Kubota Diesel 3.6L Engine

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com
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]
PART NO. 4053146 0600 SRM 1579

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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 ...........................................................................................................................................2
Crankcase Description ........................................................................................................................................2
Engine Removal and Installation ...........................................................................................................................3
Cylinder Head Assembly Repair ............................................................................................................................ 3
Valve Covers and Fuel Injectors ........................................................................................................................ 3
Remove ............................................................................................................................................................ 3
Clean and Inspect ........................................................................................................................................... 8
Install .............................................................................................................................................................. 8
Rocker Arm Assembly .........................................................................................................................................9
Remove ............................................................................................................................................................ 9
Disassemble .................................................................................................................................................. 11
Clean and Inspect ......................................................................................................................................... 11
Push Rods ................................................................................................................................................. 11
Rocker Arm Assembly .............................................................................................................................. 11
Assemble ....................................................................................................................................................... 12
Install ............................................................................................................................................................ 12
Valve Clearance Adjustments .......................................................................................................................... 12
Cylinder Head Assembly .................................................................................................................................. 13
Remove .......................................................................................................................................................... 13
Disassemble .................................................................................................................................................. 20
Valves and Valve Springs, Remove ......................................................................................................... 20
Valve Guides, Remove ..............................................................................................................................22
Cylinder Head ...........................................................................................................................................23
Valve Guides .............................................................................................................................................23
Valves ........................................................................................................................................................23
Valve Sink .................................................................................................................................................24
Valve Seat ................................................................................................................................................. 24
Valve Springs ............................................................................................................................................24
Assemble ....................................................................................................................................................... 25
Valve Guides, Install ................................................................................................................................25
Valves and Valve Springs, Install ........................................................................................................... 26
Install ............................................................................................................................................................ 26
Timing Gear Case and Timing Gears Repair ...................................................................................................... 30
Timing Gear Case Cover ...................................................................................................................................30
Remove .......................................................................................................................................................... 30
Install ............................................................................................................................................................ 30
Timing Gears .....................................................................................................................................................31
Crankshaft Gear ........................................................................................................................................... 32
Remove ......................................................................................................................................................32
Install ........................................................................................................................................................32
Idler Gear ...................................................................................................................................................... 32
Remove ......................................................................................................................................................32
Inspect .......................................................................................................................................................33
Install ........................................................................................................................................................33
Camshaft Gear ..............................................................................................................................................33
©2015 HYSTER COMPANY i

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Table of Contents
TABLE OF CONTENTS (Continued)

Remove ......................................................................................................................................................33
Install ........................................................................................................................................................34
Timing Gear Case ............................................................................................................................................. 34
Remove .......................................................................................................................................................... 34
Install ............................................................................................................................................................ 35
Drive Train, Camshaft, and Cylinder Block Repair ............................................................................................36
Remove .............................................................................................................................................................. 36
Disassemble .......................................................................................................................................................36
Pistons and Connecting Rods .......................................................................................................................36
Crankshaft .................................................................................................................................................... 37
Camshaft ....................................................................................................................................................... 40
Clean and Inspect ............................................................................................................................................. 42
Cylinder Block ...............................................................................................................................................42
Honing and Boring ................................................................................................................................... 44
Cylinder Correction (Oversize) ................................................................................................................ 45
Pistons ........................................................................................................................................................... 45
Piston Pin ......................................................................................................................................................46
Connecting Rod .............................................................................................................................................47
Tappets ..........................................................................................................................................................47
Crankshaft .................................................................................................................................................... 47
Camshaft ....................................................................................................................................................... 50
Camshaft Bushing ........................................................................................................................................ 51
Assemble ............................................................................................................................................................51
Camshaft ....................................................................................................................................................... 51
Crankshaft .................................................................................................................................................... 51
Pistons and Connecting Rods .......................................................................................................................51
Install .................................................................................................................................................................53
Lubrication System Repair ................................................................................................................................... 54
Engine Oil and Oil Filter Change .................................................................................................................... 54
Oil Pan ...............................................................................................................................................................55
Remove .......................................................................................................................................................... 55
Install ............................................................................................................................................................ 56
Oil Suction Tube ................................................................................................................................................56
Remove .......................................................................................................................................................... 56
Clean ..............................................................................................................................................................57
Install ............................................................................................................................................................ 57
Oil Pump ............................................................................................................................................................57
Remove .......................................................................................................................................................... 57
Outer Rotor Outside Clearance ............................................................................................................... 58
Outer Rotor to Inner Rotor Tip Clearance .............................................................................................. 58
Outer Rotor Side Clearance ..................................................................................................................... 58
Rotor Shaft Clearance .............................................................................................................................. 59
Install ............................................................................................................................................................ 59
Fuel System Repair ...............................................................................................................................................60
Fuel Injectors .................................................................................................................................................... 60
Remove .......................................................................................................................................................... 60
Inspect ........................................................................................................................................................... 60
Clean ..............................................................................................................................................................60
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Table of Contents

Replace .......................................................................................................................................................... 60
Install ............................................................................................................................................................ 61
Electronic Throttle System ...............................................................................................................................61
Remove .......................................................................................................................................................... 61
Bearing Replacement ................................................................................................................................... 64
Install ............................................................................................................................................................ 65
Adjustment ....................................................................................................................................................66
Fuel Injection Pump ..........................................................................................................................................66
Remove .......................................................................................................................................................... 66
Disassemble .................................................................................................................................................. 71
Assemble ....................................................................................................................................................... 74
Install ............................................................................................................................................................ 74
Cooling System Repair ..........................................................................................................................................75
Serpentine Belt ................................................................................................................................................. 75
Remove .......................................................................................................................................................... 75
Inspect ........................................................................................................................................................... 76
Install ............................................................................................................................................................ 76
Serpentine Belt, Adjustment ....................................................................................................................... 76
Water Pump ...................................................................................................................................................... 77
Remove .......................................................................................................................................................... 77
Install ............................................................................................................................................................ 78
Thermostat ........................................................................................................................................................ 80
Remove .......................................................................................................................................................... 80
Inspect ........................................................................................................................................................... 80
Install ............................................................................................................................................................ 81
Flywheel and Flywheel Housing .......................................................................................................................... 82
Flywheel ............................................................................................................................................................ 82
Remove .......................................................................................................................................................... 82
Install ............................................................................................................................................................ 83
Flywheel Housing ............................................................................................................................................. 83
Remove .......................................................................................................................................................... 83
Install ............................................................................................................................................................ 83
Electrical Equipment Repair ................................................................................................................................ 83
Alternator .......................................................................................................................................................... 83
Remove .......................................................................................................................................................... 83
Install ............................................................................................................................................................ 84
Starter ................................................................................................................................................................86
Remove .......................................................................................................................................................... 86
Install ............................................................................................................................................................ 86
Engine Specifications ............................................................................................................................................ 87
Engine Data .......................................................................................................................................................87
Engine Tuning ...................................................................................................................................................88
Cylinder Head ................................................................................................................................................... 88
Intake/Exhaust Valve and Guide .....................................................................................................................89
Valve Spring ......................................................................................................................................................89
Rocker Arm and Shaft ...................................................................................................................................... 89
Push Rod ............................................................................................................................................................90
Gear Train and Camshaft .................................................................................................................................90
Camshaft ....................................................................................................................................................... 90
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Idle Gear Shaft and Bushing ....................................................................................................................... 90
Backlash of Each Gear ................................................................................................................................. 90
Cylinder Block ...................................................................................................................................................90
Crankshaft .........................................................................................................................................................91
Piston ................................................................................................................................................................. 91
Piston Ring ........................................................................................................................................................ 91
Connecting Rod ................................................................................................................................................. 92
Rod Small End .............................................................................................................................................. 92
Tappet ............................................................................................................................................................92
Oil Pump ............................................................................................................................................................92
Engine Oil Pressure ......................................................................................................................................92
Outer Rotor Outside Clearance ................................................................................................................... 92
Outer Rotor Side Clearance ......................................................................................................................... 92
Inner Rotor to Cover .....................................................................................................................................93
Standard Torque Specifications ............................................................................................................................93
Standard Torque Chart .................................................................................................................................... 93
Special Torque Specifications ............................................................................................................................... 94
Special Tools .......................................................................................................................................................... 95
This section is for the following models:
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]
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0600 SRM 1579 General
General
This section has the repair instructions for the
Kubota 3.6L diesel engine.
ENGINE IDENTIFICATION
Major Engine Component Identification
Figure 1 shows where the major engine components

are located.
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
13. DIPSTICK (ENGINE OIL)
14. FUEL/WATER SEPARATOR
15. TURBO CHARGER
Figure 1. Major Engine Components
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General 0600 SRM 1579
Location of Labels crankcase 1, which houses combustion components

and crankcase 2, which completes crankcase 1 and
The typical location of the emission control acts as noise reduction baffle. See Figure 4.
information label is shown in Figure 2.
The Kubota Diesel engine utilizes a hanger type
The typical location of the engine nameplate is crankshaft support which allows for easy
shown in Figure 2. The emissions exempt label is disassembly/assembly and a linerless type piston
shown in Figure 3. cylinder which allows for good cooling performance
and excellent resistance to wear. See Figure 4.
1. ENGINE NAMEPLATE
2. EMISSION CONTROL INFORMATION LABEL
3. ENGINE SERIAL NUMBER
Figure 2. Typical Location of Engine Labels
Figure 3. Emissions Exempt Label

1. CRANKCASE 1 3. OIL PAN
2. CRANKCASE 2
CRANKCASE DESCRIPTION Figure 4. Kubota Diesel Crankcase Components
The Kubota diesel engine utilizes a split crankcase

to produce greater durability and operate more
quietly. The crankcase is split into two parts,
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0600 SRM 1579 Engine Removal and Installation
Engine Removal and Installation

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

• H6.0-7.0FT (H135-155FT) (K006)
Cylinder Head Assembly Repair

VALVE COVERS AND FUEL INJECTORS • H6.0-7.0FT (H135-155FT) (L006)
4. Loosen two clamps at air filter and turbo

Remove
charger for air intake hose. Remove air intake
1. Disconnect negative battery cable at battery. hose.
NOTE: Mark connectors/wires during removal to See Figure 5 for lift truck models
aid in installation. • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (R005)
2. Unclip engine wiring harness and move to side
for better access. • H6.0-7.0FT (H135-155FT) (K006)
See Figure 5 for lift truck models 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) (R005) H5.0-5.5FT (H80-120FT) (S005, U005)
• H6.0-7.0FT (H135-155FT) (K006) See Figure 7 for lift truck model
See Figure 6 for lift truck model • H6.0-7.0FT (H135-155FT) (L006)
• 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) • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (R005)
3. Disconnect wiring connector from glow plug
strip. • H6.0-7.0FT (H135-155FT) (K006)
See Figure 5 for lift truck models 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) (R005) H5.0-5.5FT (H80-120FT) (S005, U005)
• H6.0-7.0FT (H135-155FT) (K006) See Figure 7 for lift truck model
See Figure 6 for lift truck model • H6.0-7.0FT (H135-155FT) (L006)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; 6. Remove turbo outlet hose from turbo charger
H5.0-5.5FT (H80-120FT) (S005,U005) and air inlet elbows.
See Figure 7 for lift truck model
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Cylinder Head Assembly Repair 0600 SRM 1579
See Figure 5 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)

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

• H6.0-7.0FT (H135-155FT) (L006)
1. ENGINE WIRING HARNESS

2. CLAMP
3. AIR FILTER
4. TURBO CHARGER
5. AIR INTAKE HOSE
6. BREATHER TUBE
7. TURBO CHARGER OUTLET HOUSE
8. GLOW PLUG STRIP CONNECTOR
Figure 5. Breather Tube and Hoses 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) (K006)
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0600 SRM 1579 Cylinder Head Assembly Repair
1. ENGINE WIRING HARNESS 1. ENGINE WIRING HARNESS

2. CLAMP 2. CLAMP
3. AIR FILTER 3. AIR FILTER
4. TURBO CHARGER 4. TURBO CHARGER
5. AIR INTAKE HOSE 5. AIR INTAKE HOSE
6. BREATHER TUBE 6. BREATHER TUBE
7. TURBO CHARGER OUTLET HOUSE 7. TURBO CHARGER OUTLET HOUSE
8. GLOW PLUG STRIP CONNECTOR 8. GLOW PLUG STRIP CONNECTOR
Figure 6. Breather Tube and Hoses for Lift Truck Figure 7. Breather Tube and Hoses for Lift Truck
Model H4.0FT5/FT6; H4.5FTS5, H4.5FT6; Models H6.0-7.0FT (H135-155FT) (L006)
H5.0-5.5FT (H80-120FT) (S005, U005)
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7. Remove ten bolts, valve cover and gasket from 10. Remove two hose clamps. Disconnect fuel over-
cylinder head. Discard gasket. See Figure 8. flow hoses from overflow pipe assembly. See
Figure 9.
8. Remove four flange nuts. Remove glow plug
strip from glow plugs. See Figure 9. 11. Loosen four fuel lines at fuel injection pump.
See Figure 9.
NOTE: Note position and location of fuel line
clamps during removal to aid in installation. 12. Remove four fuel lines, four nuts, and overflow
pipe assembly from fuel injectors. Discard nuts.
9. Remove two pan head screws and four clamps See Figure 9.
from fuel injector lines. See Figure 9.
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
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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
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13. Remove four injectors, four gaskets and four Install

base seals from cylinder head. Discard gaskets
and base seals. See Figure 9. 1. Install four glow plugs into cylinder head.
Tighten to 20 to 24 N•m (15 to 18 lbf ft). See
14. Remove four glow plugs. See Figure 9. Figure 9.
Clean and Inspect 2. Install four new gaskets and four new base
seals onto four fuel injectors. Install four fuel
injectors into cylinder head. Tighten to 49 to
WARNING 68 N•m (37 to 50 lbf ft). See Figure 9.
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning 3. Install overflow pipe assembly and four nuts
solvents, always follow the recommendations of onto fuel injectors. Tighten nuts to 20 to
the manufacturer. 24 N•m (15 to 18 lbf ft). See Figure 9.
4. Install four fuel lines onto fuel injectors.

WARNING Tighten to 23 to 36 N•m (17 to 26 lbf ft). See
Compressed air can move particles so that they Figure 9.
cause injury to the user or to other personnel.
5. Install four fuel lines onto fuel injection pump.
Make sure that the path of the compressed air is
Tighten to 23 to 36 N•m (17 to 26 lbf ft). See
away from all personnel. Wear protective goggles
Figure 9.
or a face shield to prevent injury to the eyes.
6. Using two hose clamps, connect fuel overflow
hoses to overflow pipe assembly. See Figure 9.
CAUTION
Use caution not to scratch the gasket mating sur- 7. Install four clamps and two pan head screws
faces when cleaning the valve cover and cylinder onto fuel injector lines as noted during removal.
head. See Figure 8.
Carefully remove all gasket residue from valve 8. Using four flange nuts, install glow plug strip
cover and cylinder head. onto glow plugs. See Figure 9.
Clean valve cover in cleaning solvent. Dry valve 9. Lightly grease new valve cover gasket.
cover with compressed air. Inspect for wear, cracks, 10. Place new valve cover gasket into groove of
and any other damage. If necessary, replace valve valve cover.
cover.
11. Install valve cover and ten bolts onto cylinder
Inspect all O-rings, plugs and grommets for wear, head. Tighten bolts to 9.8 to 11.2 N•m (86.7 to
cracks, and any other damage. Replace where nec- 99 lbf in). See Figure 8.
essary.
Inspect valve cover breather and breather cover for

cracks, wear, and any other damage (see Figure 8).
if necessary see Parts Manual for replacement
parts.
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12. Install outlet hose from turbo charger and air 15. Connect wiring connector to glow plug strip as
inlet elbows. 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)
13. Install breather tube and clamp to valve cover. 16. Install engine wiring harness and attach clips
as noted during removal.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, See Figure 5 for lift truck models
H5.0-5.5FT (H80-120FT) (R005) • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
• H6.0-7.0FT (H135-155FT) (K006) H5.0-5.5FT (H80-120FT) (R005)
• H6.0-7.0FT (H135-155FT) (K006)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; See Figure 6 for lift truck model
H5.0-5.5FT (H80-120FT) (S005, U005) • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80-120FT) (S005, U005)
• H6.0-7.0FT (H135-155FT) (L006) See Figure 7 for lift truck model
• H6.0-7.0FT (H135-155FT) (L006)
14. Install air intake hose assembly and tighten
clamps at air filter and turbo charger. 17. Connect negative battery cable at battery.
See Figure 5 for lift truck models ROCKER ARM ASSEMBLY

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (R005) Remove
• H6.0-7.0FT (H135-155FT) (K006) 1. Remove valve cover, fuel injectors, and glow
See Figure 6 for lift truck model plugs. See Valve Covers and Fuel Injectors, Re-
move.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80-120FT) (S005, U005) 2. Remove four flange bolts holding rocker arm
brackets to cylinder head. See Figure 10.
• H6.0-7.0FT (H135-155FT) (L006)
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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
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3. Lift rocker arm shaft assembly from cylinder 3. Use a feeler gauge to measure gap. Refer to En-
head. See Figure 10. gine Specifications for service limit. See Fig-
ure 11.
NOTE: Mark push rods so they can be reinstalled
in original location during reassembly.
4. Remove push rods from cylinder head.
Disassemble
1. Remove c-clips and washers from each end of
rocker arm shafts. Discard washers. See Fig-
ure 10.
NOTE: Mark rocker arms so they can be reinstal-

led 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.
Figure 11. Push Rod Inspection
2. Slide rocker arm shaft out of rocker arm brack-
ets, springs, and rocker arms. See Figure 10.
3. If necessary, remove adjusting screw and lock Rocker Arm Assembly

nut from rocker arms. See Figure 10.
Rocker Arm and Support Bracket Inside Di-
Clean and Inspect ameter: Use a test indicator and micrometer to de-
termine if inside diameter of all rocker arm support
brackets and rocker arms are within limits. Refer
WARNING to Engine Specifications for service limit. See Fig-
Cleaning solvents can be flammable and toxic and ure 12.
can cause skin irritation. When using cleaning
solvents, always follow the recommendations of
the manufacturer.
WARNING
Compressed air can move particles so that they
Clean all parts in cleaning solvent. Dry parts with

compressed air. Inspect for wear, cracks, and any
other damage. Replace all parts as needed.
Figure 12. Rocker Arm Inside Diameter
Push Rods
1. Place push rods on a flat inspection block.
Shaft Outside Diameter: Use a micrometer to
2. Roll push rods until a gap can be observed be- measure rocker arm shaft outside diameter. Refer
tween a portion of push rod and surface of in- to Engine Specifications for service limit. See Fig-
spection block. ure 13.
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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 Adjust-

ments.
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 number one piston position is on fly-
wheel end of engine, opposite side of radiator, and
NOTE: The rocker arm shaft fits tightly in rocker
ignition order is 1-3-4-2 at 180 degree intervals.
arm support brackets. Clamp rocker arm shaft in a
padded vise and twist and push support brackets 2. Rotate crankshaft clockwise, as seen from radi-
onto rocker arm shaft. ator side, to bring number one piston to top
dead center (TDC) (See Fuel Injection Pump for
1. Lubricate rocker arm shaft. Slide rocker arm
TDC procedure). See Table 1 for reference to
support brackets, springs, and rocker arms onto
help determine which valves will be available
shaft, as noted during removal.
for adjustment with number one piston at TDC.
2. Position rocker arm assembly on a flat surface.
Table 1. Available Valves for Adjustment
Install washers and c-clips onto ends of rocker
arm shaft. See Figure 10. Adjustable Cylinder Intake Exhaust
Location Of Piston
3. If removed, install valve adjusting screws and
lock nuts. See Figure 10. When No. 1 1 * *
piston is at 2 *
Install compressio
n top dead 3 *
NOTE: When installing push rod, mount it se- center 4
curely in groove located in bottom of lifter.
When No. 1 1
1. Install push rods. piston is at 2 *
overlap
2. Place rocker arm assembly in position on cylin- position 3 *
der head. 4 * *
3. Install and hand tighten rocker arm shaft re- 3. Insert a feeler gauge between rocker arm and
taining flange nuts. See Figure 10. valve cap. See Figure 14. Record measured
4. Align push rods with their respective rocker valve clearance. The valve clearance should be
arms, as noted during removal. between 0.23 to 0.27 mm (0.009 to 0.011 in.).
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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 be-
tween 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.).
6. Apply clean engine oil to contact surface be-

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

urement and adjustment for number three cyl-
inder. Then turn crankshaft 180 degrees and
1. VALVE ADJUSTING SCREW make measurement and adjustment for number
2. VALVE LOCK NUT
four cylinder. Then turn crankshaft 180 de-
Figure 14. Valve Clearance Measurement grees and make measurement and adjustment
for number 2 cylinder.
4. If adjustment is needed, loosen valve adjusting 8. Install valve cover. See Valve Covers and Fuel
screw lock nut and valve adjusting screw on Injectors, Install.
rocker arm (see Figure 14) and check valve for
any inclination of valve cap, entrance of dirt, or
CYLINDER HEAD ASSEMBLY
wear. See Figure 15.
Remove
1. Disconnect negative battery cable at battery.
NOTE: Place a suitable container with a capacity

of at least 12.0 liter (13 qt) under radiator and
lower radiator hose.
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 turbo
charger.
A. NORMAL B. ABNORMAL
1. VALVE CAP • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
Figure 15. Valve Cap Check H5.0-5.5FT (H80-120FT) (R005)
• H6.0-7.0FT (H135-155FT) (K006)
NOTE: There is a tendency for clearance to de- See Figure 17 for lift truck model
crease slightly when lock nut is tightened. It is sug- • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
gested that you make clearance adjustment slightly H5.0-5.5FT (H80-120FT) (S005, U005)
on loose side before tightening lock nut.
• H6.0-7.0FT (H135-155FT) (L006)
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Legend for Figure 17
1. HOSE CLAMP 3. AIR INTAKE HOSE

2. RETAINING CLAMP

2. RETAINING CLAMP
Figure 16. Air Intake Hoses for Lift Truck Models

H6.0-7.0FT (H135-155FT) (K006)

2. RETAINING CLAMP
Figure 18. Air Intake Hoses for Lift Truck Models
H6.0-7.0FT (H135-155FT) (L006)
NOTE: Tag wiring connectors and wiring harness

before removal to aid during installation.
4. Tag and disconnect connectors for engine wir-

ing harness. Move harness aside for better ac-
cess.
5. Loosen adjustment bolt for alternator and re-

lease tension on serpentine belt. Remove ser-
pentine belt. See Figure 19.
Figure 17. Air Intake Hoses for Lift Truck Model

H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80-120FT) (S005, U005)
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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 Figure 20. Engine Pulleys
4. MOUNTING BOLT
5. WASHER
6. MOUNTING BRACKET
7. ALTERNATOR 8. Remove eight bolts, collar, spacer, and two fan
pulleys from water pump and water flange. See
Figure 19. Alternator Mounting and Adjustment Figure 20.
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 hous-
truck. See Figure 19. ing 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.
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13. Remove valve cover, fuel injectors and related

parts. See Valve Covers and Fuel Injectors, Re-
move 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 over-

flow return hose from fuel injection pump. See
Figure 22.
1. CLAMP
12. Disconnect lubricating pipe from block just be- 2. HOSE
3. OIL COOLER PIPE
low injection pump. See Figure 22. 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 assem-
bly. See Figure 24.
19. Remove water pump. See Cooling System Re-

pair section for procedures.
20. Remove four bolts, water flange assembly, and

gasket from cylinder. Discard gasket. See Fig-
ure 24.
1. BOOST COMPENSATOR HOSE

2. FUEL OVERFLOW RETURN HOSE
3. LUBRICATING PIPE
Figure 22. Fuel Lines
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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 ex-

haust manifold. See Figure 27.
26. Remove dipstick, dipstick tube, O-ring, and dip-

stick 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
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1. DIPSTICK
2. CAPSCREW
3. DIPSTICK TUBE
4. O-RING
5. GUIDE
6. ENGINE BLOCK
7. EXHAUST MANIFOLD 1. BANJO BOLT 5. CLAMP
2. WASHER SET 6. DRAIN TUBE
Figure 27. Engine Oil Dipstick 3. OIL SUPPLY LINE 7. HOSE
4. CAPSCREW 8. GASKET
Figure 28. Turbocharger Oil Lines

27. Remove two banjo bolts, two washer sets and
turbocharger oil supply line. Discard washer
sets. See Figure 28. 29. Remove engine oil filter from oil cooler. See Fig-
ure 29.
28. Remove two capscrews, two clamps, oil drain
tube, hose and gasket from turbocharger and 30. Remove two clamps and hose from oil cooler
block. Discard gasket. See Figure 28. and engine block. See Figure 29.
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31. Remove oil cooler joint, oil cooler and O-ring

from engine block. Discard O-ring. See Fig-
ure 29.
1. OIL FILTER 5. OIL COOLER

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

fold. See Figure 31.
34. Remove six flange nuts, gasket and exhaust

manifold from cylinder head. Discard gasket.
See Figure 31.
A. TIMING GEAR CASE END

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 Fig-

1. FLANGE BOLT ure 34.
2. FLANGE NUT
3. EXHAUST MANIFOLD
4. GASKET
5. CYLINDER HEAD
Figure 31. Exhaust Manifold
35. Remove rocker arm assembly. See Rocker Arm

Assembly, Remove.
36. Remove eighteen cylinder head bolts in se-

quence shown, from one to eighteen. See Fig-
ure 32.
1. LIFTERS 2. CRANKCASE
Figure 34. Lifters
A. TIMING GEAR CASE END

B. FLYWHEEL END Disassemble
Figure 32. Head Bolt Pattern
Valves and Valve Springs, Remove
NOTE: There are three cylinder head gaskets 1. Remove four valve arms, four valve arm pads
available (a, b, or c) for this engine application. and four valve arm shafts from cylinder head.
Take note which one is being used during removal. See Figure 35.
See Figure 33.
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2. Using a valve spring compressor tool, compress 4. Slowly release tension on valve spring.
valve springs.
5. Remove spring retainer, valve spring, and valve
3. Remove valve keepers and valve cap from end stem seal.
of valve. See Figure 35.
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
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6. Repeat this procedure until all intake and ex- Clean and Inspect
haust valve springs and valve stem seals are
removed.
WARNING
NOTE: If existing valves are going to be reinstalled Cleaning solvents can be flammable and toxic and
in cylinder head, mark valves so they can be instal- can cause skin irritation. When using cleaning
led in their original location. solvents, always follow the recommendations of
the manufacturer.
7. Turn cylinder head so exhaust port side faces
down. Remove intake and exhaust valves from
cylinder head. WARNING
Valve Guides, Remove cause injury to the user or to other personnel.
Press out used valve guide using valve guide re- away from all personnel. Wear protective goggles
placing tool. See Figure 36. or a face shield to prevent injury to the eyes.
CAUTION
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.
CAUTION
Any part determined to not meet the service
standard or limit before the next service, as deter-
mined 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 sur-
faces when cleaning the exhaust manifold and
cylinder head.
CAUTION
faces when cleaning the intake manifold and cyl-
inder head.
CAUTION
A. REMOVAL B. INSTALLATION
1. VALVE GUIDE INSTALLATION TOOL faces when cleaning the cylinder head and cylin-
2. CYLINDER HEAD der block.
3. VALVE GUIDE
Figure 36. Valve Guide Removal Carefully remove all gasket residue from exhaust
manifold and cylinder head. Inspect exhaust mani-
fold for scratches, cracks, or any other damage. Re-
pair or replace as needed.
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Carefully remove all gasket residue from intake Valve Guides

manifold and cylinder head. Inspect intake mani-
fold for scratches, cracks, or any other damage. Re- Visually inspect valve guides for distortions, scor-
pair or replace as needed. ing, or other damage.
Carefully remove all gasket residue from cylinder Use a test indicator and micrometer to measure in-
head and cylinder block. Inspect cylinder head for side diameter at each end of valve guide. Refer to
scratches, cracks, or any other damage. Repair or Engine Specifications for service limit.
replace as needed.
Valves
Thoroughly clean all components using a nonmetal-
lic brush and cleaning solvent. Dry parts with com- Valve Stem Diameter: Use a micrometer to meas-
pressed air. Each part must be free of carbon, metal ure valve stem diameter. Measure valve stem near
filings, and other debris. combustion end and near opposite end. Refer to En-
gine Specifications for service limit. See Figure 38.
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 (combus-
tion side up) on work bench.
2. Use a straight edge and feeler gauge to meas- A. MEASUREMENT POINTS

ure amount of cylinder head distortion. Refer to
Figure 38. Valve Stem Diameter Measurement
Engine Specifications for service limit. See Fig-
Points
ure 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 evi-
dence of fractures are found.
Figure 39. Valve Stem Straightness Check
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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 differ-
ence between cylinder head surface and combustion
surface of each exhaust and intake valve. Refer to
ure 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 de-
termine if lapping or grinding is needed. Grinding
Figure 40. Valve Sink Measurement is needed if cylinder head's seat width exceeds
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 out-

side portions of springs. If valve spring is fractured,
replace spring.
Figure 41. Valve Sink
Corrosion: Check for corrosion of spring material
caused by oxidation.
Valve Seat
Squareness: Use a flat surface and a square to
check each spring for squareness. Refer to Engine
Always check clearance between valve and valve
Specifications for service limit. See Figure 43.
guide before correcting valve seat. See Figure 42. If
clearance exceeds limit, replace valve or valve
guide to bring clearance within limit.
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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
dimension. See Table 2.
Table 2. Valve Guide Specification

Assemble
7.010 to
Valve Guides, Install Intake 7.025 mm
Valve Valve (0.2760 to
1. The valve guides are installed into cylinder Factory 0.2765 in.)
Guide
head with an extremely tight press fit. Before Specificat
Inside 7.010 to
installing valve guides, clean new valve guide ion
Diameter Exhaust 7.025 mm
and valve guide bore and apply oil to them. Valve (0.2760 to
0.2765 in.)
2. Press fit new valve guide with valve guide re-
placing tool. See Figure 45.
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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 Fig-
ure 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
9. Repeat these procedures until all intake and

1. VALVE STEM SEAL INSTALLATION TOOL exhaust valves are installed.
2. VALVE STEM SEAL
3. VALVE GUIDE 10. Install four valve shafts, four pads, and four
4. CYLINDER HEAD valve arms. See Figure 35.
Figure 46. Valve Stem Seal Installation
Install
4. Measure distance from cylinder head to valve
stem seal. Refer to Engine Specifications for 1. Lightly oil outside of lifters. Install eight lifters
clearance specifications. See Figure 47. into crankcase.
5. Place cylinder head on work bench with com- 2. Carefully clean combustion surface of cylinder
bustion chamber facing down. Install valve head and top surface of cylinder block.
springs and valve spring retainers. See Fig- 3. Measure the piston head's protrusion or reces-
ure 35. sion from crankcase cylinder face in four spots
6. Using valve compressor tool, compress valve per each piston, using a dial gauge, and get the
spring. average of measurements.
7. Install valve keepers and slowly release tension Use Table 3 to select an applicable cylinder head
in valve spring. gasket.
8. Install valve cap.
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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 dur-

ing 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
(from 1 to 18), using a two stage process: B. FLYWHEEL END
a. On first pass (1 to 18), tighten cylinder Figure 48. Cylinder Head Torque Sequence
head bolts 50 N•m (37 lbf ft). See Fig-
ure 48
b. On second pass (1 to 18), tighten cylinder 12. Install new gasket, turbocharger, two flange
head bolts to 98 to 107 N•m (72 to bolts and six flange nuts onto top of exhaust
80 lbf ft). See Figure 48. manifold. See Figure 30.
. 13. Install new O-ring, oil cooler and oil cooler joint
to engine block. Tighten oil cooler joint to 40 to
9. Install push rods and rocker arm assembly. See
44 N•m (29 to 32 lbf ft). See Figure 29.
Rocker Arm Assembly, Install.
14. Install hose and two clamps to oil cooler and en-
10. Using six flange nuts, install new exhaust
gine block. See Figure 29.
manifold gasket and exhaust manifold onto cyl-
inder head. See Figure 31. 15. Install new oil filter onto oil cooler. See Fig-
ure 29.
11. Install two flange bolts to exhaust manifold and
cylinder head. See Figure 31.
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16. Install oil drain tube, new gasket, two cap- 31. Connect lubricating pipe to engine block just
screws, two clamps, and hose onto turbocharger below injection pump. See Figure 22.
and block. See Figure 28.
32. Install fuel overflow return hose and boost com-
17. Install turbocharger oil supply line, two washer pensator hose onto fuel injection pump. See
sets and two banjo bolts onto turbocharger. See Figure 22.
Figure 28.
33. Using two capscrews, install fuel filter housing
18. Install dipstick tube guide, new O-ring, dipstick assembly to intake manifold. See Figure 21.
tube, and dipstick into engine block. See Fig-
ure 27. 34. Connect fuel hoses to fuel filter as noted during
removal.
19. Install capscrew to dipstick tube and exhaust
manifold. See Figure 27. 35. Install two fan pulleys, spacer, collar, and eight
bolts onto water pump and water flange. See
20. Install intake manifold, new gasket and eight Figure 20.
flange bolts to cylinder head. See Figure 26.
36. Install idler assembly and three bolts onto wa-
21. Install lifting eye bracket, flange nut and bolt ter pump assembly. See Figure 20.
to cylinder head. See Figure 25.
37. Install alternator, mounting bracket, three re-
22. Install lifting eye bracket, clamp and two bolts taining nuts, and three mounting bolts onto en-
to cylinder head. See Figure 25. gine. See Figure 19.
23. Install new gasket, water flange assembly and 38. Put serpentine belt on pulley's. Using a pry bar,
four bolts to cylinder head. See Figure 24. pull alternator into position and put tension
onto serpentine belt. Tighten alternator adjust-
24. Install water pump. See Cooling System Repair ment bolt. See Figure 19.
section in this manual.
39. Attach wiring harness to connectors as noted
25. Install coolant by pass hose and two clamps during removal.
onto water pump and water flange assembly.
See Figure 24. 40. Install air intake hoses, two retaining clamps,
and two hose clamps onto air cleaner and tur-
26. Using a bolt, install oil cooler pipe into engine bocharger. See Figure 16.
block. See Figure 23.
41. Install lower radiator hose.
27. Install hose and two clamps onto oil cooler and
oil cooler pipe. See Figure 23.
CAUTION
28. Install hose and two clamps onto water pump Additives may damage the cooling system. Before
and oil cooler pipe. See Figure 23. using additives, contact your local Hyster dealer.
29. Install fuel injection pump. See Fuel System 42. Fill cooling system with coolant. For correct
Repair section for procedures. coolant amount and type refer to
30. Install valve cover, fuel injectors and related
parts. See Valve Covers and Fuel Injectors, In-
stall.
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Periodic Maintenance 8000SRM1558 for lift

truck models WARNING
• H4.0FT5, H4.0FT6, H4.5FTS5, H4.5FT6, The radiator or other parts of the cooling system
H5.0FT, H5.5FT (H80-120FT) (R005) may be hot or under pressure and can cause seri-
ous injury.
truck models 46. Start engine and check for leaks.
• H6.0FT, H7.0FT (H135FT,H155FT) 47. Change engine oil and oil filter. See Lubrication
(K006) System Repair, Engine Oil and Oil Filter
Change.
truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; WARNING
H5.0-5.5FT (H80, 90, 100, 110, 120FT) DO NOT remove the radiator cap from the radiator
(S005) when the engine is hot. When the radiator cap is
removed, pressure will release from the coolant
Periodic Maintenance 8000SRM1902 for lift system. If the coolant system is hot, the steam
truck models and boiling coolant can cause severe burns.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80-120FT) (U005) WARNING
Periodic Maintenance 8000SRM1957 for lift The radiator or other parts of the cooling system
truck model may be hot or under pressure and can cause seri-
ous injury. Wait 30 minutes for the radiator and
• H6.0-7.0FT (H135-155FT) (L006) engine to cool before performing maintenance to
43. Install radiator cap. the cooling system. After 30 minutes, do a touch
test by touching the radiator with your hand. If the
44. Fill engine oil. See Lubrication System Repair, radiator is still hot to the touch, wait another 30
Engine Oil and Oil Filter Change. minutes before attempting any maintenance to the
cooling system.
45. Connect negative battery cable.
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
parts can cause serious injury. 48. Stop engine. If coolant is hot, allow engine time
to cool. Check coolant level and fill as required
between ADD and FULL marks on coolant res-
ervoir.
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Timing Gear Case and Timing Gears Repair 0600 SRM 1579
Timing Gear Case and Timing Gears Repair

TIMING GEAR CASE COVER
WARNING
Remove Compressed air can move particles so that they
1. Remove engine. Make sure that the path of the compressed air is
See Frame 0100SRM1243 for lift truck models or a face shield to prevent injury to the eyes.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (R005, S005) Clean all old sealant from timing gear case cover
and timing gear case. Clean timing gear case cover
See Frame 0100SRM1581 for lift truck models in cleaning solvent. Dry timing gear case cover with
• H6.0-7.0FT (H135-155FT) (K006) compressed air. Inspect for wear, cracks, and any
other damage. If necessary, replace timing gear
See Frame 0100SRM1891 for lift truck models case cover.
• 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)
2. Remove coolant fan, serpentine belt, and water

pump. See Cooling System Repair.
3. Remove bolt and washer retaining crankshaft

pulley.
4. Using a gear puller, remove crankshaft pulley.
5. Remove bolts retaining timing gear case cover

and plate to engine block. See Figure 49.
6. Remove timing gear case cover. 1. TIMING GEAR CASE COVER

2. BOLT
7. Remove front oil seal from timing gear case 3. TIMING GEAR CASE PLATE
cover. See Figure 49. 4. FRONT OIL SEAL
5. ENGINE BLOCK
Clean and Inspect
Figure 49. Timing Gear Case Cover
WARNING
Cleaning solvents can be flammable and toxic and Install
solvents, always follow the recommendations of 1. Apply a continuous bead of Three Bond Liquid
the manufacturer. Gasket (Hyster P/N 1599478) to outside diame-
ter of a new front oil seal.
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0600 SRM 1579 Timing Gear Case and Timing Gears Repair
2. Using a special tool, install new front oil seal See Frame 0100SRM1891 for lift truck models
into timing gear case cover. Apply lithium • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
grease to lip of front oil seal. See Figure 50. H5.0-5.5FT (H80-120FT) (U005)

• H6.0-7.0FT (H135-155FT) (L006)
8. Fill engine oil to correct level. For correct oil

amount and type refer to

truck models
• H4.0FT5, H4.0FT6, H4.5FTS5, H4.5FT6,
H5.0FT, H5.5FT (H80-120FT) (R005)

truck models
Figure 50. Front Oil Seal Installation • H6.0-7.0FT (H135-155FT) (K006)

truck models
3. Apply a continuous bead of Three Bond Liquid
Gasket (Hyster P/N 1599478) to mating surface • H4.0FT5, H4.0FT6, H4.5FTS5, H4.5FT6,
of timing gear case cover and timing gear case H5.0FT, H5.5FT (H80-120FT) (S005)
plate.
4. Place timing gear case cover and plate in posi- truck models
tion on engine block and install retaining bolts. • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
Tighten bolts to 24 to 27 N•m (18 to 20 lbf ft). H5.0-5.5FT (H80-120FT) (U005)
5. Install crankshaft pulley and bolt to crankshaft Periodic Maintenance 8000SRM1957 for lift
pulley. Tighten bolt to 255 to 274 N•m (188 to truck models
202 lbf ft). • H6.0-7.0FT (H135-155FT) (L006)
6. Install water pump, serpentine belt, and cool- 9. Start engine and check for leaks.
ant fan. See Cooling System Repair.
7. Install engine.
TIMING GEARS
See Frame 0100SRM1243 for lift truck models NOTE: For removal of fuel injection pump drive
gear, refer to Fuel System Repair.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (R005, S005)

• H6.0-7.0FT (H135-155FT) (K006)
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Before removing any of timing gears, rotate crank- NOTE: If using a gear puller to remove crankshaft
shaft to align alignment marks on gears as follows gear, be careful not to damage threads in end of
(see Figure 51): crankshaft.
• Align mark "A" on camshaft gear with mark
4. Remove crankshaft gear. See Figure 52.
"A" on idler gear 1.
• Align mark "B" on crankshaft gear with 5. Remove key from crankshaft.
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
NOTE: TIMING GEARS FOR LIFT TRUCK MODELS Figure 52. Crankshaft Gear
H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT
(H80-120FT) (R005) AND H6.0-7.0FT (H135-155FT)
(K006) SHOWN. H4.0FT5/FT6; H4.5FTS5, H4.5FT6; Install
H5.0-5.5FT (H80-120FT) (S005, U005) AND
H6.0-7.0FT (H135-155FT) (L006) ARE SIMILAR. 1. Install key into crankshaft.
1. CAMSHAFT GEAR 2. Align alignment mark "B" on crankshaft gear

2. CRANKSHAFT GEAR with alignment mark "B" on idler gear 1 and in-
3. IDLER GEAR 1 stall crankshaft gear onto crankshaft.
4. OIL PUMP GEAR
5. IDLER GEAR 2 3. Verify that all alignment marks are properly
Figure 51. Timing Gear Alignment aligned. Figure 51.
4. Install timing gear case cover. See Timing Gear

Case Cover, Install.
Crankshaft Gear
Idler Gear
Remove
Remove
1. Remove timing gear case cover. See Timing
Gear Case Cover, Remove. NOTE: There are two idler gears on this engine (id-
ler gear 1 and idler gear 2). The repair procedure is
2. Verify that gears are properly aligned with
same for both.
alignment marks. See Figure 51.
3. Remove oil pump drive gear. See Figure 52.
Gear Case Cover, Remove.
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2. Verify that gears are properly aligned with 2. Align alignment mark "C" on idler gear 1 with
alignment marks. See Figure 51. alignment mark "C" on idler gear 2 and align-
ment mark "A" on idler gear 1 with alignment
3. Remove bolts from idler gear shaft. See Fig- mark "A" on camshaft gear. Install idler gear,
ure 53. bushing, and idler gear shaft.
4. Remove idler gear shaft, alignment pin, idler
gear, idler gear collar, and bushing.
1. OUTSIDE DIAMETER
2. IDLER GEAR SHAFT
3. INSIDE DIAMETER
4. IDLER GEAR
1. ENGINE BLOCK
2. IDLER GEAR 1 Figure 54. Idler Gear and Shaft Measurement
3. IDLER GEAR 2
4. IDLER GEAR COLLAR
5. BUSHING 3. Verify that all alignment marks are properly
6. ALIGNMENT PIN aligned. See Figure 51.
7. IDLER GEAR SHAFT
8. BOLT 4. Install idler gear retaining bolts.
Figure 53. Idler Gear
Inspect Camshaft Gear

1. Measure outside diameter of idler gear shaft.
Refer to Engine Specifications for service limit.
Remove
See Figure 54. 1. Remove timing gear case cover. See Timing
2. Measure inside diameter of idler gear. Refer to
Engine Specifications for service limit. See Fig- 2. Verify that gears are properly aligned with
ure 54. alignment marks. See Figure 51.
Install 3. Remove four capscrews and pulsar gear from

camshaft gear. See Figure 55.
1. Lubricate idler gear bushing and idler gear
shaft with clean engine oil. 4. Using a gear puller, remove camshaft gear. See
Figure 55.
NOTE: Make sure oil hole in bushing is facing to-
ward top of engine. 5. Remove key from camshaft.
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• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (R005, S005)

• H6.0-7.0FT (H135-155FT) (K006)

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

• H6.0-7.0FT (H135-155FT) (L006)


Repair.
1. ENGINE BLOCK 5. BOLT
2. CAMSHAFT GEAR 6. RETAINER 4. Remove timing gears. See Timing Gears.
3. PULSE GEAR 7. KEY
4. CAPSCREW 8. CAMSHAFT
5. Remove three bolts holding gear case plate to
Figure 55. Camshaft Gear cylinder block. Remove gear case plate. See Fig-
ure 56.
Install 6. Remove two O-rings from cylinder block and
1. Install key into camshaft. discard.
2. Align alignment mark "A" on camshaft gear Clean and Inspect

with alignment mark "A" on idler gear and in-
stall camshaft gear onto camshaft.
WARNING
3. Install pulse gear and four capscrews onto cam- Cleaning solvents can be flammable and toxic and
shaft gear. Tighten capscrews to 4.7 to can cause skin irritation. When using cleaning
5.6 N•m (42 to 50 lbf in). solvents, always follow the recommendations of
the manufacturer.
TIMING GEAR CASE
Remove
1. Remove engine.
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Install
WARNING
Compressed air can move particles so that they 1. Install two new O-rings in cylinder block.
Make sure that the path of the compressed air is NOTE: Perform Step 2 and Step 3 for lift truck
away from all personnel. Wear protective goggles models H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
or a face shield to prevent injury to the eyes. H5.0-5.5FT (H80-120FT) (R005).
2. Apply a continuous bead of Three Bond Liquid

Clean all old sealant from timing gear case cover Gasket (Hyster P/N 1599478) to mating surface
and timing gear case. Clean timing gear case cover of timing gear case plate.
and gear case in cleaning solvent. Dry timing gear
case cover and gear case with compressed air. In- 3. Position gear case plate on cylinder block and
spect for wear, cracks, and any other damage. Re- install retaining bolts. Tighten to 24 to
place components as necessary. 27 N•m (18 to 20 lbf ft).
4. Install timing gears. See Timing Gears.

6. Install fuel injection pump. See Fuel System

Repair.
7. Install engine.

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (R005, S005)

• H6.0-7.0FT (H135-155FT) (K006)

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

A. THREE BOLTS HOLDING GEAR CASE PLATE
TO CYLINDER BLOCK • H6.0-7.0FT (H135-155FT) (L006)
1. TIMING GEAR CASE PLATE 8. Change engine oil and oil filter. See Lubrication
2. BOLT System Repair, Engine Oil and Oil Filter
3. O-RINGS Change.
4. CYLINDER BLOCK
9. Start engine and check for leaks.
Figure 56. Timing Gear Case
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Drive Train, Camshaft, and Cylinder Block Repair 0600 SRM 1579
Drive Train, Camshaft, and Cylinder Block Repair

REMOVE NOTE: DO NOT remove camshaft gear at this
time.
1. Remove engine.
11. Remove crankshaft gear and idler gear. See
See Frame 0100SRM1243 for lift truck models Timing Gear Case and Timing Gears Repair.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80-120FT) (S005, U005) DISASSEMBLE
See Frame 0100SRM1891 for lift truck models Pistons and Connecting Rods
• H4.0FT5, H4.0FT6, H4.5FTS5, H4.5FT6,
NOTE: It is necessary to rotate crankshaft to ac-
H5.0-5.5FT (H80-120FT) (U005)
cess some of connecting rod assemblies at bottom
See Frame 0100SRM1581 for lift truck models dead center position.
• H6.0-7.0FT (H135-155FT) (K006) 1. Using a feeler gauge, measure connecting rod
thrust clearance. See Figure 57. Refer to En-
See Frame 0100SRM1948 for lift truck models gine Specifications for standard limit. If meas-
• H6.0-7.0FT (H135-155FT) (L006) urement is out of specification, either crank-
shaft or connecting rod must be replaced.
Remove starter. See Electrical Equipment Re-
pair.
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 Re-

pair.

Repair.
6. Remove cylinder head. See Cylinder Head As-

sembly Repair.
7. Remove oil pan. See Lubrication System Re-

pair.
8. Remove oil suction tube. See Lubrication Sys-

tem Repair. Figure 57. Connecting Rod Thrust Clearance
Gear Case and Timing Gears Repair. 2. Remove two bolts from one of connecting rod
10. Remove oil pump. See Lubrication System Re- caps. See Figure 58.
pair.
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0600 SRM 1579 Drive Train, Camshaft, and Cylinder Block Repair
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.
Crankshaft
1. Remove eight bolts holding rear oil seal assem-
bly to engine block. Remove rear oil seal assem-
bly. See Figure 59.
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
Figure 58. Piston and Connecting Rod
3. Remove connecting rod cap.

1. BOLT
4. Remove bearing halves. 2. REAR MAIN SEAL HOUSING
3. REAR MAIN SEAL
4. CYLINDER BLOCK
5. Tap piston through cylinder and remove piston
assembly with connecting rod. Figure 59. Rear Main Seal
6. Mark connecting rod cap and connecting rod
and place assembly on a bench.
2. Remove rear main seal.
7. Remove piston rings from piston.
3. Measure crankshaft side gap using following
8. Remove snap rings retaining wrist pin. method:
9. Remove wrist pin. a. Set a dial indicator with it's point on end of
crankshaft. Move crankshaft to front and
rear to measure side clearance. See Fig-
ure 60.
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Description Factory Allowable Limit

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

Journal
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NOTE: Be sure to note markings on main bearing 5. Remove bearing halves and thrust bearings.
caps, or mark them yourself, so they can be rein- See Figure 62.
stalled in same location as they were removed.
6. Remove crankshaft from cylinder block.
NOTE: The arrows on main bearing caps point to
flywheel end of engine.
4. Remove bolts holding main bearing caps. Re-

move main bearing caps. See Figure 62.
1. BOLT 4. BEARING HALVES

2. MAIN BEARING CAP 5. THRUST BEARING
3. CYLINDER BLOCK 6. CRANKSHAFT
Figure 62. Crankshaft
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Camshaft 2. Using a gear puller, remove camshaft gear. See

Figure 64.
1. Using a feeler gauge, measure camshaft side
gap. Refer to Engine Specifications for service 3. Remove key from camshaft.
limit. See Figure 63.
4. Remove two bolts holding thrust plate and re-
move thrust plate.
NOTE: If engine is not installed on an engine

stand, position engine with mounting flange (fly-
wheel end) facing down. Rotate camshaft a few
turns to bump tappets out of way to prevent tap-
pets from interfering with removal of camshaft.
5. With engine installed on an engine stand, ro-

tate engine so gravity causes the tappets to
drop away from camshaft lobes.
6. Slowly pull camshaft out of cylinder block.
NOTE: Be sure to mark tappets so they can be in-

stalled in same location as they were removed.
1. THRUST METAL 7. Remove tappets.

2. CAMSHAFT
3. SIDE GAP 8. Remove three flange bolts and timing gear case
4. CAMSHAFT PULLEY plate. See Timing Gear Case and Timing Gears
Repair.
Figure 63. Camshaft Side Gap
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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
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CLEAN AND INSPECT a. Measure inside diameter of cylinder number

one, near top of cylinder (a) and in (d) direc-
tion. Record that measurement as data f.
WARNING
Cleaning solvents can be flammable and toxic and b. Measure inside diameter of cylinder number
can cause skin irritation. When using cleaning one, near top of cylinder (a) and in (e) direc-
solvents, always follow the recommendations of tion. Record that measurement as data g.
the manufacturer.
c. Measure inside diameter of cylinder number
one, near center of cylinder (b) and in (d) di-
WARNING rection. Record that measurement as data h.
d. Measure inside diameter of cylinder number
one, near center of cylinder (b) and in (e) di-
rection. Record that measurement as data I.
or a face shield to prevent injury to the eyes. e. Measure inside diameter of cylinder number
one, near bottom of cylinder (c) and in (d) di-
Clean all old sealant from all parts. Clean all parts rection. Record that measurement as data j.
in cleaning solvent. Dry parts with compressed air.
Each part must be free of carbon, metal filings, old f. Measure inside diameter of cylinder number
sealant, and other debris. Inspect for wear, cracks, one, near bottom of cylinder (c) and in (e) di-
and any other damage. Replace components as nec- rection. Record that measurement as data k.
essary.
g. Roundness: Roundness for cylinder number
Cylinder Block one is calculated as follows:
f-g = X
1. Verify that oil holes are clear and unobstructed.
Clear any oil holes as needed. h-I = Y
j-k = Z
2. Check for discoloration or evidence of cracks. If
evidence of a fracture is found, use color check X is difference between f and g measurements
method or Magnaflux method to determine if at top of cylinder.
cylinder block is fractured.
Y is difference between h and I measurements
3. Inspect cylinder roundness and cylindricity for at center/middle of cylinder.
evidence of distortions. Collect and record
measurements. See Figure 65 and Table 4. Z is difference between j and k measurements
at bottom of cylinder.
Select greatest of values X, Y and Z, then re-

cord it as V. This value represents roundness
of cylinder.
h. Cylindricity: Cylindricity for cylinder num-

ber one is calculated as follows:
Select least value of values X, Y and Z
record that value as S. Complete cal-
culation as follows:
V-S = W
W is difference between V and S measure-

Figure 65. Cylinder Measurement Points ments. This value represents cylindricity of
cylinder.
4. Perform calculations as follows:
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5. Repeat cylindricity and roundness measure- 7. Consider boring and honing, cylinder correc-
ments and calculations for remaining cylinders. tion, or replacing cylinder block if measure-
ments fall outside specifications.
6. Compare worksheet findings with specifications
listed in Table 5.
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
(a) f = __________ g = __________ X = __________ Roundness
V = __________
Least of
X, Y and Z = S
(b) h = __________ I = __________ Y = __________
S = __________
V-S = W
Cylindricity
(c) j = __________ k = __________ Z = __________
V = __________
Greatest of
(a) f = __________ g = __________ X = __________ Roundness
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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Table 4. Cylinder Measurement Worksheet (Continued)
Cylinder
Measurements Calculated Values
Number
V-S = W
Cylindricity
(c) j = __________ k = __________ Z = __________
V = __________
Greatest of
(a) f = __________ g = __________ X = __________ Roundness
V = __________
Least of
X, Y and Z = S
(b) h = __________ I = __________ Y = __________
S = __________
V-S = W
Cylindricity
(c) j = __________ k = __________ Z = __________
V = __________
Honing and Boring • After re-boring a cylinder block, each cyl-

inder must be honed.
Pistons must move freely in cylinders while main-
taining adequate compression and oil sealing. If 2. Honing: Slight cylinder imperfections might be
cylinder walls are scuffed, scored, out of round, or corrected by honing.
have poor cylindricity, boring or boring and honing a. Insert appropriate honing tool into chuck of
might correct cylinder problems. Re-boring is neces- an electric drill.
sary if bore dimensions fall outside specified limits.
See Table 5. Honing must follow any re-boring op- b. Saturate cylinder wall with solvent using a
erations. Slight imperfections can be corrected by 50% diesel fuel and 50% engine oil mixture.
honing alone.
c. Rotate honing tool at 300 to 1200 rpm.
Table 5. Cylinder Bore Specification
Cylinder Bore I.D. CAUTION

Factory Specification Allowable Limit DO NOT allow the honing tool to operate in one
position for any length of time. Damage to the cyl-
inder wall will occur. Keep the tool in constant up-
100.500 to 100.522 mm 100.650 mm and-down motion.
(3.95670 to 3.95755 in.) (3.96260 in.)
NOTE: Tilt honing tool at a 30 to 40 degree angle
1. Boring: Significant cylinder damage might be during honing operation, to leave a cross hatch
corrected by re-boring. mark on cylinder wall. See Figure 66.
• Boring out a cylinder block can only be
done in a properly equipped machine d. Insert rotating honing tool into cylinder and
shop. move it down through entire length of cylin-
der in a five-second motion. See Figure 67.
• After re-boring, existing pistons must be
replaced with oversized pistons.
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Cylinder Correction (Oversize)

1. If cylinder wear is more than allowable limit,
bore and hone to specified dimension. See Hon-
ing and Boring for procedures.
NOTE: If maximum I.D. or difference for oversize

cylinder is more than allowable limit, replace cylin-
der block.
2. Replace piston and piston rings with oversized

components. See Table 6 and Figure 68 for
oversized cylinder specifications.
Figure 66. Cylinder Honing Angle Table 6. Oversized Cylinder Specifications
Oversize Factory 100.500 to

Cylinder I.D. Specification 100.522 mm
(3.95670 to
3.95755 in.)
Maximum Allowable 100.650 mm
Wear Limit (3.96260 in.)
Finishing Hone to 1.2 to
3.0 microns (0.000048 to
0.00011 in.) Rz
Figure 67. Cylinder Honing
e. Without stopping honing tool, pull it up

through entire length of cylinder in a five-
second motion.
f. Maintain up-and-down motion for thirty to

forty seconds.
WARNING
Make sure that the path of the compressed air is 1. CYLINDER I.D. (BEFORE CORRECTION)
away from all personnel. Wear protective goggles 2. CYLINDER I.D. (OVERSIZE)
Figure 68. Oversize Piston
g. When honing is completed, wash cylinder
block with hot water and soap. Use brushes
to clean all passages and crevices. Rinse with Pistons
hot water and blow dry with compressed air.
Apply clean engine oil to all steel surfaces to 1. Using a micrometer, measure piston diameter
prevent rusting. at skirt. Refer to Engine Specifications for serv-
ice limit. See Figure 69.
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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 specifica-

tion.
e. Using a feeler gauge, measure end gap clear-

ance 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
Figure 69. Piston Skirt Measurement ring and groove dimensions.
3. Repeat Step 2 for each piston.

2. Measure piston ring and piston ring groove for
cylinder number one. Piston Pin
a. Using a micrometer, measure thickness of Measure outside diameter of piston pin and inside
top compression ring. Refer to Engine Speci- diameter of wrist pin bushing. Calculate clearance
fications for service limit. between piston pin and wrist pin bushing. Refer to
b. Place a properly-sized, top compression ring ure 71.
in groove as shown in Figure 70. Use a feeler
gauge to measure gap between ring and pis-
ton. Refer to Engine Specifications for service
limit.
NOTE: MEASURE AT POSITIONS A, B, AND C IN

DIRECTIONS A AND B.
Figure 71. Piston Pin Outside Diameter
A. WIDTH B. THICKNESS
Figure 70. Piston and Piston Ring Side Clearance
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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
2. Measure outside diameter of tappet stem. Refer

to Engine Specifications for service limit. See
Figure 74.
1. CYLINDER GAUGE
2. CONNECTING ROD SMALL END
Figure 72. Connecting Rod Small End
2. Measure crank-pin and connecting rod bearing

halves. Place connecting rod bearing halves
into connecting rod and connecting rod cap. In-
stall end of connecting rod to connecting rod
cap. Install bolts and tighten to 54 to
Figure 74. Tappet Stem Measurement
59 N•m (40 to 43 lbf ft).
3. Measure inside diameter. Refer to Engine Spec-

ifications for service limit. Crankshaft
Tappets 1. Measure trueness of crankshaft.
1. Check tappet contact surfaces with camshaft a. Place crankshaft on V-blocks at end journals.
and push rods. Slight surface defects can be See Figure 75.
corrected using an oilstone. See Figure 73.
47
HeavyManuals.com
b. Place a dial indicator on a main bearing sur-

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

to Engine Specifications for service limit.
d. Repeat this procedure for remaining bearing

surfaces.
Figure 76. Crankshaft Fracture Check
b. If color check method is not available, use

Magnaflux method. Inspect crankshaft for
cracks. Replace crankshaft if evidence of
fractures are found.
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

A. BEND B. DEFLECTION NOT move crankshaft.
1. DIAL GAUGE 3. V-BLOCK a. Clean crank pin and crank bearing. Put a
2. CRANKSHAFT strip of plastigage on center of crank pin. In-
stall connecting rod cap. Tighten connecting
Figure 75. Crankshaft Bend Measurement
rod cap screws to specified torque. Remove
connecting rod cap again. Measure width
that becomes flat with scale to get oil clear-
2. Inspect crankshaft for fractures.
ance. See Figure 77.
a. Using color check method, inspect crankshaft
for cracks. Replace crankshaft if evidence of
fractures are found. See Figure 76.
48
HeavyManuals.com
Description Factory Allowable Limit

Specification
52.977 to N/A 1. ID COLOR
52.990 mm 2. CRANK PIN BEARING
Crank Pin O.D. 3. CENTER WALL THICKNESS
(2.0857 to
2.0862 in.)
ID Color Connecting Crank Pin Bearing
Oil Clearance 0.018 to 0.20 mm Rod
Between Crank 0.051 mm (0.0079 in.)
Pin and Crank (0.00071 to Large End Class Center Wall
Pin Bearing 0.0020 in.) Diameter Thickness
56.010 to 1.496 to
Figure 77. Crank Pin Oil Clearance 56.020 mm 1.501 mm
Blue L
(2.2052 to (0.05890 to
2.2055 in.) 0.05909 in.)
NOTE: When replacing crank pin bearing with a
56.00 to 1.491 to
standard service part, make sure crank pin bearing
Without 56.01 mm 1.496 mm
and connecting rod are marked with same ID color. S
Color (2.2048 to (0.05870 to
b. If oil clearance is more than allowable limit, 2.2051 in.) 0.05889 in.)
replace pin bearing. See Figure 78. If same
dimension bearing is not applicable because Figure 78. Crankshaft Pin Bearing Identification
of crank pin wear, replace it with undersize
one. Refer to Figure 79.
49
HeavyManuals.com
Dimension Minimum Maximum Figure 80. Camshaft Runout Check

0.2 mm 0.4 mm
Undersize
(0.008 in.) (0.016 in.)
2. Measure intake/exhaust cam height. Refer to
2.8 to 3.2 mm 2.8 to 3.2 mm Engine Specifications for service limit. See Fig-
Dimension A (0.11 to (0.11 to ure 81.
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.) relief.
A. CAM HEIGHT
Figure 79. Crank Pin Journal Measurement
Figure 81. Intake/Exhaust Cam Height
Measurement
Camshaft
1. Measure trueness of camshaft. 3. Measure gear end bearing surface, intermedi-
ate position bearing surface, and flywheel end
a. Place camshaft on V-blocks positioned at end bearing surface diameters. See Figure 82. De-
journals. See Figure 80. termine oil clearance. The oil clearance is calcu-
lated by subtracting measured camshaft bear-
b. Place a dial indicator on gear side bearing
ing surface diameter from camshaft bushing in-
surface and zero gauge.
side diameter. Refer to Engine Specifications
c. Rotate camshaft and observe runout. Refer for service limit.
to Engine Specifications for service limit.
50
HeavyManuals.com
5. Place camshaft thrust plate in position and in-

stall retaining bolts. See Figure 63.
6. Install key on camshaft.
7. Install camshaft gear.
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 num-
1. FLYWHEEL END BEARING SURFACE bered 1, 2, 3, and 4 with number 1 cap at flywheel
2. INTERMEDIATE POSITION BEARING SUR- end of cylinder block. The arrows on bearing caps
FACE
3. GEAR END BEARING SURFACE should point towards flywheel end of cylinder block.
Figure 82. Camshaft Bearing Surface 2. Position bearing halves, thrust bearings, and
Measurements bearing caps on crankshaft. See Figure 62.
3. Lubricate bearing cap bolts and install bolts.
Camshaft Bushing 4. Install a new oil seal in rear oil seal housing.
If camshaft bushing is damaged, replace bushing 5. Apply a continuous bead of Three Bond Liquid
using appropriate service tool. Gasket (Hyster P/N 1599478) to mating surface
of rear oil seal housing.
ASSEMBLE 6. Align rear oil seal housing with two dowel pins
on cylinder block and install rear oil seal hous-
Camshaft ing. Install retaining bolts.
1. Verify that all parts are clean. Lightly lubricate
Pistons and Connecting Rods
all parts with clean engine oil.
1. Select parts needed to assemble piston and con-
2. Install timing gear case. See Timing Gear Case
necting rod for Number 1 cylinder.
and Timing Gears Repair.
2. Lubricate and insert wrist pin bushing into
NOTE: Rotate cylinder block into a position in
small end of connecting rod. See Figure 58.
which it allows gravity to keep tappets in place and
out of way of camshaft lobes for when camshaft is 3. Install one snap ring into piston.
installed.
4. Position connecting rod into piston under skirt.
3. Install tappets into cylinder block in same loca- The match marks on connecting rod and con-
tions as they were removed. necting rod cap, must be in line of piston identi-
fication number on top of piston. See Figure 83.
4. Slowly insert camshaft through front of engine.
51
HeavyManuals.com
Figure 84. Piston Ring Mark
b. Install top compression ring, second com-

pression 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
Figure 83. Piston and Connecting Rod 2. SECOND COMPRESSION RING
Identification Marks 3. OIL RING
4. PISTON
Figure 85. Piston Rings
5. Lubricate and install piston wrist pin through
piston and wrist pin bushing.
c. Stagger piston ring joints at 120 degree in-
6. Install second snap ring. tervals. DO NOT position top compression
7. Using piston ring pliers, install piston rings. ring joint in line with piston wrist pin. The
coil expander joint must be opposite oil ring
a. Install each piston ring on piston with joint. See Figure 86.
punched manufacture's mark facing upward.
See Figure 84.
52
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INSTALL
1. Install crankshaft gear and idler gear. See Tim-
ing Gear Case and Timing Gears Repair.
2. Install oil pump. See Lubrication System Re-

pair.

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 As-

sembly Repair.
7. Install fuel injection pump. See Fuel System

Repair.
8. Install water pump. See Cooling System Re-

pair.
9. Install alternator. See Electrical Equipment

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

1. TOP COMPRESSION RING wheel and Flywheel Housing.
2. SECOND COMPRESSION RING
3. OIL RING 11. Install starter. See Electrical Equipment Re-
4. JOINTS pair.
Figure 86. Piston Rings Staggering 12. Install engine.

8. Perform Step 1 through Step 7 for assembly of • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
remaining pistons. H5.0-5.5FT (H80-120FT) (R005, S005)
9. Lubricate Number 1 piston and piston rings See Frame 0100SRM1581 for lift truck models
with clean engine oil.
• H6.0-7.0FT (H135-155FT) (K006)
10. Using special tool, piston ring compressor, com-
press piston rings on Number 1 piston. See Frame 0100SRM1891 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
11. Carefully install piston into Number 1 cylinder. H5.0-5.5FT (H80-120FT) (U005)
Be sure matched mark on connecting rod and
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 con- 13. If not previously removed, remove and discard
necting rod cap. Install connecting rod bolts engine oil filter. Apply clean oil to gasket of
and tighten to 79 to 83 N•m (58 to 61 lbf ft). new filter. Install new filter. Turn filter until
See Figure 83. gasket touches, then tighten ½ to 3/4 turn with
your hand.
13. Perform Step 9 through Step 12 to install re-
maining pistons in their respective cylinders.
53
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14. Fill engine oil to correct level. • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;

H5.0-5.5FT (H80-120FT) (U005)
See Periodic Maintenance 8000SRM1558 for
lift truck model See Periodic Maintenance 8000SRM1583 for
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; lift truck models
H5.0-5.5FT (H80-120FT) (R005) • H6.0F-7.0FT (H135-155FT) (K006)
See Periodic Maintenance 8000SRM1604 for See Periodic Maintenance 8000SRM1957 for
lift truck model lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; • H6.0-7.0FT (H135-155FT) (L006)
H5.0-5.5FT (H80-120FT) (S005)
See Periodic Maintenance 8000SRM1902
Lubrication System Repair

ENGINE OIL AND OIL FILTER CHANGE 2. Remove engine oil filter. See Figure 88.
NOTE: Place a container with a capacity of at least

13.2 liter (3.5 gal) under oil pan drain plug.

into a suitable container. See Figure 87.
1. OIL FILTER 3. OIL COOLER

2. ADAPTER BOLT 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
Figure 87. Oil Pan
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0600 SRM 1579 Lubrication System Repair
Periodic Maintenance 8000SRM1558 for lift Periodic Maintenance 8000SRM1604 for lift
truck models 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) (S005)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
truck models
(S005)
• H6.0-7.0FT (H135-155FT) (K006)
Periodic Maintenance 8000SRM1604 for lift truck models
truck models
• 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) (S005)
Periodic Maintenance 8000SRM1902 for lift lift truck models
truck models
• H6.0-7.0FT (H135-155FT) (L006)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (U005) 2. Remove underbody shield.
See Periodic Maintenance 8000SRM1957 for See Frame 0100SRM1243 for lift truck models
lift truck models • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
• H6.0-7.0FT (H135-155FT) (L006) H5.0-5.5FT (H80-120FT) (R005, S005)
6. Start engine. Check area around oil filter for See Frame 0100SRM1581 for lift truck models
leaks. • H6.0-7.0FT (H135-155FT) (K006)
OIL PAN See Frame 0100SRM1891 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
Remove H5.0-5.5FT (H80-120FT) (U005)

WARNING
When putting the lift truck on blocks, make sure • H6.0-7.0FT (H135-155FT) (L006)
the surface is solid, even, and level. Any blocks
NOTE: Place a container with a capacity of at least
used to support the lift truck must be solid, one-
13.2 liter (3.5 gal) under oil pan drain plug.
piece units.
1. Put lift truck on blocks so that you have access
into a suitable container. See Figure 88.
under lift truck. Refer to Operating Manual
or section 4. Remove oil filter.
Periodic Maintenance 8000SRM1558 for lift 5. Remove twenty bolts holding oil pan to crank-
truck models case. See Figure 87.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (R005) 6. Remove four flange bolts holding oil pan to
crankcase. See Figure 87.
truck models 7. Remove oil pan.
• H6.0-7.0FT (H135-155FT) (K006)
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Lubrication System Repair 0600 SRM 1579

CAUTION truck models
Use care not to damage the mating surfaces when • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
removing old gaskets and sealant residues. H5.0-5.5FT (H80-120FT) (S005)
8. Carefully remove old sealant residue from mat- Periodic Maintenance 8000SRM1902 for lift
ing surfaces of oil pan and cylinder block. truck models
9. Thoroughly clean outside and inside surfaces of • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
oil pan. H5.0-5.5FT (H80-120FT) (U005)

Install
lift truck models
1. Apply a continuous bead of Three Bond Liquid • H6.0-7.0FT (H135-155FT) (L006)
Gasket (Hyster P/N 1599478) around sealing
surface of oil pan. 8. Start engine and check for leaks.
2. Place oil pan in position and install retaining OIL SUCTION TUBE
bolts. Refer to Standard Torque Specifications.
Remove
3. Apply clean oil to gasket of new filter. Install
new filter. Turn filter until gasket touches, 1. Remove oil pan. See Oil Pan, Remove
then tighten ½ to 3/4 turn with your hand.
2. Remove two bolts holding oil suction tube. See
4. Install oil pan drain plug. Figure 89.
5. Install underbody shield. 3. Remove oil suction tube.
See Frame 0100SRM1243 for lift truck models 4. Remove O-ring from oil suction tube and dis-
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, card.
H5.0-5.5FT (H80-120FT) (R005, S005)

• H6.0-7.0FT (H135-155FT) (K006)

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

• H6.0-7.0FT (H135-155FT) (L006)
6. Remove lift truck from blocks.
7. Fill engine oil to correct level. For correct oil

amount and type refer to

truck models 1. BOLT 3. O-RING
2. OIL SUCTION TUBE 4. CRANKCASE
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (R005) Figure 89. Oil Suction Tube

truck models
• H6.0-7.0FT (H135-155FT) (K006)
56
HeavyManuals.com
Clean See Frame 0100SRM1948 for lift truck models

• H6.0-7.0FT (H135-155FT) (L006)
WARNING 2. Remove coolant fan, serpentine belt, and water
Cleaning solvents can be flammable and toxic and pump. See Cooling System Repair.
solvents, always follow the recommendations of 3. Remove bolt and washer holding crankshaft
the manufacturer. pulley.
4. Using a gear puller, remove crankshaft pulley.

WARNING
Compressed air can move particles so that they 5. Remove timing gear case cover. See Timing
cause injury to the user or to other personnel. Gear Case and Timing Gears Repair.
6. Remove eight capscrews holding oil pump as-
sembly and remove oil pump assembly from
timing gear case housing. See Figure 90.
NOTE: The oil suction tube and screen are to be
serviced as an assembly. DO NOT attempt to repair
wire mesh portion of tube and screen assembly.
Clean oil suction tube in cleaning solvent. Dry oil

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

to Standard Torque Specifications.
4. Install oil pan. See Oil Pan, Install. 1. CAPSCREW

2. OIL PUMP COVER
OIL PUMP 3. OIL PUMP ROTOR
4. GEAR CASE HOUSING
Remove Figure 90. Oil Pump Assembly
1. Remove engine.
See Frame 0100SRM1243 for lift truck models 7. Remove outer rotor from timing gear case hous-
ing. See Figure 90.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (R005, S005) Clean and Inspect
• H6.0-7.0FT (H135-155FT) (K006) WARNING
Cleaning solvents can be flammable and toxic and
See Frame 0100SRM1891 for lift truck models can cause skin irritation. When using cleaning
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; solvents, always follow the recommendations of
H5.0-5.5FT (H80-120FT) (U005) the manufacturer.
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Lubrication System Repair 0600 SRM 1579
WARNING
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.
Clean all parts in cleaning solvent. Dry parts with 1. FEELER GAUGE 3. OUTER ROTOR
compressed air. Inspect for wear and damage. If 2. INNER ROTOR
necessary, replace oil pump assembly. Figure 92. Outer Rotor to Inner Rotor Tip
Clearance Check
Outer Rotor Outside Clearance
Insert a feeler gauge between outer rotor and tim-

ing gear case oil pump cavity and measure clear- Outer Rotor Side Clearance
ance. Refer to section Engine Specifications for
clearance limits. See Figure 91. Using a depth micrometer, measure depression of
outer rotor across pump cavity to determine side
clearance. Refer to section Engine Specifications for
clearance limits. See Figure 93.
1. OUTER ROTOR 3. OIL PUMP CAVITY

2. FEELER GAUGE
Figure 91. Outer Rotor Outside Clearance Check
Outer Rotor to Inner Rotor Tip Clearance 1. DEPTH MICROMETER

2. PUMP CAVITY
Insert a feeler gauge between top of an inner rotor 3. OUTER ROTOR
tooth and top of an outer rotor tooth and measure
Figure 93. Outer Rotor Side Clearance Check
clearance. Refer to section Engine Specifications for
clearance limits. See Figure 92.
58
HeavyManuals.com
Rotor Shaft Clearance 6. Install water pump, serpentine belt, and cool-
ant fan. See Cooling System Repair.
Measure outside diameter of rotor shaft and bore
diameter in gear case housing to determine rotor
shaft clearance. Refer to section Engine Specifica-
tions for clearance limits. See Figure 94.
1. PUNCH MARK
2. OUTER ROTOR
3. TIMING GEAR CASE
1. ROTOR SHAFT Figure 95. Outer Rotor

2. GEAR CASE HOUSING
Figure 94. Rotor Shaft Clearance Check
7. Install engine.
Install See Frame 0100SRM1243 for lift truck models

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
1. Lubricate outer rotor and pump bore in gear H5.0-5.5FT (H80-120FT) (R005, S005)
case with clean engine oil.
NOTE: The punch mark end of outer rotor must
face away from gear case housing. • H6.0-7.0FT (H135-155FT) (K006)
2. Install outer rotor in gear case housing. Verify See Frame 0100SRM1891 for lift truck models
that punch mark end of outer rotor faces away • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
from gear case housing. See Figure 95. H5.0-5.5FT (H80-120FT) (U005)
3. Position oil pump assembly in gear case hous- See Frame 0100SRM1948 for lift truck models
ing. Install bolts to retain oil pump. Refer to • H6.0-7.0FT (H135-155FT) (L006)
Standard Torque Specifications. See Figure 95.
8. Change engine oil and oil filter. See Engine Oil
4. Install timing gear case cover. See Timing Gear and Oil Filter Change.
Case and Timing Gears Repair.
5. Install crankshaft pulley, washer, and bolt to
retain crankshaft pulley. Tighten bolt to 255 to
274 N•m (188 to 202 lbf ft).
59
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Fuel System Repair 0600 SRM 1579
Fuel System Repair

FUEL INJECTORS 1. Clean exterior of nozzle so that nozzle hole is
free from obstruction.
Remove
Replace
NOTE: Note position of each fuel injector prior to
removal. If it becomes to necessary to replace a fuel injector,
follow procedure outlined below:
NOTE: Store fuel injectors and fuel injector lines so
they DO NOT get any dirt or debris in them. • Remove fuel injector from cylinder head.
• Push a screw driver into hole located in mid-
1. Remove fuel injector lines and fuel injectors. dle of seal. See Figure 96.
See Valve Covers and Fuel Injectors.
• Turn screw driver three or four times in each
direction to help secure screw driver in seal.
CAUTION See Figure 96.
Remove the fuel lines as an assembly whenever • While turning screw driver, slowly pull up
possible. Disassembling the fuel lines from the re- seal out of cylinder head. The injector gasket
tainers or bending any of the fuel lines will make it will also come out with seal at this time. See
difficult to reinstall the fuel lines. Figure 96.
2. Remove fuel lines. See Valve Covers and Fuel • If seal falls off screw driver before it is suc-
Injectors. cessfully removed, repeat this procedure.
Inspect
Visually inspect fuel injectors and nozzle holes for

carbon deposits or damage. Clean and replace as
necessary.
Clean
CAUTION
DO NOT use a wire brush or similar tool to clean
the nozzle hole. It will damage the hole.
1. FUEL INJECTOR 3. INJECTOR SEAL
CAUTION 2. INJECTOR GASKET 4. SCREW DRIVER
DO NOT disassemble the injector to clean it. Figure 96. Kubota Diesel Fuel Injector
60
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0600 SRM 1579 Fuel System Repair
Install 3. Remove two Allen-head capscrews from TPS

mounting bracket and fuel shut off solenoid.
1. Install fuel lines. See Valve Covers and Fuel In- See Figure 98.
jectors for procedure.
2. Install fuel injectors and fuel injector lines. See

Valve Covers and Fuel Injectors section for pro-
cedure.
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 actua-
tor. See Figure 97.
NOTE: The TPS mounting screws are non-mag-

netic stainless steel to avoid interference with sen-
sor magnet and must be reused if TPS is replaced.
2. Remove two Torx-head capscrews, two lock 1. THROTTLE POSITION SENSOR

washers, and throttle position sensor (TPS) 2. ACTUATOR ELECTRICAL CONNECTOR
from TPS mounting bracket and TPS plate. See
Figure 98. Figure 97. Electrical Connections
61
HeavyManuals.com
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 98. TPS Assembly
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4. If required, pull TPS rotor from throttle lever

plate. See Figure 98.
5. Pull rubber boot from collar and rotate throttle

lever plate to full open position. See Figure 99.
6. Unscrew inline ball joint from actuator rod. See

Figure 99.
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 98.
8. Remove nut from stud securing linkage to bell-

crank weldment. See Figure 100.
1. THROTTLE ROD
2. RUBBER BOOT
3. LOCK WASHER
4. CAPSCREW
5. INLINE BALL SOCKET
6. INSERT
7. ACTUATOR ENGINE MOUNT BRACKET
8. COLLAR
9. ACTUATOR NUT
10. ACTUATOR ROD
11. ALLEN HEAD CAPSCREW
12. ACTUATOR
Figure 99. Electronic Throttle Actuator
63
HeavyManuals.com
12. If required, remove three capscrews and actua-

tor engine mount bracket from engine. See Fig-
ure 101.
NOTE: SPEED CONTROL LEVER REMOVED

FROM FUEL PUMP TO SHOW ASSEMBLY. SPEED
CONTROL LEVER IS FIXED TO FUEL PUMP.
1. SPEED CONTROL LEVER 1. CAPSCREW

2. THROTTLE LEVER PLATE 2. ACTUATOR ENGINE MOUNT BRACKET
3. NUT 3. RUBBER BOOT
4. WASHER
5. CAPSCREW Figure 101. Actuator Engine Mount Bracket To
6. LINKAGE Engine
7. BELLCRANK WELDMENT
8. STUD
Figure 100. Linkage Arrangement 13. If required, remove four Allen head capscrews
and actuator from actuator engine mount
bracket. See Figure 99.
9. Remove nut, washer, and capscrew securing
linkage to throttle lever plate and speed control Bearing Replacement
lever. See Figure 100.
1. Place bellcrank weldment in a soft jawed vice.
10. Remove shoulder bolt, washer, shim, and nut
from crank bracket and bellcrank weldment. 2. Using a brass punch and hammer, drive sealed
bearings (#3 and #5, Figure 102) from the bell-
Set bellcrank weldment aside. See Figure 100.
crank weldment.
11. If required, pull throttle lever plate from speed
control lever on fuel injection pump. See Fig-
ure 98.
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2. If removed, install acutator engine mount

bracket on engine using three capscrews. See
Figure 101.
3. If removed, install throttle lever plate on speed

control lever of fuel injection pump. See Fig-
ure 98.
4. Assemble shoulder bolt through washer, bear-

ings, bellcrank weldment, and shim. Install as-
sembly onto crank bracket (with shim facing to-
ward engine) and secure into position with nut.
Tighten shoulder bolt to
25.6 N•m (226.6 lbf in). See Figure 102.
1. NUT 5. Install linkage and nut onto set screw in bell-

2. SHIM crank weldment. DO NOT tighten nut. See Fig-
3. INBOARD BEARING ure 100.
4. BELLCRANK WELDMENT
5. OUTBOARD BEARING 6. Install capscrew, washer, nut, and linkage onto
6. WASHER throttle lever plate. Tighten capscrew to
7. SHOULDER BOLT
8. CRANK BRACKET 10.5 N•m (92.9 lbf in). See Figure 100.
Figure 102. Bellcrank Weldment To Crank Bracket 7. Tighten nut on stud in bellcrank weldment to
Assembly 10.5 N•m (92.9 lbf in).
8. Rotate throttle lever plate into full open posi-

tion to install capscrew, ball joint rod end,
3. Clean dirt and debris from sealed bearings.
washer, and nut. Tighten nut to
4. Inspect bearings and shoulder bolt for wear or 7.9 N•m (70 lbf in).
damage. Replace shoulder bolt and bearings (as
9. Rotate throttle lever into full closed position
a set) if worn or damaged.
and install throttle rod with inline ball joint
5. Install bearings into bellcrank weldment. Be onto actuator rod. Fully seat inline ball joint on
sure to fully seat bearing in bellcrank weld- actuator rod. Tighten inline ball joint to
ment. 7.9 N•m (70 lbf in). See Figure 99.
10. Connect rubber boot to collar on actuator en-

Install gine mount bracket. See Figure 99.
1. If removed, install actuator, four capscrews, 11. If removed, install TPS rotor on throttle lever
washers, and nuts into actuator engine mount plate. See Figure 99.
bracket. See Figure 99.
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12. Install TPS mounting bracket and two Allen- engine life. If the idle speed limit screws require
head capscrews on fuel injection pump at fuel adjustment, see your authorized Kubota industrial
shut off solenoid. Tighten Allen-head capscrews engine dealer or distributor.
to 10.5 N•m (92.9 lbf in). See Figure 99.
1. Rotate throttle lever plate manually to verify if
NOTE: The TPS mounting screws are non-mag- lever is in full contact with low and high idle
netic stainless steel to avoid interference with sen- stop screws.
sor magnet and must be reused if TPS is replaced.
2. With the engine at idle, adjust the ball joint rod
NOTE: When installing TPS, rotate throttle lever end on the actuator rod up or down to align
plate to match TPS rotor to TPS. hole in ball joint rod end with hole in bellcrank
weldment. Once holes are aligned install cap-
13. Install TPS, two Torx-head screws, two lock screw, washer, and nut. Tighten capscrew to
washers, and TPS plate on TPS mounting 7.9 N•m (70 lbf in). See Figure 98.
bracket using. See Figure 98.
3. With truck power ON and engine OFF, navi-
14. Connect electrical connectors as tagged during gate display consule menus to read throttle po-
removal. Remove tags as electrical connections sition sensor "A" voltage under no-run data di-
are made. See Figure 97. play menu. PC Service Tool may also be used.
With the accelerator released and the throttle
15. Perform adjustment procedures. See section
lever against low idle stop, throttle sensor "A"
Adjustment.
voltage must be with in 1.0 - 1.1 volts.
16. Tighten Torx-head screws (installed in Step 13)
4. Manually rotate throttle lever to full open posi-
to 2.25 N•m (20 lbf in).
tion. Adjust actuator rod upstop set screw to
permit full speed control lever stroke. Tighten
Adjustment nut on ball joint rod to 25.6 N•m (226.6 lbf in).
See Figure 98.
CAUTION
FUEL INJECTION PUMP
DO NOT attempt to adjust the low or high idle
speed limit screws. This may impair the safety
and performance of the lift truck and shorten it’s
Remove
1. Disconnect electrical connector from solenoid on
top of fuel injection pump. See Figure 103.
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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 103. Fuel System Components
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2. Unclip electrical harness from bracket and 8. Remove serpentine belt and fan assembly. See
move to side. See Figure 103. Cooling System Repair section for procedure.
3. Remove two capscrews, flange bolt and engine 9. Remove six flange bolts, injection pump gear
harness bracket from intake manifold. See Fig- cover, and gasket from front of timing gear case
ure 103. cover. Discard gasket. See Figure 104.
4. Remove clamp and fuel supply hose from fuel NOTE: When positioning piston of 4th cylinder to
lift pump. Plug hose so debris DOES NOT enter TDC, rotate flywheel counterclockwise and align
fuel line. See Figure 103. TC mark on flywheel with top of inspection port on
flywheel housing (see Figure 105). If fuel injection
5. Remove fuel return hose from overflow pipe pump gear timing mark meshes with idler gear,
and bleeder valve. Cap overflow pipe and then piston of 4th cylinder is TDC. If they do not
bleeder valve so debris DOES NOT enter fuel mesh, rotate flywheel counterclockwise one revolu-
system. See Figure 103. tion.
6. Remove fuel injection lines from fuel injection 10. Put piston of number 4 cylinder at top dead
pump assembly and fuel injectors. See Valve center (TDC). See Figure 105.
Covers and Fuel Injectors.
7. Disconnect lubricating pipe from engine block

just below fuel injection pump assembly. See
Figure 103.
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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 104. Fuel Injection Pump
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1. FUEL INJECTION PUMP DRIVE GEAR

2. FUEL INJECTION PUMP GEAR MOUNTING
NUT
3. TIMING MARK
4. IDLER GEAR
5. ALIGNMENT MARK
Figure 106. Fuel Pump Drive Gear Timing

Alignment
12. While holding flywheel from turning with a fly-

wheel stopper tool, remove fuel injection pump
drive gear locknut. See Figure 104.
13. Remove two plugs and two washers from side of

fuel injection pump housing. See Figure 107.
1. TDC MARK 3. INSPECTION PORT

2. SERVICE HOLE
Figure 105. Kubota 3.6L TDC Mark
NOTE: This alignment mark is extremely useful

during assembly of fuel injection pump drive gear A. REMOVE PLUGS HERE
and idler gear to get timing correct. 1. PLUG 2. WASHER
11. To aid in reassembly, mark one tooth on idler Figure 107. Fuel Injection Pump Plugs
gear with a dot of white paint. See Figure 106.
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NOTE: Use 8 mm x 1.25 mm x 45 mm (0.315 in x

0.05 in x 1.77 in.) socket setscrew for fuel injection
pump camshaft lock screw.
14. Insert socket setscrew into upper port in side of

fuel injection pump assembly housing. This
screw will act as a fuel injection pump camshaft
lock screw. See Figure 108.
1. FLANGE NUT 3. BRACKET

2. FLANGE BOLT
Figure 109. Fuel Injection Pump Assembly

Mounting
CAUTION
1. SOCKET SETSCREW As mounting nuts are removed the fuel injection
pump assembly will need to be supported during
Figure 108. Fuel Injection Pump Camshaft Lock removal. Failure to do so could result in injury or
Screw damage to component if it is dropped.
19. Remove three flange nuts holding fuel injection

15. Insert socket setscrew into lower port in side of pump assembly to back of timing case housing.
fuel injection pump assembly housing. This See Figure 109.
screw will act as a fuel injection pump camshaft
lock screw. See Figure 108. 20. Remove fuel injection pump assembly, woodruff
key, and O-ring. Discard O-ring. See Fig-
NOTE: The fuel injection pump shaft is tapered ure 104.
with a woodruff key. Once you have applied some
pressure with a puller, a slight tap with a hammer Disassemble
on center puller bolt will help pop gear from shaft.
NOTE: It is not necessary to remove fuel injection
16. Using a two-bolt gear puller, remove fuel injec- pump assembly from lift truck to perform Disas-
tion pump drive gear from fuel injection pump semble procedure.
shaft.
1. If fuel injection lift pump assembly has not
17. Remove two flange nuts from bracket at back of been removed from lift truck, remove fuel injec-
fuel injection pump assembly. See Figure 109. tion lines and hoses. See Valve Covers and Fuel
Injectors for procedure.
18. Remove two flange bolts and bracket from en-
gine block and back of fuel injection pump as- 2. Remove two socket head bolts and fuel shut-
sembly. See Figure 109. down solenoid from fuel injection pump assem-
bly. See Figure 110.
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NOTE: SOME ASSEMBLY COMPONENTS RE- NOTE: SOME ASSEMBLY COMPONENTS RE-
MOVED FOR CLARITY. MOVED FOR CLARITY.
1. SOCKET HEAD BOLT 1. BOOST ACTUATOR

2. FUEL SHUT DOWN SOLENOID 2. O-RING
3. FUEL INJECTION PUMP ASSEMBLY 3. FUEL INJECTION PUMP ASSEMBLY
Figure 110. Fuel Shut Down Solenoid Figure 111. Boost Actuator
3. Remove boost actuator and O-ring from fuel in- 4. Remove inspection port cover from fuel injec-
jection pump assembly. Discard O-ring. See tion pump assembly housing. See Figure 112.
Figure 111.
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Legend for Figure 113
1. START SPRING 3. LOCK NUT

2. RACK PIN 4. GOVERNOR ROD
6. Remove lock nut from rack pin. See Figure 113.
7. Remove governor connector rod from rack pin of

fuel injection pump. See Figure 114.
1. INSPECTION PORT COVER
Figure 112. Inspection Port Cover
5. Unhook start spring from rack pin on fuel injec-

tion pump. See Figure 113.
1. GOVERNOR CONNECTOR ROD
Figure 114. Governor Connector Rod
Figure 113. Governor Connector Rod Components
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8. Remove four flange nuts and two flange bolts 3. Install four flange nuts onto fuel injection
from fuel injection pump assembly. See Fig- pump assembly. Tighten nuts to 18 to
ure 115. 20 N•m (13 to 15 lbf ft). See Figure 115.
4. Slide governor connecting rod onto rack pin of

fuel injection pump. See Figure 114.
5. Insert governor connecting rod JIG (Hyster P/N

4621033) into fuel shut down solenoid mount-
ing hole on fuel injection pump assembly.
6. Install governor connecting rod lock nut onto

rack pin. DO NOT tighten at this time. See Fig-
ure 113.
7. While holding down governor connecting rod

JIG (Hyster P/N 4621033), tighten lock nut for
governor connecting rod. Tighten lock nut to 2.8
to 4.0 N•m (24.7 to 35 lbf in). See Figure 113.
8. Remove governor connecting rod JIG from shut

down solenoid mounting hole.
9. Install start spring onto rack pin of fuel injec-

tion pump. See Figure 113.
10. Install inspection port cover to side of fuel injec-

tion pump housing. See Figure 112.
11. Install new O-ring and boost actuator onto fuel

injection pump assembly. Tighten actuator to
1. FLANGE NUT 40 to 45 N•m (29 to 33 lbf ft). See Figure 111.
2. FLANGE BOLT
3. FUEL INJECTION PUMP 12. Install fuel shut down solenoid and two socket
4. GASKET head bolts onto fuel injection pump assembly.
5. FUEL INJECTION PUMP ASSEMBLY See Figure 110.
Figure 115. Fuel Injection Pump
13. If fuel injection lift pump assembly was not re-
moved from lift truck, install fuel injection lines
9. Remove fuel injection pump and gasket from and hoses. See Valve Covers and Fuel Injectors
fuel injection pump assembly. Discard gasket. for procedure.
See Figure 115.
Install
Clean and Inspect
1. Install new O-ring, woodruff key, and injection
Clean all old sealant from timing gear case cover pump onto rear of timing gear case. See Fig-
and fuel injection pump drive gear cover. Inspect ure 104.
all parts for damage. Replace as needed.
2. Install three flange nuts onto three studs hold-
Assemble ing injection pump in place. Tighten nuts to 18
to 20 N•m (13 to 15 lbf ft). See Figure 109.
1. Install gasket and fuel injection pump onto fuel
injection pump assembly. See Figure 115. 3. Install bracket and two flange bolts to engine
block and back of fuel injection pump assembly.
2. Install two flange bolts onto fuel injection pump See Figure 109.
assembly. Tighten bolts to 24 to 27 N•m (18 to
20 lbf ft). See Figure 115.
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4. Install two flange nuts to bracket on back of 13. Remove caps from overflow pipe and bleeder
fuel injection pump assembly. See Figure 109. valve. Install fuel return hose to overflow pipe
and bleeder valve. See Figure 103.
5. Install fuel injection pump drive gear using
alignment marks on fuel injection pump gear 14. Remove plug from fuel supply hose. Install fuel
and idler gear. See Figure 106. supply hose and clamp to fuel lift pump. See
Figure 103.
6. Install locknut onto shaft of fuel injection
pump. Tighten locknut to 74 to 83 N•m (55 to 15. Install engine harness bracket, flange bolt and
61 lbf ft). two capscrews onto intake manifold. See Fig-
ure 103.
7. Install new cover gasket, injection pump gear
cover, and six flange bolts into timing gear case 16. Attach electrical harness and clips to engine
cover. Tighten bolts to 24 to 27 N•m (18 to harness bracket. See Figure 103.
20 lbf ft).
17. Connect electrical connector to solenoid on top
8. Install fan assembly and serpentine belt. See of fuel injection pump. See Figure 103.
Cooling System Repair for procedure.
18. Prime fuel system using procedure outlined be-
9. Connect lubricating pipe to engine block just low:
below fuel injection pump assembly. See Fig- • Open bleeder valve located on fuel injec-
ure 103. tion pump. See Figure 103.
10. Remove two socket setscrews from side of fuel • Pump fuel into fuel system using hand
injection pump housing. See Figure 107. primer pump on fuel filter.
• Continue pumping until fuel is present
11. Install two washers and two plugs into side of
at bleeder valve.
fuel injection pump housing. See Figure 107.
• Close bleeder valve.
CAUTION 19. Turn ignition to ON position and start engine

DO NOT bend any of the fuel lines when installing normally.
them.
20. Check fuel lines and hoses for leaks.
12. Install fuel injector lines, fuel injectors, and
valve covers. See Valve Covers and Fuel Injec-
tors section.
Cooling System Repair

SERPENTINE BELT cool. Do a touch test by touching the radiator with
your hand. If the radiator is still hot to the touch,
Remove wait another 30 minutes before attempting to
check or fix any part of the cooling system.
WARNING 1. Turn ignition switch to OFF position.

During engine operation, be careful not to touch
2. Remove fan assembly.
the fan, pulleys, or drive belts. Contact with these
parts can cause serious injury. See Cooling System 0700SRM1123
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
WARNING H5.0-5.5FT (H80-120FT) (R005, S005)
The radiator or other parts of the cooling system • H6.0-7.0FT (H135-155FT) (K006)
may be hot or under pressure and can cause seri-
ous injury. Wait 30 minutes for the radiator to
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Cooling System Repair 0600 SRM 1579
See Cooling System 0700SRM1895 for lift

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

truck models
• H6.0-7.0FT (H135-155FT) (L006)
3. Loosen alternator set bolt and pivot alternator

toward engine.
4. Remove serpentine belt from pulleys.
Inspect
Inspect serpentine belt for cracks, oil, wear, and

damage. If any of these conditions exist, replace
serpentine belt.
A. TENSION CHECK POSITION
Install B. TENSION CHECK POSITION
1. Place serpentine belt over pulleys. Figure 116. Serpentine Tension Check Points
2. Adjust tension of serpentine belt as shown in

section Serpentine Belt, Adjustment. 2. If adjustment is necessary, loosen alternator
set bolt and move alternator with a pry bar to
3. Tighten set bolt for alternator to tighten serpentine belt. See Figure 117.
25.5 N•m (18.8 lbf ft).
4. Install fan assembly.
See Cooling System 0700SRM1123

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (R005, S005)
• H6.0-7.0FT (H135-155FT) (K006)

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

truck models
• H6.0-7.0FT (H135-155FT) (L006)
Serpentine Belt, Adjustment

NOTE: The serpentine belt is to be checked at posi- 1. SET BOLT 3. PRY BAR
2. ALTERNATOR
tion A or B shown in Figure 116.
Figure 117. Serpentine Belt Adjustment
1. Using a belt tension gauge, adjust belt tension
to 500 to 550 N (112 to 124 lbf).
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0600 SRM 1579 Cooling System Repair
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 1. COOLANT DRAIN PLUG
when the engine is hot. When the radiator cap is
removed, pressure will release from the coolant Figure 118. Engine Block Coolant Drain Plug
system. If the coolant system is hot, the steam
and boiling coolant can cause severe burns.
6. Remove fan assembly.
WARNING See Cooling System 0700SRM1123
The radiator or other parts of the cooling system • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
may be hot or under pressure and can cause seri- H5.0-5.5FT (H80-120FT) (R005, S005)
engine to cool before performing maintenance to • H6.0-7.0FT (H135-155FT) (K006)
the cooling system. After 30 minutes, do a touch
truck models
radiator is still hot to the touch, wait another 30
minutes before attempting any maintenance to the • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
cooling system. H5.0-5.5FT (H80-120FT) (U005)

CAUTION truck models
Disposal of lubricants must meet local environ- • H6.0-7.0FT (H135-155FT) (L006)
mental regulations.
7. Remove serpentine belt. See Serpentine Belt,
3. Remove radiator cap. Remove.
4. Loosen lower radiator hose and drain coolant 8. Remove three bolts and idler assembly from
from coolant system into a suitable container. water pump assembly. See Figure 119.
5. Remove coolant drain plug and drain coolant 9. Remove eight bolts, collar, spacer, and two fan
from engine block. See Figure 118. pulleys from water pump and water flange. See
Figure 119.
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1. BOLT
2. WATER PUMP
3. GASKET
4. WATER PUMP HOUSING
1. IDLER ASSEMBLY 5. O-RING
2. BOLT 6. ENGINE BLOCK
3. PULLEY
4. SPACER Figure 120. Water Pump
5. COLLAR
6. WATER FLANGE
7. WATER PUMP
Install
Figure 119. Water Pump Pulley
1. Install new gasket, water pump, and two bolts
to water pump housing. See Figure 120.
10. Pivot alternator away from engine.
2. Install new O-ring, water pump assembly, and
11. Disconnect electrical connector for coolant tem- four bolts to engine block. See Figure 120.
perature sensor.
3. Connect coolant hoses to water pump. See Cyl-
12. If necessary, remove coolant temperature sen- inder Head Assembly Repair for procedure.
sor.
4. If removed, install coolant temperature sensor
13. Disconnect coolant hoses from water pump. See and tighten to 16 to 23 N•m (12 to 17 lbf ft).
Cylinder Head Assembly Repair section for pro-
cedure. 5. Connect electrical connector for coolant temper-
ature sensor.
14. Remove four water pump bolts and water
pump. See Figure 120. 6. Install plate with tension pulley and three cap-
screws. See Figure 119.
15. Remove two bolts, gasket, and water pump
from water pump housing. Discard gasket. See 7. Install water pump pulley and four capscrews.
Figure 120. See Figure 119.
16. Remove and discard O-ring. See Figure 120. 8. Install fan pulley.
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9. Install serpentine belt. See Serpentine Belt, In- Periodic Maintenance 8000SRM1902 for lift
stall. truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
10. Install fan assembly.
H5.0-5.5FT (H80-120FT) (U005)
See Cooling System 0700SRM1123
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, lift truck models
H5.0-5.5FT (H80-120FT) (R005, S005)
• H6.0-7.0FT (H135-155FT) (L006)
• H6.0-7.0FT (H135-155FT) (K006)
14. Install radiator cap.
truck models 15. Connect negative battery cable.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (U005) WARNING
See Cooling System 0700SRM1950 for lift During engine operation, be careful not to touch
truck models the fan, pulleys, or drive belts. Contact with these
parts can cause serious injury.
• H6.0-7.0FT (H135-155FT) (L006)
11. Connect lower radiator hose. WARNING

12. Install coolant drain plug in engine block. See The radiator or other parts of the cooling system
Figure 118. may be hot or under pressure and can cause seri-
ous injury.
CAUTION 16. Start engine and check cooling system for

leaks.
Additives may damage the cooling system. Before
using additives, contact your local Hyster dealer.
WARNING
13. Fill cooling system with coolant. For correct
DO NOT remove the radiator cap from the radiator
coolant amount and type refer to
when the engine is hot. When the radiator cap is
Periodic Maintenance 8000SRM1558 for lift removed, pressure will release from the coolant
truck models system. If the coolant system is hot, the steam
and boiling coolant can cause severe burns.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (R005)
WARNING
The radiator or other parts of the cooling system
truck models
• H6.0-7.0FT (H135-155FT) (K006) ous injury. Wait 30 minutes for the radiator and
engine to cool before performing maintenance to
Periodic Maintenance 8000SRM1604 for lift the cooling system. After 30 minutes, do a touch
truck models test by touching the radiator with your hand. If the
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, radiator is still hot to the touch, wait another 30
H5.0-5.5FT (H80-120FT) (S005) minutes before attempting any maintenance to the
cooling system.
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CAUTION
17. Stop engine. If coolant is hot, allow engine time

to cool. Check coolant level and fill as required
between ADD and FULL marks on coolant res-
ervoir.
THERMOSTAT
Remove
WARNING
the cooling system. After 30 minutes, do a touch
radiator is still hot to the touch, wait another 30
minutes before attempting any maintenance to the
cooling system. 1. BOLT
2. THERMOSTAT COVER
3. GASKET
CAUTION 4. THERMOSTAT
DO NOT operate the engine without a thermostat. 5. WATER FLANGE
The engine and cooling system can be damaged. Figure 121. Thermostat
CAUTION
4. Remove thermostat from water flange. See Fig-
Disposal of lubricants must meet local environ-
ure 121.
mental regulations.
1. Drain cooling system to level of thermostat. Inspect
2. Disconnect coolant hose from thermostat cover. 1. Place thermostat and an accurate thermometer
in warm water. See Figure 122.
3. Remove three bolts holding thermostat cover.
Remove thermostat cover and gasket. Discard
gasket. See Figure 121.
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CAUTION
4. Fill cooling system with coolant. For correct

coolant amount and type refer to

truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (R005)

truck models
• H6.0-7.0FT (H135-155FT) (K006)
1. THERMOMETER Periodic Maintenance 8000SRM1604 for lift

2. THERMOSTAT truck models
Figure 122. Thermostat Check • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (S005)

2. Slowly increase temperature of water.
truck models
3. The thermostat is operating correctly if it starts • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
to open at temperature value stamped on flange H5.0-5.5FT (H80-120FT) (U005)
of thermostat and fully opens as temperature of
water is increased. See Periodic Maintenance 8000SRM1957 for
lift truck models
Install • H6.0-7.0FT (H135-155FT) (L006)
1. Install thermostat into water flange. See Fig-
ure 121. WARNING
During engine operation, be careful not to touch
2. Install thermostat cover and a new gasket. In- the fan, pulleys, or drive belts. Contact with these
stall bolts to hold thermostat cover. Tighten parts can cause serious injury.
bolts to 23 to 28 N•m (17 to 21 lbf ft).
3. Connect coolant hose to thermostat cover. See

Figure 121.
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WARNING the cooling system. After 30 minutes, do a touch
The radiator or other parts of the cooling system test by touching the radiator with your hand. If the
may be hot or under pressure and can cause seri- radiator is still hot to the touch, wait another 30
ous injury. minutes before attempting any maintenance to the
cooling system.
5. Start engine and check cooling system for
leaks.
CAUTION
WARNING using additives, contact your local Hyster dealer.
DO NOT remove the radiator cap from the radiator
when the engine is hot. When the radiator cap is 6. Stop engine. If coolant is hot, allow engine time
removed, pressure will release from the coolant to cool. Check coolant level and fill as required
system. If the coolant system is hot, the steam between ADD and FULL marks on coolant res-
and boiling coolant can cause severe burns. ervoir.
WARNING
Flywheel and Flywheel Housing

FLYWHEEL
Remove
1. Remove engine. See section

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80-120FT) (R005, S005)

• H6.0-7.0FT (H135-155FT) (K006)

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; 1. FLYWHEEL HOUSING
H5.0-5.5FT (H80-120FT) (U005) 2. FLYWHEEL
3. BOLT
See Frame 0100SRM1948 for lift truck models 4. CRANKSHAFT
5. ENGINE BLOCK
• H6.0-7.0FT (H135-155FT) (L006)
Figure 123. Flywheel and Housing
2. Remove seven bolts holding flywheel to crank-
shaft flange and remove flywheel. See Fig-
ure 123.
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0600 SRM 1579 Flywheel and Flywheel Housing
Install • H6.0-7.0FT (H135-155FT) (L006)
1. Place flywheel in position on crankshaft flange FLYWHEEL HOUSING

and install seven bolts. Tighten bolts to 98 to
107 N•m (72 to 80 lbf ft).
Remove
2. Install engine.
1. Remove flywheel. See Flywheel, Remove.
See Frame 0100SRM1243 for lift truck model
2. Remove ten bolts holding flywheel housing to
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, cylinder block. See Figure 123.
H5.0-5.5FT (H80-120FT) (R005, S005)
3. Remove flywheel housing.
• H6.0-7.0FT (H135-155FT) (K006) Install
1. Place flywheel housing in position on cylinder
See Frame 0100SRM1891 for lift truck models block and install bolts. Tighten bolts to 78 to
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; 90 N•m (58 to 66 lbf ft).
H5.0-5.5FT (H80-120FT) (U005)
2. Install flywheel. See Flywheel, Install.
Electrical Equipment Repair

NOTE: This section covers repair procedures for ALTERNATOR
major electrical components only, if engine specific
sensors or switches need to be serviced Remove
See Electrical System 2200SRM1142 for lift truck
models WARNING
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, Always disconnect the cables at the battery be-
H5.0-5.5FT (H80-120FT) (R005, S005) fore you make repairs to the engine. Disconnect
• H6.0-7.0FT (H135-155FT) (K006) the cable at the negative terminal first. Install a
tag on the battery terminals so that no one con-
See Electrical System 2200SRM1901 for lift truck nects the cables on the terminals.
models
1. Disconnect battery negative cable at negative
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; terminal.
H5.0-5.5FT (H80-120FT) (U005)
2. Disconnect battery positive cable at positive
See Electrical System 2200SRM1954 for lift truck terminal.
models
• H6.0-7.0FT (H135-155FT) (L006)
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Electrical Equipment Repair 0600 SRM 1579
3. Put labels on wires prior to disconnecting to aid 3. Install set bolt for alternator and adjustment
in correct installation. bracket but do not tighten.
4. Disconnect wires from alternator. 4. Connect electrical wires to alternator.
5. Loosen set bolt on alternator and tilt alternator 5. Install serpentine belt and adjust to proper ten-
towards engine. sion. See Cooling System Repair, Serpentine
Belt, Adjustment.
6. Remove serpentine belt from alternator pulley.
6. Tighten set bolt to 25.5 N•m (18.8 lbf ft).
7. Remove set bolt from alternator. See Fig-
ure 124. 7. Connect battery positive cable at positive termi-
nal.
8. If necessary, remove bolt holding alternator ad-
justment bracket to water flange and remove 8. Connect battery negative cable at negative ter-
bracket. minal.
9. Remove bolt holding alternator to alternator 9. Start engine and listen for any unusual sounds
mounting bracket. Remove alternator. from alternator.
Install 10. Verify that charge indicator is ON while engine

is operating. If charge indicator is not ON, re-
1. If removed, place alternator adjustment pair problem before operating engine.
bracket in position and install bolt to retain
bracket to water flange.
2. Position alternator on alternator mounting

bracket. Install bolt holding alternator to alter-
nator mounting bracket, but do not tighten.
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0600 SRM 1579 Electrical Equipment Repair
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 124. Alternator
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Electrical Equipment Repair 0600 SRM 1579
STARTER Install
1. Place starter in position in flywheel housing.
Remove
Install two M10 bolts on starter and flywheel
housing.
WARNING
2. Connect wires and cables as labeled in removal.
Always disconnect the cables at the battery be-
Tighten M8 nut, B terminal, to 7.9 to
fore you make repairs to the engine. Disconnect
9.8 N•m (70 to 87 lbf in). Be sure to place cover
the cable at the negative terminal first. Install a
over M4 screw connection. See Figure 126.
tag on the battery terminals so that no one con-
nects the cables on the terminals. 3. Connect battery positive cable at positive termi-
nal.
1. Disconnect battery negative cable at negative
terminal. 4. Connect battery negative cable at negative ter-
minal.
2. Disconnect battery positive cable at positive
terminal.
3. Put labels on wires and cables prior to discon-

necting to aid in correct installation.
4. Disconnect wires and cables from starter.
5. Hold starter so it won't fall. Remove two M10

bolts and starter from flywheel housing. See
Figure 125.
NOTE: ILLUSTRATION USED FOR REFERENCE

ONLY.
1. M8 NUT 3. M4 SCREW
2. COVER 4. STARTER
1. FLYWHEEL HOUSING
2. M10 BOLT Figure 126. Starter Connections
3. STARTER
Figure 125. Starter
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0600 SRM 1579 Engine Specifications
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 Crank-
ing 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, Radia-
tor, Muffler, and Air Cleaner.
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Engine Specifications 0600 SRM 1579
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 2.99 MPa
(569 psi) (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 90°C (194°F)
(166.1 to 173.3°F)
CYLINDER HEAD
Combustion Surface Distortion (Flatness) 0.05 mm (0.0020 in.)
Valve Sink Intake -0.2 to 0.0 mm 0.4 mm (0.02 in.)
(-0.007 to 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°
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INTAKE/EXHAUST VALVE AND GUIDE

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
Diameter (0.2741 to 0.2746 in.)
Oil Clearance 0.055 to 0.085 mm 0.10 mm
(0.0022 to 0.0033 in.) (0.004 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
Diameter (0.3134 to 0.3439 in.)
Oil Clearance 0.040 to 0.070 mm 0.10 mm
(0.0016 to 0.0027 in.) (0.004 in.)
VALVE SPRING
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.)
ROCKER ARM AND SHAFT

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
(0.00063 to 0.0017 in.) (0.0059 in.)
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PUSH ROD
Push Rod Bend 0.25 mm
(0.0098 in.)
GEAR TRAIN AND CAMSHAFT
Camshaft

Camshaft Oil Clearance 0.070 to 0.22 mm 0.30 mm
(0.0028 to 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

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
(1.7727 to 1.7736 in.) (1.8140 in.)
(0.0019 to 0.0030 in.) (0.0039 in.)
Backlash of Each Gear

Crank Gear and Cam Gear 0.049 to 0.193 mm 0.22 mm
(0.0031 to 0.0055 in.) (0.0087 in.)
Idler Gear and Fuel Injection Pump Gear 0.0300 to 0.165 mm 0.22 mm
(0.00119 to 0.00649 in.) (0.0087 in.)
CYLINDER BLOCK
Cylinder Inside Diameter 98.00 to 98.022 mm 98.150 mm
(3.8583 to 3.8591 in.) (3.8642 in.)
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CRANKSHAFT
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.)
(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.)
(0.00071 to 0.0024 in.) (0.0079 in.)
PISTON
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.)
(0.0079 to 0.0015 in.) (0.0059 in.)
PISTON RING
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.)
(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.)
(0.0099 to 0.017 in.) (0.0492 in.)
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CONNECTING ROD
Thrust Clearance 0.05 mm
(0.002 in.)
Rod Small End

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

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.)
(0.00079 to 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

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

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

STANDARD TORQUE CHART
Nominal Thread Di-
Item × Pitch Tightening Torque
ameter
Hexagon Bolt (7T) and Nut M6 × 1.0 mm 9.8 to 11.8 N•m
(87 to 104 lbf in)
NOTE: Use 80% of the value of M8 × 1.25 mm 24 to 27 N•m

the Tightening Torque when the (18 to 20 lbf ft)
tightening part is aluminum. M10 × 1.5 mm 49 to 55 N•m
Use 60% of the value of the (37 to 41 lbf ft)
Tightening Torque for 4T bolts
M12 × 1.75 mm 78.0 to 90.0 N•m
and lock nuts.
(58 to 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.
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Special Torque Specifications 0600 SRM 1579
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

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

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
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

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
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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0600 SRM 1579 Special Torque Specifications
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)
Throttle Position Sensor Torx-head Screws

2.25 N•m (20 lbf in)
Special Tools
No. Tool Name Applicable Model and Tool Size Illustration

1 Valve Guide
L1 L2 L3 d1 d2 d3
Tool (for
Extracting/ 225 mm 70 mm 45 mm 20 mm 11.7 to 6.50 to
Inserting (8.86 in.) (2.8 in.) (1.8 in.) (0.79 in.) 11.9 mm 6.60 mm
Valve Guide) (0.461 to (0.256 to
0.468 in.) 0.259 in.)
Locally Manufactured
2 Small End A 157 mm (6.16 in.)
Bushing B 14.5 mm (0.571 in.)
Replacemen
t Tool (Press C 120 mm (4.72 in.)
Out) D 30.0 dia. mm (1.18 dia. in.)
E 32.95 dia. mm (1.297 dia. in.)
F 20 mm (0.79 in.)
a 6.3 microns (250 micro inches)
b 6.3 microns (250 micro inches)
C1 Chamfer 1.0 mm (0.039 in.)
3 Small End A 157 mm (6.16 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.)
5 Idler Gear A 196 mm (7.72 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 1579

F 20 mm (0.79 in.)
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.)
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.)
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0600 SRM 1579 Special Tools

O 115 mm (4.53 in.)
P 16.9 to 17.1 mm ( 0.666 to 0.673 in.)
C0.2 Chamfer 0.2 mm (0.008 in.)
C0.3 Chamfer 0.3 mm (0.01 in.)
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.)
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.)
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I 56.5 mm (2.22 in.)
J 8 mm (0.3 in.)
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.)
12 Flex-Hone Model Part Number Cylinder Bore
(for
Preparation 4TNE92 83 to 95 mm
Hyster P/N 1607212
of Cylinder ( in.)
Walls) 4TNE98 Hyster P/N 1599906 89 to 101 mm
( in.)
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.)
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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.)
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)
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.
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5 Cylinder Gauge For measuring the inside diameters of cyl-
inder 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.
9 V-Block For measuring shaft bend.
10 Torque Wrench For tightening nuts and bolts to the speci-

fied 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
100
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13 Battery Coolant Tester For checking concentration of antifreeze
and the battery electrolyte charge status.
16 Digital Thermometer For measuring temperature.
17 Tachometer Contact Type For measuring revolution by contacting the

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

Type flecting 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 ob-
Clamp Type ject.
18 Circuit Tester For measuring resistance, voltage, and con-
tinuity of electrical circuits.
19 Compression Gauge Kit For measuring compression pressure. Use

Hyster P/N 4621032 for compression test
adaptor.
101
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NOTES
102
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HeavyManuals.com
TECHNICAL PUBLICATIONS
0600 SRM 1579 12/15 (9/15)(4/15)(1/14)(3/13)(9/12)

Kubota Diesel 3.6L Engine

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Kubota Diesel 3.6L Engine

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KUBOTA DIESEL 3.6L

PART NO. 4053146 0600 SRM 1579

©2015 HYSTER COMPANY i

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

This section is for the following models:

H4.0FT5, H4.0FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80-120FT) [R005, S005,

Major Engine Component Identification

Figure 1 shows where the major engine components

1. TOP FILLER PORT (ENGINE OIL)

Figure 1. Major Engine Components

Location of Labels crankcase 1, which houses combustion components

Figure 3. Emissions Exempt Label

The Kubota diesel engine utilizes a split crankcase

Engine Removal and Installation

Frame 0100SRM1581 for lift truck models

Cylinder Head Assembly Repair

4. Loosen two clamps at air filter and turbo

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

• H6.0-7.0FT (H135-155FT) (K006) See Figure 7 for lift truck model

See Figure 6 for lift truck model • H6.0-7.0FT (H135-155FT) (L006)

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

• H6.0-7.0FT (H135-155FT) (K006) See Figure 7 for lift truck model

See Figure 6 for lift truck model • H6.0-7.0FT (H135-155FT) (L006)

See Figure 7 for lift truck model

See Figure 5 for lift truck models

See Figure 6 for lift truck model

See Figure 7 for lift truck model

1. ENGINE WIRING HARNESS

Figure 5. Breather Tube and Hoses for Lift Truck

1. ENGINE WIRING HARNESS 1. ENGINE WIRING HARNESS

1. CYLINDER HEAD 7. BREATHER TUBE

Figure 8. Valve Cover

1. CYLINDER HEAD 9. NUT

Figure 9. Fuel Injectors and Fuel Lines

13. Remove four injectors, four gaskets and four Install

4. Install four fuel lines onto fuel injectors.

Inspect valve cover breather and breather cover for

See Figure 5 for lift truck models ROCKER ARM ASSEMBLY

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

Figure 10. Rocker Arm Assembly

4. Remove push rods from cylinder head.

NOTE: Mark rocker arms so they can be reinstal-

NOTE: The rocker arm shaft fits tightly in rocker

3. If necessary, remove adjusting screw and lock Rocker Arm Assembly

Clean all parts in cleaning solvent. Dry parts with

5. Tighten rocker arm shaft retaining flange nuts.

6. Adjust valve lash. See Valve Clearance Adjust-

7. Install valve cover. See Valve Covers and Fuel

VALVE CLEARANCE ADJUSTMENTS

5. Insert a feeler gauge between rocker arm and

6. Apply clean engine oil to contact surface be-

7. Turn crankshaft 180 degrees and make meas-

NOTE: Place a suitable container with a capacity

2. Remove lower radiator hose and radiator cap.

3. Remove two hose clamps, two retaining clamps

Legend for Figure 17

1. HOSE CLAMP 3. AIR INTAKE HOSE

1. HOSE CLAMP 3. AIR INTAKE HOSE

Figure 16. Air Intake Hoses for Lift Truck Models

1. HOSE CLAMP 3. AIR INTAKE HOSE