Kubota Diesel 3.8L Engines With Diesel Particulate Filter (DPF)

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KUBOTA DIESEL 3.8L ENGINES

WITH DIESEL PARTICULATE
FILTER (DPF)
H4.0FT5, H4.0FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT
(H80-120FT) [S005, U005];
S6.0-7.0FT (S135-155FT) [G024];
H6.0-7.0FT (H135-155FT) [K006];
H8.0-9.0FT, H8.0FT9 (H170-190FT, H175FT36)
[B299]
PART NO. 4057092 0600 SRM 1590

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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 ...........................................................................................................................................1
Crankcase Description ........................................................................................................................................3
Precautions Before Beginning Repair ................................................................................................................4
Engine Removal and Installation ...........................................................................................................................4
Cylinder Head Assembly Repair ............................................................................................................................ 5
Valve Covers and Fuel Injectors ........................................................................................................................ 5
Remove ............................................................................................................................................................ 5
Clean and Inspect ........................................................................................................................................... 8
Install .............................................................................................................................................................. 8
Rocker Arm Assembly .........................................................................................................................................9
Remove ............................................................................................................................................................ 9
Disassemble .................................................................................................................................................. 10
Clean and Inspect ......................................................................................................................................... 10
Push Rods ................................................................................................................................................. 10
Rocker Arm Assembly .............................................................................................................................. 10
Assemble ....................................................................................................................................................... 11
Install ............................................................................................................................................................ 11
Valve Clearance Adjustments .......................................................................................................................... 11
Cylinder Head Assembly .................................................................................................................................. 13
Remove .......................................................................................................................................................... 13
Disassemble .................................................................................................................................................. 21
Valves and Valve Springs, Remove ......................................................................................................... 21
Valve Guides, Remove ..............................................................................................................................22
Cylinder Head ...........................................................................................................................................23
Valve Guides .............................................................................................................................................24
Valves ........................................................................................................................................................24
Valve Sink .................................................................................................................................................24
Valve Seat ................................................................................................................................................. 25
Valve Springs ............................................................................................................................................25
Assemble ....................................................................................................................................................... 26
Valve Guides, Install ................................................................................................................................26
Valves and Valve Springs, Install ........................................................................................................... 27
Install ............................................................................................................................................................ 28
Timing Gear Case and Timing Gears Repair ...................................................................................................... 30
Timing Gear Case Cover ...................................................................................................................................30
Remove .......................................................................................................................................................... 30
Install ............................................................................................................................................................ 32
Timing Gears .....................................................................................................................................................33
Crankshaft Gear ........................................................................................................................................... 33
Remove ......................................................................................................................................................33
Install ........................................................................................................................................................33
Idler Gear ...................................................................................................................................................... 34
Remove ......................................................................................................................................................34
Inspect .......................................................................................................................................................35
Install ........................................................................................................................................................35
©2015 HYSTER COMPANY i

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Table of Contents
TABLE OF CONTENTS (Continued)

Camshaft Gear ..............................................................................................................................................35
Remove ......................................................................................................................................................35
Install ........................................................................................................................................................35
Drive Train, Camshaft, and Cylinder Block Repair ............................................................................................36
Remove .............................................................................................................................................................. 36
Disassemble .......................................................................................................................................................36
Pistons and Connecting Rods .......................................................................................................................36
Crankshaft .................................................................................................................................................... 37
Camshaft ....................................................................................................................................................... 39
Clean and Inspect ............................................................................................................................................. 41
Cylinder Block ...............................................................................................................................................41
Honing and Boring ................................................................................................................................... 43
Cylinder Correction (Oversize) ................................................................................................................ 44
Pistons ........................................................................................................................................................... 45
Piston Pin ......................................................................................................................................................45
Connecting Rod .............................................................................................................................................45
Tappets ..........................................................................................................................................................46
Crankshaft .................................................................................................................................................... 46
Camshaft ....................................................................................................................................................... 49
Camshaft Bushing ........................................................................................................................................ 49
Assemble ............................................................................................................................................................49
Camshaft ....................................................................................................................................................... 49
Crankshaft .................................................................................................................................................... 50
Pistons and Connecting Rods .......................................................................................................................50
Install .................................................................................................................................................................52
Angular Deviation Procedure - Kubota 3.8L Diesel Engine .......................................................................52
Lubrication System Repair ................................................................................................................................... 56
Engine Oil and Oil Filter Change .................................................................................................................... 56
Oil Pan ...............................................................................................................................................................57
Remove .......................................................................................................................................................... 57
Install ............................................................................................................................................................ 57
Oil Suction Tube ................................................................................................................................................58
Remove .......................................................................................................................................................... 58
Clean ..............................................................................................................................................................58
Install ............................................................................................................................................................ 59
Oil Pump ............................................................................................................................................................59
Remove .......................................................................................................................................................... 59
Outer Rotor Outside Clearance ............................................................................................................... 60
Outer Rotor to Inner Rotor Tip Clearance .............................................................................................. 60
Outer Rotor Side Clearance ..................................................................................................................... 60
Rotor Shaft Clearance .............................................................................................................................. 60
Install ............................................................................................................................................................ 61
Fuel System Repair ...............................................................................................................................................62
Fuel Injectors .................................................................................................................................................... 62
Remove .......................................................................................................................................................... 62
Inspect ........................................................................................................................................................... 62
Clean ..............................................................................................................................................................62
Replace .......................................................................................................................................................... 63
Install ............................................................................................................................................................ 63
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Table of Contents

Test ................................................................................................................................................................ 63
Fuel Injection Pump ..........................................................................................................................................63
Remove .......................................................................................................................................................... 63
Install ............................................................................................................................................................ 66
Cooling System Repair ..........................................................................................................................................66
Serpentine Belt ................................................................................................................................................. 66
Remove .......................................................................................................................................................... 66
Inspect ........................................................................................................................................................... 67
Install ............................................................................................................................................................ 67
Adjust ............................................................................................................................................................ 67
Water Pump ...................................................................................................................................................... 68
Remove .......................................................................................................................................................... 68
Install ............................................................................................................................................................ 70
Thermostat ........................................................................................................................................................ 71
Remove .......................................................................................................................................................... 71
Inspect ........................................................................................................................................................... 72
Install ............................................................................................................................................................ 72
Flywheel and Flywheel Housing .......................................................................................................................... 74
Flywheel ............................................................................................................................................................ 74
Remove .......................................................................................................................................................... 74
Install ............................................................................................................................................................ 75
Flywheel Housing ............................................................................................................................................. 75
Remove .......................................................................................................................................................... 75
Install ............................................................................................................................................................ 75
Electrical Equipment Repair ................................................................................................................................ 75
Alternator .......................................................................................................................................................... 75
Remove .......................................................................................................................................................... 75
Install ............................................................................................................................................................ 77
Starter ................................................................................................................................................................77
Remove .......................................................................................................................................................... 77
Install ............................................................................................................................................................ 77
Engine Specifications ............................................................................................................................................ 78
Engine Data .......................................................................................................................................................78
Engine Tuning ...................................................................................................................................................82
Cylinder Head ................................................................................................................................................... 82
Intake/Exhaust Valve and Guide .....................................................................................................................83
Valve Spring ......................................................................................................................................................83
Rocker Arm and Shaft ...................................................................................................................................... 83
Push Rod ............................................................................................................................................................84
Gear Train and Camshaft .................................................................................................................................84
Camshaft ....................................................................................................................................................... 84
Idle Gear Shaft and Bushing ....................................................................................................................... 84
Backlash of Each Gear ................................................................................................................................. 84
Cylinder Block ...................................................................................................................................................84
Crankshaft .........................................................................................................................................................85
Piston ................................................................................................................................................................. 85
Piston Ring ........................................................................................................................................................ 85
Connecting Rod ................................................................................................................................................. 86
Rod Small End .............................................................................................................................................. 86
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Table of Contents

Tappet ............................................................................................................................................................86
Oil Pump ............................................................................................................................................................86
Engine Oil Pressure ......................................................................................................................................86
Outer Rotor Outside Clearance ................................................................................................................... 86
Outer Rotor Side Clearance ......................................................................................................................... 86
Inner Rotor to Cover .....................................................................................................................................87
Standard Torque Specifications ............................................................................................................................87
Standard Torque Chart .................................................................................................................................... 87
Special Torque Specifications ............................................................................................................................... 88
Special Tools .......................................................................................................................................................... 89
This section is for the following models:
H4.0FT5, H4.0FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80-120FT) [S005, U005];

S6.0-7.0FT (S135-155FT) [G024];
H6.0-7.0FT (H135-155FT) [K006];
H8.0-9.0FT, H8.0FT9 (H170-190FT, H175FT36) [B299]
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0600 SRM 1590 General
General
This section has the repair instructions for the Location of Labels
Kubota 3.8L diesel engines.
The typical location of the emission control
ENGINE IDENTIFICATION information label is shown in Figure 2.
Major Engine Component Identification The typical location of the engine nameplate is
shown in Figure 2. The engine nameplate is shown
Figure 1 shows where the major engine components in Figure 3.
are located.
A. RIGHT SIDE OF ENGINE B. LEFT SIDE OF ENGINE

1. FUEL RAIL/INJECTORS/FUEL LINES 9. ENGINE OIL FILL PORT
2. EGR VALVE 10. TURBO CHARGER
3. THROTTLE VALVE 11. STARTER MOTOR
4. FUEL INJECTION PUMP 12. DIPSTICK (ENGINE OIL)
5. CRANKCASE BREATHER FILTER 13. CRANKSHAFT PULLEY
6. ENGINE OIL COOLER 14. SERPENTINE BELT
7. ENGINE OIL FILTER 15. ALTERNATOR
8. DRAIN PLUG 16. WATER PUMP
Figure 1. Major Engine Components
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General 0600 SRM 1590
1. ENGINE NAMEPLATE Figure 3. Engine Nameplate (Typical)

2. EMISSION CONTROL INFORMATION LABEL
3. ENGINE SERIAL NUMBER
Figure 2. Typical Location of Engine Labels
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0600 SRM 1590 General
CRANKCASE DESCRIPTION
The Kubota 3.8L diesel engine, utilizes a split

cylinder block to produce greater durability and
operate more quietly. The cylinder block is split
into two parts, crankcase 1, which houses
combustion components and crankcase 2, which
completes crankcase 1 and acts as noise reduction
baffle. See Figure 4.
The Kubota Diesel engine utilizes a hanger type

crankshaft support which allows for easy
disassembly/assembly and a linerless type piston
cylinder which allows for good cooling performance
and excellent resistance to wear. See Figure 4.
1. CRANKCASE 1 3. OIL PAN

2. CRANKCASE 2
Figure 4. Kubota Diesel Crankcase Components
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General 0600 SRM 1590
PRECAUTIONS BEFORE BEGINNING

REPAIR
The information contained below provides some

general precautions that must be followed before
and during the repair of the Kubota 3.8L diesel
engine described in this Service Manual. Read,
understand, and follow these precautions before
beginning any repair procedures. Also, see Safety
Precautions Maintenance and Repair page at the
front of this manual for additional precautions to
follow prior to beginning repair procedures on the
Kubota 3.8L diesel engine covered in this Service
Manual.
• If a procedure requires a special tool, use
only those tools listed in the Special Tools
section in the back of this manual. See your
Hyster dealer if a tool is needed, but not
listed in the Special Tools section.
• Remove oil, dirt, and grease from all parts
before taking any measurements. A. O-RINGS AND OIL SEALS
B. EXTERNAL SNAP RING
• Replace gaskets, O-rings, and oil seals C. INTERNAL SNAP RING
whenever a part is re-assembled. Apply
grease to new O-rings and oil seals before 1. GREASE
2. DIRECTION OF FORCE
assembling the part. See Figure 5. 3. SHARP EDGE
• When assembling external or internal snap
rings, the sharp edge must face against the Figure 5. O-Ring and Oil Seals Grease Location
direction from which force is applied. See and Snap Rings Installation
Figure 5.
• Turn on and operate engine after a repair
procedure has been completed to ensure
engine is operating properly.
Engine Removal and Installation

The procedures to remove and install engine are • H6.0-7.0FT (H135-155FT) (K006)
not included in this section. For procedures refer to
Frame 0100SRM1581 for lift truck models
Frame 0100SRM1316 for lift truck models • H8.0-9.0FT, H8.0FT9 (H170-190FT,
• S6.0-7.0FT (S135-155FT) (G024) H175FT36) (B299)
Frame 0100SRM1243 for lift truck models Frame 0100SRM1891 for lift truck models
• H4.0FT5, H4.0FT6, H4.5FTS5, H4.5FT6, • H4.0FT5, H4.0FT6, H4.5FTS5, H4.5FT6,
H5.0FT, H5.5FT (H80-120FT) (S005) H5.0-5.5FT (H80-120FT) (U005)
Frame 0100SRM1581 for lift truck models
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0600 SRM 1590 Cylinder Head Assembly Repair
Cylinder Head Assembly Repair

VALVE COVERS AND FUEL INJECTORS
Remove
1. Disconnect the negative battery cable at the
battery.
2. Disconnect breather tube from bottom of crank-

case breather filter and lower block. See Fig-
ure 6.
3. Disconnect breather tubes from upper cylinder

head cover and turbo air inlet pipe. See Fig-
ure 6.
4. Remove turbo outlet hose from turbo charger

and air inlet elbows. See Figure 6.
5. Remove EGR tube from back of EGR valve and

EGR cooler. See Figure 6.
NOTE: Mark connectors/wires during removal to

aid in installation.
1. BREATHER TUBE
6. Disconnect wiring connector from fuel injector 2. CRANKCASE BREATHER FILTER
harness on upper cylinder head cover. See Fig- 3. TURBO CHARGER AIR OUTLET HOSE
ure 6. 4. EGR TUBE
5. WIRING CONNECTOR
7. Remove thirteen capscrews, upper valve cover
and gasket from lower valve cover. Discard gas- Figure 6. Breather Tube and Hoses
ket. See Figure 7.
8. Remove eight terminal nuts. Disconnect fuel in-

jector harness from fuel injectors. See Figure 7.
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Cylinder Head Assembly Repair 0600 SRM 1590
1. CAPSCREW 4. FUEL INJECTOR HARNESS

2. UPPER VALVE COVER 5. FUEL INJECTOR
3. GASKET 6. LOWER VALVE COVER
Figure 7. Upper Valve Cover
NOTE: Note position and location of fuel line 11. Remove ten lower valve cover bolts, lower valve
clamps during removal to aid in installation. cover and gasket from cylinder head. Discard
gasket. See Figure 8.
9. Remove three pan head screws and six clamps
from fuel injector lines. See Figure 8. 12. Remove four banjo bolts and eight washers
holding fuel overflow pipe to four injectors. Dis-
card washers. See Figure 8.
CAUTION
DO NOT loosen the fuel injection lines when the 13. Remove four flange nuts holding injector
fuel is under high pressure (within five minutes of clamps to fuel injectors. See Figure 8.
stopping the engine).
10. Loosen four fuel lines at fuel rail. Remove four

fuel lines and O-rings from fuel injectors at
lower valve cover. See Figure 8.
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1. CAPSCREW 11. FLANGE NUT

2. FUEL LINE CLAMP 12. INJECTOR CLAMP
3. FUEL LINE 13. BALL BEARING
4. O-RING 14. FUEL INJECTOR
5. BOLT 15. BASE GASKET
6. LOWER VALVE COVER 16. ROCKER ARM BRACKET
7. GASKET 17. CYLINDER HEAD
8. BANJO BOLT 18. TUBE SEAL
9. WASHER 19. FUEL RAIL
10. OVERFLOW PIPE
Figure 8. Fuel Injectors and Lower Valve Cover
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3. Install four flange nuts to injector clamps.

CAUTION Tighten to 24 to 27 N•m (18 to 20 lbf ft).
Carefully remove injector clamps so as to not lose
ball bearing from rocker arm bracket. 4. Install eight new washers and four banjo bolts
to fuel over flow pipe and injectors. Tighten to
14. Remove four injector clamps holding fuel injec- 10 to 11 N•m (89 to 97 lbf in).
tors to cylinder head. See Figure 8.
5. Lightly grease new lower valve cover gasket.
15. Remove four fuel injectors, four O-rings, and
four base gaskets from cylinder head. Discard 6. Place new valve cover gasket into groove of
gaskets. See Figure 8. lower valve cover.
7. Install lower valve cover and ten bolts onto cyl-

Clean and Inspect inder head. Torque to 7 to 11 N•m (62 to
97 lbf in).
WARNING 8. Install four O-rings and fuel lines to fuel injec-
Cleaning solvents can be flammable and toxic and tors at lower valve cover. See Figure 8.
can cause skin irritation. When using cleaning
solvents, always follow the recommendations of 9. Install four fuel lines to common fuel rail.
the manufacturer.
10. Install six clamps and three pan head screws
on fuel injector lines as noted during removal.
WARNING See Figure 8.
Compressed air can move particles so that they
cause injury to the user or to other personnel. 11. Install fuel injector harness onto fuel injectors.
Make sure that the path of the compressed air is Install eight terminal nuts. Torque to 1.6 to
away from all personnel. Wear protective goggles 2.2 N•m (14 to 20 lbf in). See Figure 7.
or a face shield to prevent injury to the eyes.
12. Lightly grease new upper valve cover gasket.
CAUTION 13. Place new valve cover gasket into groove of up-
per valve cover.
Use caution not to scratch the gasket mating sur-
faces when cleaning the valve cover and cylinder 14. Install upper valve cover and thirteen cap-
head. screws onto lower valve cover. Torque to 10 to
11 N•m (89 to 97 lbf in). See Figure 7.
Carefully remove all gasket residue from the valve
cover and cylinder head. 15. Connect wiring connector to fuel injector har-
ness on upper cylinder head cover.
Clean the valve cover in cleaning solvent. Dry the
valve cover with compressed air. Inspect for wear, 16. Install EGR tube to back of EGR valve and
cracks, and any other damage. If necessary, replace EGR cooler. See Figure 6.
valve cover.
17. Install turbo air outlet hose to turbo charger
and air inlet elbow. See Figure 6.
Inspect all O-rings and grommets for wear, cracks,
and any other damage. Replace where necessary. 18. Connect breather tubes to turbo air inlet pipe
and upper cylinder head cover. See Figure 6.
Install
19. Connect breather tube to bottom of crankcase
1. Install four O-rings and four new base gaskets breather filter and lower block.
onto four fuel injectors. Install four fuel injec-
tors into cylinder head. See Figure 8. 20. Connect negative battery cable at battery.
2. Install four injector clamps to rocker arm

brackets. Ensure ball bearing is present in
rocker arm bracket. See Figure 8.
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ROCKER ARM ASSEMBLY 3. Lift the rocker arm shaft assembly from the cyl-
inder head.
Remove
NOTE: Mark the push rods so they can be reinstal-
1. Remove valve cover and fuel injectors. See led in original location during reassembly.
Valve Covers and Fuel Injectors, Remove.
4. Remove the push rods from the cylinder head.
2. Remove four flange nuts holding rocker arm
brackets to cylinder head. See Figure 9.
1. ROCKER ARM SHAFT 8. ADJUSTING SCREW

2. SLOTTED SCREW 9. NUT
3. ROCKER ARM BRACKET 10. EXHAUST ROCKER ARM ASSEMBLY
4. WASHER 11. FLANGE NUT
5. C-CLIP 12. PUSH ROD
6. ROCKER ARM SPRING 13. CYLINDER HEAD
7. INTAKE ROCKER ARM ASSEMBLY 14. LIFTER
Figure 9. Rocker Arm Assembly
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Disassemble
1. Remove rocker arm shaft c-clips and washers
from each end of the rocker arm shafts. Discard
washers. See Figure 9.
2. Remove the c-clips and washers from the ends

of the rocker arm shaft.
NOTE: Mark the rocker arms so they can be rein-

stalled in original location during reassembly.
NOTE: The rocker arm shaft fits tightly in the

rocker arm support brackets. Clamp the support
bracket in a padded vise and twist and pull the
rocker arm shaft to remove the shaft.
3. Slide the rocker arm shaft out of the rocker arm Figure 10. Push Rod Inspection
brackets, springs, and rocker arms.
4. If necessary, remove the valve adjusting screw

and lock nut from the rocker arms.
Rocker Arm Assembly
Rocker Arm and Support Bracket Inside Di-

Clean and Inspect
ameter Use a test indicator and micrometer to de-
termine if the inside diameter of all the rocker arm
WARNING support brackets and rocker arms are within limits.
Cleaning solvents can be flammable and toxic and Refer to the Engine Specifications for the service
can cause skin irritation. When using cleaning limit. See Figure 11.
solvents, always follow the recommendations of
the manufacturer.
WARNING
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles
Clean all parts in cleaning solvent. Dry the parts

with compressed air. Inspect for wear, cracks, and
any other damage. Replace all parts as needed.
Push Rods Figure 11. Rocker Arm Inside Diameter
1. Place the push rods on a flat inspection block.

Shaft Outside Diameter Use a micrometer to
2. Roll the push rods until a gap can be observed
measure the rocker arm shaft outside diameter. Re-
between a portion of the push rod and the sur-
fer to the Engine Specifications for the service
face of the inspection block.
limit. See Figure 12.
3. Use a feeler gauge to measure the gap. Refer to
the Engine Specifications for the service limit.
See Figure 10.
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5. Tighten the rocker arm shaft retaining flange

nuts. Torque to 49 to 55 N•m (37 to 41 lbf in).
6. Adjust the valve lash. See Valve Clearance Ad-

justments.
7. Install the valve cover. See Valve Covers and

Fuel Injectors, Install.
VALVE CLEARANCE ADJUSTMENTS

NOTE: Make measurements and adjustments
while the engine is cold.
Figure 12. Rocker Arm Shaft Outside Diameter
1. Remove the valve cover. See Valve Covers and
Fuel Injectors, Remove.
Assemble NOTE: The number one piston position is on the
flywheel end of the engine, opposite side of the radi-
NOTE: The rocker arm shaft fits tightly in the
ator, and the ignition order is 1-3-4-2 at 180 degree
rocker arm support brackets. Clamp the rocker arm
intervals.
shaft in a padded vise and twist and push the sup-
port brackets onto the rocker arm shaft. 2. Rotate the crankshaft clockwise, as seen from
the radiator side, to bring the number one pis-
1. Lubricate the rocker arm shaft. Slide the rocker
ton to top dead center (TDC). See Table 1 for
arm support brackets, springs, and rocker arms
reference to help determine which valves will
onto the shaft, as noted during removal.
be available for adjustment with number one
2. Position the rocker arm assembly on a flat sur- piston at TDC.
face. Install the washers and c-clips onto the
Table 1. Available Valves for Adjustment
ends of the rocker arm shaft. See Figure 9.
Adjustable Cylinder Intake Exhaust
3. If removed, install the valve adjusting screws Location Of Piston
and lock nuts.
When No. 1 1 ⋆ ⋆
Install piston is at 2 ⋆
compres-
NOTE: When installing push rod, mount it se- sion top 3 ⋆
curely in the groove located in the bottom of the dead center 4
lifter.
When No. 1 1
1. Install the push rods. piston is at 2 ⋆
overlap po-
2. Place the rocker arm assembly in position on sition 3 ⋆
the cylinder head. 4 ⋆ ⋆
3. Install and hand tighten the rocker arm shaft 3. Insert a feeler gauge between the rocker arm
retaining flange nuts. and valve cap. See Figure 13. Record the meas-
4. Align the push rods with their respective rocker ured valve clearance. The valve clearance
arms, as noted during removal. should be between 0.23 to 0.27 mm (0.009 to
0.011 in.).
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Legend for Figure 14
A. NORMAL B. ABNORMAL
1. VALVE CAP
5. When valve clearence has been correctly adjus-

ted, tighten the valve lock nut of the adjusting
screw. See Figure 13.
NOTE: There is a tendency for the clearance to de-

crease slightly when the lock nut is tightened. It is
suggested that you make the clearance adjustment
slightly on the loose side before tightening the lock
1. VALVE ADJUSTING SCREW nut.
2. VALVE LOCK NUT
6. Insert a feeler gauge between the rocker arm
Figure 13. Valve Clearance Measurement
and valve cap and adjust the clearance so there
is a slight drag on the feeler gauge when sliding
it between the rocker arm and valve cap.
4. If adjustment is needed, loosen the valve ad-
Tighten the valve adjusting screw lock nut and
justing screw lock nut and valve adjusting
recheck the clearance. The valve clearance
screw on the rocker arm (see Figure 13) and
should be between 0.23 to 0.27 mm (0.009 to
check the valve for any inclination of valve cap,
0.011 in.).
entrance of dirt, or wear. See Figure 14.
7. Apply clean engine oil to the contact surface be-
tween the adjusting screw and push rod.
Figure 14. Valve Cap Check
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8. Measure and adjust the cylinders as follows:

a. Turn the crankshaft 180 degrees and
make the measurement and adjustment
for the number three cylinder.
b. Turn the crankshaft 180 degrees and
for the number four cylinder.
c. Turn the crankshaft 180 degrees and
for the number two cylinder.
9. Install the valve cover. See Valve Covers and

Fuel Injectors, Install.
CYLINDER HEAD ASSEMBLY
Remove
1. HOSE CLAMP
1. Disconnect the negative battery cable at the 2. RETAINING CLAMP
battery. 3. AIR INTAKE HOSE
4. AIR FLOW SENSOR CONNECTOR
NOTE: Place a suitable container with a capacity
of at least 12.0 liter (13 qt) under the radiator and Figure 15. Air Intake Hoses
lower radiator hose.
2. Remove the lower radiator hose and radiator NOTE: Tag wiring connectors and wiring harness
cap. Allow cooling system to drain. before removal to aid during installation.
3. Disconnect electrical connectors from air flow 5. Tag and disconnect connectors for engine wir-
sensor. ing harness. Move harness aside for better ac-
cess.
4. Remove two hose clamps, two retaining clamps
and air intake hoses from air cleaner and turbo 6. Loosen adjustment bolt for the alternator and
charger. See Figure 15. release tension on serpentine belt. Remove ser-
pentine belt. See Figure 16.
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1. ADJUSTMENT BOLT 5. WASHER

2. ADJUSTER BRACKET 6. MOUNTING BRACKET
3. RETAINING NUT 7. ALTERNATOR
4. MOUNTING BOLT
Figure 16. Alternator Mounting and Adjustment
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7. Remove three mounting bolts, three retaining

nuts, mounting bracket and alternator from lift
truck. See Figure 16.
8. Remove three bolts and idler assembly from

water pump assembly. See Figure 17.
9. Remove eight bolts, collar, spacer, and two fan

pulleys from water pump and water flange. See
Figure 17.
10. Loosen two hose clamps and remove hose from

water pipe to EGR cooler. See Figure 18.
11. Loosen two hose clamps and remove hose from

water pipe to water pump. See Figure 18.
12. Remove water pipe bolt from cylinder head. Re-

move water pipe and O-ring from water pump.
Discard O-ring. See Figure 18.
1. IDLER ASSEMBLY 5. COLLAR
2. BOLT 6. WATER FLANGE
3. PULLEY 7. WATER PUMP
4. SPACER
Figure 17. Engine Pulleys
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1. CLAMP 5. BOLT
2. HOSE 6. WATER PUMP ASSEMBLY
3. WATER PIPE 7. EGR COOLER
4. O-RING
Figure 18. Water Pump Components
13. Loosen two clamps and remove coolant by pass

hose from water pump and water flange assem-
bly. See Figure 19.
14. Remove four bolts, water flange assembly, and

gasket from cylinder. Discard gasket. See Fig-
ure 19.
1. WATER FLANGE ASSEMBLY

2. CLAMP
3. BYPASS HOSE
4. BOLT
5. GASKET
6. CYLINDER HEAD
Figure 19. Water Flange
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15. Tag and disconnect fuel hoses from fuel filter

and back of fuel injection pump.
16. Remove valve cover, fuel injectors and related

parts. See Valve Covers and Fuel Injectors, Re-
move section of this manual.
17. Remove two fuel lines from common fuel rail

and fuel pump. See Figure 20.
18. Remove fuel return line from fuel pump and

end of common fuel rail. See Figure 20.
1. FLANGE BOLT 3. FUEL RAIL

2. BRACKET 4. INTAKE MANIFOLD
Figure 21. Fuel Rail
1. FUEL LINES 3. FUEL PUMP

2. FUEL RETURN LINE
Figure 20. Fuel Lines
19. Remove two flange bolts, bracket and fuel rail

side of intake manifold. See Figure 21.
20. Remove nine bolts, intake manifold and gasket

1. INTAKE MANIFOLD 3. GASKET
from cylinder head. Discard gasket. See Fig- 2. BOLT 4. CYLINDER HEAD
ure 22.
Figure 22. Intake Manifold
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21. Remove two banjo bolts, two washer sets and

turbocharger oil supply line. Discard washer
sets. See Figure 23.
22. Remove two capscrews, two clamps, oil drain

tube, hose and gasket from turbocharger and
block. Discard gasket. See Figure 23.
23. Remove two clamps and hose from EGR cooler

and engine block. See Figure 24.
24. Remove two flange bolts, gasket and EGR

cooler assembly from exhaust manifold. Discard
gasket. See Figure 24.
25. Remove two flange bolts, gasket and EGR

cooler flange from EGR cooler. Discard gasket.
See Figure 24.
1. BANJO BOLT 5. CLAMP

2. WASHER SET 6. DRAIN TUBE
3. OIL SUPPLY LINE 7. HOSE
4. CAPSCREW 8. GASKET
Figure 23. Turbocharger Oil Lines
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1. CLAMP 6. EXHAUST MANIFOLD

2. HOSE 7. COOLER FLANGE
3. EGR COOLER 8. EGR PIPE FLANGE
4. FLANGE BOLT 9. EGR PIPE
5. GASKET
Figure 24. EGR Cooler
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26. Remove two flange bolts, gasket and EGR pipe

from EGR pipe flange, See Figure 24.
27. Remove two flange bolts, gasket and EGR pipe

flange from EGR cooler. Discard gasket. See
Figure 24.
28. Remove two upper flange nuts, two lower

flange nuts, gasket and turbocharger from ex-
haust manifold. Discard gasket. See Figure 25.
1. HEAT SHIELD
2. FLANGE BOLT
3. FLANGE NUT
4. EXHAUST MANIFOLD
5. GASKET
6. CYLINDER HEAD
Figure 26. Exhaust Manifold
31. Remove banjo bolt and washer set holding fuel

return line to back of cylinder head. Discard
washer set. See Figure 27.
32. Remove banjo bolt, two washers and fuel return

line from fuel pump. Discard washers. See Fig-
ure 27.
1. TURBOCHARGER
2. FLANGE NUT
3. STUD
4. GASKET
5. EXHAUST MANIFOLD
Figure 25. Turbocharger
29. Remove two flange bolts and heat shield from

exhaust manifold. See Figure 26. 1. BANJO BOLT 4. FUEL PUMP
2. WASHER 5. CYLINDER HEAD
30. Remove four flange nuts, four flange bolts, gas- 3. FUEL RETURN LINE
ket and exhaust manifold from cylinder head. Figure 27. Fuel Return Line
Discard gasket. See Figure 26.
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33. Remove rocker arm assembly. See Rocker Arm 35. Remove cylinder head and gasket from engine
AssemblyRemove. block. Discard gasket.
34. Remove eighteen cylinder head bolts in se- 36. Remove eight lifters from crankcase. See Fig-
quence shown, from eighteen to one. See Fig- ure 30.
ure 28.
A. TIMING GEAR CASE END

B. FLYWHEEL END
Figure 28. Head Bolt Pattern
NOTE: There are three cylinder head gaskets

available (a, b, or c) for this engine application. 1. LIFTERS 2. CRANKCASE
Take note which one is being used during removal
and replace it with a new one during assembly. See Figure 30. Lifters
Figure 29.
Disassemble
Valves and Valve Springs, Remove

1. Remove eight valve bridge arms, eight pads
and eight valve shafts from cylinder head. See
Figure 31.
2. Using a valve spring compressor tool, compress

valve springs.
A. TIMING GEAR CASE END 3. Remove the valve keepers and the valve cap
B. FLYWHEEL END from the end of the valve. See Figure 31.
1. HEAD GASKET
Figure 29. Head Gasket
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NOTE: If existing valves are going to be reinstalled

in the cylinder head, mark the valves so they can
be installed in their original location.
7. Turn the cylinder head so the exhaust port side

faces down. Remove the intake and exhaust
valves from the cylinder head.
Valve Guides, Remove
Press out used valve guide using the valve guide re-
placing tool. See Figure 32.
1. PAD
2. VALVE BRIDGE ARM
3. VALVE SHAFT
4. VALVE KEEPERS
5. VALVE SPRING RETAINER
6. VALVE SPRING
7. VALVE STEM SEAL
8. VALVE GUIDE
9. INTAKE VALVE
10. EXHAUST VALVE
11. CYLINDER HEAD
Figure 31. Valves and Valve Springs
4. Slowly release the tension on the valve spring.
5. Remove the spring retainer, valve spring, and A. REMOVAL B. INSTALLATION

valve stem seal. 1. VALVE GUIDE INSTALLATION TOOL
2. CYLINDER HEAD
6. Repeat this procedure until all intake and ex- 3. VALVE GUIDE
haust valve springs and valve stem seals are
removed. Figure 32. Valve Guide Removal
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Clean and Inspect Carefully remove all gasket residue from the intake
manifold and cylinder head. Inspect the intake
manifold for scratches, cracks, or any other dam-
WARNING age. Repair or replace as needed.
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning Carefully remove all gasket residue from the cylin-
solvents, always follow the recommendations of der head and cylinder block. Inspect the cylinder
the manufacturer. head for scratches, cracks, or any other damage.
Repair or replace as needed.
WARNING
Thoroughly clean all components using a nonmetal-
Compressed air can move particles so that they lic brush and cleaning solvent. Dry the parts with
cause injury to the user or to other personnel. compressed air. Each part must be free of carbon,
Make sure that the path of the compressed air is metal filings, and other debris.
or a face shield to prevent injury to the eyes. Visually inspect the parts. Replace any parts that
are obviously discolored, heavily pitted, or other-
CAUTION wise damaged. Replace parts that do not meet the
specified limit.
Any part which is found defective as a result of in-
spection or any part whose measured value does
not satisfy the standard or limit must be replaced. Cylinder Head
1. Place the cylinder head flat and inverted (com-
CAUTION bustion side up) on the work bench.
Any part determined to not meet the service 2. Use a straight edge and feeler gauge to meas-
standard or limit before the next service, as deter- ure the amount of cylinder head distortion. Re-
mined from the state of current rate of wear, fer to the Engine Specifications for the service
should be replaced even though the part currently limit. See Figure 33.
meets the service standard limit.
CAUTION
faces when cleaning the exhaust manifold and
cylinder head.
CAUTION
faces when cleaning the intake manifold and cyl-
inder head.
CAUTION
faces when cleaning the cylinder head and cylin- Figure 33. Cylinder Head Distortion Check
der block.
Carefully remove all gasket residue from the ex- 3. Use the Magnaflux method and inspect the cyl-
haust manifold and cylinder head. Inspect the ex- inder head for cracks. Replace the cylinder
haust manifold for scratches, cracks, or any other head if evidence of fractures are found.
damage. Repair or replace as needed.
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Valve Guides
Visually inspect the valve guides for distortions,

scoring, or other damage.
Use a test indicator and micrometer to measure the

inside diameter at each end of the valve guide. Re-
fer to the Engine Specifications for the service
limit.
Valves
Valve Stem Diameter Use a micrometer to meas-

ure the valve stem diameter. Measure the valve
stem near the combustion end and near the oppo-
site end. Refer to the Engine Specifications for the Figure 35. Valve Stem Straightness Check
service limit. See Figure 34.
Valve Sink
Insert the valves into their proper places in the cyl-

inder head and press them down until they are
fully seated. Using a depth micrometer, measure
the difference between the cylinder head surface
and the combustion surface of each exhaust and in-
take valve. Refer to the Engine Specifications for
A. MEASUREMENT POINTS the service limit. See Figure 36 and Figure 37.
Figure 34. Valve Stem Diameter Measurement
Points
Valve Stem Straightness Place the valve stem on

a flat surface. Roll the valve until a gap can be ob-
served between a portion of the valve stem and the
flat surface. Use a feeler gauge to measure the gap.
Refer to the Engine Specifications for the service
Figure 36. Valve Sink Measurement
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Roughness or burrs will cause poor seating of a

valve. Visually inspect the seating of each valve
and determine if lapping or grinding is needed.
Grinding is needed if the cylinder head's seat width
exceeds standard limits. Refer to the Engine Speci-
fications for the service limit.
Lap the valve seat and the cylinder head with a

mixture of valve compound and engine oil.
If the valve requires grinding, lap the valve after

grinding. Be sure to thoroughly wash the parts to
remove all grinding powder or compound.
Valve Springs
Inspect the valve springs. If damage or corrosion is

Figure 37. Valve Sink seen, or if measurements exceed the specified lim-
its, replace the springs.
Valve Seat Fractures Check for fractures on the inside and

outside portions of the springs. If the valve spring
Always check the clearance between the valve and is fractured, replace the spring.
valve guide before correcting the valve seat. See
Figure 38. If the clearance exceeds the limit, re- Corrosion Check for corrosion of spring material
place the valve or valve guide to bring the clearance caused by oxidation.
within the limit.
Squareness Use a flat surface and a square to
check each spring for squareness. Refer to the En-
gine Specifications for the service limit. See Fig-
ure 39.
1. VALVE SEAT Figure 39. Spring Squareness Check
Figure 38. Valve Seat
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Free Length Use a caliper to measure the length

of the spring. Refer to the Engine Specifications for
the service limit. See Figure 40.
Figure 40. Spring Free Length Check
Assemble
Valve Guides, Install

1. The valve guides are installed into the cylinder
head with an extremely tight press fit. Before A. REMOVAL B. INSTALLATION
installing the valve guides, clean the new valve
guide and valve guide bore and apply oil to 1. VALVE GUIDE INSTALLATION TOOL
them. 2. CYLINDER HEAD
3. VALVE GUIDE
2. Press fit the new valve guide with the valve
Figure 41. Valve Guide Installation
guide replacing tool. See Figure 41.
3. Accurately size the I.D. of valve guide to speci-

fied dimension. See Table 2.
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Table 2. Valve Guide Specification Legend for Figure 42
7.010 to 1. VALVE STEM SEAL INSTALLATION TOOL

Intake 7.025 mm 2. VALVE STEM SEAL
Valve (0.2760 to 3. VALVE GUIDE
Valve
Factory 0.2765 in.)
4. CYLINDER HEAD
Guide
Specificat
Inside 7.010 to
ion
Diameter Exhaust 7.025 mm 4. Measure the distance from the cylinder head to
Valve (0.2760 to the valve stem seal. Refer to the Engine Specifi-
0.2765 in.) cations for the clearance specifications. See Fig-
ure 43.
Valves and Valve Springs, Install
1. Place the cylinder head assembly on the ex-
haust port side.
2. Place all the valves in their proper positions, as

marked when disassembled, in the cylinder
head.
3. Apply clean engine oil to the lip of the valve

stem seal. Using valve stem seal installation
tool, insert a new valve stem seal on each of the
valves. See Figure 42.
1. VALVE STEM SEAL

2. VALVE GUIDE
3. VALVE GUIDE PROTECTION
4. VALVE STEM SEAL PROTECTION
5. CLEARANCE
Figure 43. Valve Stem Seal Clearance
5. Place the cylinder head on the work bench with

Figure 42. Valve Stem Seal Installation the combustion chamber facing down. Install
the valve springs and valve spring retainers.
See Figure 31.
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6. Using the valve compressor tool, compress the 8. Install two new washers, banjo bolt and fuel re-
valve spring. turn line onto back of fuel pump. See Figure 27.
7. Install the valve keepers and slowly release the 9. Install new washer set, banjo bolt and fuel re-
tension in the valve spring. turn line onto back of cylinder head. See Fig-
ure 27.
8. Install the valve cap.
10. Install new gasket, exhaust manifold, four
9. Repeat these procedures until all the intake flange bolts and four flange nuts onto cylinder
and exhaust valves are installed. head. See Figure 26.
10. Install eight valve shafts, eight pads, and eight
valve bridge arms. See Figure 31.
Install
NOTE: See one of the following sections, Standard
Torque Specifications and Special Torque Specifica-
tions for torque values to use during the installa-
tion process.
1. Lightly oil outside of lifters. Install eight lifters

into crankcase. See Figure 30. A. TIMING GEAR CASE END
B. FLYWHEEL END
2. Carefully clean the combustion surface of the
cylinder head and the top surface of the cylin- Figure 44. Cylinder Head Torque Sequence
der block.
3. Place a new cylinder head gasket, as noted dur- 11. Install heat shield and two flange bolts to ex-
ing removal, on the cylinder block. haust manifold. See Figure 26.
4. Position the cylinder head on the cylinder head 12. Install new gasket, turbocharger, two lower
gasket and cylinder block. flange nuts and two upper flange nuts onto ex-
haust manifold. See Figure 25.
5. Lightly oil the threads of the cylinder head
bolts. 13. Install new gasket, EGR pipe and two flange
bolts onto EGR pipe flange. See Figure 24.
6. Install the cylinder head bolts and tighten the
cylinder head bolts, 1 to 18, using a two stage 14. Install new gasket, EGR pipe flange and two
process: flange bolts onto EGR cooler. See Figure 24.
a. On first pass (1 to 18), tighten cylinder 15. Install new gasket, EGR cooler flange, and two
head bolts to 50 N•m (37 lbf ft). See Fig- flange bolts onto EGR cooler. See Figure 24.
ure 44.
b. On second pass (1 to 18), tighten cylinder 16. Install EGR cooler assembly, new gasket, and
head bolts to 98 to 107 N•m (72 to two flange bolts onto exhaust manifold. See
80 lbf ft). See Figure 44. Figure 24.
7. Install the push rods and rocker arm assembly. 17. Install hose and two clamps to EGR cooler and
See Rocker Arm Assembly, Install. engine block. See Figure 24.
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18. Install oil drain tube, new gasket, two cap- 33. Install alternator, mounting bracket, three re-
screws, two clamps, and hose onto turbocharger taining nuts, and three mounting bolts onto en-
and block. See Figure 23. gine. See Figure 16.
19. Install turbocharger oil supply line, two washer 34. Put serpentine belt on pulley's. Using a pry bar,
sets and two banjo bolts onto turbocharger. See pull alternator into position and put tension
Figure 23. onto serpentine belt. Tighten alternator adjust-
ment bolt. See Figure 16.
20. Install intake manifold, new gasket and nine
bolts to cylinder head. See Figure 22. 35. Attach wiring harness to connectors as noted
during removal.
21. Install common fuel rail and two flange bolts
onto side of intake manifold. Torque nuts to 24 36. Install air intake hoses, retaining clamp, and
to 27 N•m (18 to 20 lbf ft). See Figure 21. two hose clamps onto air cleaner and turbo-
charger. See Figure 15.
22. Install fuel supply line to fuel pump and end of
fuel rail. See Figure 20. 37. Connect electrical connector to air flow sensor.
See Figure 15.
23. Install two fuel lines to fuel rail and fuel pump.
See Figure 20. 38. Install lower radiator hose.
24. Install fuel injectors, valve covers and related

parts. See Valve Covers and Fuel Injectors, In- CAUTION
stall. Additives may damage the cooling system. Before
using additives, contact your local Hyster dealer.
25. Connect fuel hoses to fuel filter and back of fuel
injection pump, as noted during removal. 39. Fill the cooling system with coolant. Refer to
the Periodic Maintenance section for your
26. Install water flange assembly, new gasket, and lift truck for the correct coolant amount and
four bolts to cylinder head. See Figure 19. type.
27. Install coolant by pass hose and two clamps 40. Install the radiator cap.
onto the water pump and water flange assem-
bly. See Figure 19. 41. Connect the negative battery cable.
28. Install water pipe bolt into cylinder head. See
Figure 18. WARNING
During engine operation, be careful not to touch
29. Install hose and two clamps onto water pipe the fan, pulleys, or drive belts. Contact with these
and water pump. See Figure 18. parts can cause serious injury.
30. Install hose and two clamps onto water pipe
and EGR cooler. See Figure 18. WARNING
31. Install two fan pulleys, spacer, collar, and eight The radiator or other parts of the cooling system
bolts onto water pump and water flange. See may be hot or under pressure and can cause seri-
Figure 17. ous injury.
32. Install idler assembly and three bolts onto the 42. Start the engine and check for leaks.
water pump assembly. See Figure 17.
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43. Change the engine oil and oil filter. See Lubri- the cooling system. After 30 minutes, do a touch
cation System Repair. test by touching the radiator with your hand. If the
radiator is still hot to the touch, wait another 30
minutes before attempting any maintenance to the
WARNING cooling system.
DO NOT remove the radiator cap from the radiator
when the engine is hot. When the radiator cap is
removed, pressure will release from the coolant CAUTION
system. If the coolant system is hot, the steam Additives may damage the cooling system. Before
and boiling coolant can cause severe burns. using additives, contact your local Hyster dealer.
44. Stop engine. If coolant is hot, allow engine time

WARNING to cool. Check coolant level and fill as required
The radiator or other parts of the cooling system between the ADD and FULL marks on the cool-
may be hot or under pressure and can cause seri- ant reservoir.
ous injury. Wait 30 minutes for the radiator and
engine to cool before performing maintenance to
Timing Gear Case and Timing Gears Repair

TIMING GEAR CASE COVER 2. Remove the coolant fan, serpentine belt, and
water pump. See Cooling System Repair.
Remove
3. Remove the bolt and washer retaining the
1. Remove the engine. crankshaft pulley.
See Frame 0100SRM1581 for lift truck models 4. Using a gear puller, remove the crankshaft pul-
ley.
• H6.0-7.0FT (H135-155FT) (K006)
• H8.0-9.0FT, H8.0FT9 (H170-190FT, 5. Remove the bolts holding the timing gear case
H175FT36) (B299) cover to engine block. See Figure 45.
See Frame 0100SRM1316 for lift truck models 6. Remove the timing gear case cover and O-rings
from engine block. Discard O-rings. See Fig-
• S6.0-7.0FT (S135-155FT) (G024)
ure 45.
See Frame 0100SRM1243 for lift truck models
7. Remove the front oil seal from the timing gear
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; case cover. See Figure 45.
H5.0-5.5FT (H80-120FT) (S005)

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80-120FT) (U005)
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0600 SRM 1590 Timing Gear Case and Timing Gears Repair
1. TIMING GEAR CASE COVER 4. FRONT OIL SEAL

2. BOLT 5. ENGINE BLOCK
3. O-RING
Figure 45. Timing Gear Case Cover
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Timing Gear Case and Timing Gears Repair 0600 SRM 1590
Clean and Inspect 4. Apply a continuous bead of Three Bond Liquid

Gasket (Hyster P/N 1599478) to the mating
surface of the timing gear case cover and the
WARNING engine block.
can cause skin irritation. When using cleaning 5. Place the timing gear case cover and plate in
solvents, always follow the recommendations of position on the engine block and install retain-
the manufacturer. ing bolts. Torque to 24 to 27 N•m (18 to
20 lbf ft).
WARNING 6. Install the crankshaft pulley and bolt to crank-

Compressed air can move particles so that they shaft pulley. Tighten bolt to 255 to
cause injury to the user or to other personnel. 274 N•m (188 to 202 lbf ft).
away from all personnel. Wear protective goggles 7. Install the water pump, serpentine belt, and
or a face shield to prevent injury to the eyes. coolant fan. See Cooling System Repair.
8. Install the engine.

Clean all old sealant from the timing gear case
cover and the timing gear case. Clean the timing See Frame 0100SRM1581 for lift truck models
gear case cover in cleaning solvent. Dry the timing
• H6.0-7.0FT (H135-155FT) (K006)
gear case cover with compressed air. Inspect for
wear, cracks, and any other damage. If necessary, • H8.0-9.0FT, H8.0FT9 (H170-190FT,
replace timing gear case cover. H175FT36) (B299)

Install
• S6.0-7.0FT (S135-155FT) (G024)
1. Apply a continuous bead of Three Bond Liquid
Gasket (Hyster P/N 1599478) to the outside di- See Frame 0100SRM1243 for lift truck models
ameter of a new front oil seal. • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80-120FT) (S005)
2. Using a special tool, install the new front oil
seal into the timing gear case cover. Apply lith- See Frame 0100SRM1891 for lift truck models
ium grease to the lip of the front oil seal. See
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
Figure 46.
H5.0-5.5FT (H80-120FT) (U005)
9. Fill the engine oil to the correct level. For cor-

rect oil amount and type refer to
Periodic Maintenance 8000SRM1583 for lift

truck models
• H6.0-7.0FT (H135-155FT) (K006)

truck models
• H8.0-9.0FT, H8.0FT9 (H170-190FT,
H175FT36) (B299)

truck models
Figure 46. Front Oil Seal Installation
• S6.0-7.0FT (S135-155FT) (G024)
3. Install new O-rings into back of timing gear

case cover. See Figure 45.
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Periodic Maintenance 8000SRM1604 for lift 2. Verify that the gears are properly aligned with
truck models the alignment marks. See Figure 47.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
3. Remove oil pump drive gear. See Figure 48.
H5.0-5.5FT (H80-120FT) (S005)
NOTE: If using a gear puller to remove the crank-
shaft gear, be careful not to damage the threads in
truck models
the end of the crankshaft.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80-120FT) (U005) 4. Remove the crankshaft gear. See Figure 48.
10. Start the engine and check for leaks. 5. Remove the key from the crankshaft.
TIMING GEARS
NOTE: For removal of the fuel injection pump
drive gear, refer to the section Fuel System Repair.
Before removing any of the timing gears, rotate the

crankshaft to align the alignment marks on the
gears as follows (see Figure 47):
• Align mark "A" on the camshaft gear with
mark "A" on the idler gear.
• Align mark "B" on the crankshaft gear with
mark "B" on the idler gear.
1. OIL PUMP DRIVE GEAR

2. CRANKSHAFT GEAR
3. CRANKSHAFT
4. KEY
Figure 48. Crankshaft Gear
Install
1. Install the key into the crankshaft.
2. Align the alignment mark "B" on the crank-

shaft gear with the alignment mark "B" on the
idler gear 1 and install the crankshaft gear
1. CAMSHAFT GEAR onto the crankshaft.
2. CRANKSHAFT GEAR
3. IDLER GEAR 3. Verify that all alignment marks are properly
4. OIL PUMP GEAR
aligned. Figure 47.
Figure 47. Timing Gear Alignment
4. Install the timing gear case cover. See Timing
Gear Case Cover, Install.
Crankshaft Gear
Remove
1. Remove the timing gear case cover. See Timing
Gear Case Cover, Remove.
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Timing Gear Case and Timing Gears Repair 0600 SRM 1590
Idler Gear 3. Remove the bolts from the idler gear shaft. See
Figure 49.
Remove
4. Remove the idler gear shaft, alignment pin, id-
1. Remove the timing gear case cover. See Timing ler gear, idler gear collar, and bushing.
2. Verify that the gears are properly aligned with

the alignment marks. See Figure 47.
1. ENGINE BLOCK 8. BOLT

2. CAMSHAFT GEAR 9. PULSAR GEAR
3. IDLER GEAR 10. CAPSCREW
4. IDLER GEAR COLLAR 11. CAMSHAFT
5. BUSHING 12. KEY
6. ALIGNMENT PIN 13. RETAINER
7. IDLER GEAR SHAFT
Figure 49. Idler Gear
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Inspect 3. Verify that all alignment marks are properly

aligned. See Figure 47.
1. Measure the outside diameter of the idler gear
shaft. Refer to the Engine Specifications for the 4. Install the idler gear retaining bolts.
2. Measure the inside diameter of the idler gear. Gear Case Cover, Install.
Refer to the Engine Specifications for the serv-
ice limit. See Figure 50. Camshaft Gear
Remove
2. Verify that the gears are properly aligned with

the alignment marks. See Figure 47.
3. Remove four capscrews and pulsar gear from

camshaft gear. See Figure 49.
4. Using a gear puller, remove the camshaft gear.

See Figure 49.
1. OUTSIDE DIAMETER
2. IDLER GEAR SHAFT 5. Remove the key from the camshaft.
3. INSIDE DIAMETER
4. IDLER GEAR Install
Figure 50. Idler Gear and Shaft Measurement
1. Install the key into the camshaft.
Install 2. Align the alignment mark "A" on the camshaft

gear with the alignment mark "A" on the idler
1. Lubricate the idler gear bushing and idler gear gear and install the camshaft gear onto the
shaft with clean engine oil. camshaft.
NOTE: Make sure the oil hole in the bushing is fac- 3. Install pulse gear and four capscrews onto cam-
ing toward the top of the engine. shaft gear. Tighten capscrews to 4.7 to
5.6 N•m (42 to 50 lbf in).
2. Align the alignment mark "C" on the idler gear
1 with the alignment mark "C" on idler gear 2 4. Install the timing gear case cover. See Timing
and the alignment mark "A" on idler gear 1 Gear Case Cover, Install.
with the alignment mark "A" on the camshaft
gear. Install the idler gear, bushing, and idler
gear shaft.
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Drive Train, Camshaft, and Cylinder Block Repair 0600 SRM 1590
Drive Train, Camshaft, and Cylinder Block Repair

REMOVE NOTE: DO NOT remove the camshaft gear at this
time.
1. Remove the engine.
12. Remove the crankshaft gear and idler gear. See
See Frame 0100SRM1581 for lift truck models Timing Gear Case and Timing Gears Repair.
• H6.0-7.0FT (H135-155FT) (K006)
DISASSEMBLE
• H8.0-9.0FT, H8.0FT9 (H170-190FT,
H175FT36) (B299) Pistons and Connecting Rods
NOTE: It is necessary to rotate the crankshaft to
• S6.0-7.0FT (S135-155FT) (G024) access some of the connecting rod assemblies at the
bottom dead center position.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; 1. Using a feeler gauge, measure the connecting
H5.0-5.5FT (H80-120FT) (S005) rod thrust clearance. See Figure 51. Refer to
Engine Specifications for the standard limit. If
See Frame 0100SRM1891 for lift truck models the measurement is out of specification, either
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; the crankshaft or the connecting rod must be
H5.0-5.5FT (H80-120FT) (U005) replaced.
2. Remove the starter. See Electrical Equipment

Repair.
3. Remove the flywheel and flywheel housing. See

Flywheel and Flywheel Housing.
4. Remove the alternator. See Electrical Equip-

ment Repair.
5. Remove water pump. See Cooling System Re-

pair.
6. Remove the fuel injection pump. See Fuel Sys-

tem Repair.
7. Remove the cylinder head. See Cylinder Head

Assembly Repair.
8. Remove the oil pan. See Lubrication System

Repair.
9. Remove the oil suction tube. See Lubrication Figure 51. Connecting Rod Thrust Clearance
System Repair.
10. Remove the timing gear case cover. See Timing 2. Remove the two bolts from one of the connect-
Gear Case and Timing Gears Repair. ing rod caps. See Figure 52.
11. Remove the oil pump. See Lubrication System

Repair.
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0600 SRM 1590 Drive Train, Camshaft, and Cylinder Block Repair
11. Remove the wrist pin bushing from the connect-

ing rod.
12. Repeat Step 2 through Step 11 for the remain-

ing pistons and piston rods.
Crankshaft
1. Remove eight bolts holding the rear oil seal as-
sembly to the engine block. Remove the rear oil
seal assembly. See Figure 53.
1. PISTON RINGS
2. PISTON
3. WRIST PIN
4. SNAP RING
5. WRIST PIN BUSHING
6. CONNECTING ROD
7. CONNECTING ROD CAP
8. BEARING HALVES
9. BOLT
Figure 52. Piston and Connecting Rod
3. Remove the connecting rod cap. 1. BOLT

2. REAR MAIN SEAL HOUSING
4. Remove the bearing halves. 3. REAR MAIN SEAL
4. CYLINDER BLOCK
5. Tap the piston through the cylinder and remove
Figure 53. Rear Main Seal
the piston assembly with the connecting rod.
6. Mark the connecting rod cap and the connect-

ing rod and place the assembly on a bench. 2. Remove the rear main seal.
7. Remove piston rings from the piston. 3. Measure the crankshaft side gap using the fol-
lowing method:
8. Remove the snap rings retaining the wrist pin.
a. Set a dial indicator with it's point on the end
9. Remove the wrist pin. of the crankshaft. Move the crankshaft to the
front and rear to measure side clearance. See
10. Remove the piston from the connecting rod. Figure 54.
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4. Remove the bolts holding the main bearing

caps. Remove the main bearing caps. See Fig-
ure 56.
Description Factory Allowable Limit

Specification
Side Clearance 0.15 to 0.31 mm 0.50 mm
of Crankshaft (0.0059 to (0.020 in.)
0.012 in.)
Dimension Minimum Maximum
Figure 54. Crankshaft Side Gap Measurement Oversize Journal 0.2 mm 0.4 mm
With Dial Indicator (0.008 in.) (0.016 in.)
Dimension A 169.10 to 169.2 to
169.15 mm 169.25 mm
b. If the measurement is more than allowable (6.6575 to (6.6615 to
limit, replace the thrust bearings. If the 6.6594 in.) 6.6633 in.)
same dimension bearing is not applicable be- Dimension B 29.20 to 29.25 mm 29.40 to 29.45 mm
cause of journal wear, replace it with an (1.150 to (1.158 to
oversize one. See Figure 55. 1.151 in.) 1.159 in.)
Dimension C 2.8 to 3.2 mm 2.8 to 3.2 mm
NOTE: Be sure to note the markings on the main (0.11 to 0.12 in.) (0.11 to 0.12 in.)
bearing caps, or mark them yourself, so they can be radius radius
reinstalled in the same location as they were re-
moved. Figure 55. Crankshaft Measurement With Oversize
Journal
NOTE: The arrows on the main bearing caps point
to the flywheel end of the engine.
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1. BOLT 4. BEARING HALVES

2. MAIN BEARING CAP 5. THRUST BEARING
3. CYLINDER BLOCK 6. CRANKSHAFT
Figure 56. Crankshaft
5. Remove the bearing halves and thrust bear-

ings. See Figure 56.
6. Remove the crankshaft from the cylinder block.
Camshaft
1. Using a feeler gauge, measure the camshaft
side gap. Refer to Engine Specifications for the
2. Using a gear puller, remove the camshaft gear.

See Figure 58.
3. Remove the key from the camshaft.
4. Remove the two bolts holding thrust plate and

remove thrust plate. 1. THRUST METAL
2. CAMSHAFT
3. SIDE GAP
4. CAMSHAFT PULLEY
Figure 57. Camshaft Side Gap
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NOTE: If the engine is not installed on an engine NOTE: Be sure to mark the tappets so they can be
stand, position the engine with the mounting flange installed in the same location as they were re-
(flywheel end) facing down. Rotate the camshaft a moved.
few turns to bump the tappets out of the way to
prevent the tappets from interfering with the re- 7. Remove the tappets.
moval of the camshaft.
8. Remove three flange bolts and the timing gear
5. With the engine installed on an engine stand, case plate. See Timing Gear Case and Timing
rotate the engine so the gravity causes the tap- Gears Repair.
pets to drop away from the camshaft lobes.
6. Slowly pull the camshaft out of the cylinder

block.
1. CYLINDER BLOCK 9. PULSE GEAR

2. CAMSHAFT GEAR 10. CAPSCREW
3. IDLER GEAR 11. CAMSHAFT
4. IDLER GEAR COLLAR 12. KEY
5. BUSHING 13. RETAINER
6. ALIGNMENT PIN 14. PULSAR GEAR
7. IDLER GEAR SHAFT 15. TIMING CASE PLATE
8. BOLT 16. FLANGE BOLT
Figure 58. Camshaft
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CLEAN AND INSPECT 4. Perform the calculations as follows:
a. Measure the inside diameter of cylinder

WARNING number one, near the top of the cylinder (a)
Cleaning solvents can be flammable and toxic and and in the (d) direction. Record that meas-
can cause skin irritation. When using cleaning urement as data f.
solvents, always follow the recommendations of
b. Measure the inside diameter of cylinder
the manufacturer.
number one, near the top of the cylinder (a)
and in the (e) direction. Record that meas-
WARNING urement as data g.
c. Measure the inside diameter of cylinder
number one, near the center of the cylinder
(b) and in the (d) direction. Record that
measurement as data h.
d. Measure the inside diameter of cylinder
Clean all old sealant from all parts. Clean all parts number one, near the center of the cylinder
in cleaning solvent. Dry the parts with compressed (b) and in the (e) direction. Record that
air. Each part must be free of carbon, metal filings, measurement as data i.
old sealant, and other debris. Inspect for wear,
cracks, and any other damage. Replace components e. Measure the inside diameter of cylinder
as necessary. number one, near the bottom of the cylinder
(c) and in the (d) direction. Record that
Cylinder Block measurement as data j.
1. Verify that oil holes are clear and unobstructed. f. Measure the inside diameter of cylinder
Clear any oil holes as needed. number one, near the bottom of the cylinder
(c) and in the (e) direction. Record that
2. Check for discoloration or evidence of cracks. If measurement as data k.
evidence of a fracture is found, use the color
check method or the Magnaflux method to de- g. Roundness: Roundness for cylinder number
termine if the cylinder block is fractured. one is calculated as follows:
f-g = X
3. Inspect the cylinder roundness and cylindricity
for evidence of distortions. Collect and record h-i = Y
the measurements. See Figure 59 and Table 3. j-k = Z
X is the difference between the f and g meas-

urements at the top of the cylinder.
Y is the difference between the h and i meas-

urements at the center/middle of the cylinder.
Z is the difference between the j and k meas-

urements at the bottom of the cylinder.
Select the greatest of values X, Y and Z, then

record it as V. This value represents the
roundness of the cylinder.
Figure 59. Cylinder Measurement Points
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h. Cylindricity: Cylindricity for cylinder num- 5. Repeat the cylindricity and roundness measure-
ber one is calculated as follows: ments and calculations for the remaining cylin-
Select the least value of values X, Y ders.
and Z record that value as S. Com-
6. Compare the worksheet findings with the speci-
plete the calculation as follows: fications listed in Table 4.
V-S = W
7. Consider honing, re-boring, cylinder correction,
W is the difference between the V and S meas- or replacing the cylinder block if the measure-
urements. This value represents the cylindric- ments fall outside the specifications.
ity of the cylinder.
Table 3. 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 3. 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 the cylinders while
maintaining adequate compression and oil sealing. 2. Honing: Slight cylinder imperfections might be
If the cylinder walls are scuffed, scored, out of corrected by honing.
round, or have poor cylindricity, boring or boring a. Insert the appropriate honing tool into the
and honing might correct cylinder problems. Re- chuck of an electric drill.
boring is necessary if the bore dimensions fall out-
side specified limits. See Table 4. Honing must fol- b. Saturate the cylinder wall with solvent using
low any re-boring operations. Slight imperfections a 50% diesel fuel and 50% engine oil mix-
can be corrected by honing alone. ture.
Table 4. Cylinder Bore Specification c. Rotate the honing tool at 300 to 1200 rpm.
Cylinder Bore I.D.

Factory Specification Allowable Limit CAUTION
DO NOT allow the honing tool to operate in one
position for any length of time. Damage to the cyl-
100.500 to 100.522 mm 100.650 mm inder wall will occur. Keep the tool in constant up-
(3.95670 to 3.95755 in.) (3.96260 in.) and-down motion.
1. Boring: Significant cylinder damage might be NOTE: Tilt the honing tool at a 30 to 40 degree an-
corrected by re-boring. gle during the honing operation, to leave a cross
• Boring out a cylinder block can only be hatch mark on the cylinder wall. See Figure 60.
done in a properly equipped machine
shop. d. Insert the rotating honing tool into the cylin-
der and move it down through the entire
• After re-boring, existing pistons must be length of the cylinder in a five-second mo-
replaced with oversized pistons. tion. See Figure 61.
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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 the difference for over-

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

components. See Table 5 and Figure 62 for
oversized cylinder specifications.
Figure 60. Cylinder Honing Angle

Table 5. 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 61. Cylinder Honing
e. Without stopping the honing tool, pull it up

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

to forty seconds.
WARNING
or a face shield to prevent injury to the eyes. 1. CYLINDER I.D. (BEFORE CORRECTION)
2. CYLINDER I.D. (OVERSIZE)
g. When the honing is completed, wash the cyl-
inder block with hot water and soap. Use Figure 62. Oversize Piston
brushes to clean all passages and crevices.
Rinse with hot water and blow dry with com-
pressed air. Apply clean engine oil to all steel
surfaces to prevent rusting.
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Pistons c. Add the top compression ring groove width

and the top compression ring side clearance
1. Using a micrometer, measure the piston diame- together to determine the top ring groove
ter at the skirt. Refer to the Engine Specifica- width. Refer to the Engine Specifications for
tions for the service limit. See Figure 63. the service limit.
d. Replace the piston if the values fall outside

the specification.
e. Using a feeler gauge, measure the end gap

clearance of the top compression ring. Refer
to the Engine Specifications for the service
limit.
f. Measure the rings and ring grooves for the

second compression ring and oil ring using
the same method used to measure the top
compression ring and groove dimensions.
3. Repeat Step 2 for each of the pistons.
Figure 63. Piston Skirt Measurement Piston Pin
Measure the outside diameter of the piston pin

2. Measure the piston ring and the piston ring and the inside diameter of the wrist pin bushing.
groove for cylinder number one. Calculate the clearance between the piston pin and
wrist pin bushing. Refer to the Engine Specifica-
a. Using a micrometer, measure the thickness tions for the service limit. See Figure 65.
of the top compression ring. Refer to the En-
gine Specifications for the service limit.
b. Place a properly-sized, top compression ring

in the groove as shown in Figure 64. Use a
feeler gauge to measure the gap between the
ring and the piston. Refer to the Engine
Specifications for the service limit.
NOTE: MEASURE AT POSITIONS A, B, AND C IN

DIRECTIONS A AND B.
Figure 65. Piston Pin Outside Diameter
Connecting Rod
1. Measure the inside diameter of the connecting
rod small end. Refer to the Engine Specifica-
tions for the service limit. See Figure 66.
A. WIDTH B. THICKNESS
Figure 64. Piston and Piston Ring Side Clearance
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1. ABNORMAL CONTACT SURFACE

2. NORMAL CONTACT SURFACE
2. Measure the outside diameter of the tappet

stem. Refer to the Engine Specifications for the
1. CYLINDER GAUGE
2. CONNECTING ROD SMALL END
Figure 66. Connecting Rod Small End

Figure 68. Tappet Stem Measurement
2. Measure the crank-pin and connecting rod

bearing halves. Place the connecting rod bear-
Crankshaft
ing halves into the connecting rod and connect-
ing rod cap. Install the end of the connecting 1. Measure the trueness of the crankshaft.
rod to the connecting rod cap. Install the bolts
and tighten to 54 to 59 N•m (40 to 43 lbf ft). a. Place the crankshaft on V-blocks at the end
journals. See Figure 69.
3. Measure the inside diameter. Refer to the En-
gine Specifications for the service limit. b. Place a dial indicator on a main bearing sur-
face and zero the gauge.
Tappets
c. Rotate the crankshaft and observe the run-
1. Check the tappet contact surfaces with the out. Refer to the Engine Specifications for
camshaft and push rods. Slight surface defects the service limit.
can be corrected using an oilstone. See Fig-
ure 67. d. Repeat this procedure for the remaining
bearing surfaces.
2. Inspect the crankshaft for fractures.
a. Using the color check method, inspect the

crankshaft for cracks. Replace the crankshaft
if evidence of fractures are found. See Fig-
ure 70.
Figure 67. Tappet Contact Surface
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3. Measure the oil clearance between crank-pin

and crank pin bearing.
NOTE: DO NOT put Plastigage into crank pin

hole.
NOTE: When tightening the connecting rod screws,

DO NOT move the crankshaft.
a. Clean the crank pin and crank bearing. Put a

strip of plastigage on the center of crank pin.
Install connecting rod cap. Tighten connect-
ing rod cap screws to specified torque. Re-
move connecting rod cap again. Measure
width that becomes flat with the scale to get
the oil clearance. See Figure 71.
A. BEND B. DEFLECTION
1. DIAL GAUGE 3. V-BLOCK
2. CRANKSHAFT
Figure 69. Crankshaft Bend Measurement
Description Factory Allowable Limit

Specification
52.977 to N/A
52.990 mm
Crank Pin O.D.
(2.0857 to
2.0862 in.)
Oil Clearance 0.018 to 0.20 mm
Between Crank 0.051 mm (0.0079 in.)
Pin and Crank (0.00071 to
Pin Bearing 0.0020 in.)
Figure 70. Crankshaft Fracture Check Figure 71. Crank Pin Oil Clearance
b. If the color check method is not available, NOTE: When replacing the crank pin bearing with
use the Magnaflux method. Inspect the a standard service part, make sure the crank pin
crankshaft for cracks. Replace the crankshaft bearing and connecting rod are marked with the
if evidence of fractures are found. same ID color.
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b. If oil clearance is more than allowable limit,

replace pin bearing. See Figure 72. If same
dimension bearing is not applicable because
of crank pin wear, replace it with undersize
one. Refer to Figure 73.
Dimension Minimum Maximum

0.2 mm 0.4 mm
Undersize
(0.008 in.) (0.016 in.)
2.8 to 3.2 mm 2.8 to 3.2 mm
Dimension A (0.11 to (0.11 to
0.12 in.) radius 0.12 in.) radius
1.0 to 1.5 mm 1.0 to 1.5 mm
*Dimension B (0.040 to (0.040 to
1. ID COLOR 0.059 in.) relief 0.059 in.) relief
2. CRANK PIN BEARING
3. CENTER WALL THICKNESS 52.777 to 52.577 to
52.790 mm 52.590 mm
Dimension C
ID Color Connecting Crank Pin Bearing (2.0779 to (2.0700 to
Rod 2.0783 in.) dia. 2.0704 in.) dia.
Large End Class Center Wall The crank pin must be fine-finished to higher to
Diameter Thickness Rmax=0.8S. *Holes to be de-burred and edges
rounded with 10 to 1.5 mm (0.040 to 0.059 in.) relief.
56.010 to 1.496 to
56.020 mm 1.501 mm Figure 73. Crank Pin Journal Measurement
Blue L
(2.2052 to (0.05890 to
2.2055 in.) 0.05909 in.)
56.00 to 1.491 to
Without 56.01 mm 1.496 mm
S
Color (2.2048 to (0.05870 to
2.2051 in.) 0.05889 in.)
Figure 72. Crankshaft Pin Bearing Identification
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Camshaft Legend for Figure 75
1. Measure the trueness of the camshaft. A. CAM HEIGHT
a. Place the camshaft on V-blocks positioned at

the end journals. See Figure 74. 3. Measure the gear end bearing surface, inter-
mediate position bearing surface, and flywheel
b. Place a dial indicator on the gear side bear- end bearing surface diameters. See Figure 76.
ing surface and zero the gauge. Determine the oil clearance. The oil clearance
is calculated by subtracting the measured cam-
c. Rotate the camshaft and observe the runout.
shaft bearing surface diameter from the cam-
Refer to the Engine Specifications for the
shaft bushing inside diameter. Refer to the En-
service limit.
gine Specifications for the service limit.
1. FLYWHEEL END BEARING SURFACE

Figure 74. Camshaft Runout Check 2. INTERMEDIATE POSITION BEARING SUR-
FACE
3. GEAR END BEARING SURFACE
2. Measure the intake/exhaust cam height. Refer Figure 76. Camshaft Bearing Surface
to the Engine Specifications for the service Measurements
Camshaft Bushing
If the camshaft bushing is damaged, replace the

bushing using the appropriate service tool.
ASSEMBLE
Camshaft
1. Verify that all parts are clean. Lightly lubricate
all parts with clean engine oil.
Figure 75. Intake/Exhaust Cam Height
Measurement
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2. Install the timing gear case. See Timing Gear 2. Lubricate and insert the wrist pin bushing into
Case and Timing Gears Repair. the small end of the connecting rod. See Fig-
ure 52.
NOTE: Rotate the cylinder block into a position in
which it allows gravity to keep the tappets in place 3. Install one snap ring into the piston.
and out of the way of the camshaft lobes for when
the camshaft is installed. 4. Position the connecting rod into the piston un-
der the skirt. The match marks on the connect-
3. Install the tappets into the cylinder block in the ing rod must be opposite of the piston identifi-
same locations as they were removed. cation mark on the top of the piston. See Fig-
ure 77.
4. Slowly insert the camshaft through the front of
the engine.
5. Place the camshaft thrust plate in position and

install the retaining bolts. See Figure 57.
6. Install the key on the camshaft.
7. Install the camshaft gear.
Crankshaft
1. Place the crankshaft in position in the cylinder
block.
NOTE: The numbers and arrows on the main bear-

ing caps are for proper positioning. The caps are
numbered 1, 2, 3, and 4 with the number 1 cap at
the flywheel end of the cylinder block. The arrows
on the bearing caps should point towards the fly-
wheel end of the cylinder block.
2. Position the bearing halves, thrust bearings,

and bearing caps on the crankshaft. See Fig-
ure 56. A. FUEL INJECTION PUMP SIDE
B. FLYWHEEL SIDE
C. CAMSHAFT SIDE
3. Lubricate the bearing cap bolts and install the
bolts. 1. PISTON IDENTIFICATION MARK
2. CYLINDER SIZE MARK
4. Install a new oil seal in the rear oil seal hous- 3. EMBOSSED MARK (FLYWHEEL SIDE)
ing. 4. PUNCHED MARK
5. Apply a continuous bead of Three Bond Liquid Figure 77. Piston and Connecting Rod
Gasket (Hyster P/N 1599478) to the mating Identification Marks
surface of the rear oil seal housing.
6. Align the rear oil seal housing with the two 5. Lubricate and install the piston wrist pin
dowel pins on the cylinder block and install the through the piston and wrist pin bushing.
rear oil seal housing. Install the retaining bolts.
6. Install the second snap ring.
Pistons and Connecting Rods
7. Using piston ring pliers, install the piston
1. Select the parts needed to assemble the piston rings.
and connecting rod for the Number 1 cylinder.
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a. Install each piston ring on the piston with

the punched manufacture's mark facing up-
ward. See Figure 78.
Figure 78. Piston Ring Mark
b. Install the top compression ring, second com-

pression ring, and oil ring. See Figure 79.
c. Stagger the piston ring joints at 120 degree

intervals. DO NOT position the top compres-
sion ring joint in line with the piston wrist
pin. The coil expander joint must be opposite
the oil ring joint. See Figure 80.
1. TOP COMPRESSION RING

2. SECOND COMPRESSION RING
3. OIL RING
4. JOINTS
Figure 80. Piston Rings Staggering
8. Perform Step 1 through Step 7 for the assembly

of the remaining pistons.
9. Lubricate the Number 1 piston and piston rings

with clean engine oil.
10. Using special tool, piston ring compressor, com-

press the piston rings on the Number 1 piston.
11. Carefully install the piston into the Number 1

1. TOP COMPRESSION RING
2. SECOND COMPRESSION RING cylinder. Be sure the punched mark on the con-
3. OIL RING necting rod is facing the fuel injector side and
4. PISTON the embossed mark is facing the flywheel. See
Figure 77.
Figure 79. Piston Rings
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HeavyManuals.com
12. Install the connecting rod bearing halves and See Frame 0100SRM1891 for lift truck models
connecting rod cap. Install the connecting rod • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
bolts and tighten to 79 to 83 N•m (58 to H5.0-5.5FT (H80-120FT) (U005)
61 lbf ft).
13. If not previously removed, remove and discard
13. Perform Step 9 through Step 12 to install the engine oil filter. Apply clean oil to gasket of
remaining pistons in their respective cylinders. new filter. Install new filter. Turn filter until
gasket touches, then tighten 1/2 to 3/4 turn
INSTALL with your hand.
1. Install the crankshaft gear and idler gear. See 14. Fill the engine oil to the correct level. For cor-
Timing Gear Case and Timing Gears Repair. rect amount of oil and type refer to
2. Install the oil pump. See Lubrication System Periodic Maintenance 8000SRM1583 for lift
Repair. truck models
3. Install the timing gear case cover. See Timing • H6.0-7.0FT (H135-155FT) (K006)
Gear Case and Timing Gears Repair.
4. Install the oil suction tube. See Lubrication truck model
System Repair. • H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299)
5. Install the oil pan. See Lubrication System Re-
pair. Periodic Maintenance 8000SRM1606 for lift
truck models
6. Install the cylinder head. See Cylinder Head
Assembly Repair. • S6.0-7.0FT (S135-155FT) (G024)
7. Install the fuel injection pump. See Fuel Sys- Periodic Maintenance 8000SRM1604 for lift
tem Repair. truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
8. Install the water pump. See Cooling System Re-
H5.0-5.5FT (H80-120FT) (S005)
pair.
9. Install the alternator. See Electrical Equipment
truck models
Repair.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
10. Install the flywheel and flywheel housing. See H5.0-5.5FT (H80-120FT) (U005)
Flywheel and Flywheel Housing.
15. Start the engine and check for leaks.
11. Install the starter. See Electrical Equipment
Repair. Angular Deviation Procedure - Kubota 3.8L
Diesel Engine
NOTE: This procedure ONLY needs to be per-
formed if the crankshaft has been replaced.
• H6.0-7.0FT (H135-155FT) (K006)
• H8.0-9.0FT, H8.0FT9 (H170-190FT, NOTE: The angular deviation procedure is used to
H175FT36) (B299) measure the angular difference between crankshaft
top dead center (TDC) and the detected TDC by the
See Frame 0100SRM1316 for lift truck models crankshaft position sensor.
• S6.0-7.0FT (S135-155FT) (G024) 1. Remove cylinder head cover, number four injec-
tor and rocker arm. See Cylinder Head Assem-
bly Repair for procedures.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80-120FT) (S005)
52
HeavyManuals.com
2. Position piston of number four cylinder at top

dead center. See Fuel System Repair for proce-
dures.
3. Remove number four cylinder exhaust valve

bridge arm and valve spring. See Cylinder
Head Assembly Repair for procedures.
NOTE: DO NOT drop valve into cylinder.
4. Install a small O-ring onto number four ex-

haust valve to help prevent valve from falling
into cylinder. See Figure 81.
1. TRI-SQUARE
2. FLYWHEEL HOUSING
3. FLYWHEEL
Figure 82. Cranksahft TDC Reference Line
1. DIAL GAUGE 3. O-RING

2. EXHAUST VALVE
Figure 81. Valve Height Measurement
5. Set a dial gauge on tip of valve. See Figure 81. 1. REFERENCE LINE
2. FLYWHEEL HOUSING
NOTE: When measuring the highest position of the 3. FLYWHEEL
exhaust valve tip, DO NOT rotate the flywheel
Figure 83. Complete TDC Reference Line
clockwise. If you go past the highest point of the
valve, back the flywheel up slightly and measure
the highest point of the exhaust valve.
8. Connect engine harness and ignition switch.
6. Turn flywheel counterclockwise and measure
9. Connect battery.
position where tip of exhaust valve is at its
highest. See Figure 81. 10. Attach a tester to output terminal and ground
terminal of crankshaft position sensor. See Fig-
NOTE: The reference line indicates the TDC of the
ure 84 and Figure 85.
crankshaft.
7. Place a tri-square on flywheel housing and fly-

wheel and draw a reference line. See Figure 82
and Figure 83.
53
HeavyManuals.com
WARNING
When turning the ignition switch to the ON posi-
tion, DO NOT start the lift truck. Injury may occur.
11. Turn ignition switch to ON position.
12. Rotate the flywheel by hand and make sure

that voltage of crankshaft position sensor goes
from 0 to 5 V or 5 to 0 V.
NOTE: When the crankshaft position sensor de-

tects the teeth of the pulsar gear, the tester indi-
cates 0 V.
1. TESTER
2. CRANKSHAFT POSITION SENSOR 13. Rotate flywheel and align crankshaft position
sensor to part of pulsar gear without teeth. The
Figure 84. Crankshaft Position Sensor Tester
fourteenth tooth from missing teeth opening is
the standard. See Figure 86.
1. GROUND TERMINAL 1. PULSAR GEAR

2. OUTPUT TERMINAL 2. FOURTEENTH TOOTH
3. CRANKSHAFT POSITION SENSOR 3. MISSING TEETH
Figure 85. Crankshaft Position Sensor Connector Figure 86. Pulsar Gear
54
HeavyManuals.com
NOTE: The position where the needle of the tester 16. Measure the interval between crankshaft TDC
changes momentarily from 0 to 5 V is the TDC as and crankshaft position sensor TDC (see Fig-
detected by the crankshaft position sensor. ure 88). This measurement will be used to cal-
culate any necessary fuel injection timing cor-
14. Slowly turn flywheel counterclockwise and stop rection.
the flywheel at the point where the needle of
the tester changes momentarily from 0 to 5V.
This should be the fourteenth tooth from miss-
ing teeth opening on pulsar gear. This point is
when the crankshaft position sensor detects
TDC. See Figure 86.
15. Set the tri-square on the reference line previ-

ously marked on flyweel housing side and mark
crankshaft position sensor TDC point on the
flywheel. See Figure 87.
1. INTERVAL
Figure 88. TDC Interval Measurement
17. Using PC Service tool, overwrite the injection

timing value in the ECU. See Diagnostic
Troubleshooting Manual 9000SRM1112 for
procedures.
18. Remove dial gauge from valve.

1. CRANKSHAFT TDC
2. CRANKSHAFT POSITION SENSOR TDC NOTE: DO NOT drop valve into cylinder.
Figure 87. Crankshaft Position Sensor TDC 19. Remove O-ring from exhaust valve.
20. Install number four exhaust valve spring and

NOTE: The reference line indicates the TDC of the bridge arm. See Cylinder Head Assembly Re-
crankshaft. If the detected TDC is ahead of the pair for procedures.
crankshaft TDC, it is considered minus. If the de-
21. Install rocker arm, number four cylinder fuel
tected TDC lags behind the crankshaft TDC, it is injector, and cylinder head cover. See Cylinder
considered plus. Head Assembly Repair for procedures.
55
HeavyManuals.com
Lubrication System Repair 0600 SRM 1590
Lubrication System Repair

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

engine oil into a suitable container. See Fig-
ure 89.
1. OIL FILTER 3. OIL COOLER

2. ADAPTER BOLT 4. CRANK CASE
Figure 90. Oil Filter


truck model
• H6.0FT, H7.0FT (H135FT, H155FT)
(K006)

truck model
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299)
1. DRAIN PLUG 4. BOLT
2. GASKET 5. FLANGE BOLT Periodic Maintenance 8000SRM1606 for lift
3. OIL PAN 6. CRANK CASE truck models
• S6.0-7.0FT (S135-155FT) (G024)
Figure 89. Oil Pan
truck models
2. Remove the engine oil filter. See Figure 90.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
3. Install the oil pan drain plug. H5.0-5.5FT (H80-120FT) (S005)
4. Apply clean oil to gasket of new filter. Install Periodic Maintenance 8000SRM1902 for lift
new filter. Turn filter until gasket touches, truck models
then tighten 1/2 to 3/4 turn with your hand. • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80-120FT) (U005)
56
HeavyManuals.com
0600 SRM 1590 Lubrication System Repair
6. Start engine. Check area around oil filter for See Frame 0100SRM1316 for lift truck models
leaks. • S6.0-7.0FT (S135-155FT) (G024)
OIL PAN See Frame 0100SRM1243 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
Remove H5.0-5.5FT (H80-120FT) (S005)

WARNING
When putting the lift truck on blocks, make sure • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
the surface is solid, even, and level. Any blocks H5.0-5.5FT (H80-120FT) (U005)
used to support the lift truck must be solid, one-
NOTE: Place a container with a capacity of at least
piece units.
13.2 liter (3.5 gal) under the oil pan drain plug.
1. Put the lift truck on blocks so that you have ac-
3. Remove the oil pan drain plug and drain the
cess under the lift truck. Refer to the Operat-
engine oil into a suitable container. See Fig-
ing Manual or the section
ure 90.
4. Remove the oil filter.
truck model
• H6.0FT, H7.0FT (H135FT, H155FT) 5. Remove twenty bolts holding the oil pan to the
(K006) crankcase. See Figure 89.
Periodic Maintenance 8000SRM1586 for lift 6. Remove four flange bolts holding the oil pan to
truck model the crankcase. See Figure 89.
• H8.0FT, H8.0FT9, H9.0FT (H170FT, 7. Remove the oil pan.
H175FT36, H190FT) (B299)
Periodic Maintenance 8000SRM1606 for lift CAUTION

truck models Use care not to damage the mating surfaces when
• S6.0-7.0FT (S135-155FT) (G024) removing old gaskets and sealant residues.
Periodic Maintenance 8000SRM1604 for lift 8. Carefully remove old sealant residue from the
truck models mating surfaces of the oil pan and cylinder
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; block.
H5.0-5.5FT (H80-120FT) (S005)
9. Thoroughly clean the outside and inside surfa-
Periodic Maintenance 8000SRM1902 for lift ces of the oil pan.
truck models
Install
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80-120FT) (U005) 1. Apply a continuous bead of Three Bond Liquid
Gasket (Hyster P/N 1599478) around the seal-
2. Remove the underbody shield.
ing surface of the oil pan.
2. Place the oil pan in position and install the re-
• H6.0-7.0FT (H135-155FT) (K006) taining bolts. Refer to Standard Torque Specifi-
• H8.0-9.0FT, H8.0FT9 (H170-190FT, cations.
H175FT36) (B299)
57
HeavyManuals.com
3. Apply clean oil to gasket of new filter. Install

new filter. Turn filter until gasket touches,
then tighten 1/2 to 3/4 turn with your hand.
4. Install the oil pan drain plug.
5. Install the underbody shield.
6. Remove the lift truck from blocks.


truck model
• H6.0FT, H7.0FT (H135FT, H155FT)
(K006)
Periodic Maintenance 8000SRM1586 for lift 1. BOLT 3. O-RING

2. OIL SUCTION TUBE 4. CRANKCASE
truck model
• H8.0FT, H8.0FT9, H9.0FT (H170FT, Figure 91. Oil Suction Tube
H175FT36, H190FT) (B299)
Periodic Maintenance 8000SRM1606 for lift Clean

truck models
• S6.0-7.0FT (S135-155FT) (G024)
WARNING
Periodic Maintenance 8000SRM1604 for lift Cleaning solvents can be flammable and toxic and
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) (S005) the manufacturer.

truck models WARNING
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80-120FT) (U005)
8. Start the engine and check for leaks. away from all personnel. Wear protective goggles
OIL SUCTION TUBE
NOTE: The oil suction tube and screen are to be
serviced as an assembly. DO NOT attempt to repair
Remove the wire mesh portion of the tube and screen as-
1. Remove the oil pan. See Oil Pan, Remove. sembly.
2. Remove the two bolts holding the oil suction Clean the oil suction tube in cleaning solvent. Dry
tube. See Figure 91. the oil suction tube with compressed air. Inspect for
wear and damage. If necessary, replace oil suction
3. Remove the oil suction tube. tube.
4. Remove O-ring from the oil suction tube and
discard.
58
HeavyManuals.com
Install 2. Remove the bolt and washer holding the crank-

shaft pulley.
1. Install a new O-ring on the oil suction tube.
3. Using a gear puller, remove the crankshaft pul-
2. Position the oil suction tube in the cylinder ley.
block.
3. Install the two bolts to retain the oil suction Gear Case and Timing Gears Repair.
tube. Refer to Standard Torque Specifications.
5. Remove eight capscrews holding the oil pump
4. Install the oil pan. See Oil Pan, Install. assembly and remove the oil pump assembly
from the timing gear case housing. See Fig-
OIL PUMP ure 92.
Remove 6. Remove the outer rotor from the timing gear

case housing. See Figure 92.
1. Remove the coolant fan, serpentine belt, and
water pump. See Cooling System Repair.
1. CAPSCREW 3. OIL PUMP ROTOR

2. OIL PUMP COVER 4. GEAR CASE HOUSING
Figure 92. Oil Pump Assembly
59
HeavyManuals.com
Clean and Inspect Legend for Figure 93
1. OUTER ROTOR 3. OIL PUMP CAVITY

WARNING 2. FEELER GAUGE
can cause skin irritation. When using cleaning
solvents, always follow the recommendations of Outer Rotor to Inner Rotor Tip Clearance
the manufacturer.
Insert a feeler gauge between the top of an inner
rotor tooth and the top of an outer rotor tooth and
WARNING measure the clearance. Refer to the section Engine
Compressed air can move particles so that they Specifications for the clearance limits. See Fig-
cause injury to the user or to other personnel. ure 94.
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 of the parts in cleaning solvent. Dry the

parts with compressed air. Inspect for wear and
damage. If necessary, replace oil pump assembly.
Outer Rotor Outside Clearance

1. FEELER GAUGE 3. OUTER ROTOR
Insert a feeler gauge between the outer rotor and 2. INNER ROTOR
the timing gear case oil pump cavity and measure
Figure 94. Outer Rotor to Inner Rotor Tip
the clearance. Refer to the section Engine Specifica-
Clearance Check
tions for the clearance limits. See Figure 93.
Outer Rotor Side Clearance
Using a depth micrometer, measure the depression

of the outer rotor across the pump cavity to deter-
mine the side clearance. Refer to the section Engine
Specifications for the clearance limits. See Fig-
ure 95.
Rotor Shaft Clearance
Measure the outside diameter of the rotor shaft and

the bore diameter in the gear case housing to deter-
mine the rotor shaft clearance. Refer to the section
Figure 93. Outer Rotor Outside Clearance Check Engine Specifications for the clearance limits. See
Figure 96.
60
HeavyManuals.com
2. Install the outer rotor in the gear case housing.

Verify that the punch mark end of the outer ro-
tor faces away from the gear case housing. See
Figure 97.
1. DEPTH MICROMETER
2. PUMP CAVITY
3. OUTER ROTOR 1. PUNCH MARK
2. OUTER ROTOR
Figure 95. Outer Rotor Side Clearance Check 3. TIMING GEAR CASE
Figure 97. Outer Rotor
3. Position the oil pump assembly in the gear case

housing. Install the bolts to retain the oil pump.
Refer to Standard Torque Specifications. See
Figure 89.

Gear Case and Timing Gears Repair.
5. Install the crankshaft pulley, washer, and bolt

to retain the crankshaft pulley. Tighten bolt to
255 to 274 N•m (188 to 202 lbf ft).
6. Install the water pump, serpentine belt, and

1. ROTOR SHAFT
2. GEAR CASE HOUSING coolant fan. See Cooling System Repair.
Figure 96. Rotor Shaft Clearance Check 7. Install the engine.

• H6.0-7.0FT (H135-155FT) (K006)
Install
• H8.0-9.0FT, H8.0FT9 (H170-190FT,
1. Lubricate the outer rotor and pump bore in the H175FT36) (B299)
gear case with clean engine oil.
NOTE: The punch mark end of the outer rotor
• S6.0-7.0FT (S135-155FT) (G024)
must face away from the gear case housing.
61
HeavyManuals.com
See Frame 0100SRM1243 for lift truck models 8. Change engine oil and oil filter. See Engine Oil
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; and Oil Filter Change.
H5.0-5.5FT (H80-120FT) (S005)
9. Start engine and check for leaks.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80-120FT) (U005)
Fuel System Repair

FUEL INJECTORS 2. Remove the high pressure fuel lines. See Cylin-
der Head Assembly Repair.
Remove
Inspect
CAUTION Visually inspect the fuel injectors and nozzle holes

DO NOT loosen the fuel injection lines when the for carbon deposits or damage. Clean and replace
fuel is under high pressure (within five minutes of as necessary.
Clean
NOTE: Note position of each fuel injector prior to
removal.
CAUTION
NOTE: Store fuel injectors and fuel injector lines so DO NOT use a wire brush or similar tool to clean
they DO NOT get any dirt or debris in them. the nozzle hole. It will damage the hole.
1. Remove fuel injector lines, valve covers, and
fuel injectors. See Valve Covers and Fuel Injec- CAUTION
tors.
DO NOT disassemble the injector to clean it.
1. Clean the exterior of the nozzle so that nozzle

CAUTION
hole is free from obstruction.
Remove the high pressure fuel lines as an assem-
bly whenever possible. Disassembling the high
pressure fuel lines from the retainers or bending
any of the fuel lines will make it difficult to rein-
stall the fuel lines.
62
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0600 SRM 1590 Fuel System Repair
Replace
If it becomes necessary to replace a fuel injector,

note the QR/ID codes located on the tabs at the top
of each injector.
Fuel injectors are manufactured with precise toler-

ances, but there may be minute variations with the
injector fuel flow. To correct these variations, a cor-
rection volume is recorded on the QR/ID codes of
the injectors.
After replacing an injector it will be necessary to in-

put the new ID code into the ECU. See Diagnostic
Troubleshooting Manual 9000SRM1112 for pro- 1. QR CODE 2. ID CODE
cedures. Figure 98. Kubota Diesel Fuel Injector
Install
1. Install high pressure fuel lines. See Cylinder FUEL INJECTION PUMP
Head Assembly Repair for procedure.
Remove
2. Install fuel injectors, valve covers, and fuel in-
jector lines. See Valve Covers and Fuel Injec-
tors section for procedure. CAUTION
DO NOT loosen the fuel injection lines when the
Test fuel is under high pressure (within five minutes of
1. Test the fuel system for proper operation using
PC service tool. See Diagnostic Trouble- 1. Remove banjo bolt, fuel supply line, and two
shooting Manual 9000SRM1112 for test and washers from back of injection pump. Discard
procedures. washers and plug line to help prevent debris
from entering line. See Figure 99.
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HeavyManuals.com
Fuel System Repair 0600 SRM 1590
1. FUEL INJECTION PUMP 10. ENGNINE BLOCK (REFERENCE ONLY)

2. STUD 11. BASE GASKET
3. NUT 12. FLANGE BOLT
4. FUEL SUPPLY LINE 13. GEAR
5. WASHERS 14. LOCKNUT
6. BANJO BOLT 15. TIMING GEAR CASE
7. O-RING 16. COVER GASKET
8. OVERFLOW PIPE RETURN LINE 17. INJECTION PUMP GEAR COVER
9. INJECTION PUMP BASE 18. KEY
Figure 99. Fuel Injection Pump
2. Remove banjo bolt, overflow pipe return line,

and two washers from side of injection pump. CAUTION
Discard washers and plug line to help prevent DO NOT loosen the fuel injection lines when the
debris from entering fuel line. See Figure 99. fuel is under high pressure (within five minutes of
3. Disconnect fuel supply and return lines to fuel
rail. See Figure 99. 5. Remove fuel lines, fuel injectors and valve cov-
ers. See Valve Covers and Fuel Injectors section
4. Disconnect the electrical connectors for the fuel for procedure.
temperature sensor and fuel pump solenoid.
64
HeavyManuals.com
0600 SRM 1590 Fuel System Repair
NOTE: This alignment mark is extremely useful

CAUTION during assembly of fuel injection pump drive gear
DO NOT loosen the fuel injection lines when the and idler gear to get timing correct.
fuel is under high pressure (within five minutes of
stopping the engine). 10. To aid in reassembly, mark one tooth on the id-
ler gear with a dot of white paint. See Fig-
6. Remove high pressure fuel lines and fuel filter ure 101.
assembly. See Cylinder Head Assembly Repair
for procedure.
7. Remove serpentine belt and fan assembly. See

Cooling System Repair section for procedure.
8. Remove six flange bolts, injection pump gear

cover, and gasket from front of timing gear case
cover. Discard gasket. See Figure 99.
NOTE: When positioning the piston of the 4th cyl-

inder to TDC, rotate the flywheel counterclockwise
and align the TC mark on the flywheel with the
mark on the inspection port on the flywheel hous- 1. FUEL INJECTION PUMP DRIVE GEAR
ing (see Figure 100). If the fuel injection pump gear 2. FUEL INJECTION PUMP GEAR MOUNTING
timing mark meshes with idler gear, then the pis- NUT
ton of the 4th cylinder is TDC. If they do not mesh, 3. TIMING MARK
rotate the flywheel counterclockwise one revolu- 4. ALIGNMENT MARK
5. IDLER GEAR
tion.
Figure 101. Fuel Pump Drive Gear Timing
9. Put piston of number 4 cylinder at top dead
Alignment
center (TDC). See Figure 100.
11. While holding the flywheel from turning with a

flywheel stopper tool, remove the fuel injection
pump drive gear locknut. See Figure 99.
NOTE: The fuel injection pump shaft is tapered

with a woodruff key. Once you have applied some
pressure with a puller, a slight tap with a hammer
on the center puller bolt will help pop the gear from
the shaft.
12. Using a two-bolt gear puller, remove the fuel

injection pump drive gear from the fuel injec-
tion pump shaft.
1. FLYWHEEL HOUSING
2. FLYWHEEL 13. Remove the two nuts securing the fuel injection
3. TDC MARK pump to the rear of the timing gear case.
Figure 100. Kubota TDC Mark 14. Remove the fuel injection pump, woodruff key,
and O-ring. Discard O-ring. See Figure 99.
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Fuel System Repair 0600 SRM 1590
Clean and Inspect 8. Install fuel filter assembly and high pressure
fuel lines. See Cylinder Head Assembly Repair.
Clean all old sealant from the timing gear case
cover and the fuel injection pump drive gear cover.
Inspect all parts for damage. Replace as needed.
CAUTION
DO NOT bend any of the fuel lines when installing
Install them.
1. Using alignment pins to locate proper position, 9. Install fuel injector lines, fuel injectors, and
install new base gasket, injection pump base, valve covers. See Valve Covers and Fuel Injec-
and three flange bolts into rear of timing gear tors section.
case. See Figure 99. 10. Connect electrical connectors for the fuel tem-
2. Install new O-ring, woodruff key, and injection perature sensor and fuel pump solenoid.
pump onto rear of timing gear case. See Fig- 11. Connect fuel supply and return lines to fuel
ure 99. rail.
3. Install two nuts onto two studs holding injec- 12. Remove plug from fuel line. Install two wash-
tion pump in place. Torque to 24 to 27 N•m (18 ers, overflow pipe return line, and banjo bolt to
to 20 lbf ft). side of injection pump. See Figure 99.
4. Install injection pump drive gear using align- 13. Remove plug from fuel line. Install two wash-
ment marks on the fuel injection pump gear ers, fuel supply line, and banjo bolt to back of
and idler gear. See Figure 101. injection pump. See Figure 99.
5. Install locknut onto shaft of fuel injection 14. Turn ignition to ON position to cycle fuel pump.
pump. Torque to 59 to 68 N•m (44 to 50 lbf ft).
15. Check fuel lines and hoses for leaks.
6. Install new cover gasket, injection pump gear
cover, and six flange bolts into timing gear case 16. After removing or replacing the fuel injection
cover. Torque to 24 to 27 N•m (18 to 20 lbf ft). pump it will be necessary to reset the operating
parameters for fuel injection pump. See Diag-
7. Install the fan assembly and serpentine belt. nostic Troubleshooting Manual
See Cooling System Repair for procedure. 9000SRM1112 for procedure.
Cooling System Repair

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

WARNING
2. Remove the fan assembly.
the fan, pulleys, or drive belts. Contact with these See Cooling System 0700SRM1123 for lift
parts can cause serious injury. truck models
• H6.0-7.0FT (H135-155FT) (K006)
WARNING • H8.0-9.0FT, H8.0FT9 (H170-190FT,
The radiator or other parts of the cooling system H175FT36) (B299)
may be hot or under pressure and can cause seri-
• S6.0-7.0FT (S135-155FT) (G024)
ous injury. Wait 30 minutes for the radiator to
cool. Do a touch test by touching the radiator with • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80-120FT) (S005)
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0600 SRM 1590 Cooling System Repair
See Cooling System 0700SRM1895 for lift

truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80-120FT) (U005)
3. Loosen the alternator set bolt and pivot the al-

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

damage. If any of these conditions exist, replace the
serpentine belt.
Install
1. Place serpentine belt over pulleys.
A. TENSION CHECK POSITION
2. Adjust tension of serpentine belt as shown in B. TENSION CHECK POSITION
section Adjust.
Figure 102. Serpentine Tension Check Points
3. Tighten set bolt for alternator to
25.5 N•m (18.8 lbf ft).
2. If adjustment is necessary, loosen alternator
4. Install fan assembly.
set bolt and move alternator with a pry bar to
See Cooling System 0700SRM1123 for lift tighten serpentine belt. See Figure 103.
truck models
• H6.0-7.0FT (H135-155FT) (K006)
• H8.0-9.0FT, H8.0FT9 (H170-190FT,
H175FT36) (B299)
• S6.0-7.0FT (S135-155FT) (G024)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80-120FT) (S005)

truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80-120FT) (U005)
Adjust
NOTE: The serpentine belt is to be checked at posi-
tion A or B shown in Figure 102.
1. Using a belt tension gauge, adjust belt tension 1. SET BOLT 3. PRY BAR
to 500 to 550 N (112 to 124 lbf). 2. ALTERNATOR
Figure 103. Serpentine Belt Adjustment
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Cooling System Repair 0600 SRM 1590
3. When tension is correct, tighten set bolt to 5. Remove coolant drain plug and drain coolant
25.5 N•m (18.8 lbf ft). Check belt tension again from engine block. See Figure 104.
to verify tension is still correct.
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
removed, pressure will release from the coolant
system. If the coolant system is hot, the steam
and boiling coolant can cause severe burns. 1. COOLANT DRAIN PLUG
Figure 104. Engine Block Coolant Drain Plug

WARNING
The radiator or other parts of the cooling system
may be hot or under pressure and can cause seri- 6. Remove fan assembly.
engine to cool before performing maintenance to See Cooling System 0700SRM1123 for lift
the cooling system. After 30 minutes, do a touch truck models
test by touching the radiator with your hand. If the • H6.0-7.0FT (H135-155FT) (K006)
radiator is still hot to the touch, wait another 30 • H8.0-9.0FT, H8.0FT9 (H170-190FT,
minutes before attempting any maintenance to the H175FT36) (B299)
cooling system.
• S6.0-7.0FT (S135-155FT) (G024)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
CAUTION H5.0-5.5FT (H80-120FT) (S005)
Disposal of lubricants must meet local environ-
mental regulations. See Cooling System 0700SRM1895 for lift
truck models
3. Remove radiator cap.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
4. Loosen lower radiator hose and drain coolant H5.0-5.5FT (H80-120FT) (U005)
from coolant system.
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7. Remove serpentine belt. See Serpentine Belt, 11. If necessary, remove coolant temperature sen-
Remove. sor.
8. Remove fan pulley. 12. Disconnect coolant hoses from water pump. See
Cylinder Head Assembly Repair section for pro-
9. Pivot alternator away from engine. cedure.
10. Disconnect electrical connector for coolant tem- 13. Remove four water pump bolts and water pump
perature sensor. from water pump/timing gear housing. See Fig-
ure 105.
1. BOLT 3. GASKET
2. WATER PUMP
Figure 105. Water Pump
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Install 10. Fill cooling system with coolant. For the correct
coolant amount and type refer to
1. Install new gasket, water pump, and four bolts
to water pump/timing gear housing. See Fig- Periodic Maintenance 8000SRM1583 for lift
ure 105. truck model
• H6.0FT, H7.0FT (H135FT, H155FT)
2. Connect coolant hoses to water pump. See Cyl-
(K006)
inder Head Assembly Repair for procedure.
3. If removed, install coolant temperature sensor
truck model
and tighten to 16 to 23 N•m (12 to 17 lbf ft).
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
4. Connect electrical connector for coolant temper- H175FT36, H190FT) (B299)
ature sensor.
5. Install the fan pulley. truck models
6. Install serpentine belt. See Serpentine Belt, In- • S6.0-7.0FT (S135-155FT) (G024)
stall. Periodic Maintenance 8000SRM1604 for lift
7. Install fan assembly. truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
See Cooling System 0700SRM1123 for lift H5.0-5.5FT (H80-120FT) (S005)
truck models
• H6.0-7.0FT (H135-155FT) (K006) Periodic Maintenance 8000SRM1902 for lift
truck models
• H8.0-9.0FT, H8.0FT9 (H170-190FT,
H175FT36) (B299) • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80-120FT) (U005)
• S6.0-7.0FT (S135-155FT) (G024)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; 11. Install radiator cap.
H5.0-5.5FT (H80-120FT) (S005)
12. Connect negative battery cable.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; During engine operation, be careful not to touch
H5.0-5.5FT (H80-120FT) (U005) the fan, pulleys, or drive belts. Contact with these
parts can cause serious injury.
8. Connect lower radiator hose.
9. Install coolant drain plug in engine block. See WARNING

Figure 104.
CAUTION ous injury.
Additives may damage the cooling system. Before 13. Start engine and check cooling system for
using additives, contact your local Hyster dealer. leaks.
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WARNING CAUTION
DO NOT remove the radiator cap from the radiator DO NOT operate the engine without a thermostat.
when the engine is hot. When the radiator cap is The engine and cooling system can be damaged.
removed, pressure will release from the coolant
system. If the coolant system is hot, the steam
and boiling coolant can cause severe burns. CAUTION
Disposal of lubricants must meet local environ-
mental regulations.
WARNING
The radiator or other parts of the cooling system 1. Drain cooling system to level of thermostat.
ous injury. Wait 30 minutes for the radiator and 2. Disconnect coolant hose from thermostat cover.
engine to cool before performing maintenance to 3. Remove three bolts holding thermostat cover.
the cooling system. After 30 minutes, do a touch Remove thermostat cover and gasket. Discard
test by touching the radiator with your hand. If the gasket. See Figure 106.
cooling system.
CAUTION
Additives may damage the cooling system. Before
14. 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
engine to cool before performing maintenance to
the cooling system. After 30 minutes, do a touch
test by touching the radiator with your hand. If the
radiator is still hot to the touch, wait another 30 1. BOLT
minutes before attempting any maintenance to the 2. THERMOSTAT COVER
3. GASKET
cooling system. 4. THERMOSTAT
5. WATER FLANGE
Figure 106. Thermostat
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4. Remove thermostat from water flange. See Fig- Install

ure 106.
1. Install thermostat into water flange. See Fig-
Inspect ure 106.
1. Place thermostat and an accurate thermometer 2. Install thermostat cover and a new gasket. In-
in warm water. See Figure 107. stall bolts to hold thermostat cover. Tighten
bolts to 23 to 28 N•m (17 to 21 lbf ft).
3. Connect coolant hose to thermostat cover. See

Figure 106.
CAUTION
Additives may damage the cooling system. Before
4. Fill cooling system with coolant. For correct

coolant amount and type refer to

truck model
• H6.0FT, H7.0FT (H135FT, H155FT)
(K006)

1. THERMOMETER 2. THERMOSTAT truck model
Figure 107. Thermostat Check • H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299)
2. Slowly increase the temperature of the water.
3. The thermostat is operating correctly if it starts

to open at temperature value stamped on flange
of thermostat and fully opens as temperature of
water is increased.
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• S6.0-7.0FT (S135-155FT) (G024) DO NOT remove the radiator cap from the radiator
Periodic Maintenance 8000SRM1604 for lift removed, pressure will release from the coolant
truck models system. If the coolant system is hot, the steam
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; and boiling coolant can cause severe burns.
H5.0-5.5FT (H80-120FT) (S005)
WARNING
truck models The radiator or other parts of the cooling system
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; ous injury. Wait 30 minutes for the radiator and
H5.0-5.5FT (H80-120FT) (U005) engine to cool before performing maintenance to
the cooling system. After 30 minutes, do a touch
WARNING test by touching the radiator with your hand. If the
the fan, pulleys, or drive belts. Contact with these
cooling system.
parts can cause serious injury.
WARNING CAUTION
The radiator or other parts of the cooling system Additives may damage the cooling system. Before
may be hot or under pressure and can cause seri- using additives, contact your local Hyster dealer.
ous injury. 6. Stop engine. If coolant is hot, allow engine time
5. Start engine and check cooling system for to cool. Check coolant level and fill as required
leaks. between the ADD and FULL marks on coolant
reservoir.
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Flywheel and Flywheel Housing 0600 SRM 1590
Flywheel and Flywheel Housing

FLYWHEEL See Frame 0100SRM1243 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
Remove H5.0-5.5FT (H80-120FT) (S005)
1. Remove the engine. See Frame 0100SRM1891 for lift truck models
SeeFrame 0100SRM1581 for lift truck models • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;

H5.0-5.5FT (H80-120FT) (U005)
• H6.0-7.0FT (H135-155FT) (K006)
• H8.0-9.0FT, H8.0FT9 (H170-190FT, 2. Remove seven bolts holding the flywheel to the
H175FT36) (B299) crankshaft flange and remove the flywheel. See
Figure 108.
• S6.0-7.0FT (S135-155FT) (G024)
1. FLYWHEEL HOUSING 4. CRANKSHAFT

2. FLYWHEEL 5. ENGINE BLOCK
3. BOLT
Figure 108. Flywheel
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0600 SRM 1590 Flywheel and Flywheel Housing
Install • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;

H5.0-5.5FT (H80-120FT) (U005)
1. Place the flywheel in position on the crankshaft
flange and install seven bolts. Tighten bolts to FLYWHEEL HOUSING
98 to 107 N•m (72 to 80 lbf ft).
Remove
1. Remove the flywheel. See Flywheel, Remove.
SeeFrame 0100SRM1581 for lift truck models
• H6.0-7.0FT (H135-155FT) (K006) 2. Remove ten bolts holding the flywheel housing
to the cylinder block. See Figure 108.
• H8.0-9.0FT, H8.0FT9 (H170-190FT,
H175FT36) (B299) 3. Remove the flywheel housing.
Install
• S6.0-7.0FT (S135-155FT) (G024)
1. Place the flywheel housing in position on the
See Frame 0100SRM1243 for lift truck models cylinder block and install bolts. Tighten the
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; bolts to 78 to 90 N•m (58 to 66 lbf ft).
H5.0-5.5FT (H80-120FT) (S005)
2. Install the flywheel. See Flywheel, Install.
Electrical Equipment Repair

NOTE: This section covers the repair procedures ALTERNATOR
for the major electrical components only, if engine
specific sensors or switches need to be serviced Remove
See Electrical System 2200SRM1142
• H6.0-7.0FT (H135-155FT) (K006) WARNING
• H8.0-9.0FT, H8.0FT9 (H170-190FT, Always disconnect the cables at the battery be-
H175FT36) (B299) fore you make repairs to the engine. Disconnect
the cable at the negative terminal first. Install a
• S6.0-7.0FT (S135-155FT) (G024) tag on the battery terminals so that no one con-
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; nects the cables on the terminals.
H5.0-5.5FT (H80-120FT) (S005)
1. Disconnect battery negative cable at negative
See Electrical System 2200SRM1901 terminal.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; 2. Disconnect the battery positive cable at positive
H5.0-5.5FT (H80-120FT) (U005) terminal.
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Electrical Equipment Repair 0600 SRM 1590
3. Put labels on wires prior to disconnecting to aid 6. Remove the serpentine belt from the alternator
in correct installation. pulley.
4. Disconnect wires from alternator. 7. Remove the set bolt from the alternator. See
Figure 109.
5. Loosen the set bolt on the alternator and tilt
the alternator towards the engine.
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 109. Alternator
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0600 SRM 1590 Electrical Equipment Repair
8. If necessary, remove the bolt holding the alter- 1. Disconnect battery negative cable at negative
nator adjustment bracket to the water flange terminal.
and remove the bracket.
2. Disconnect the battery positive cable at positive
9. Remove the bolt holding the alternator to the terminal.
alternator mounting bracket. Remove the alter-
nator. 3. Put labels on wires and cables prior to discon-
necting to aid in correct installation.
Install 4. Disconnect wires and cables from starter.
1. If removed, place the alternator adjustment 5. Hold starter so it won't fall. Remove the two
bracket in position and install the bolt to retain M12 bolts and starter from flywheel housing.
the bracket to the water flange. See Figure 110.
2. Position the alternator on the alternator
mounting bracket. Install the bolt holding the
alternator to the alternator mounting bracket,
but do not tighten.
3. Install the set bolt for the alternator and ad-

justment bracket but do not tighten.
4. Connect the electrical wires to the alternator.
5. Install the serpentine belt and adjust to the

proper tension. See Serpentine Belt, Adjust.
6. Tighten the set bolt to 25.5 N•m (18.8 lbf ft).
7. Connect battery positive cable at positive termi-

nal.
1. FLYWHEEL HOUSING
8. Connect battery negative cable at negative ter- 2. M12 BOLT
minal. 3. STARTER
9. Start the engine and listen for any unusual Figure 110. Starter
sounds from the alternator.
10. Verify that the charge indicator is ON while Install

the engine is operating. If the charge indicator
is not ON, repair the problem before operating 1. Place starter in position in flywheel housing.
the engine. Install two M12 bolts on starter and flywheel
housing.
STARTER
2. Connect wires and cables as labeled in removal.
Remove Tighten the M8 nut, B terminal, to 7.9 to
9.8 N•m (70 to 87 lbf in). Tighten the M4
screw, S terminal, to 1.7 to 2.4 N•m (15 to
WARNING 21 lbf in). Be sure to place the cover over the
Always disconnect the cables at the battery be- M4 screw connection. See Figure 111.
fore you make repairs to the engine. Disconnect
the cable at the negative terminal first. Install a
tag on the battery terminals so that no one con-
nects the cables on the terminals.
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Electrical Equipment Repair 0600 SRM 1590
1. M8 NUT 3. M4 SCREW
2. COVER 4. STARTER
3. Connect battery positive cable at positive termi-

nal.
4. Connect battery negative cable at negative ter-

minal.
Figure 111. Starter Connections
Engine Specifications
ENGINE DATA
Table 6. V3800-CR-TIE4C Engine for Lift Truck Model H6.0FT, H7.0FT (H135FT, H155FT) (K006)
Engine Model 1J434-00000 (Hyster P/N 4611459)

Type Vertical Inline Diesel Engine
Combustion System Direct Injection
Aspiration Turbo Charged
No. of Cylinders 4
Ignition Order 1-3-4-2
Bore × Stroke 100 × 120 mm (3.94 × 4.72 in.)
Displacement 3.769 liter (230 cu in.)
Max. Rated Output (Net) rpm 2200
(min-1)
hp SAE 94
kW 70
High Idle Speed (Bare Engine) 2200 ± 25 rpm
*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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0600 SRM 1590 Engine Specifications
Table 6. V3800-CR-TIE4C Engine for Lift Truck Model H6.0FT, H7.0FT (H135FT, H155FT) (K006) (Contin-
ued)
Low Idle Speed (Bare Engine) 800 ± 25 rpm

Engine Weight (Dry)* 308 kg (679 lb)
Direction of Rotation 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, 2x900 CCA (Cold Cranking
Amps)
Dimensions (L × W × H)* 632 × 498 × 711 mm (24.9 × 19.6 × 28.0 in.)
Engine Oil Pan Capacity 13.2 liter (13.9 qt)
Engine Coolant Capacity 4.9 liter (1.3 gal) Engine Only
Table 7. V3800-CR-TIE4C Engine for Lift Truck Model H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
H190FT) (B299)

No. of Cylinders 4
Bore × Stroke 100 × 120 mm (3.94 × 4.72 in.)
(min-1)
hp SAE 110
kW 82
*Engine Specifications do not include height of lifting eyes nor dimensions or specifications for the Cooling Fan,
Radiator, Muffler, and Air Cleaner.
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Engine Specifications 0600 SRM 1590
Table 7. V3800-CR-TIE4C Engine for Lift Truck Model H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
H190FT) (B299) (Continued)

Amps)
*Engine Specifications do not include height of lifting eyes nor dimensions or specifications for the Cooling Fan,
Radiator, Muffler, and Air Cleaner.
Table 8. V3800-CR-TIE4C Engine for Lift Truck Model S6.0-7.0FT (S135-155FT) (G024)

No. of Cylinders 4
Bore × Stroke 100 × 120 mm (3.94 × 4.72 in.)
(min-1)
hp SAE 94
kW 70
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Table 8. V3800-CR-TIE4C Engine for Lift Truck Model S6.0-7.0FT (S135-155FT) (G024) (Continued)

Amps)
Table 9. V3800-CR-TIE4C Engine for Lift Truck Model H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80-120FT) (S005, U005)

No. of Cylinders 4
Bore × Stroke 100 × 120 mm (3.94 × 4.72 in.)
(min-1)
hp SAE 94
kW 70
Amps)
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ENGINE TUNING
Inspection Item Standard Limit
Valve Gap Intake/Exhaust (Engine Cold) 0.23 to 0.27 mm
(0.009 to 0.011 in.)
Compression Pressure at 250 rpm 3.09 to 3.28 MPa 2.41 MPa
(448 to 476 psi) (350 psi)
Lubricating Oil Pressure At rated output 0.20 to 0.39 MPa
(29 to 57 psi)
When Idling 0.05 MPa or greater
(7.3 psi)
Thermostat Valve Opening Temperature Full Opening Lift
Temperature
75°C 90°C (194°F)
(167°F)
CYLINDER HEAD
Combustion Surface Distortion (Flatness) 0.05 mm (0.0020 in.)
Valve Sink Intake 0.6 to 0.8 mm 1.2 mm
(0.024 to 0.031 in.) (0.047 in.)
Exhaust 0.85 to 1.05 mm 1.2 mm
(0.0335 to 0.0413 in.) (0.047 in.)
Valve Seat Angle Intake 60°
Exhaust 45°
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INTAKE/EXHAUST VALVE AND GUIDE

Intake Valve Guide Inside Diameter 7.010 to 7.025 mm
(0.2760 to 0.2765 in.)
Valve Stem Outside 6.960 to 6.975 mm
Diameter (0.2741 to 0.2746 in.)
Oil Clearance 0.035 to 0.065 mm 0.10 mm
(0.0014 to 0.0026 in.) (0.004 in.)
Exhaust Valve Guide Inside Diameter 7.010 to 7.025 mm
(0.3156 to 0.3161 in.)
Valve Stem Outside 6.960 to 6.975 mm
Diameter (0.2741 to 0.2746 in.)
Oil Clearance 0.035 to 0.065 mm 0.10 mm
(0.0018 to 0.0030 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 37.14 mm
(1.482 in.) (1.462 in.)
Exhaust 38.96 mm 38.46 mm
(1.534 in.) (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
(0.0017 to 0.0073 in.) (0.0087 in.)
CYLINDER BLOCK
Cylinder Inside Diameter 100.000 to 100.022 mm 100.150 mm
(3.93701 to 3.93787 in.) (3.9429 in.)
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CRANKSHAFT
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.)
(0.00079 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 0.3 mm (0.01 in.)
(0.0039 to 0.0062 in.)
Outer Rotor Side Clearance

All models 0.040 to 0.16 mm 0.3 mm (0.01 in.)
(0.0016 to 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 1590
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 1590 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 1590

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 1590 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.)
Supply A 41 mm (1.6 in.)
Pump Gear B 40.5 mm (1.59 in.)
Puller
Hyster P/N C 20 mm (0.79 in.)
4648857 D 18 mm (0.71 in.)
E 2.5 mm (0.098 in.)
F 13 mm (0.51 in.)
G M16 × Pitch 1.5
H 16 dia. mm (0.63 dia. in.)
I 1 radius mm (0.04 radius in.)
J 0.87 rad (50°)
C1 Chamfer1.0 mm (0.039 in.)
Supply A 43.95 to 44.05 mm (1.731 to 1.734 in.)
Pump Gear B 21 mm (0.83 in.)
Reinstall Jig
C 8 mm (0.3 in.)
D 12.9 to 13.1 square mm (0.508 to 0.515 square in.)
E 10 radius mm (0.39 radius in.)
F 5 radius mm (0.2 radius in.)
G 43.95 to 44.05 mm (1.731 to 1.734 in.)
H 5.240 to 5.255 dia. mm (0.2063 to 0.2068 dia in.)
I 0.4 radius mm (0.02 radius in.)
J 42 mm (1.7 in.)
K 13 mm (0.51 in.)
L 21 mm (0.83 in.)
M 1 mm (0.04 in.)
N 20 mm (0.79 in.)
O 5.265 to 5.275 dia. mm (0.2073 to 0.2076 dia in.)
P 0.52 rad (30°)
C0.3 Chamfer0.3 mm (0.01 in.)
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Compressio A 29.80 to 30.00 dia. mm (1.174 to 1.181 dia in.)
n Test B 14 mm (0.55 in.)
Adaptor
C 39.2 to 40.2 mm (1.55 to 1.58 in.)
D 5/8 - 18 UNF - 2b
E 0.8 radius mm (0.3 radius in.)
F 19.84 to 19.95 mm (0.7911 to 0.7854 in.)
G Ra = 3.2a
H 16.14 to 16.20 mm (0.6355 to 0.6377 in.)
I 19.08 to 19.20 mm (0.7512 to 0.7559 in.)
J 16.89 to 17.00 mm (0.6850 to 0.6692 in.)
K 3.0 dia. mm (0.12 dia. in.)
L 7.10 to 7.20 mm (0.280 to 0.283 in.)
M 11 mm (0.43 in.)
N 13 dia. mm (0.51 dia. in.)
O 16 dia. mm (0.63 dia. in.)
P 0.4 radius mm (0.02 radius in.)
Q 18 mm (0.71 in.)
R 20.4 mm (0.803 in.)
S 48.6 mm (1.91 in.)
T 3.20 to 3.45 mm (0.126 to 0.135 in.)
U 53.6 mm (2.11 in.)
V 65 mm (2.6 in.)
W 116 mm (4.57 in.)
X 120.7 to 121.3 mm (4.752 to 4.775 in.)
Y 28.5 mm (1.12 in.)
Z 150 mm (5.91 in.)
C1 Chamfer1.0 mm (0.039 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)
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No. Instrument Name Application Illustration

1 Dial Indicator Measurements of shaft bending, and strain
and gap of surfaces.
2 Test Indicator Measurements of narrow or deep portions

that cannot be measured by dial Indicator.
3 Magnetic Stand For holding the dial gauge when measuring.
4 Micrometer For measuring the outside diameters of

crankshaft, pistons, piston pins, etc.
5 Cylinder Gauge For measuring the inside diameters of 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.
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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
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.
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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.
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NOTES
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HeavyManuals.com
TECHNICAL PUBLICATIONS
0600 SRM 1590 12/15 (3/15)(9/13)(7/12)

Kubota Diesel 3.8L Engines With Diesel Particulate Filter (DPF)

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Kubota Diesel 3.8L Engines With Diesel Particulate Filter (DPF)

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KUBOTA DIESEL 3.8L ENGINES

PART NO. 4057092 0600 SRM 1590

©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) [S005, U005];

A. RIGHT SIDE OF ENGINE B. LEFT SIDE OF ENGINE

Figure 1. Major Engine Components

1. ENGINE NAMEPLATE Figure 3. Engine Nameplate (Typical)

Figure 2. Typical Location of Engine Labels

The Kubota 3.8L diesel engine, utilizes a split

The Kubota Diesel engine utilizes a hanger type

1. CRANKCASE 1 3. OIL PAN

Figure 4. Kubota Diesel Crankcase Components

PRECAUTIONS BEFORE BEGINNING

The information contained below provides some

Engine Removal and Installation

Frame 0100SRM1581 for lift truck models

Cylinder Head Assembly Repair

2. Disconnect breather tube from bottom of crank-

3. Disconnect breather tubes from upper cylinder

4. Remove turbo outlet hose from turbo charger

5. Remove EGR tube from back of EGR valve and

NOTE: Mark connectors/wires during removal to

8. Remove eight terminal nuts. Disconnect fuel in-

1. CAPSCREW 4. FUEL INJECTOR HARNESS

Figure 7. Upper Valve Cover

10. Loosen four fuel lines at fuel rail. Remove four

1. CAPSCREW 11. FLANGE NUT

Figure 8. Fuel Injectors and Lower Valve Cover

3. Install four flange nuts to injector clamps.

7. Install lower valve cover and ten bolts onto cyl-

2. Install four injector clamps to rocker arm

1. ROCKER ARM SHAFT 8. ADJUSTING SCREW

Figure 9. Rocker Arm Assembly

2. Remove the c-clips and washers from the ends

NOTE: Mark the rocker arms so they can be rein-

NOTE: The rocker arm shaft fits tightly in the

4. If necessary, remove the valve adjusting screw

Rocker Arm and Support Bracket Inside Di-

Clean all parts in cleaning solvent. Dry the parts

Push Rods Figure 11. Rocker Arm Inside Diameter

1. Place the push rods on a flat inspection block.

5. Tighten the rocker arm shaft retaining flange

6. Adjust the valve lash. See Valve Clearance Ad-

7. Install the valve cover. See Valve Covers and

VALVE CLEARANCE ADJUSTMENTS

Legend for Figure 14

5. When valve clearence has been correctly adjus-

NOTE: There is a tendency for the clearance to de-

Figure 14. Valve Cap Check

8. Measure and adjust the cylinders as follows:

9. Install the valve cover. See Valve Covers and

CYLINDER HEAD ASSEMBLY

1. ADJUSTMENT BOLT 5. WASHER

Figure 16. Alternator Mounting and Adjustment

7. Remove three mounting bolts, three retaining

8. Remove three bolts and idler assembly from

9. Remove eight bolts, collar, spacer, and two fan

10. Loosen two hose clamps and remove hose from