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KUBOTA 3.8L LPG SI

ENGINE
S4.0-5.5FT, S5.5FTS (S80-120FT;
S80-100FTBCS; S120FTS; S120FTPRS) [J004];
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80-120FT) [U005]

PART NO. 4128418 0600 SRM 1893

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SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow in-
structions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or ex-
ceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flamma-
ble. Be sure to follow the necessary safety precautions when handling these fuels and when working
on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this
manual:

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

CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
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Table of Contents

TABLE OF CONTENTS

General .....................................................................................................................................................................1
Engine Identification .......................................................................................................................................... 1
Major Engine Component Identification ....................................................................................................... 1
Location of Labels ...........................................................................................................................................2
Crankcase Description ........................................................................................................................................3
Engine Removal and Installation ...........................................................................................................................4
Cylinder Head Assembly Repair ............................................................................................................................ 4
Valve Covers and Ignition Coils .........................................................................................................................4
Remove ............................................................................................................................................................ 4
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 .................................................................................................................................. 12
Remove .......................................................................................................................................................... 12
Disassemble .................................................................................................................................................. 18
Valves and Valve Springs, Remove ......................................................................................................... 18
Valve Guides, Remove ..............................................................................................................................19
Clean and Inspect ......................................................................................................................................... 19
Cylinder Head ...........................................................................................................................................20
Valve Guides .............................................................................................................................................20
Valves ........................................................................................................................................................20
Valve Sink .................................................................................................................................................21
Valve Seat ................................................................................................................................................. 21
Valve Springs ............................................................................................................................................21
Assemble ....................................................................................................................................................... 22
Valve Guides, Install ................................................................................................................................22
Valves and Valve Springs, Install ........................................................................................................... 23
Install ............................................................................................................................................................ 23
Timing Gear Case and Timing Gears Repair ...................................................................................................... 26
Timing Gear Case Cover ...................................................................................................................................26
Remove .......................................................................................................................................................... 26
Clean and Inspect ......................................................................................................................................... 26
Install ............................................................................................................................................................ 26
Timing Gears .....................................................................................................................................................27
Crankshaft Gear ........................................................................................................................................... 27
Remove ......................................................................................................................................................27
Install ........................................................................................................................................................27
Idler Gear ...................................................................................................................................................... 27
Remove ......................................................................................................................................................27
Inspect .......................................................................................................................................................28
Install ........................................................................................................................................................28
Camshaft Gear ..............................................................................................................................................28

©2015 HYSTER COMPANY i

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TABLE OF CONTENTS (Continued)

Remove ......................................................................................................................................................28
Install ........................................................................................................................................................29
Timing Gear Case ............................................................................................................................................. 29
Remove .......................................................................................................................................................... 29
Clean and Inspect ......................................................................................................................................... 29
Install ............................................................................................................................................................ 29
Drive Train, Camshaft, and Cylinder Block Repair ............................................................................................30
Remove .............................................................................................................................................................. 30
Disassemble .......................................................................................................................................................30
Pistons and Connecting Rods .......................................................................................................................30
Crankshaft .................................................................................................................................................... 31
Camshaft ....................................................................................................................................................... 34
Clean and Inspect ............................................................................................................................................. 34
Cylinder Block ...............................................................................................................................................35
Honing and Boring ................................................................................................................................... 37
Cylinder Correction (Oversize) ................................................................................................................ 38
Pistons ........................................................................................................................................................... 38
Piston Pin ......................................................................................................................................................39
Connecting Rod .............................................................................................................................................39
Tappets ..........................................................................................................................................................40
Crankshaft .................................................................................................................................................... 40
Camshaft ....................................................................................................................................................... 43
Camshaft Bushing ........................................................................................................................................ 44
Assemble ............................................................................................................................................................44
Camshaft ....................................................................................................................................................... 44
Crankshaft .................................................................................................................................................... 44
Pistons and Connecting Rods .......................................................................................................................44
Install .................................................................................................................................................................46
Lubrication System Repair ................................................................................................................................... 47
Engine Oil and Oil Filter Change .................................................................................................................... 47
Oil Pan ...............................................................................................................................................................48
Remove .......................................................................................................................................................... 48
Install ............................................................................................................................................................ 48
Oil Suction Tube ................................................................................................................................................48
Remove .......................................................................................................................................................... 48
Clean ..............................................................................................................................................................49
Install ............................................................................................................................................................ 49
Oil Pump ............................................................................................................................................................49
Remove .......................................................................................................................................................... 49
Clean and Inspect ......................................................................................................................................... 50
Outer Rotor Outside Clearance ............................................................................................................... 50
Outer Rotor to Inner Rotor Tip Clearance .............................................................................................. 50
Outer Rotor Side Clearance ..................................................................................................................... 50
Rotor Shaft Clearance .............................................................................................................................. 51
Install ............................................................................................................................................................ 51
Fuel System Repair ...............................................................................................................................................52
Cooling System Repair ..........................................................................................................................................52
Serpentine Belt ................................................................................................................................................. 52
Remove .......................................................................................................................................................... 52
Inspect ........................................................................................................................................................... 52

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TABLE OF CONTENTS (Continued)

Install ............................................................................................................................................................ 52
Serpentine Belt, Adjustment ....................................................................................................................... 52
Water Pump ...................................................................................................................................................... 54
Remove .......................................................................................................................................................... 54
Install ............................................................................................................................................................ 55
Thermostat ........................................................................................................................................................ 56
Remove .......................................................................................................................................................... 56
Inspect ........................................................................................................................................................... 57
Install ............................................................................................................................................................ 57
Flywheel and Flywheel Housing .......................................................................................................................... 59
Flywheel ............................................................................................................................................................ 59
Remove .......................................................................................................................................................... 59
Install ............................................................................................................................................................ 59
Flywheel Housing ............................................................................................................................................. 59
Remove .......................................................................................................................................................... 59
Install ............................................................................................................................................................ 59
Electrical Equipment Repair ................................................................................................................................ 60
Alternator .......................................................................................................................................................... 60
Remove .......................................................................................................................................................... 60
Install ............................................................................................................................................................ 61
Starter ................................................................................................................................................................61
Remove .......................................................................................................................................................... 61
Install ............................................................................................................................................................ 61
Engine Specifications ............................................................................................................................................ 62
Engine Data .......................................................................................................................................................62
Engine Tuning ...................................................................................................................................................64
Cylinder Head ................................................................................................................................................... 64
Intake/Exhaust Valve and Guide .....................................................................................................................65
Valve Spring ......................................................................................................................................................65
Rocker Arm and Shaft ...................................................................................................................................... 65
Push Rod ............................................................................................................................................................66
Gear Train and Camshaft .................................................................................................................................66
Camshaft ....................................................................................................................................................... 66
Idle Gear Shaft and Bushing ....................................................................................................................... 66
Backlash of Each Gear ................................................................................................................................. 66
Cylinder Block ...................................................................................................................................................66
Crankshaft .........................................................................................................................................................67
Piston ................................................................................................................................................................. 67
Piston Ring ........................................................................................................................................................ 67
Connecting Rod ................................................................................................................................................. 68
Rod Small End .............................................................................................................................................. 68
Tappet ............................................................................................................................................................68
Oil Pump ............................................................................................................................................................69
Engine Oil Pressure ......................................................................................................................................69
Outer Rotor Outside Clearance ................................................................................................................... 69
Outer Rotor Side Clearance ......................................................................................................................... 69
Inner Rotor to Cover .....................................................................................................................................69
Standard Torque Specifications ............................................................................................................................70
Standard Torque Chart .................................................................................................................................... 70
Special Torque Specifications ............................................................................................................................... 71

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TABLE OF CONTENTS (Continued)

Special Tools .......................................................................................................................................................... 72

This section is for the following models:

S4.0-5.5FT, S5.5FTS (S80-120FT; S80-100FTBCS; S120FTS; S120FTPRS) [J004];

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

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0600 SRM 1893 General

General
This section has repair instructions for Kubota ENGINE IDENTIFICATION
LPG SI engines.
Major Engine Component Identification

Figure 1 shows where major engine components are

located.

NOTE: NOT ALL COMPONENTS SHOWN ARE ATTACHED DIRECTLY TO ENGINE, BUT ARE SHOWN FOR
REFERENCE AND ORIENTATION.

1. PCV (POSITIVE CRANKCASE VENTILATION) 9. LPG LOCK-OFF VALVE

VALVE 10. WATER PUMP
2. TOP FILLER PORT (ENGINE OIL) 11. CRANKSHAFT PULLEY
3. DEPR (DIRECT ELECTRIC PRESSURE 12. DRAIN PLUG
REGULATOR) 13. LPG CONVERTER
4. DIPSTICK (ENGINE OIL) 14. LPG VAPOR SENSOR
5. STARTER MOTOR 15. FUEL FILTER
6. ALTERNATOR 16. ENGINE OIL COOLER
7. SERPENTINE BELT 17. ENGINE OIL FILTER
8. AIR/FUEL MIXER ASSEMBLY 18. COOLANT DRAIN PLUG

Figure 1. Major Engine Components

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General 0600 SRM 1893

Location of Labels

The typical location of emission control information

label is shown in Figure 2.

The typical location of engine nameplate is shown

in Figure 2. The engine nameplate is shown in
Figure 3.

Figure 3. Engine Nameplate (Typical)

1. ENGINE NAMEPLATE
2. EMISSION CONTROL INFORMATION LABEL
3. ENGINE SERIAL NUMBER
Figure 2. Typical Location of Engine Labels

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0600 SRM 1893 General

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

The Kubota Diesel engine utilizes a hanger type

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

1. CRANKCASE 1 3. OIL PAN

2. CRANKCASE 2

Figure 4. Kubota SI Crankcase Components

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Engine Removal and Installation 0600 SRM 1893

Engine Removal and Installation

The procedures to remove and install engine are not included in this section. For procedures refer to Frame
0100SRM1891.

Cylinder Head Assembly Repair

VALVE COVERS AND IGNITION COILS NOTE: Mark connectors/wires during removal to
aid in installation.
Remove
5. Disconnect engine wiring harness from TMAP
1. Close valve on LPG supply tank. Start and run (Total Manifold Absolute Pressure) sensor. See
lift truck to use all fuel left in system. When lift Figure 5.
truck stops running, turn ignition to OFF posi-
tion. 6. Remove capscrew holding breather hose con-
nector to top of intake plenum. See Figure 5.
2. Disconnect negative battery cable at battery.
7. Remove two clamps and breather hose from
3. Loosen two hose clamps and remove fresh air valve cover and air/fuel mixer assembly. See
intake hose from air/fuel mixer assembly and Figure 5 .
air cleaner housing. See Figure 5.
8. Remove two clamps and PCV breather hose
NOTE: Mark connectors/wires during removal to from cylinder head and intake plenum. See Fig-
aid in installation. ure 5.

4. Disconnect engine wiring harness from ignition

coils. See Figure 5.

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0600 SRM 1893 Cylinder Head Assembly Repair

1. CLAMP 8. VALVE COVER

2. AIR INTAKE HOSE 9. PCV BREATHER HOSE
3. CAPSCREW 10. BREATHER HOSE
4. TMAP SENSOR 11. BREATHER HOSE CONNECTOR
5. INTAKE PLENUM 12. AIR/FUEL MIXER ASSEMBLY
6. IGNITION COIL 13. AIR FILTER HOUSING
7. ENGINE WIRING HARNESS

Figure 5. Breather Hoses and Air Intake Hose

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Cylinder Head Assembly Repair 0600 SRM 1893

9. Remove ten capscrews, valve cover and valve 12. Remove radiator cap.
cover gasket from cylinder head. Discard gas-
ket. See Figure 6. 13. Loosen hose clamp and remove lower radiator
hose, draining coolant from cooling system.
10. Turn valve cover upside down. Remove thirteen
capscrews, shield and shield gasket from valve 14. Remove coolant drain plug and drain coolant
cover. Discard gasket. See Figure 6. from engine block. See Cooling System Re-
pair in this manual for procedures.
11. Remove PCV filters from filter covers. Discard
filters. See Figure 6.
CAUTION
DO NOT loosen the fuel injection lines when the
fuel is under high pressure (within five minutes of
stopping the engine).

15. Remove two clamps and fuel hose from LPG

converter and DEPR. See Figure 7.

1. CAPSCREW 1. DEPR 3. LPG CONVERTER

2. VALVE COVER 2. CLAMP 4. FUEL HOSE
3. FILTER COVER
4. PCV FILTER Figure 7. Fuel Hose
5. SHIELD GASKET
6. SHIELD
7. VALVE COVER GASKET

Figure 6. Valve Cover

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0600 SRM 1893 Cylinder Head Assembly Repair

16. Remove two clamps and heater hose from oil 21. Remove eight bolts from ignition coil flanges.
cooler and LPG converter. See Figure 8. See Figure 9.

17. Remove two clamps and heater hose from LPG 22. Remove four ignition coil flanges and four
converter and water pump. See Figure 8. flange gaskets from cylinder head. Discard gas-
kets. See Figure 9.

1. LPG CONVERTER 4. OIL COOLER

2. CLAMP 5. WATER PUMP
3. HEATER HOSE

Figure 8. Heater Hose

1. CAPSCREW
18. Remove four capscrews from four ignition coils. 2. IGNITION COIL
See Figure 9 . 3. SPARK PLUG
4. IGNITION COIL FLANGE
19. Remove four ignition coils from cylinder head. 5. FLANGE GASKET
See Figure 9. 6. CYLINDER HEAD
7. BOLT
20. Remove four sparkplugs from ignition coil
flanges. See Figure 9. Figure 9. Ignition Coils

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Cylinder Head Assembly Repair 0600 SRM 1893

Clean and Inspect 7. Using two clamps, install fuel hose onto LPG
converter and DEPR. See Figure 7.
WARNING 8. Install coolant drain plug into engine block.
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning 9. Using two clamps, install lower radiator hose
solvents, always follow the recommendations of onto radiator and water pump.
the manufacturer.
10. Fill cooling system. See Cooling System Re-
pair section of this service manual.
WARNING
11. Install radiator cap.
Compressed air can move particles so that they
cause injury to the user or to other personnel. 12. Install new PCV filters into filter covers. See
Make sure that the path of the compressed air is Figure 6.
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes. 13. Turn valve cover upside down; install PCV fil-
ters and covers into proper position. See Fig-
ure 6.
CAUTION
Use caution not to scratch the gasket mating sur- 14. Using thirteen capscrews, install new shield
faces when cleaning the valve cover and cylinder gasket and shield onto valve cover. See Fig-
head. ure 6.

Carefully remove all gasket residue from valve 15. Using ten capscrews, install new valve cover
cover and cylinder head. gasket and valve cover onto cylinder head. See
Figure 6.
Clean valve cover in cleaning solvent. Dry valve 16. Install two clamps and PCV breather hose onto
cover with compressed air. Inspect for wear, cracks, cylinderhead and intake plenum. See Figure 5.
and any other damage. If necessary, replace valve
cover. 17. Install two clamps and and breather hose onto
valve cover and air/fuel mixer assembly. See
Inspect all O-rings and grommets for wear, cracks, Figure 5.
and any other damage. Replace where necessary.
18. Using capscrew, attach breather hose connector
Install to top of intake plenum. See Figure 5.

1. Install new gaskets onto four ignition coil 19. Connect engine wiring harness to TMAP sen-
flanges. See Figure 9. sor. See Figure 5.

2. Using eight bolts, install four ignition coil 20. Connect engine wiring harness to ignition coils.
flanges onto cylinder head. See Figure 9. See Figure 5.

3. Install four spark plugs into ignition coil 21. Install two hose clamps and fresh air intake
flanges. See Figure 9. hose onto air/fuel mixer assembly and air
cleaner housing. See Figure 5.
4. Using four capscrews, install four ignition coils
onto ignition coil flanges and cylinder head. See 22. Connect negative battery cable at battery.
Figure 9.
23. Open valve on LPG supply tank. Start and run
5. Using two clamps, install heater hose onto LPG lift truck to ensure all systems are operating as
converter and water pump. See Figure 8. designed.

6. Using two clamps, install heater hose onto oil

cooler and LPG converter. See Figure 8.

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0600 SRM 1893 Cylinder Head Assembly Repair

ROCKER ARM ASSEMBLY 2. Remove four flange bolts holding rocker arm
brackets to cylinder head. See Figure 10.
Remove
1. Remove valve cover and ignition coils. See
Valve Covers and Ignition Coils, Step 1.

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 BOLT
5. C-CLIP 12. PUSH ROD
6. ROCKER ARM SPRING 13. CYLINDER HEAD
7. INTAKE ROCKER ARM ASSEMBLY 14. LIFTER

Figure 10. Rocker Arm Assembly

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Cylinder Head Assembly Repair 0600 SRM 1893

3. Lift rocker arm shaft assembly from cylinder Push Rods

head.
1. Place push rods on a flat inspection block.
NOTE: Mark push rods so they can be reinstalled
in original location during reassembly. 2. Roll push rods until a gap can be observed be-
tween a portion of push rod and surface of in-
4. Remove push rods from cylinder head. spection block.

Disassemble 3. Use a feeler gauge to measure gap. Refer to En-

gine Specifications for service limit. See Fig-
1. Remove rocker arm shaft c-clips and washers ure 11.
from each end of rocker arm shafts. Discard
washers. See Figure 10.

NOTE: Mark rocker arms so they can be reinstal-

led in original location during reassembly.

NOTE: The rocker arm shaft fits tightly in rocker

arm support brackets. Clamp support bracket in a
padded vise and twist and pull rocker arm shaft to
remove shaft.

2. Slide rocker arm shaft out of rocker arm brack-

ets, springs, and rocker arms.

3. If necessary, remove valve adjusting screw and

lock nut from rocker arms.

Clean and Inspect

Figure 11. Push Rod Inspection

WARNING
Cleaning solvents can be flammable and toxic and Rocker Arm Assembly
can cause skin irritation. When using cleaning
Rocker Arm and Support Bracket Inside Di-
solvents, always follow the recommendations of
ameter: Use a test indicator and micrometer to de-
the manufacturer.
termine if inside diameter of all rocker arm support
brackets and rocker arms are within limits. Refer
WARNING to Engine Specifications for service limit. See Fig-
Compressed air can move particles so that they ure 12.
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.

Clean all parts in cleaning solvent. Dry parts with

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

Figure 12. Rocker Arm Inside Diameter

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0600 SRM 1893 Cylinder Head Assembly Repair

Shaft Outside Diameter: Use a micrometer to 4. Align push rods with their respective rocker
measure rocker arm shaft outside diameter. Refer arms, as noted during removal.
to Engine Specifications for service limit. See Fig-
ure 13. 5. Tighten rocker arm shaft retaining flange bolts.
Torque to 49 to 55 N•m (37 to 41 lbf ft).

6. Adjust valve lash. See Valve Clearance Adjust-

ments.

7. Install valve cover. See Valve Covers and Igni-

tion Coils, Step 3.

VALVE CLEARANCE ADJUSTMENTS

NOTE: Make measurements and adjustments
while engine is cold.

1. Remove valve cover. See Valve Covers and Igni-

tion CoilsRemove.
Figure 13. Rocker Arm Shaft Outside Diameter
NOTE: The number one piston position is on fly-
wheel end of engine, opposite side of radiator, and
Assemble ignition order is 1-3-4-2 at 180 degree intervals.

NOTE: The rocker arm shaft fits tightly in rocker 2. Rotate crankshaft clockwise, as seen from radi-
arm support brackets. Clamp rocker arm shaft in a ator side, to bring number one piston to top
padded vise and twist and push support brackets dead center (TDC). See Table 1 for reference to
onto rocker arm shaft. help determine which valves will be available
for adjustment with number one piston at TDC.
1. Lubricate rocker arm shaft. Slide rocker arm
support brackets, springs, and rocker arms onto Table 1. Available Valves for Adjustment
shaft, as noted during removal.
Adjustable Cylinder Intake Exhaust
2. Position rocker arm assembly on a flat surface. Location Of Piston
Install washers and c-clips onto ends of rocker When No. 1 1 ⋆ ⋆
arm shaft. See Figure 10. piston is at 2 ⋆
compressio
3. If removed, install valve adjusting screws and n top dead 3 ⋆
lock nuts. center 4
Install When No. 1 1
piston is at 2 ⋆
NOTE: When installing push rod, mount it se- overlap
curely in groove located in bottom of lifter. position 3 ⋆

1. Install push rods. 4 ⋆ ⋆

2. Place rocker arm assembly in position on cylin- 3. Insert a feeler gauge between rocker arm and
der head. valve cap. See Figure 14. Record measured
valve clearance. The valve clearance should be
3. Install and hand tighten rocker arm shaft re- between 0.23 to 0.27 mm (0.009 to 0.011 in.).
taining flange bolts.

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Cylinder Head Assembly Repair 0600 SRM 1893

NOTE: There is a tendency for clearance to de-

crease slightly when lock nut is tightened. It is sug-
gested that you make clearance adjustment slightly
on loose side before tightening lock nut.

5. Insert a feeler gauge between rocker arm and

valve cap and adjust clearance so there is a
slight drag on feeler gauge when sliding it be-
tween rocker arm and valve cap. Tighten valve
adjusting screw lock nut and recheck clearance.
The valve clearance should be between 0.23 to
0.27 mm (0.009 to 0.011 in.).

6. Apply clean engine oil to contact surface be-

1. VALVE ADJUSTING SCREW tween adjusting screw and push rod.
2. VALVE LOCK NUT
7. Turn crankshaft 180 degrees and make meas-
Figure 14. Valve Clearance Measurement urement and adjustment for number three cyl-
inder. Then turn crankshaft 180 degrees and
make measurement and adjustment for number
NOTE: Make measurements and adjustments four cylinder. Then turn crankshaft 180 de-
while engine is cold. grees and make measurement and adjustment
for number 2 cylinder.
4. If adjustment is needed, loosen valve adjusting
screw lock nut and valve adjusting screw on 8. Install valve cover. See Valve Covers and Igni-
rocker arm (see Figure 14) and check valve for tion Coils, Install.
any inclination of valve cap, entrance of dirt, or
wear. See Figure 15. CYLINDER HEAD ASSEMBLY
Remove
1. Disconnect negative battery cable at battery.

NOTE: Place a suitable container with a capacity

of at least 12.0 liter (13 qt) under radiator and
lower radiator hose.

2. Remove lower radiator hose and radiator cap.

Allow cooling system to drain.

3. Remove two hose clamps and air intake hoses

from air cleaner. See Figure 16.
A. NORMAL B. ABNORMAL
1. VALVE CAP

Figure 15. Valve Cap Check

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0600 SRM 1893 Cylinder Head Assembly Repair

1. HOSE CLAMP 2. AIR INTAKE HOSE

Figure 16. Air Intake Hoses 1. ADJUSTMENT BOLT

2. ADJUSTER BRACKET
3. RETAINING NUT
4. MOUNTING BOLT
NOTE: Tag wiring connectors and wiring harness 5. WASHER
before removal to aid during installation. 6. MOUNTING BRACKET
7. ALTERNATOR
4. Tag and disconnect connectors for engine wir-
ing harness. Move harness aside for better ac- Figure 17. Alternator Mounting and Adjustment
cess.

5. Loosen adjustment bolt for alternator and re- 6. Remove three mounting bolts, three retaining
lease tension on serpentine belt. Remove ser- nuts, mounting bracket and alternator from lift
pentine belt. See Figure 17. truck. See Figure 17.

7. Remove three bolts and idler assembly from

water pump assembly. See Figure 18.

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Cylinder Head Assembly Repair 0600 SRM 1893

9. Loosen two hose clamps and remove hose from

water pump and water flange assembly. See
Figure 19.

10. Loosen two hose clamps and remove hose from

water pump and LPG converter. See Figure 19.

11. Loosen two clamps and remove hose from LPG

converter and engine oil cooler. See Figure 19.

A. APPLIES TO LIFT TRUCKS MANUFACTURED

WITHOUT HYDRAULIC FAN UNIT.
1. IDLER ASSEMBLY
2. BOLT
3. PULLEY
4. SPACER
5. COLLAR
6. WATER FLANGE
7. WATER PUMP
1. WATER FLANGE ASSEMBLY
Figure 18. Engine Pulleys 2. HOSE
3. WATER PUMP
4. ENGINE OIL COOLER
NOTE: Lift trucks equipped with hydraulic fan will 5. LPG CONVERTER
not have a water flange pulley.
Figure 19. Water Pump Components
8. Remove eight bolts, collar, spacer, and two fan
pulleys from water pump and water flange. See
Figure 18.

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0600 SRM 1893 Cylinder Head Assembly Repair

12. Loosen two clamps and remove coolant by pass 14. Remove four bolts, water flange assembly, and
hose from water pump and water flange assem- gasket from cylinder head. Discard gasket. See
bly fitting. See Figure 20. Figure 20.

13. Remove water pump. See Cooling System Re-

pair section in this manual for procedure.

1. WATER FLANGE ASSEMBLY 5. GASKET

2. CLAMP 6. CYLINDER HEAD
3. BYPASS HOSE 7. BYPASS HOSE FITTING
4. BOLT

Figure 20. Water Flange

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Cylinder Head Assembly Repair 0600 SRM 1893

15. Remove valve cover, ignition coils and related 16. Remove six bolts, two nuts, intake manifold as-
parts. See Valve Covers and Ignition Coils, Re- sembly and gasket from cylinder head. Discard
move. gasket. See Figure 21.

1. INTAKE MANIFOLD ASSEMBLY 9. O-RING

2. NUT 10. THROTTLE BODY ADAPTER
3. GASKET 11. BOLT
4. STUD 12. CAPSCREW
5. CYLINDER HEAD 13. DEPR INLET FLANGE
6. THROTTLE BODY GASKET 14. FUEL MIXER ASSEMBLY
7. THROTTLE BODY 15. INTAKE MANIFOLD BOLT
8. SPACER 16. DEPR

Figure 21. Intake Manifold

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0600 SRM 1893 Cylinder Head Assembly Repair

17. Remove capscrew from dipstick tube. See Fig-

ure 22.

18. Remove dipstick, dipstick tube, O-ring, and dip-

stick tube guide from engine block. Discard O-
ring. See Figure 22.

1. STUD
2. EXHAUST MANIFOLD GASKET
3. EXHAUST MANIFOLD
4. FLANGE NUT
5. FLANGE BOLT
6. HEAT SHIELD

Figure 23. Exhaust Manifold

1. CAPSCREW 4. O-RING
2. DIPSTICK 5. GUIDE NOTE: Note position of remaining head bolts to aid
3. DIPSTICK TUBE in installation.
Figure 22. Engine Oil Dipstick
22. Remove remaining ten cylinder head bolts in
sequence shown, from one to eighteen. See Fig-
ure 24.
19. Remove six flange bolts and heat shield from
exhaust manifold. See Figure 23.

20. Remove eight flange nuts, exhaust manifold

and exhaust manifold gasket from cylinder
head. Discard gasket (exhaust manifold). See
Figure 23.

21. Remove rocker arm assembly. See Rocker Arm

Assembly, Remove.

A. TIMING GEAR CASE END

B. FLYWHEEL END

Figure 24. Head Bolt Pattern

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Cylinder Head Assembly Repair 0600 SRM 1893

23. Remove eight lifters from crankcase. See Fig- 6. Turn cylinder head so exhaust port side faces
ure 25. down. Remove intake and exhaust valves from
cylinder head.

1. LIFTERS 2. CRANKCASE
Figure 25. Lifters

Disassemble

Valves and Valve Springs, Remove

1. Using a valve spring compressor tool, compress
valve springs.

2. Remove valve keepers and valve cap from the 1. PAD

end of valve. See Figure 26. 2. VALVE KEEPERS
3. VALVE SPRING RETAINER
4. VALVE SPRING
3. Slowly release tension on valve spring. 5. VALVE STEM SEAL
6. VALVE GUIDE
4. Remove spring retainer, valve spring, and valve 7. CYLINDER HEAD
stem seal. 8. INTAKE VALVE
9. EXHAUST VALVE
5. Repeat this procedure until all intake and ex- 10. ROCKER ARM
haust valve springs and valve stem seals are 11. ROCKER ARM BRACKET
removed.
Figure 26. Valves and Valve Springs
NOTE: If existing valves are going to be reinstalled
in cylinder head, mark valves so they can be instal-
led in their original location.

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0600 SRM 1893 Cylinder Head Assembly Repair

Valve Guides, Remove

WARNING
Press out used valve guide using valve guide re- Compressed air can move particles so that they
placing tool. See Figure 27. cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.

CAUTION
Any part which is found defective as a result of in-
spection or any part whose measured value does
not satisfy the standard or limit must be replaced.

CAUTION
Any part determined to not meet the service
standard or limit before the next service, as deter-
mined from the state of current rate of wear,
should be replaced even though the part currently
meets the service standard limit.

CAUTION
Use caution not to scratch the gasket mating sur-
faces when cleaning the exhaust manifold and
cylinder head.

CAUTION
Use caution not to scratch the gasket mating sur-
faces when cleaning the intake manifold and cyl-
A. REMOVAL B. INSTALLATION inder head.

1. VALVE GUIDE INSTALLATION TOOL

2. CYLINDER HEAD CAUTION
3. VALVE GUIDE Use caution not to scratch the gasket mating sur-
Figure 27. Valve Guide Removal faces when cleaning the cylinder head and cylin-
der block.

Carefully remove all gasket residue from exhaust

Clean and Inspect manifold and cylinder head. Inspect exhaust mani-
fold for scratches, cracks, or any other damage. Re-
WARNING pair or replace as needed.
Cleaning solvents can be flammable and toxic and
Carefully remove all gasket residue from intake
can cause skin irritation. When using cleaning
manifold and cylinder head. Inspect intake mani-
solvents, always follow the recommendations of
fold for scratches, cracks, or any other damage. Re-
the manufacturer.
pair or replace as needed.

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Cylinder Head Assembly Repair 0600 SRM 1893

Carefully remove all gasket residue from cylinder Valve Guides

head and cylinder block. Inspect cylinder head for
scratches, cracks, or any other damage. Repair or Visually inspect valve guides for distortions, scor-
replace as needed. ing, or other damage.

Thoroughly clean all components using a nonmetal- Use a test indicator and micrometer to measure in-
lic brush and cleaning solvent. Dry parts with com- side diameter at each end of valve guide. Refer to
pressed air. Each part must be free of carbon, metal Engine Specifications for service limit.
filings, and other debris.
Valves
Visually inspect parts. Replace any parts that are
obviously discolored, heavily pitted, or otherwise Valve Stem Diameter: Use a micrometer to meas-
damaged. Replace parts that do not meet specified ure valve stem diameter. Measure valve stem near
limit. combustion end and near opposite end. Refer to En-
gine Specifications for service limit. See Figure 29.
Cylinder Head
1. Place cylinder head flat and inverted (combus-
tion side up) on work bench.

2. Use a straight edge and feeler gauge to meas-

ure amount of cylinder head distortion. Refer to
Engine Specifications for service limit. See Fig-
ure 28.

A. MEASUREMENT POINTS

Figure 29. Valve Stem Diameter Measurement

Points

Valve Stem Straightness: Place valve stem on a

flat surface. Roll valve until a gap can be observed
between a portion of valve stem and flat surface.
Use a feeler gauge to measure gap. Refer to Engine
Specifications for service limit. See Figure 30.

Figure 28. Cylinder Head Distortion Check

3. Use Magnaflux method and inspect cylinder

head for cracks. Replace cylinder head if evi-
dence of fractures are found.

Figure 30. Valve Stem Straightness Check

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0600 SRM 1893 Cylinder Head Assembly Repair

Valve Sink

Insert valves into their proper places in cylinder

head and press them down until they are fully
seated. Using a depth micrometer, measure differ-
ence between cylinder head surface and combustion
surface of each exhaust and intake valve. Refer to
Engine Specifications for service limit. See Fig-
ure 31 and Figure 32.

1. VALVE SEAT

Figure 33. Valve Seat

Roughness or burrs will cause poor seating of a

valve. Visually inspect seating of each valve and de-
termine if lapping or grinding is needed. Grinding
Figure 31. Valve Sink Measurement is needed if cylinder head's seat width exceeds
standard limits. Refer to Engine Specifications for
service limit.

Lap valve seat and cylinder head with a mixture of

valve compound and engine oil.

If valve requires grinding, lap valve after grinding.

Be sure to thoroughly wash parts to remove all
grinding powder or compound.

Valve Springs

Inspect valve springs. If damage or corrosion is

seen, or if measurements exceed specified limits,
replace springs.

Fractures: Check for fractures on inside and out-

side portions of springs. If the valve spring is frac-
tured, replace spring.
Figure 32. Valve Sink
Corrosion: Check for corrosion of spring material
caused by oxidation.
Valve Seat Squareness: Use a flat surface and a square to
check each spring for squareness. Refer to Engine
Always check clearance between valve and valve
Specifications for service limit. See Figure 34.
guide before correcting valve seat. See Figure 33. If
clearance exceeds the limit, replace valve or valve
guide to bring clearance within limit.

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Cylinder Head Assembly Repair 0600 SRM 1893

Figure 34. Spring Squareness Check

Free Length: Use a caliper to measure length of

spring. Refer to Engine Specifications for service
limit. See Figure 35.

A. REMOVAL B. INSTALLATION
1. VALVE GUIDE INSTALLATION TOOL
2. CYLINDER HEAD
3. VALVE GUIDE

Figure 36. Valve Guide Installation

3. Accurately size I.D. of valve guide to specified

Figure 35. Spring Free Length Check
dimension. See Table 2.

Table 2. Valve Guide Specification

Assemble
7.010 to
Valve Guides, Install Intake 7.025 mm
Valve Valve (0.2760 to
1. The valve guides are installed into cylinder Factory 0.2765 in.)
Guide
head with an extremely tight press fit. Before Specificat
Inside 7.010 to
installing valve guides, clean new valve guide ion
Diameter Exhaust 7.025 mm
and valve guide bore and apply oil to them.
Valve (0.2760 to
2. Press fit new valve guide with valve guide re- 0.2765 in.)
placing tool. See Figure 36.

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0600 SRM 1893 Cylinder Head Assembly Repair

Valves and Valve Springs, Install

1. Place cylinder head assembly on exhaust port
side.

2. Place all valves in their proper positions, as

marked when disassembled, in cylinder head.

3. Apply clean engine oil to lip of valve stem seal.

Using valve stem seal installation tool, insert a
new valve stem seal on each of valves. See Fig-
ure 37.

1. VALVE STEM SEAL

2. VALVE GUIDE
3. VALVE GUIDE PROTECTION
4. VALVE STEM SEAL PROTECTION
5. CLEARANCE

Figure 38. Valve Stem Seal Clearance

7. Install valve keepers and slowly release tension

1. VALVE STEM SEAL INSTALLATION TOOL in valve spring.
2. VALVE STEM SEAL
3. VALVE GUIDE 8. Install valve cap.
4. CYLINDER HEAD
Figure 37. Valve Stem Seal Installation 9. Repeat these procedures until all intake and
exhaust valves are installed.

4. Measure distance from cylinder head to valve 10. Install eight valve shafts, eight pads, and eight
stem seal. Refer to Engine Specifications for valve bridge arms. See Figure 26.
clearance specifications. See Figure 38.
Install
5. Place cylinder head on work bench with com-
bustion chamber facing down. Install valve 1. Lightly oil outside of lifters. Install eight lifters
springs and valve spring retainers. See Fig- into crankcase.
ure 26. 2. Carefully clean combustion surface of cylinder
6. Using valve compressor tool, compress valve head and top surface of cylinder block.
spring.

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Cylinder Head Assembly Repair 0600 SRM 1893

3. Place a new cylinder head gasket on cylinder 11. Install capscrew to dipstick tube and engine
block. block. See Figure 22.

4. Position cylinder head on cylinder head gasket 12. Install new gasket, intake manifold assembly,
and cylinder block. two nuts and nine bolts to cylinder head. See
Figure 21.
5. Lightly oil threads of cylinder head bolts.
13. Install ignition coils, valve cover and related
6. Install ten cylinder head bolts (as noted during parts. See Valve Covers and Ignition Coils, In-
removal) and tighten cylinder head bolts to 98 stall.
to 107 N•m (72 to 80 lbf ft) in sequence shown
(from 1 to 18) in Figure 39. 14. Install water flange assembly, new gasket, and
four bolts to cylinder head. See Figure 20.

15. Install water pump. See Cooling System Re-

pair section in this manual for procedure.

16. Install coolant by pass hose and two clamps

onto water pump and water flange assembly fit-
ting. See Figure 20.

17. Install two hose clamps and hose onto LPG con-
verter and engine oil cooler. See Figure 19 .

A. TIMING GEAR CASE END 18. Install two hose clamps and hose onto water
B. FLYWHEEL END pump ans LPG converter. See Figure 19.
Figure 39. Cylinder Head Torque Sequence
19. Install two hose clamps and hose onto water
pump and water flange assembly. See Fig-
7. Install push rods and rocker arm assembly. See ure 19.
Rocker Arm Assembly, Install.
NOTE: Lift trucks equipped with hydraulic fan will
8. Install new gasket, exhaust manifold, and eight not have water flange pulley.
flange nuts onto cylinder head. See Figure 23 .
20. Install two fan pulleys, spacer, collar, and eight
9. Install heat shield and six flange bolts to ex- bolts onto water pump and water flange. See
haust manifold. See Figure 23. Figure 18.

10. Install dipstick tube guide, new O-ring, dipstick 21. Install idler assembly and three bolts onto wa-
tube, and dipstick into engine block. See Fig- ter pump assembly. See Figure 18.
ure 22.

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0600 SRM 1893 Cylinder Head Assembly Repair

22. Install alternator, mounting bracket, three re- 30. Start engine and check for leaks.
taining nuts, and three mounting bolts onto en-
gine. See Figure 17. 31. Change engine oil and oil filter. See Lubrication
System Repair, Engine Oil and Oil Filter
23. Put serpentine belt on pulley's. Using a pry bar, Change.
pull alternator into position and put tension
onto serpentine belt. Tighten alternator adjust-
ment bolt. See Figure 17. WARNING
DO NOT remove the radiator cap from the radiator
24. Attach wiring harness to connectors as noted when the engine is hot. When the radiator cap is
during removal. removed, pressure will release from the coolant
system. If the coolant system is hot, the steam
25. Install air intake hoses and two hose clamps and boiling coolant can cause severe burns.
onto air cleaner. See Figure 16.

26. Install lower radiator hose. WARNING

The radiator or other parts of the cooling system
CAUTION may be hot or under pressure and can cause seri-
ous injury. Wait 30 minutes for the radiator and
Additives may damage the cooling system. Before
engine to cool before performing maintenance to
using additives, contact your local Hyster dealer.
the cooling system. After 30 minutes, do a touch
27. Fill cooling system with coolant. Refer to Peri- test by touching the radiator with your hand. If the
odic Maintenance section for your lift truck radiator is still hot to the touch, wait another 30
for correct coolant amount and type. minutes before attempting any maintenance to the
cooling system.
28. Install radiator cap.

29. Connect negative battery cable. CAUTION

Additives may damage the cooling system. Before
using additives, contact your local Hyster dealer.
WARNING
During engine operation, be careful not to touch 32. Stop engine. If coolant is hot, allow engine time
the fan, pulleys, or drive belts. Contact with these to cool. Check coolant level and fill as required
parts can cause serious injury. between ADD and FULL marks on coolant res-
ervoir.
WARNING
The radiator or other parts of the cooling system
may be hot or under pressure and can cause seri-
ous injury.

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Timing Gear Case and Timing Gears Repair 0600 SRM 1893

Timing Gear Case and Timing Gears Repair

TIMING GEAR CASE COVER
WARNING
Remove Compressed air can move particles so that they
cause injury to the user or to other personnel.
1. Remove coolant fan, serpentine belt, and water Make sure that the path of the compressed air is
pump. See Cooling System Repair. away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.
2. Remove bolt and washer holding crankshaft
pulley.
Clean all old sealant from timing gear case cover
3. Using a gear puller, remove crankshaft pulley. and timing gear case. Clean timing gear case cover
in cleaning solvent. Dry timing gear case cover with
4. Remove bolts holding timing gear case cover compressed air. Inspect for wear, cracks, and any
and plate to engine block. See Figure 40. other damage. If necessary, replace timing gear
case cover.

Install
1. Apply a continuous bead of Three Bond Liquid
Gasket (Hyster P/N 1599478) to outside diame-
ter of a new front oil seal.

2. Using a special tool, install new front oil seal

into timing gear case cover. Apply lithium
grease to lip of front oil seal. See Figure 41 .

1. TIMING GEAR CASE COVER

2. BOLT
3. FRONT OIL SEAL
4. O-RING
5. ENGINE BLOCK
Figure 40. Timing Gear Case Cover

5. Remove front oil seal from timing gear case Figure 41. Front Oil Seal Installation
cover. See Figure 40.

Clean and Inspect 3. Apply a continuous bead of Three Bond Liquid

Gasket (Hyster P/N 1599478) to mating surface
of timing gear case cover.
WARNING
Cleaning solvents can be flammable and toxic and 4. Place timing gear case cover in position on en-
can cause skin irritation. When using cleaning gine block and install retaining bolts. Torque to
solvents, always follow the recommendations of 24 to 27 N•m (18 to 20 lbf ft).
the manufacturer.
5. Install crankshaft pulley and bolt to crankshaft
pulley. Tighten bolt to 255 to 274 N•m (188 to
202 lbf ft).

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0600 SRM 1893 Timing Gear Case and Timing Gears Repair

6. Install water pump, serpentine belt, and cool- NOTE: If using a gear puller to remove crankshaft
ant fan. See Cooling System Repair. gear, be careful not to damage threads in end of
crankshaft.
7. Fill engine oil to correct level. For correct oil
amount and type refer to Periodic Mainte- 4. Remove crankshaft gear. See Figure 43.
nance 8000SRM1902.
5. Remove key from crankshaft.
8. Start engine and check for leaks.

TIMING GEARS
NOTE: For removal of fuel injection pump drive
gear, refer to section Fuel System Repair.

Before removing any of timing gears, rotate crank-

shaft to align alignment marks on gears as follows
(see Figure 42):
• Align mark "A" on camshaft gear with mark
"A" on idler gear.
• Align mark "B" on crankshaft gear with
mark "B" on idler gear.
1. OIL PUMP DRIVE GEAR
2. CRANKSHAFT GEAR
3. CRANKSHAFT
4. KEY

Figure 43. Crankshaft Gear

Install
1. Install key into crankshaft.

2. Align alignment mark "B" on crankshaft gear

with alignment mark "B" on idler gear 1 and in-
stall crankshaft gear onto crankshaft.
1. CAMSHAFT GEAR 3. Verify that all alignment marks are properly
2. CRANKSHAFT GEAR aligned. Figure 42.
3. IDLER GEAR 1
4. OIL PUMP GEAR
4. Install timing gear case cover. See Timing Gear
Figure 42. Timing Gear Alignment Case Cover, Install .

Idler Gear
Crankshaft Gear
Remove
Remove 1. Remove timing gear case cover. See Timing
Gear Case Cover , Remove .
1. Remove timing gear case cover. See Timing
Gear Case Cover, Remove . 2. Verify that gears are properly aligned with
alignment marks. See Figure 42.
2. Verify that gears are properly aligned with
alignment marks. See Figure 42. 3. Remove bolts from idler gear shaft. See Fig-
ure 44.
3. Remove oil pump drive gear. See Figure 43.

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 HeavyManuals.com
Timing Gear Case and Timing Gears Repair 0600 SRM 1893

4. Remove idler gear shaft, alignment pin, idler Legend for Figure 45
gear, idler gear collar, and bushing.
1. OUTSIDE DIAMETER
2. IDLER GEAR SHAFT
3. INSIDE DIAMETER
4. IDLER GEAR

Install
1. Lubricate idler gear bushing and idler gear
shaft with clean engine oil.

NOTE: Make sure oil hole in bushing is facing to-

ward top of engine.
1. ENGINE BLOCK
2. IDLER GEAR COLLAR 2. Align alignment mark "C" on idler gear 1 with
3. IDLER GEAR alignment mark "C" on idler gear 2 and align-
4. BUSHING
5. ALIGNMENT PIN ment mark "A" on idler gear 1 with alignment
6. IDLER GEAR SHAFT mark "A" on camshaft gear. Install idler gear,
7. BOLT bushing, and idler gear shaft.

Figure 44. Idler Gear 3. Verify that all alignment marks are properly
aligned. See Figure 42.

4. Install idler gear retaining bolts.

Inspect
5. Install timing gear case cover. See Timing Gear
1. Measure outside diameter of idler gear shaft.
Case Cover, Install .
Refer to Engine Specifications for service limit.
See Figure 44.
Camshaft Gear
2. Measure inside diameter of idler gear. Refer to
Engine Specifications for service limit. See Fig- Remove
ure 44.
1. Remove timing gear case cover. See Timing
Gear Case Cover, Remove.

2. Verify that gears are properly aligned with

alignment marks. See Figure 42.

3. Remove four capscrews and pulsar gear from

camshaft gear. See Figure 46.

4. Using a gear puller, remove camshaft gear. See

Figure 46.

5. Remove key from camshaft.

Figure 45. Idler Gear and Shaft Measurement

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 HeavyManuals.com
0600 SRM 1893 Timing Gear Case and Timing Gears Repair

2. Remove timing gear case cover. See Timing

Gear Case Cover, Remove.

3. Remove timing gears. See Timing Gears.

4. Remove three O-rings from cylinder block and

discard. See Figure 40.

Clean and Inspect

WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the recommendations of
the manufacturer.

WARNING
1. ENGINE BLOCK Compressed air can move particles so that they
2. CAMSHAFT GEAR cause injury to the user or to other personnel.
3. PULSE GEAR Make sure that the path of the compressed air is
4. CAPSCREW
5. BOLT away from all personnel. Wear protective goggles
6. RETAINER or a face shield to prevent injury to the eyes.
7. KEY
8. CAMSHAFT Clean all old sealant from timing gear case cover
Figure 46. Camshaft Gear and timing gear case. Clean timing gear case cover
and gear case in cleaning solvent. Dry timing gear
case cover and gear case with compressed air. In-
Install spect for wear, cracks, and any other damage. Re-
place components as necessary.
1. Install key into camshaft.

2. Align alignment mark "A" on camshaft gear Install

with alignment mark "A" on idler gear and in-
1. Install three new O-rings in cylinder block. See
stall camshaft gear onto camshaft.
Figure 40.
3. Install pulse gear and four capscrews onto cam-
2. Install timing gears. See Timing Gears.
shaft gear. Tighten capscrews to 4.7 to
5.6 N•m (42 to 50 lbf in). 3. Install timing gear case cover. See Timing Gear
Case Cover, Install.
4. Install timing gear case cover. See Timing Gear
Case Cover, Install. 4. Change engine oil and oil filter. See Lubrication
System Repair, Engine Oil and Oil Filter
TIMING GEAR CASE Change .
Remove 5. Start engine and check for leaks.
1. Remove engine. See section Frame
0100SRM1891.

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Drive Train, Camshaft, and Cylinder Block Repair 0600 SRM 1893

Drive Train, Camshaft, and Cylinder Block Repair

REMOVE DISASSEMBLE
1. Remove engine. See section Frame Pistons and Connecting Rods
0100SRM1891.
NOTE: It is necessary to rotate crankshaft to ac-
2. Remove starter. See Electrical Equipment Re- cess some of connecting rod assemblies at bottom
pair. dead center position.
3. Remove flywheel and flywheel housing. See 1. Using a feeler gauge, measure connecting rod
Flywheel and Flywheel Housing. thrust clearance. See Figure 47. Refer to En-
gine Specifications for standard limit. If meas-
4. Remove alternator. See Electrical Equipment
urement is out of specification, either crank-
Repair.
shaft or connecting rod must be replaced.
5. Remove water pump. See Cooling System Re-
pair.

6. Remove cylinder head. See Cylinder Head As-

sembly Repair.

7. Remove oil pan. See Lubrication System Re-

pair.

8. Remove oil suction tube. See Lubrication Sys-

tem Repair.

9. Remove timing gear case cover. See Timing

Gear Case and Timing Gears Repair.

10. Remove oil pump. See Lubrication System Re-

pair.

NOTE: DO NOT remove camshaft gear at this

time.

11. Remove crankshaft gear and idler gear. See

Timing Gear Case and Timing Gears Repair. Figure 47. Connecting Rod Thrust Clearance

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 HeavyManuals.com
0600 SRM 1893 Drive Train, Camshaft, and Cylinder Block Repair

2. Remove two bolts from one of connecting rod 6. Mark connecting rod cap and connecting rod
caps. See Figure 48. and place assembly on a bench.

7. Remove piston rings from piston.

8. Remove snap rings retaining wrist pin.

9. Remove wrist pin.

10. Remove piston from connecting rod.

11. Remove wrist pin bushing from connecting rod.

12. Repeat Step 2 through Step 11 for remaining

pistons and piston rods.

Crankshaft
1. Remove eight bolts holding rear oil seal assem-
bly to engine block. Remove rear oil seal assem-
bly. See Figure 49.

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 48. Piston and Connecting Rod

3. Remove connecting rod cap.

4. Remove bearing halves.

5. Tap piston through cylinder and remove piston

assembly with connecting rod.
1. BOLT
2. REAR MAIN SEAL HOUSING
3. REAR MAIN SEAL
4. ENGINE BLOCK

Figure 49. Rear Main Seal

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Drive Train, Camshaft, and Cylinder Block Repair 0600 SRM 1893

2. Remove rear main seal.

3. Measure crankshaft side gap using following

method:

a. Set a dial indicator with it's point on end of

crankshaft. Move crankshaft to front and
rear to measure side clearance. See Fig-
ure 50.

Dimension Minimum Maximum

Oversize Journal 0.2 mm 0.4 mm
(0.008 in.) (0.016 in.)
Dimension A 54.50 to 54.60 to
54.70 mm 54.80 mm
(2.146 to (2.150 to
2.153 in.) 2.157 in.)
Description Factory Allowable Limit Dimension B 26.20 to 26.40 to
Specification 26.25 mm 26.45 mm
(1.032 to (1.040 to
Side Clearance 0.15 to 0.35 mm 0.50 mm 1.033 in.) 1.041 in.)
of Crankshaft (0.0059 to (0.020 in.)
0.013 in.) Dimension C 2.8 to 3.2 mm 2.8 to 3.2 mm
(0.11 to (0.11 to
Figure 50. Crankshaft Side Gap Measurement 0.12 in.) radius 0.12 in.) radius
With Dial Indicator
Figure 51. Crankshaft Measurement With Oversize
b. If measurement is more than allowable limit, Journal
replace thrust bearings. If same dimension
bearing is not applicable because of journal
wear, replace it with an oversize one. See
Figure 51.

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 HeavyManuals.com
0600 SRM 1893 Drive Train, Camshaft, and Cylinder Block Repair

NOTE: Be sure to note markings on main bearing 5. Remove bearing halves and thrust bearings.
caps, or mark them yourself, so they can be rein- See Figure 52.
stalled in same location as they were removed.
6. Remove crankshaft from cylinder block.
NOTE: The arrows on main bearing caps point to
flywheel end of engine.

4. Remove bolts holding main bearing caps. Re-

move main bearing caps. See Figure 52.

1. BOLT 4. BEARING HALVES

2. MAIN BEARING CAP 5. THRUST BEARING
3. CYLINDER BLOCK 6. CRANKSHAFT

Figure 52. Crankshaft

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Drive Train, Camshaft, and Cylinder Block Repair 0600 SRM 1893

Camshaft
1. Using a feeler gauge, measure camshaft side
gap. Refer to Engine Specifications for service
limit. See Figure 53.

1. ENGINE BLOCK 5. BOLT

2. CAMSHAFT GEAR 6. THRUST PLATE
3. PULSAR GEAR 7. KEY
4. CAPSCREW 8. CAMSHAFT
1. THRUST METAL
2. CAMSHAFT Figure 54. Camshaft
3. SIDE GAP
4. CAMSHAFT PULLEY
Figure 53. Camshaft Side Gap CLEAN AND INSPECT

2. Using a gear puller, remove camshaft gear. See WARNING

Figure 54. Cleaning solvents can be flammable and toxic and
3. Remove key from camshaft. can cause skin irritation. When using cleaning
solvents, always follow the recommendations of
4. Remove two bolts holding thrust plate and re- the manufacturer.
move thrust plate.

NOTE: If engine is not installed on an engine WARNING

stand, position engine with mounting flange (fly- Compressed air can move particles so that they
wheel end) facing down. Rotate camshaft a few cause injury to the user or to other personnel.
turns to bump tappets out of way to prevent tap- Make sure that the path of the compressed air is
pets from interfering with removal of camshaft. away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.
5. With engine installed on an engine stand, ro-
tate engine so gravity causes the tappets to Clean all old sealant from all parts. Clean all parts
drop away from camshaft lobes. in cleaning solvent. Dry parts with compressed air.
Each part must be free of carbon, metal filings, old
6. Slowly pull camshaft out of engine block. sealant, and other debris. Inspect for wear, cracks,
NOTE: Be sure to mark tappets so they can be in- and any other damage. Replace components as nec-
stalled in same location as they were removed. essary.

7. Remove tappets.

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 HeavyManuals.com
0600 SRM 1893 Drive Train, Camshaft, and Cylinder Block Repair

Cylinder Block f. Measure inside diameter of cylinder number

one, near bottom of cylinder (c) and in (e) di-
1. Verify that oil holes are clear and unobstructed. rection. Record that measurement as data k.
Clear any oil holes as needed.
g. Roundness: Roundness for cylinder number
2. Check for discoloration or evidence of cracks. If one is calculated as follows:
evidence of a fracture is found, use color check
method or Magnaflux method to determine if f-g = X
cylinder block is fractured. h-i = Y
j-k = Z
3. Inspect cylinder roundness and cylindricity for
evidence of distortions. Collect and record X is difference between f and g measurements
measurements. See Figure 55 and Table 3. at top of cylinder.

Y is difference between h and i measurements

at center/middle of cylinder.

Z is difference between j and k measurements

at bottom of cylinder.

Select greatest of values X, Y and Z, then re-

cord it as V. This value represents roundness
of cylinder.

h. Cylindricity: Cylindricity for cylinder num-

ber one is calculated as follows:
Select least value of values X, Y and Z
Figure 55. Cylinder Measurement Points
record that value as S. Complete cal-
culation as follows:
4. Perform calculations as follows:
V-S = W
a. Measure inside diameter of cylinder number
W is difference between V and S measure-
one, near top of cylinder (a) and in (d) direc-
ments. This value represents cylindricity of
tion. Record that measurement as data f.
cylinder.
b. Measure inside diameter of cylinder number
5. Repeat cylindricity and roundness measure-
one, near top of cylinder (a) and in (e) direc-
ments and calculations for remaining cylinders.
tion. Record that measurement as data g.
6. Compare worksheet findings with specifications
c. Measure inside diameter of cylinder number
listed in Table 4.
one, near center of cylinder (b) and in (d) di-
rection. Record that measurement as data h. 7. Consider honing, re-boring, cylinder correction,
or replacing cylinder block if measurements fall
d. Measure inside diameter of cylinder number
outside specifications.
one, near center of cylinder (b) and in (e) di-
rection. Record that measurement as data i.

e. Measure inside diameter of cylinder number

one, near bottom of cylinder (c) and in (d) di-
rection. Record that measurement as data j.

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 HeavyManuals.com
Drive Train, Camshaft, and Cylinder Block Repair 0600 SRM 1893

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
Top Dimension (d) Dimension (e) f-g = X X, Y and Z = V
(a) f = __________ g = __________ X = __________ Roundness
V = __________
Least of
Cylinder #2 Center Dimension (d) Dimension (e) h-i = Y
X, Y and Z = S
(b) h = __________ i = __________ Y = __________
S = __________
V-S = W
Bottom Dimension (d) Dimension (e) j-k = Z
Cylindricity
(c) j = __________ k = __________ Z = __________
V = __________
Greatest of
Top Dimension (d) Dimension (e) f-g = X X, Y and Z = V
(a) f = __________ g = __________ X = __________ Roundness
V = __________
Least of
Cylinder #3 Center Dimension (d) Dimension (e) h-i = Y
X, Y and Z = S
(b) h = __________ i = __________ Y = __________
S = __________
V-S = W
Bottom Dimension (d) Dimension (e) j-k = Z
Cylindricity
(c) j = __________ k = __________ Z = __________
V = __________
Greatest of
Top Dimension (d) Dimension (e) f-g = X X, Y and Z = V
(a) f = __________ g = __________ X = __________ Roundness
V = __________
Least of
Cylinder #4 Center Dimension (d) Dimension (e) h-i = Y
X, Y and Z = S
(b) h = __________ i = __________ Y = __________
S = __________
V-S = W
Bottom Dimension (d) Dimension (e) j-k = Z
Cylindricity
(c) j = __________ k = __________ Z = __________
V = __________

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 HeavyManuals.com
0600 SRM 1893 Drive Train, Camshaft, and Cylinder Block Repair

Honing and Boring d. Insert rotating honing tool into cylinder and
move it down through entire length of cylin-
Pistons must move freely in cylinders while main- der in a five-second motion. See Figure 57.
taining adequate compression and oil sealing. If
cylinder walls are scuffed, scored, out of round, or
have poor cylindricity, boring or boring and honing
might correct cylinder problems. Re-boring is neces-
sary if bore dimensions fall outside specified limits.
See Table 4. Honing must follow any re-boring op-
erations. Slight imperfections can be corrected by
honing alone.

Table 4. Cylinder Bore Specification

Cylinder Bore I.D.

Factory Specification Allowable Limit

100.500 to 100.522 mm 100.650 mm Figure 56. Cylinder Honing Angle

(3.95670 to 3.95755 in.) (3.96260 in.)

1. Boring: Significant cylinder damage might be

corrected by re-boring.
• Boring out a cylinder block can only be
done in a properly equipped machine
shop.
• After re-boring, existing pistons must be
replaced with oversized pistons.
• After re-boring a cylinder block, each cyl-
inder must be honed.

2. Honing: Slight cylinder imperfections might be Figure 57. Cylinder Honing

corrected by honing.

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

WARNING
CAUTION Compressed air can move particles so that they
DO NOT allow the honing tool to operate in one cause injury to the user or to other personnel.
position for any length of time. Damage to the cyl- Make sure that the path of the compressed air is
inder wall will occur. Keep the tool in constant up- away from all personnel. Wear protective goggles
and-down motion. or a face shield to prevent injury to the eyes.
NOTE: Tilt honing tool at a 30 to 40 degree angle g. When honing is completed, wash cylinder
during honing operation, to leave a cross hatch block with hot water and soap. Use brushes
mark on cylinder wall. See Figure 56. to clean all passages and crevices. Rinse with
hot water and blow dry with compressed air.
Apply clean engine oil to all steel surfaces to
prevent rusting.

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 HeavyManuals.com
Drive Train, Camshaft, and Cylinder Block Repair 0600 SRM 1893

Cylinder Correction (Oversize) Pistons

1. If cylinder wear is more than allowable limit, 1. Using a micrometer, measure piston diameter
bore and hone to specified dimension. See Hon- at skirt. Refer to Engine Specifications for serv-
ing and Boring for procedures. ice limit. See Figure 59.

NOTE: If maximum I.D. or difference for oversize

cylinder is more than allowable limit, replace cylin-
der block.

2. Replace piston and piston rings with oversized

components. See Table 5 and Figure 58 for
oversized cylinder specifications.

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 Figure 59. Piston Skirt Measurement
Wear Limit (3.96260 in.)
Finishing Hone to 1.2 to
3.0 microns (0.000048 to 2. Measure piston ring and piston ring groove for
0.00011 in.) Rz cylinder number one.

a. Using a micrometer, measure thickness of

top compression ring. Refer to Engine Speci-
fications for service limit.

b. Place a properly-sized, top compression ring

in groove as shown in Figure 60. Use a feeler
gauge to measure gap between ring and pis-
ton. Refer to Engine Specifications for service
limit.

1. CYLINDER I.D. (BEFORE CORRECTION)

2. CYLINDER I.D. (OVERSIZE)

Figure 58. Oversize Piston

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 HeavyManuals.com
0600 SRM 1893 Drive Train, Camshaft, and Cylinder Block Repair

NOTE: MEASURE AT POSITIONS A, B, AND C IN

DIRECTIONS A AND B.

A. WIDTH B. THICKNESS Figure 61. Piston Pin Outside Diameter

Figure 60. Piston and Piston Ring Side Clearance

Connecting Rod
c. Add top compression ring groove width and 1. Measure inside diameter of connecting rod
top compression ring side clearance together small end. Refer to Engine Specifications for
to determine top ring groove width. Refer to service limit. See Figure 62.
Engine Specifications for service limit.

d. Replace piston if values fall outside specifica-

tion.

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

ance of top compression ring. Refer to Engine
Specifications for service limit.

f. Measure rings and ring grooves for second

compression ring and oil ring using same
method used to measure top compression
ring and groove dimensions.

3. Repeat Step 2 for each piston.

Piston Pin

Measure outside diameter of piston pin and inside

diameter of wrist pin bushing. Calculate clearance
between piston pin and wrist pin bushing. Refer to 1. CYLINDER GAUGE
Engine Specifications for service limit. See Fig- 2. CONNECTING ROD SMALL END
ure 61. Figure 62. Connecting Rod Small End

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 HeavyManuals.com
Drive Train, Camshaft, and Cylinder Block Repair 0600 SRM 1893

2. Measure crank-pin and connecting rod bearing Crankshaft

halves. Place connecting rod bearing halves
into connecting rod and connecting rod cap. In- 1. Measure trueness of crankshaft.
stall end of connecting rod to connecting rod
a. Place crankshaft on V-blocks at end journals.
cap. Install bolts and tighten to 54 to
See Figure 65.
59 N•m (40 to 43 lbf ft).
b. Place a dial indicator on a main bearing sur-
3. Measure inside diameter. Refer to Engine Spec-
face and zero gauge.
ifications for service limit.
c. Rotate crankshaft and observe runout. Refer
Tappets to Engine Specifications for service limit.
1. Check tappet contact surfaces with camshaft d. Repeat this procedure for remaining bearing
and push rods. Slight surface defects can be surfaces.
corrected using an oilstone. See Figure 63.

1. ABNORMAL CONTACT SURFACE

2. NORMAL CONTACT SURFACE

Figure 63. Tappet Contact Surface

2. Measure outside diameter of tappet stem. Refer

to Engine Specifications for service limit. See
Figure 64. A. BEND B. DEFLECTION
1. DIAL GAUGE 3. V-BLOCK
2. CRANKSHAFT

Figure 65. Crankshaft Bend Measurement

2. Inspect crankshaft for fractures.

a. Using color check method, inspect crankshaft

for cracks. Replace crankshaft if evidence of
fractures are found. See Figure 66.

Figure 64. Tappet Stem Measurement

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0600 SRM 1893 Drive Train, Camshaft, and Cylinder Block Repair

Figure 66. Crankshaft Fracture Check Description Factory Allowable Limit

Specification
46.959 to N/A
b. If color check method is not available, use 46.975 mm
Magnaflux method. Inspect crankshaft for Crank Pin O.D.
(1.8504 to
cracks. Replace crankshaft if evidence of 1.8522 in.)
fractures are found.
Oil Clearance 0.025 to 0.20 mm
3. Measure oil clearance between crank-pin and Between Crank 0.087 mm (0.0079 in.)
crank pin bearing. Pin and Crank (0.00099 to
Pin Bearing 0.0034 in.)
NOTE: DO NOT put Plastigage into crank pin
hole. Figure 67. Crank Pin Oil Clearance

NOTE: When tightening connecting rod screws, DO

NOT move crankshaft. NOTE: When replacing crank pin bearing with a
standard service part, make sure crank pin bearing
a. Clean crank pin and crank bearing. Put a
and connecting rod are marked with same ID color.
strip of plastigage on center of crank pin. In-
stall connecting rod cap. Tighten connecting b. If oil clearance is more than allowable limit,
rod cap screws to specified torque. Remove replace pin bearing. See Figure 68. If same
connecting rod cap again. Measure width dimension bearing is not applicable because
that becomes flat with scale to get oil clear- of crank pin wear, replace it with undersize
ance. See Figure 67. one. Refer to Figure 69.

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Drive Train, Camshaft, and Cylinder Block Repair 0600 SRM 1893

Dimension Minimum Maximum

0.2 mm 0.4 mm
Undersize
(0.008 in.) (0.016 in.)
1. ID COLOR
2. CRANK PIN BEARING 3.2 to 3.7 mm 3.3 to 3.7 mm
3. CENTER WALL THICKNESS Dimension A (0.13 to (0.13 to
0.14 in.) radius 0.14 in.) radius
ID Color Connecting Crank Pin Bearing
1.0 to 1.5 mm 1.0 to 1.5 mm
Rod
*Dimension B (0.040 to (0.040 to
Large End Class Center Wall 0.059 in.) relief 0.059 in.) relief
Diameter Thickness
46.759 to 46.559 to
56.010 to 1.496 to 46.775 mm 46.575 mm
Dimension C
56.020 mm 1.501 mm (1.8409 to (1.8331 to
Blue L
(2.2052 to (0.05890 to 1.8415 in.) dia. 1.8336 in.) dia.
2.2055 in.) 0.05909 in.)
The crank pin must be fine-finished to higher to
56.00 to 1.491 to Rmax=0.8S. *Holes to be de-burred and edges
Without 56.01 mm 1.496 mm rounded with 10 to 1.5 mm (0.040 to 0.059 in.) relief.
S
Color (2.2048 to (0.05870 to
2.2051 in.) 0.05889 in.) Figure 69. Crank Pin Journal Measurement

Figure 68. Crankshaft Pin Bearing Identification

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 HeavyManuals.com
0600 SRM 1893 Drive Train, Camshaft, and Cylinder Block Repair

Camshaft
1. Measure trueness of camshaft.

a. Place camshaft on V-blocks positioned at end

journals. See Figure 70.

b. Place a dial indicator on gear side bearing

surface and zero gauge.

c. Rotate camshaft and observe runout. Refer

to Engine Specifications for service limit.
A. CAM HEIGHT

Figure 71. Intake/Exhaust Cam Height

Measurement

3. Measure gear end bearing surface, intermedi-

ate position bearing surface, and flywheel end
bearing surface diameters. See Figure 72. De-
termine oil clearance. The oil clearance is calcu-
lated by subtracting measured camshaft bear-
ing surface diameter from camshaft bushing in-
side diameter. Refer to Engine Specifications
for service limit.
Figure 70. Camshaft Runout Check

2. Measure intake/exhaust cam height. Refer to

Engine Specifications for service limit. See Fig-
ure 71.

1. FLYWHEEL END BEARING SURFACE

2. INTERMEDIATE POSITION BEARING SUR-
FACE
3. GEAR END BEARING SURFACE

Figure 72. Camshaft Bearing Surface

Measurements

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Drive Train, Camshaft, and Cylinder Block Repair 0600 SRM 1893

Camshaft Bushing Pistons and Connecting Rods

If camshaft bushing is damaged, replace bushing 1. Select parts needed to assemble piston and con-
using appropriate service tool. necting rod for Number 1 cylinder.

2. Lubricate and insert wrist pin bushing into

ASSEMBLE small end of connecting rod. See Figure 48.
Camshaft 3. Install one snap ring into piston.
1. Verify that all parts are clean. Lightly lubricate 4. Position connecting rod into piston under skirt.
all parts with clean engine oil. The match marks on connecting rod and con-
necting rod cap, must be in line of piston identi-
2. Install timing gear case. See Timing Gear Case
fication number on top of piston. See Figure 73.
and Timing Gears Repair.

NOTE: Rotate cylinder block into a position in

which it allows gravity to keep tappets in place and
out of way of camshaft lobes for when camshaft is
installed.

3. Install tappets into cylinder block in same loca-

tions as they were removed.

4. Slowly insert camshaft through front of engine.

5. Place camshaft thrust plate in position and in-

stall retaining bolts. See Figure 53.

6. Install key on camshaft.

7. Install camshaft gear.

Crankshaft
1. Place crankshaft in position in cylinder block.

NOTE: The numbers and arrows on main bearing A. TOP OF PISTON (LOOKING DOWN)
caps are for proper positioning. The caps are num-
bered 1, 2, 3, and 4 with number 1 cap at flywheel 1. PISTON RINGS
2. PISTON
end of cylinder block. The arrows on bearing caps 3. WRIST PIN
should point towards flywheel end of cylinder block. 4. SNAP RING
5. WRIST PIN BEARING
2. Position bearing halves, thrust bearings, and 6. CONNECTING ROD
bearing caps on crankshaft. See Figure 52. 7. CONNECTING ROD BEARING
8. CONNECTING ROD CAP
3. Lubricate bearing cap bolts and install bolts. 9. CONNECTING ROD BOLTS
10. MATCH MARKS
4. Install a new oil seal in rear oil seal housing. 11. TOP RING GAP
12. OIL RING GAP
5. Apply a continuous bead of Three Bond Liquid 13. SECOND RING GAP
14. PISTON WRIST PIN HOLE
Gasket (Hyster P/N 1599478) to mating surface 15. FUEL SUPPLY PUMP DIRECTION
of rear oil seal housing.
Figure 73. Piston and Connecting Rod
6. Align rear oil seal housing with two dowel pins Identification Marks
on cylinder block and install rear oil seal hous-
ing. Install retaining bolts.

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 HeavyManuals.com
0600 SRM 1893 Drive Train, Camshaft, and Cylinder Block Repair

5. Lubricate and install piston wrist pin through

piston and wrist pin bushing.

6. Install second snap ring.

7. Using piston ring pliers, install piston rings.

a. Install each piston ring on piston with

punched manufacture's mark facing upward.
See Figure 74.

Figure 74. Piston Ring Mark

b. Install top compression ring, second com-

pression ring, and oil ring. See Figure 75.

1. TOP COMPRESSION RING

2. SECOND COMPRESSION RING
3. OIL RING
4. JOINTS

Figure 76. Piston Rings Staggering

8. Perform Step 1 through Step 7 for assembly of

remaining pistons.

9. Lubricate Number 1 piston and piston rings

with clean engine oil.

10. Using special tool, piston ring compressor, com-

press piston rings on Number 1 piston.

11. Carefully install piston into Number 1 cylinder.

1. TOP COMPRESSION RING
2. SECOND COMPRESSION RING Be sure matched mark on connecting rod and
3. OIL RING connecting rod cap is facing towards fuel mix-
4. PISTON ing chamber side. See Figure 73.
Figure 75. Piston Rings
12. Install connecting rod bearing halves and con-
necting rod cap. Install connecting rod bolts
c. Stagger piston ring joints at 120 degree in- and tighten to 79 to 83 N•m (58 to 61 lbf ft).
tervals. DO NOT position top compression See Figure 73.
ring joint in line with piston wrist pin. The
coil expander joint must be opposite oil ring 13. Perform Step 9 through Step 12 to install re-
joint. See Figure 76. maining pistons in their respective cylinders.

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 HeavyManuals.com
Drive Train, Camshaft, and Cylinder Block Repair 0600 SRM 1893

INSTALL 9. Install flywheel and flywheel housing. See Fly-

wheel and Flywheel Housing.
1. Install crankshaft gear and idler gear. See Tim-
ing Gear Case and Timing Gears Repair. 10. Install starter. See Electrical Equipment Re-
pair.
2. Install oil pump. See Lubrication System Re-
pair. 11. Install engine. See section Frame
0100SRM1891.
3. Install timing gear case cover. See Timing Gear
Case and Timing Gears Repair. 12. If not previously removed, remove and discard
engine oil filter. Apply clean oil to gasket of
4. Install oil suction tube. See Lubrication System new filter. Install new filter. Turn filter until
Repair. gasket touches, then tighten 1/2 to 3/4 turn
with your hand.
5. Install oil pan. See Lubrication System Repair.
13. Fill engine oil to correct level. See section Peri-
6. Install cylinder head. See Cylinder Head As-
odic Maintenance 8000SRM1902.
sembly Repair.
14. Start engine and check for leaks.
7. Install water pump. See Cooling System Re-
pair.

8. Install alternator. See Electrical Equipment

Repair.

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 HeavyManuals.com
0600 SRM 1893 Lubrication System Repair

Lubrication System Repair

ENGINE OIL AND OIL FILTER CHANGE 2. Remove engine oil filter. See Figure 78.

NOTE: Place a container with a capacity of at least

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

1. Remove oil pan drain plug and drain engine oil

into a suitable container. See Figure 77.

1. OIL FILTER 4. O-RING

2. ADAPTER BOLT 5. ENGINE BLOCK
3. OIL COOLER

Figure 78. Oil Filter

3. Install oil pan drain plug.

4. Apply clean oil to gasket of new filter. Install

new filter. Turn filter until gasket touches,
then tighten 1/2 to 3/4 turn with your hand.

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

amount and type refer to Periodic Mainte-
nance 8000SRM1902.

6. Start engine. Check area around oil filter for

leaks.

1. DRAIN PLUG 4. BOLT

2. GASKET 5. FLANGE BOLT
3. OIL PAN 6. CRANK CASE 2

Figure 77. Oil Pan

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 HeavyManuals.com
Lubrication System Repair 0600 SRM 1893

OIL PAN 3. Apply clean oil to gasket of new filter. Install

new filter. Turn filter until gasket touches,
Remove then tighten 1/2 to 3/4 turn with your hand.

4. Install oil pan drain plug.

WARNING
When putting the lift truck on blocks, make sure 5. Remove lift truck from blocks.
the surface is solid, even, and level. Any blocks
6. Fill engine oil to correct level. For correct oil
used to support the lift truck must be solid, one-
amount and type refer to Periodic Mainte-
piece units.
nance 8000SRM1902.
1. Put lift truck on blocks so that you have access
7. Start engine and check for leaks.
under lift truck. Refer to Operating Manual
or Periodic Maintenance 8000SRM1902. OIL SUCTION TUBE
NOTE: Place a container with a capacity of at least
Remove
13.2 liter (3.5 gal) under oil pan drain plug.
1. Remove oil pan. See Engine Oil and Oil Filter
2. Remove oil pan drain plug and drain engine oil
ChangeRemove.
into a suitable container. See Figure 78.
2. Remove two bolts holding oil suction tube. See
3. Remove oil filter.
Figure 79.
4. Remove twenty bolts holding oil pan to crank-
3. Remove oil suction tube.
case 2. See Figure 77.
4. Remove O-ring from oil suction tube and dis-
5. Remove four flange bolts holding oil pan to
card.
crankcase 2. See Figure 77.

6. Remove oil pan.

CAUTION
Use care not to damage the mating surfaces when
removing old gaskets and sealant residues.

7. Carefully remove old sealant residue from mat-

ing surfaces of oil pan and cylinder block.

8. Thoroughly clean outside and inside surfaces of

oil pan.

Install
1. Apply a continuous bead of Three Bond Liquid
Gasket (Hyster P/N 1599478) around sealing
surface of oil pan. 1. BOLT 3. O-RING
2. OIL SUCTION TUBE 4. CRANKCASE 2
2. Place oil pan in position and install retaining
bolts. Refer to Standard Torque Specifications. Figure 79. Oil Suction Tube

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 HeavyManuals.com
0600 SRM 1893 Lubrication System Repair

Clean 2. Remove bolt and washer holding crankshaft

pulley.
WARNING 3. Using a gear puller, remove crankshaft pulley.
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning 4. Remove timing gear case cover. See Timing
solvents, always follow the recommendations of Gear Case and Timing Gears Repair.
the manufacturer.
5. Remove eight capscrews holding oil pump as-
sembly and remove oil pump assembly from
WARNING timing gear case housing. See Figure 80.
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.

NOTE: The oil suction tube and screen are to be

serviced as an assembly. DO NOT attempt to repair
wire mesh portion of tube and screen assembly.

Clean oil suction tube in cleaning solvent. Dry oil

suction tube with compressed air. Inspect for wear
and damage. If necessary, replace oil suction tube.

Install
1. Install a new O-ring on oil suction tube.

2. Position oil suction tube in cylinder block.

1. CAPSCREW
3. Install two bolts to retain oil suction tube. Refer 2. OIL PUMP COVER
to Standard Torque Specifications. 3. OIL PUMP ROTOR
4. GEAR CASE HOUSING
4. Install oil pan. See Engine Oil and Oil Filter
ChangeInstall. Figure 80. Oil Pump Assembly

OIL PUMP
6. Remove outer rotor from timing gear case hous-
Remove ing. See Figure 80.

1. Remove coolant fan, serpentine belt, and water

pump. See Cooling System Repair.

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Lubrication System Repair 0600 SRM 1893

Clean and Inspect Legend for Figure 81

1. OUTER ROTOR 3. OIL PUMP CAVITY

WARNING 2. FEELER GAUGE
Cleaning solvents can be flammable and toxic and
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 top of an inner rotor
tooth and top of an outer rotor tooth and measure
WARNING clearance. Refer to section Engine Specifications for
Compressed air can move particles so that they clearance limits. See Figure 82.
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.

CAUTION
If any oil pump component clearance exceeds its
limit, the oil pump must be replaced as an assem-
bly. Failure to replace the complete pump assem-
bly could result in pump failure and damage to the
engine.

Clean all parts in cleaning solvent. Dry parts with

compressed air. Inspect for wear and damage. If
necessary, replace oil pump assembly.

Outer Rotor Outside Clearance 1. FEELER GAUGE

2. INNER ROTOR
Insert a feeler gauge between outer rotor and tim- 3. OUTER ROTOR
ing gear case oil pump cavity and measure clear- Figure 82. Outer Rotor to Inner Rotor Tip
ance. Refer to section Engine Specifications for Clearance Check
clearance limits. See Figure 81.

Outer Rotor Side Clearance

Using a depth micrometer, measure depression of

outer rotor across pump cavity to determine side
clearance. Refer to section Engine Specifications for
clearance limits. See Figure 83.

Figure 81. Outer Rotor Outside Clearance Check

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 HeavyManuals.com
0600 SRM 1893 Lubrication System Repair

Install
1. Lubricate outer rotor and pump bore in gear
case with clean engine oil.

NOTE: The punch mark end of outer rotor must

face away from gear case housing.

2. Install outer rotor in gear case housing. Verify

that punch mark end of outer rotor faces away
from gear case housing. See Figure 85.

1. DEPTH MICROMETER
2. PUMP CAVITY
3. OUTER ROTOR

Figure 83. Outer Rotor Side Clearance Check

Rotor Shaft Clearance

1. PUNCH MARK 3. TIMING GEAR
Measure outside diameter of rotor shaft and bore 2. OUTER ROTOR CASE
diameter in gear case housing to determine rotor
shaft clearance. Refer to section Engine Specifica- Figure 85. Outer Rotor
tions for clearance limits. See Figure 84.

3. Position oil pump assembly in gear case hous-

ing. Install bolts to retain oil pump. Refer to
Standard Torque Specifications. See Figure 77.

4. Install timing gear case cover. See Timing Gear

Case and Timing Gears Repair.

5. Install crankshaft pulley, washer, and bolt to

retain crankshaft pulley. Tighten bolt to 255 to
274 N•m (188 to 202 lbf ft).

6. Install water pump, serpentine belt, and cool-

ant fan. See Cooling System Repair.

1. ROTOR SHAFT 7. Change engine oil and oil filter. See Engine Oil
2. GEAR CASE HOUSING and Oil Filter Change.

Figure 84. Rotor Shaft Clearance Check 8. Start engine and check for leaks.

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Fuel System Repair 0600 SRM 1893

Fuel System Repair

For repair procedures on the fuel system see LPG Fuel System, Kubota 3.8L SI Engine 0900SRM1905.

Cooling System Repair

SERPENTINE BELT Inspect

Remove Inspect serpentine belt for cracks, oil, wear, and

damage. If any of these conditions exist, replace
serpentine belt.
WARNING
During engine operation, be careful not to touch Install
the fan, pulleys, or drive belts. Contact with these
parts can cause serious injury. 1. Place serpentine belt over pulleys.

2. Adjust tension of serpentine belt as shown in

WARNING section Step 4.
The radiator or other parts of the cooling system
may be hot or under pressure and can cause seri- 3. Tighten set bolt for alternator to
ous injury. Wait 30 minutes for the radiator to 25.5 N•m (18.8 lbf ft).
cool. Do a touch test by touching the radiator with
4. Install fan assembly. Refer to section Cooling
your hand. If the radiator is still hot to the touch,
System 0700SRM1895 for procedures.
wait another 30 minutes before attempting to
check or fix any part of the cooling system.
Serpentine Belt, Adjustment
1. Turn ignition switch to OFF position.
NOTE: The serpentine belt is to be checked at posi-
2. Remove fan assembly. Refer to Cooling Sys- tion A or B shown in Figure 86 or Figure 87.
tem 0700SRM1895.
1. Using a belt tension gauge, adjust belt tension
3. Loosen alternator set bolt and pivot alternator to 500 to 550 N (112 to 124 lbf).
toward engine.

4. Remove serpentine belt from pulleys.

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 HeavyManuals.com
0600 SRM 1893 Cooling System Repair

A. TENSION CHECK POSITION A. TENSION CHECK POSITION

B. TENSION CHECK POSITION B. TENSION CHECK POSITION

Figure 86. Serpentine Tension Check Points for Figure 87. Serpentine Tension Check Points for
Lift Trucks NOT Equipped with Hydraulic Fan Unit Lift Trucks Equipped with Hydraulic Fan Unit

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 HeavyManuals.com
Cooling System Repair 0600 SRM 1893

2. If adjustment is necessary, loosen alternator

set bolt and move alternator with a pry bar to WARNING
tighten serpentine belt. See Figure 88. The radiator or other parts of the cooling system
may be hot or under pressure and can cause seri-
ous injury. Wait 30 minutes for the radiator and
engine to cool before performing maintenance to
the cooling system. After 30 minutes, do a touch
test by touching the radiator with your hand. If the
radiator is still hot to the touch, wait another 30
minutes before attempting any maintenance to the
cooling system.

CAUTION
Disposal of lubricants must meet local environ-
mental regulations.

3. Remove radiator cap.

4. Loosen lower radiator hose and drain coolant

from coolant system into a suitable container.

5. Remove coolant drain plug and drain coolant

NOTE: IMAGE SHOWN IS FOR PROCEDURE REF- from engine block. See Figure 89.
ERENCE ONLY. YOUR LIFT TRUCK MAY BE DIF-
FERENT.

1. SET BOLT 3. PRY BAR

2. ALTERNATOR

Figure 88. Serpentine Belt Adjustment

3. When tension is correct, tighten set bolt to

25.5 N•m (18.8 lbf ft). Check belt tension again
to verify tension is still correct.

4. Repeat Step 1 through Step 3 if necessary.

WATER PUMP
Remove
1. Turn ignition switch to OFF position.
1. COOLANT DRAIN PLUG
2. Disconnect negative battery cable at battery.
Figure 89. Engine Block Coolant Drain Plug

WARNING
DO NOT remove the radiator cap from the radiator 6. Remove fan assembly. Refer to section Cooling
when the engine is hot. When the radiator cap is System 0700SRM1895 for procedures.
removed, pressure will release from the coolant
system. If the coolant system is hot, the steam 7. Remove serpentine belt. See Serpentine Belt,
and boiling coolant can cause severe burns. Remove.

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 HeavyManuals.com
0600 SRM 1893 Cooling System Repair

NOTE: Perform Step 8 and Step 9 on lift trucks 14. Disconnect coolant hoses from water pump. See
manufactured without hydraulic fan unit. Cylinder Head Assembly Repair section for pro-
cedure.
8. Remove three bolts and idler assembly from
water pump assembly. See Figure 90. Install
9. Remove four bolts, collar, spacer, and fan pulley 1. Connect coolant hoses to water pump. See Cyl-
from water flange. See Figure 90. inder Head Assembly Repair for procedure.
10. Remove four bolts and fan pulley from water 2. If removed, install coolant temperature sensor
pump. See Figure 90. and tighten to 16 to 23 N•m (12 to 17 lbf ft).

3. Connect electrical connector for coolant temper-

ature sensor.

NOTE: Perform Step 4 and Step 5 on lift trucks

manufactured without hydraulic fan unit.

4. Install plate with tension pulley and three cap-

screws. See Figure 90.

5. Using four bolts, install fan pulley, spacer and

collar. See Figure 90.

6. Install water pump pulley and four capscrews.

See Figure 90.

7. Install serpentine belt. See Serpentine Belt, In-

stall.

8. Install fan assembly. Refer to section Cooling

System 0700SRM1895 for procedures.

9. Connect lower radiator hose.

10. Install coolant drain plug in engine block. See

A. APPLIES TO LIFT TRUCKS MANUFACTURED Figure 89.
WITHOUT HYDRAULIC FAN UNIT.
1. IDLER ASSEMBLY 5. COLLAR CAUTION
2. BOLT 6. WATER FLANGE
3. PULLEY 7. WATER PUMP Additives may damage the cooling system. Before
4. SPACER using additives, contact your local Hyster dealer.

Figure 90. Water Pump Pulley 11. Fill cooling system with coolant. For correct
coolant amount and type refer to Periodic
Maintenance 8000SRM1902.
11. Pivot alternator away from engine.
12. Install radiator cap.
12. Disconnect electrical connector for coolant tem-
perature sensor. 13. Connect negative battery cable.

13. If necessary, remove coolant temperature sen-

sor.

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 HeavyManuals.com
Cooling System Repair 0600 SRM 1893

15. Stop engine. If coolant is hot, allow engine time

WARNING to cool. Check coolant level and fill as required
During engine operation, be careful not to touch between ADD and FULL marks on coolant res-
the fan, pulleys, or drive belts. Contact with these ervoir.
parts can cause serious injury.
THERMOSTAT
WARNING Remove
The radiator or other parts of the cooling system
may be hot or under pressure and can cause seri-
ous injury.
WARNING
The radiator or other parts of the cooling system
14. Start engine and check cooling system for may be hot or under pressure and can cause seri-
leaks. ous injury. Wait 30 minutes for the radiator and
engine to cool before performing maintenance to
the cooling system. After 30 minutes, do a touch
WARNING test by touching the radiator with your hand. If the
DO NOT remove the radiator cap from the radiator radiator is still hot to the touch, wait another 30
when the engine is hot. When the radiator cap is minutes before attempting any maintenance to the
removed, pressure will release from the coolant cooling system.
system. If the coolant system is hot, the steam
and boiling coolant can cause severe burns.
CAUTION
DO NOT operate the engine without a thermostat.
WARNING The engine and cooling system can be damaged.
The radiator or other parts of the cooling system
may be hot or under pressure and can cause seri-
ous injury. Wait 30 minutes for the radiator and CAUTION
engine to cool before performing maintenance to Disposal of lubricants must meet local environ-
the cooling system. After 30 minutes, do a touch mental regulations.
test by touching the radiator with your hand. If the
radiator is still hot to the touch, wait another 30 1. Drain cooling system to level of thermostat.
minutes before attempting any maintenance to the
cooling system. 2. Disconnect coolant hose from thermostat cover.

3. Remove three bolts holding thermostat cover.

CAUTION Remove thermostat cover and gasket. Discard
gasket. See Figure 91.
Additives may damage the cooling system. Before
using additives, contact your local Hyster dealer. 4. Remove thermostat from water flange. See Fig-
ure 91.

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 HeavyManuals.com
0600 SRM 1893 Cooling System Repair

1. THERMOMETER
2. THERMOSTAT

Figure 92. Thermostat Check

2. Slowly increase temperature of water.

NOTE: WATER FLANGE HUB DOES NOT APPLY
3. The thermostat is operating correctly if it starts
TO LIFT TRUCKS EQUIPPED WITH HYDRAULIC
to open at temperature value stamped on flange
FAN UNIT.
of thermostat and fully opens as temperature of
1. BOLT water is increased.
2. THERMOSTAT COVER
3. GASKET Install
4. THERMOSTAT
5. WATER FLANGE 1. Install thermostat into water flange. See Fig-
ure 91.
Figure 91. Thermostat
2. Install thermostat cover and a new gasket. In-
stall bolts to hold thermostat cover. Tighten
Inspect bolts to 23 to 28 N•m (17 to 21 lbf ft).

1. Place thermostat and an accurate thermometer 3. Connect coolant hose to thermostat cover. See
in warm water. See Figure 92. Figure 91.

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 HeavyManuals.com
Cooling System Repair 0600 SRM 1893

CAUTION WARNING
Additives may damage the cooling system. Before The radiator or other parts of the cooling system
using additives, contact your local Hyster dealer. may be hot or under pressure and can cause seri-
ous injury. Wait 30 minutes for the radiator and
4. Fill cooling system with coolant. For correct engine to cool before performing maintenance to
coolant amount and type refer to Periodic the cooling system. After 30 minutes, do a touch
Maintenance 8000SRM1902. 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.
During engine operation, be careful not to touch
the fan, pulleys, or drive belts. Contact with these
parts can cause serious injury. CAUTION
Additives may damage the cooling system. Before
WARNING using additives, contact your local Hyster dealer.
The radiator or other parts of the cooling system 6. Stop engine. If coolant is hot, allow engine time
may be hot or under pressure and can cause seri- to cool. Check coolant level and fill as required
ous injury. between ADD and FULL marks on coolant res-
ervoir.
5. Start engine and check cooling system for
leaks.

WARNING
DO NOT remove the radiator cap from the radiator
when the engine is hot. When the radiator cap is
removed, pressure will release from the coolant
system. If the coolant system is hot, the steam
and boiling coolant can cause severe burns.

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 HeavyManuals.com
0600 SRM 1893 Flywheel and Flywheel Housing

Flywheel and Flywheel Housing

FLYWHEEL Install

Remove 1. Place flywheel in position on crankshaft flange

and install seven bolts. Tighten bolts to 98 to
1. Remove seven bolts holding flywheel to crank- 107 N•m (72 to 80 lbf ft).
shaft flange and remove flywheel.
FLYWHEEL HOUSING
Remove
1. Remove flywheel. See Flywheel,Remove.

2. Remove ten bolts holding flywheel housing to

cylinder block. See Figure 93.

3. Remove flywheel housing.

Install
1. Place flywheel housing in position on cylinder
block and install bolts. Tighten bolts to 78 to
90 N•m (58 to 66 lbf ft).

NOTE: LIFT TRUCK MODEL H4.0FT5/FT6, 2. Install flywheel. See Flywheel,Install.

H4.5FTS5, H4.5FT6, H5.5-5.5FT (H80-120FT) (U005)
SHOWN.

1. FLYWHEEL HOUSING
2. FLYWHEEL
3. BOLT
4. CRANKSHAFT
5. ENGINE BLOCK
Figure 93. Flywheel

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 HeavyManuals.com
Electrical Equipment Repair 0600 SRM 1893

Electrical Equipment Repair

NOTE: This section covers repair procedures for 1. Disconnect battery negative cable at negative
major electrical components only, if engine specific terminal.
sensors or switches need to be serviced see Electri-
cal System 2200SRM1901. 2. Disconnect battery positive cable at positive
terminal.
ALTERNATOR
3. Put labels on wires prior to disconnecting to aid
Remove in correct installation.

4. Disconnect wires from alternator.

WARNING
5. Loosen set bolt on alternator and tilt alternator
Always disconnect the cables at the battery be-
towards engine.
fore you make repairs to the engine. Disconnect
the cable at the negative terminal first. Install a 6. Remove serpentine belt from alternator pulley.
tag on the battery terminals so that no one con-
nects the cables on the terminals. 7. Remove set bolt from alternator. See Figure 94.

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 94. Alternator

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 HeavyManuals.com
0600 SRM 1893 Electrical Equipment Repair

8. If necessary, remove bolt holding alternator ad- 1. Disconnect battery negative cable at negative
justment bracket to water flange and remove terminal.
bracket.
2. Disconnect battery positive cable at positive
9. Remove bolt holding alternator to alternator terminal.
mounting bracket. Remove alternator.
3. Put labels on wires and cables prior to discon-
Install necting to aid in correct installation.

1. If removed, place alternator adjustment 4. Disconnect wires and cables from starter.
bracket in position and install bolt to retain
5. Hold starter so it won't fall. Remove two M10
bracket to water flange.
bolts and starter from flywheel housing. See
2. Position alternator on alternator mounting Figure 95.
bracket. Install bolt holding alternator to alter-
nator mounting bracket, but do not tighten.

3. Install set bolt for alternator and adjustment

bracket but do not tighten.

4. Connect electrical wires to alternator.

5. Install serpentine belt and adjust to proper ten-

sion. See Cooling System Repair, Serpentine
Belt, Adjustment.

6. Tighten set bolt to 25.5 N•m (18.8 lbf ft).

7. Tighten bolt holding alternator to alternator

mounting bracket.

8. Connect battery positive cable at positive termi- NOTE: LIFT TRUCK MODEL S4.0-S5.5FT, S5.5FTS
nal. (S80-120FT, S80-100FTBCS, S120FTS,
S120FTPRS) (J004) SHOWN.
9. Connect battery negative cable at negative ter-
minal. 1. FLYWHEEL HOUSING
2. M10 BOLT
10. Start engine and listen for any unusual sounds 3. STARTER
from alternator.
Figure 95. Starter
11. Verify that charge indicator is ON while engine
is operating. If charge indicator is not ON, re-
pair problem before operating engine. Install
STARTER 1. Place starter in position in flywheel housing.
Install two M10 bolts on starter and flywheel
Remove housing.

2. Connect wires and cables as labeled in removal.

WARNING Tighten M8 nut, B terminal, to 7.9 to
Always disconnect the cables at the battery be- 9.8 N•m (70 to 87 lbf in). Be sure to place cover
fore you make repairs to the engine. Disconnect over M4 screw connection. See Figure 96.
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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 HeavyManuals.com
Electrical Equipment Repair 0600 SRM 1893

3. Connect battery positive cable at positive termi-

nal.

4. Connect battery negative cable at negative ter-

minal.

NOTE: ILLUSTRATION USED FOR REFERENCE

ONLY.

1. M8 NUT 3. M4 SCREW
2. COVER 4. STARTER

Figure 96. Starter Connections

Engine Specifications
ENGINE DATA
Table 6. WG3800-L-E3 Engine

Engine Model EG505-XXXXX (Hyster P/N 8817524)

Type Vertical Inline LPG Engine
Combustion System Spark Injected
Aspiration Naturally Aspirated
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.)
*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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0600 SRM 1893 Engine Specifications

Table 6. WG3800-L-E3 Engine (Continued)

Max. Rated Output rpm S4.0-S5.5FT, S5.5FTS H4.0FT5/FT6, H4.5FTS5,

(Net) (min-1) (S80-120FT, H4.5FT6, H5.5-5.5FT
S80-100FTBCS, (H80-120FT) (U005)
S120FTS, S120FTPRS)
(J004)
2400 2200
hp SAE 92 86
kW 68 64
PS 93 87
High Idle Speed (Bare 2200 ± 25 rpm 2400 ±25 rpm
Engine)
Low Idle Speed (Bare 800 ± 25 rpm
Engine)
Engine Weight (Dry)* 258 kg (569 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, 622 CCA (Cold Cranking Amps)(Minimum)
Dimensions 632 × 498 × 711 mm (24.9 × 19.6 × 28.0 in.)
(L × W × H)*
Engine Oil Pan 12.2 liter (12.9 qt)
Capacity
Engine Coolant 4.9 liter (1.3 gal) Engine Only
Capacity
*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 1893

ENGINE TUNING
Inspection Item Standard Limit
Valve Gap Intake/Exhaust (Engine Cold) 0.23 to 0.27 mm
(0.009 to 0.011 in.)
Compression Pressure at 250 rpm 3.09 to 3.28 MPa 2.41 MPa
(448 to 476 psi) (350 psi)
Lubricating Oil Pressure At rated output 0.20 to 0.39 MPa
(29 to 57 psi)
When Idling 0.05 MPa or greater
(7.3 psi)
Thermostat Valve Opening Temperature Full Opening Lift
Temperature
75°C 90°C (194°F)
(167°F)

CYLINDER HEAD
Inspection Item Standard Limit
Combustion Surface Distortion (Flatness) 0.05 mm (0.0020 in.)
Valve Sink Intake 0.6 to 0.8 mm 1.2 mm (0.047 in.)
(0.024 to 0.031 in.)
Exhaust 0.85 to 1.05 mm 1.2 mm (0.047 in.)
(0.0335 to 0.0413 in.)
Valve Seat Angle Intake 60°
Exhaust 45°

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0600 SRM 1893 Engine Specifications

INTAKE/EXHAUST VALVE AND GUIDE

Inspection Item Standard Limit
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 0.045 to 0.075 mm 0.10 mm
(0.0018 to 0.0030 in.) (0.004 in.)

VALVE SPRING
Inspection Item Standard Limit
Free Length 35.1 to 35.6 mm 34.6 mm
(1.39 to 1.40 in.) (1.36 in.)
Inclination 1.0 mm
(0.039 in.)

ROCKER ARM AND SHAFT

Inspection Item Standard Limit
Arm Shaft Hole Diameter 16.0 to 16.018 mm
(0.62993 to 0.63062 in.)
Shaft Outside Diameter 15.973 to 15.984 mm
(0.62886 to 0.62929 in.)
Clearance 0.0016 to 0.045 mm 0.15 mm
(0.00063 to 0.0017 in.) (0.0059 in.)

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Engine Specifications 0600 SRM 1893

PUSH ROD
Inspection Item Standard Limit
Push Rod Bend 0.25 mm
(0.0098 in.)

GEAR TRAIN AND CAMSHAFT

Camshaft

Inspection Item Standard Limit

Camshaft Oil Clearance 0.070 to 0.22 mm (0.0028 to 0.30 mm
0.0086 in.) (0.0118 in.)
Cam Height Intake 37.64 mm (1.482 in.) 37.14 mm
(1.462 in.)
Exhaust 38.96 mm (1.534 in.) 38.46 mm
(1.514 in.)

Idle Gear Shaft and Bushing

Inspection Item Standard Limit

Shaft Outside Diameter 44.959 to 44.975 mm
(1.7701 to 1.7706 in.)
Bushing Inside Diameter 45.025 to 45.050 mm 46.075 mm
(1.7727 to 1.7736 in.) (1.8140 in.)
Clearance 0.050 to 0.091 mm 0.10 mm
(0.0019 to 0.0030 in.) (0.0039 in.)

Backlash of Each Gear

Inspection Item Standard Limit

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 0.044 to 0.185 mm 0.17 mm
(0.0017 to 0.0073 in.) (0.0067 in.)

CYLINDER BLOCK
Inspection Item Standard Limit
Cylinder Inside Diameter 100.000 to 100.022 mm 100.150 mm
(3.93701 to 3.93787 in.) (3.9429 in.)

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0600 SRM 1893 Engine Specifications

CRANKSHAFT
Inspection Item Standard Limit
Bending (1/2 the dial gauge reading) 0.02 mm
(0.0008 in.)
Connecting Rod Journals Pin Outside Diameter 52.977 to 52.990 mm
(2.0857 to 2.0862 in.)
Clearance 0.018 to 0.062 mm 0.20 mm
(0.00071 to 0.0024 in.) (0.0079 in.)
Crank Journal Selective Journal Outside 74.977 to 74.990 mm
Pairing Diameter (2.9519 to 2.9528 in.)
Clearance 0.018 to 0.062 mm 0.20 mm
(0.00071 to 0.0024 in.) (0.0079 in.)

PISTON
Inspection Item Standard Limit
Piston Pin Hole Inside Diameter 30.006 to 30.013 mm 30.05 mm
(1.1814 to 1.1816 in.) (1.183 in.)
Pin Outside Diameter 29.989 to 30.000 mm 29.959 mm
(1.1807 to 1.1811 in.) (1.1795 in.)
Clearance 0.000 to 0.020 mm 0.080 mm
(0.0000 to 0.0008 in.) (0.0032 in.)

PISTON RING
Inspection Item Standard Limit
Top Ring Side Clearance 0.05 to 0.09 mm 0.15 mm
(0.002 to 0.003 in.) (0.0059 in.)
End Clearance 0.30 to 0.450 mm 1.25 mm
(0.012 to 0.017 in.) (0.0492 in.)
Second Ring Side Clearance 0.093 to 0.120 mm 0.20 mm
(0.00367 to 0.00472 in.) (0.0079 in.)
End Clearance 0.30 to 0.45 mm 1.25 mm
(0.012 to 0.017 in.) (0.0492 in.)
Oil Ring Side Clearance 0.020 to 0.060 mm 0.15 mm
(0.00079 to 0.0023 in.) (0.0059 in.)
End Clearance 0.250 to 0.450 mm 1.25 mm
(0.0099 to 0.017 in.) (0.0492 in.)

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 HeavyManuals.com
Engine Specifications 0600 SRM 1893

CONNECTING ROD
Inspection Item Standard Limit
Thrust Clearance 0.05 mm
(0.002 in.)

Rod Small End

Inspection Item Standard Limit

Bushing Outside Diameter 30.031 to 30.046 mm
(1.1824 to 1.1829 in.)
Pin Outside Diameter 30.006 to 30.011 mm
(1.1814 to 1.1815 in.)
Clearance 0.020 to 0.040 mm 0.15 mm
(0.00079 to 0.0015 in.) (0.0059 in.)

Tappet

Inspection Item Standard Limit

Tappet Hole (Block) Inside Diameter 24.000 to 24.021 mm
(0.94489 to 0.94570 in.)
Tappet Stem Outside Diameter 23.959 to 23.980 mm
(0.94327 to 0.94409 in.)
Clearance 0.020 to 0.062 mm 0.07 mm
(0.00079 to 0.0024 in.) (0.003 in.)

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0600 SRM 1893 Engine Specifications

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

Model Standard Limit

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

Inner Rotor to Cover

Model Standard Limit

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

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Standard Torque Specifications 0600 SRM 1893

Standard Torque Specifications

STANDARD TORQUE CHART
Nominal Thread
Item × Pitch Tightening Torque
Diameter
Hexagon Bolt (7T) and Nut M6 × 1.0 mm 9.8 to 11.8 N•m
(87 to 104 lbf in)

NOTE: Use 80% of the value of M8 × 1.25 mm 24 to 27 N•m (18 to 20 lbf ft)
the Tightening Torque when the M10 × 1.5 mm 49 to 55 N•m (37 to 41 lbf ft)
tightening part is aluminum.
M12 × 1.75 mm 78.0 to 90.0 N•m
Use 60% of the value of the
(58 to 66 lbf ft)
Tightening Torque for 4T bolts
and lock nuts. 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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0600 SRM 1893 Special Torque Specifications

Special Torque Specifications

Alternator Pulley Nut Engine Oil Cooler to Cylinder Block Adapter/
58.4 to 78.9 N•m (43.1 to 58.2 lbf ft) Mounting Bolt
40 to 44 N•m (29 to 32 lbf ft)
Bearing Cap Set Bolt
138 to 147 N•m (102 to 108 lbf ft) Flywheel Bolts
98.1 to 107 N•m (72.4 to 79.5 lbf ft)
Camshaft Position Pulsar Gear Mounting
Screw Flywheel Housing Bolts
4.7 to 5.6 N•m (41.6 to 50 lbf in) 78 to 90 N•m (58 to 66 lbf ft)

Camshaft Position Sensor Mounting Screw Idler Gear Mounting Screw

4 to 5 N•m (35 to 44 lbf in) 24 to 27 N•m (18 to 20 lbf ft)

Connecting Rod Bolt Intake Air Temperature Sensor Mounting

79 to 83 N•m (58 to 61 lbf ft) Screw
30 to 39 N•m (22 to 28 lbf ft)
Coolant Temperature Sensor
16 to 23 N•m (12 to 17 lbf ft) Oil Pressure Switch Screw
15 to 19 N•m (11 to 14 lbf ft)
Crankshaft Position Sensor Mounting Screw
4 to 5 N•m (35 to 44 lbf in) Rocker Arm Bracket Nut
49 to 55 N•m (37 to 41 lbf ft)
Crankshaft Pulley Bolt
255 to 274 N•m (188 to 202 lbf ft) Starter Solenoid Nut (B Terminal)
9.8 to 11 N•m (87 to 97 lbf in)
Cylinder Head Bolt
98.1 to 107 N•m (72.4 to 79.5 lbf ft) Timing Gear Case Cover Mounting Screw
24 to 27 N•m (18 to 20 lbf ft)
Cylinder Head Cover Screw
10 to 11 N•m (61 to 99 lbf in) Timing Gear Case Plate Mounting Screw
24 to 27 N•m (18 to 20 lbf ft)
Engine Oil Pump Cover Screw
7.9 to 9.3 N•m (70 to 82 lbf in) Thermostat Cover Bolts
23 to 28 N•m (17 to 21 lbf ft)

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Special Tools 0600 SRM 1893

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 Valve (8.86 in.) (2.8 in.) (1.8 in.) (0.79 in.) 11.9 mm 6.60 mm

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.)
Replacement
C 120 mm (4.72 in.)
Tool (Press
Out) D 30.0 dia. mm (1.18 dia. in.)

E 32.95 dia. mm (1.297 dia. in.)

F 20 mm (0.79 in.)

a 6.3 microns (250 micro inches)

b 6.3 microns (250 micro inches)

C1 Chamfer 1.0 mm (0.039 in.)

C2 Chamfer 2.0 mm (0.079 in.)

Locally Manufactured

3 Small End A 157 mm (6.16 in.)

Bushing
B 14.5 mm (0.571 in.)
Replacement
C 120 mm (4.72 in.)
Tool (Press In)
D 30 dia. mm (1.18 dia. in.)

E 42 dia. mm (1.6535 dia. in.)

F 20 mm (0.79 in.)

a 6.3 microns (250 micro inches)

b 6.3 microns (250 micro inches)

C1 Chamfer 1.0 mm (0.039 in.)

C2 Chamfer 2.0 mm (0.079 in.)

Locally Manufactured

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 HeavyManuals.com
0600 SRM 1893 Special Tools

No. Tool Name Applicable Model and Tool Size Illustration

5 Idler Gear A 196 mm (7.72 in.)

Bushing
B 3.75 mm (1.48 in.)
Replacement
C 150 mm (5.91 in.)
Tool
D 44.95 dia. mm (1.770 dia. in.)

E 48.075 to 48.100 dia. mm (1.8928 to 1.8937 dia. in.)

F 20 mm (0.79 in.)

a 6.3 microns (250 micro inches)

b 6.3 microns (250 micro inches)

C1 Chamfer 1.0 mm (0.039 in.)

C2 Chamfer 2.0 mm (0.079 in.)

Locally Manufactured

6 Filter Wrench
(for Removal/
Installation of Available Locally
Engine Oil
Filter)

7 Gear Case Oil A 148.8 mm (5.858 in.)

Seal Press Fit
B 50 mm (2.0 in.)
Tool
C 18.8 mm (0.740 in.)

D 13.7 to 13.9 mm (0.540 to 0.547 in.)

E 11 mm (0.43 in.)

F 18 dia. mm (0.71 dia. in.)

G 38 dia. mm (1.5 dia. in.)

H 45 dia. mm (1.8 dia. in.)

I 57.90 to 58.10 dia. mm ( 2.280 to 2.287 dia. in.)

J 79.5 dia. mm (3.13 dia. in.)

K 87 dia. mm (3.4 dia. in.)

L 12 mm (0.47 in.)

M 40 mm (1.6 in.)

N 120 mm (4.72 in.)

Locally Manufactured

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 HeavyManuals.com
Special Tools 0600 SRM 1893

No. Tool Name Applicable Model and Tool Size Illustration

8 Crankshaft A Rmax = 12.5 S

Sleeve Press
B 94.5 to 95.0 dia. mm (3.72 to 3.74 dia. in.)
Tool
C 40 dia. mm (1.6 dia. in.)

D 30 dia. mm (1.2 dia. in.)

E 12 mm (0.47 in.)

F 7.90 to 8.10 mm (0.311 to 0.318 in.)

G 20 mm (0.79 in.)

H 130 dia. mm (5.12 dia. in.)

I 99.40 to 99.60 dia. mm (3.914 to 3.921 dia. in.)

J 95.05 to 95.20 dia. mm (3.743 to 3.748 dia. in.)

K 3 dia. mm (0.1 dia. in.)

L 15 mm (0.59 in.)

M 10 mm (0.39 in.)

N 90 mm (3.5 in.)

O 115 mm (4.53 in.)

P 16.9 to 17.1 mm ( 0.666 to 0.673 in.)

C1 Chamfer 1.0 mm (0.039 in.)

C3 Chamfer 3.0 mm (0.12 in.)

C5 Chamfer 5.0 mm (0.20 in.)

C0.2 Chamfer 0.2 mm (0.008 in.)

C0.3 Chamfer 0.3 mm (0.01 in.)

Locally Manufactured

10 Flywheel A 140 mm (5.51 in.)

Stopper Tool
B 80 mm (3.1 in.)

C 49.3 mm (1.94 in.)

D 49.3 mm (1.94 in.)

E 23.8 mm (0.937 in.)

F 23.8 mm (0.937 in.)

G 11 dia. mm (0.43 dia. in.)

H 56.5 mm (2.22 in.)

I 56.5 mm (2.22 in.)

J 8 mm (0.3 in.)

Locally Manufactured

74
 HeavyManuals.com
0600 SRM 1893 Special Tools

No. Tool Name Applicable Model and Tool Size Illustration

12 Flex-Hone (for Model Part Number Cylinder Bore

Preparation of
4TNE92 83 to 95 mm
Cylinder Walls) Hyster P/N 1607212
( in.)

4TNE98 Hyster P/N 1599906 89 to 101 mm

( in.)

13 Piston Ring
Hyster P/N 1607213
Compressor
The Piston Insertion Tool is Applicable for
(for Inserting
60 to 125 mm (2.362 to 4.921 in.)
Piston)
Diameter Pistons

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

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 HeavyManuals.com
Special Tools 0600 SRM 1893

No. Tool Name Applicable Model and Tool Size Illustration

15 Crankshaft A 92 mm (3.6 in.) radius

Position
B 13.0 to 13.1 mm (0.0512 to 0.51 in.) dia.
Sensor
C 10.000 to 10.015 mm (0.39370 to 0.39429 in.) dia.
Measuring JIG
1 D 18 mm (0.71 in.) dia.

E 16 mm (0.63 in.)

F Chamfer 0.3 mm (0.01 in.)

G Chamfer 0.5 mm (0.02 in.)

H Chamfer 0.5 mm (0.02 in.)

I Chamfer 0.5 mm (0.02 in.)

J 5.0 to 5.05 mm (0.197 to 0.198 in.)

K 7.0 mm (0.28 in.)

L 39.990 to 40.010 mm (1.5744 to 1.5751 in.)

M 50 mm (2.0 in.)

N 5.0 mm (0.20 in.) radius

O 0.35 rad (20°)

P 0.35 rad (20°)

Q 2.0 mm (0.079 in.)

R 18.380 to 18.393 mm (0.72363 to 0.72413 in.) dia.

S 92 mm (3.6 in.) radius

T Chamfer 0.5 mm (0.02 in.)

U 11 mm (0.43 in.)

V 13 mm (0.51 in.) radius

W 80.0 mm (3.1 in.) dia.

X 8.0 mm (0.31 in.) radius

Y 6.5 mm (0.26 in.) dia.

Z 19.5 mm (0.768 in.)

a 12.8 to 12.9 mm (0.504 to 0.507 in.) dia.

b Chamfer 0.3 mm (0.01 in.)

c Chamfer 0.5 mm (0.02 in.)

d 0.4 mm (0.02 in.) radius

e 12.8 to 12.9 mm (0.504 to 0.507 in.) dia.

f 4.95 to 5.00 mm (0.195 to 0.196 in.) dia.

g 2.0 mm (0.079 in.)

h 0.35 rad (20°)

i 9.978 to 9.987 mm (0.3929 to 0.3931 in.)

Locally Manufactured

76
 HeavyManuals.com
0600 SRM 1893 Special Tools

No. Tool Name Applicable Model and Tool Size Illustration

16 Crankshaft A 8.0 mm (0.31 in.) dia. reamer

Position
B 22 mm (0.866 in.)
Sensor
C M4 X Pitch 0.7
Measuring JIG
2 D 6.5 mm (0.26 in.)

E 34.0 mm (1.34 in.)

F 35 mm (1.14 in.) radius

G 20 mm (0.79 in.) radius

H 68.0 mm (2.68 in.)

Locally Manufactured

77
 HeavyManuals.com
Special Tools 0600 SRM 1893

No. Instrument Name Application Illustration

1 Dial Indicator Measurements of shaft bending, and strain
and gap of surfaces.

2 Test Indicator Measurements of narrow or deep portions

that cannot be measured by dial Indicator.

3 Magnetic Stand For holding the dial gauge when measuring.

4 Micrometer For measuring the outside diameters of

crankshaft, pistons, piston pins, etc.

5 Cylinder Gauge For measuring the inside diameters of

cylinder liners, rod metal, etc.

6 Calipers For measuring outside diameters, depth,

thickness, and width.

7 Depth Micrometer For measuring of valve sink.

78
 HeavyManuals.com
0600 SRM 1893 Special Tools

No. Instrument Name Application Illustration

8 Square For measuring valve spring inclination and
straightness of parts.

9 V-Block For measuring shaft bend.

10 Torque Wrench For tightening nuts and bolts to the

specified torque.

11 Thickness Gauge ("Feeler" For measuring gaps between ring and ring
Gauge) groove and shaft joints during assembly.

12 Cooling System Tester For checking water leakage

13 Battery Coolant Tester For checking concentration of antifreeze

and the battery electrolyte charge status.

79
 HeavyManuals.com
Special Tools 0600 SRM 1893

No. Instrument Name Application Illustration

16 Digital Thermometer For measuring temperature.

17 Tachometer Contact Type For measuring revolution by contacting the

revolving shaft.

Photoelectric For measuring revolution by sensing the

Type reflecting mark on the outer periphery of
the revolving shaft.

Fuel High This measures the revolution regardless of

Pressure Pipe the center of periphery of the revolving
Clamp Type object.
18 Circuit Tester For measuring resistance, voltage, and
continuity of electrical circuits.

19 Compression Gauge Kit For measuring compression pressure.

80
HeavyManuals.com
 HeavyManuals.com

TECHNICAL PUBLICATIONS

0600 SRM 1893 3/15