- Electronic Throttle Ball Joint Rod Nut
len-head Capscrews 25.6 N•m (226.6 lbf in)
10.5 N•m (92.9 lbf in)
Special Tools
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
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.)
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Special Tools 0600 SRM 1590
15 Piston Ring
Replacer
(for
Removal/ Available Locally
Installation
of Piston
Ring)
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Special Tools 0600 SRM 1590
11 Thickness Gauge ("Feeler" For measuring gaps between ring and ring
Gauge) groove and shaft joints during assembly.
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NOTES
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