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PERKINS DIESEL ENGINES

1004-42 (AR), 1006-60 (YG), 1006-60T (YH)

H3.50-5.00XL (H70-110XL) [G005];

S3.50-5.50XL (S70-120XL) [D004];

H6.00-7.00XL (H135-155XL, H135-155XL 2) [F006];

S6.00-7.00XL(S135-155XL, S135-155XL 2) [B024];

H13.00-16.00XL (H300-360XL) [D019];

H8.00-12.00XL (H165-280XL) [E007];

H3.50-5.50XM (H70-120XM) [K005];

H8.00-12.00XM (H170-280HD) [F007];H13.00-16.00XM (H300-360HD) [E019];

H10.00-12.00XM-12EC (H360HD-EC) [E019];

H3.50-5.50XM (H70-120XM) [E004, F004]

PART NO. 1455747 600 SRM 705

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SAFETY PRECAUTIONS

MAINTENANCE AND REPAIR

When lifting parts or assemblies, make sure all slings, chains, or cables are correctly

fastened, and that the load being lifted is balanced. Make sure the crane, cables, and

chains have the capacity to support the weight of the load.

Do not lift heavy parts by hand, use a lifting mechanism.

Wear safety glasses.

DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair

on electric lift trucks. Disconnect the battery ground cable on internal combustion lift

trucks.

Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT

THE LIFT TRUCK ON BLOCKS in the Operating Manualor the Periodic Mainte-

nance section.

Keep the unit clean and the working area clean and orderly.

Use the correct tools for the job.

Keep the tools clean and in good condition.

Always use HYSTER APPROVED parts when making repairs. Replacement parts

must meet or exceed the specifications of the original equipment manufacturer.

Make sure all nuts, bolts, snap rings, and other fastening devices are removed before

using force to remove parts.

Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,

or if the unit needs repairs.

Be sure to follow the WARNINGand CAUTIONnotes in the instructions.

Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel

are flammable. Be sure to follow the necessary safety precautions when handling these

fuels and when working on these fuel systems.

Batteries generate flammable gas when they are being charged. Keep fire and sparks

away from the area. Make sure the area is well ventilated.

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

manual:

WARNINGIndicates a condition that can cause immediate death or injury!

CAUTION

Indicates a condition that can cause property damage!

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Perkins Diesel Engines Table of Contents

TABLE OF CONTENTS

General .................................................................................................................................................................

General Safety Rules .......................................................................................................................................

Description ........................................................................................................................................................... 2

Engine Serial Number Codes .......................................................................................................................... 5

Engine Data ..................................................................................................................................................... 5Engine Removal and Installation .......................................................................................................................

Lift Engine .......................................................................................................................................................

Cylinder Head Assembly Repair.........................................................................................................................

Valve Cover ......................................................................................................................................................

Remove.........................................................................................................................................................

Install........................................................................................................................................................... 8

Rocker Arm Assembly ..................................................................................................................................... 8

Remove......................................................................................................................................................... 8

Install........................................................................................................................................................... 8

Disassemble ................................................................................................................................................. 8

Inspect.......................................................................................................................................................... 9

Assemble ...................................................................................................................................................... 9Valve Clearance Adjustments ......................................................................................................................... 9

Four-Cylinder Engines.............................................................................................................................. 10

Six-Cylinder Engines ................................................................................................................................ 10

Valve Springs ................................................................................................................................................. 10

Cylinder Head Assembly ............................................................................................................................... 12

Remove....................................................................................................................................................... 12

Install......................................................................................................................................................... 14

Valves and Valve Springs .............................................................................................................................. 18

Remove....................................................................................................................................................... 18

Inspect........................................................................................................................................................ 18

Install......................................................................................................................................................... 19

Valve Guides .................................................................................................................................................. 19

Inspect........................................................................................................................................................ 19Remove....................................................................................................................................................... 20

Install......................................................................................................................................................... 20

Cylinder Head and Valve Seats .................................................................................................................... 20

Inspect........................................................................................................................................................ 20

Repair......................................................................................................................................................... 20

New Valve Seats, Install ........................................................................................................................... 20

Piston and Connecting Rod Assemblies Repair ............................................................................................... 22

Rod Bearings.................................................................................................................................................. 22

Remove....................................................................................................................................................... 23

Install......................................................................................................................................................... 23

Piston and Connecting Rod Assembly .......................................................................................................... 24

Service Note ............................................................................................................................................... 24

Remove....................................................................................................................................................... 24Install......................................................................................................................................................... 25

Piston Rings ................................................................................................................................................... 26

Remove....................................................................................................................................................... 26

Inspect........................................................................................................................................................ 26

Install......................................................................................................................................................... 26

Piston and Connecting Rod ........................................................................................................................... 2

Disassemble ............................................................................................................................................... 2

Inspect........................................................................................................................................................ 28

2006 HYSTER COMPANY

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Table of Contents Perkins Diesel Engines

TABLE OF CONTENTS (Continued)

How to Select Correct Replacements ....................................................................................................... 28

Install......................................................................................................................................................... 29

Piston Cooling Jets ........................................................................................................................................ 29

Remove....................................................................................................................................................... 29Install......................................................................................................................................................... 30

Crankshaft Assembly Repair ............................................................................................................................ 30

General........................................................................................................................................................... 30

Crankshaft Pulley.......................................................................................................................................... 31

Engine AR, Remove................................................................................................................................... 31

Engines YG and YH, Remove ................................................................................................................... 31

Inspect........................................................................................................................................................ 32

Engine AR, Install..................................................................................................................................... 32

Engines YG and YH, Install ..................................................................................................................... 32

Rear Oil Seal .................................................................................................................................................. 33

Replace ....................................................................................................................................................... 33

Main Bearings................................................................................................................................................ 34

Remove....................................................................................................................................................... 34Inspect........................................................................................................................................................ 35

Install......................................................................................................................................................... 35

Thrust Washers.............................................................................................................................................. 35

Crankshaft Axial Movement, Check ........................................................................................................ 35

Remove....................................................................................................................................................... 36

Install......................................................................................................................................................... 36

Crankshaft ..................................................................................................................................................... 37

Remove....................................................................................................................................................... 37

Inspect........................................................................................................................................................ 37

Install......................................................................................................................................................... 37

Flywheel ......................................................................................................................................................... 39

Remove....................................................................................................................................................... 39

Ring Gear, Replace .................................................................................................................................... 39Install......................................................................................................................................................... 39

Flywheel Housing.......................................................................................................................................... 40

Remove....................................................................................................................................................... 40

Install......................................................................................................................................................... 40

Timing Case and Timing Gears Repair ............................................................................................................ 41

General........................................................................................................................................................... 41

Timing Case Cover ........................................................................................................................................ 41

Remove....................................................................................................................................................... 41

Install......................................................................................................................................................... 42

Front Oil Seal................................................................................................................................................. 42

Remove....................................................................................................................................................... 42

Install......................................................................................................................................................... 42

Crankshaft Pulley Wear Sleeve .................................................................................................................... 43

Install......................................................................................................................................................... 43

Idler Gear and Hub ....................................................................................................................................... 43

Remove....................................................................................................................................................... 43

Install......................................................................................................................................................... 44

Air Compressor Drive, Bendix ...................................................................................................................... 45

Disassemble ............................................................................................................................................... 45

Assemble .................................................................................................................................................... 46

Fuel Injection Pump Gear ............................................................................................................................. 46

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Remove....................................................................................................................................................... 4

Install......................................................................................................................................................... 4

Camshaft Gear............................................................................................................................................... 48

Remove....................................................................................................................................................... 48Install......................................................................................................................................................... 48

Crankshaft Gear ............................................................................................................................................ 49

Remove....................................................................................................................................................... 49

Install......................................................................................................................................................... 49

Timing Case ................................................................................................................................................... 49

Remove....................................................................................................................................................... 49

Install......................................................................................................................................................... 50

Camshaft and Tappets .................................................................................................................................. 5

Remove....................................................................................................................................................... 5

Install......................................................................................................................................................... 5

Cylinder Block Assembly Repair....................................................................................................................... 52

Description ..................................................................................................................................................... 52

Cylinder Block ............................................................................................................................................... 52Disassemble ............................................................................................................................................... 52

Inspect........................................................................................................................................................ 53

Assemble .................................................................................................................................................... 53

Cylinder Bore (Four-Cylinder Engines) ....................................................................................................... 54

Cylinder Liner (Six-Cylinder Engines)......................................................................................................... 54

Inspect........................................................................................................................................................ 54

Cylinder Liner Condition, Check.............................................................................................................. 54

Remove....................................................................................................................................................... 55

Service Liner, Install ................................................................................................................................. 56

Partially Finished Liner, Install............................................................................................................... 5

Engine Timing.................................................................................................................................................... 58

Description ..................................................................................................................................................... 58

How to Set Number One Piston to TDC on Compression Stroke ........................................................... 59How to Set Number One Piston to TDC on Compression Stroke (Alternate Procedure)...................... 60

Valve Timing, Check.................................................................................................................................. 60

Fuel Injection Pump Timing, Check......................................................................................................... 6

Turbocharger - Engine YH Repair .................................................................................................................... 62

General........................................................................................................................................................... 62

Remove....................................................................................................................................................... 62

Install......................................................................................................................................................... 62

Impeller and Compressor Housing, Clean ............................................................................................... 63

Lubrication System Repair................................................................................................................................ 64

General........................................................................................................................................................... 64

Oil Filter, Replace .......................................................................................................................................... 64

Filter Head..................................................................................................................................................... 65

Remove and Install ................................................................................................................................... 65

Oil Sump ........................................................................................................................................................ 65

Remove....................................................................................................................................................... 65

Install......................................................................................................................................................... 66

Oil Pump ........................................................................................................................................................ 66

Remove....................................................................................................................................................... 66

Inspect........................................................................................................................................................ 66

Install......................................................................................................................................................... 6

Relief Valve .................................................................................................................................................... 6

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Remove....................................................................................................................................................... 67

Disassemble ............................................................................................................................................... 68

Inspect........................................................................................................................................................ 68

Assemble .................................................................................................................................................... 68Install......................................................................................................................................................... 69

Idler Gear Shaft, Replace .............................................................................................................................. 69

Remove....................................................................................................................................................... 69

Remove (Alternative) ................................................................................................................................ 69

Install......................................................................................................................................................... 70

Install (Alternative) .................................................................................................................................. 70

Install (Alternative for Four-Cylinder Engines Only)............................................................................. 71

Fuel System Repair............................................................................................................................................ 71

Description ..................................................................................................................................................... 71

Fuel Injection Pump ...................................................................................................................................... 72

Remove....................................................................................................................................................... 72

Install......................................................................................................................................................... 73

Check and Adjust ...................................................................................................................................... 74Fuel System Air Removal.............................................................................................................................. 74

Fuel Filter, Replace ....................................................................................................................................... 75

Canister Type ............................................................................................................................................ 76

Quick Release Canister Type .................................................................................................................... 76

Fuel Injectors ................................................................................................................................................. 77

Remove....................................................................................................................................................... 77

Inspect........................................................................................................................................................ 78

Install......................................................................................................................................................... 78

Fuel Pump...................................................................................................................................................... 79

Remove....................................................................................................................................................... 79

Disassemble ............................................................................................................................................... 79

Assemble .................................................................................................................................................... 79

Install......................................................................................................................................................... 80Test ............................................................................................................................................................. 80

Cooling System Repair ...................................................................................................................................... 81

General........................................................................................................................................................... 81

Thermostat..................................................................................................................................................... 81

Remove....................................................................................................................................................... 81

Install......................................................................................................................................................... 81

Test ............................................................................................................................................................. 82

Coolant Pump ................................................................................................................................................ 82

Remove....................................................................................................................................................... 82

Disassemble ............................................................................................................................................... 82

Assemble .................................................................................................................................................... 84

Install......................................................................................................................................................... 86

Fan and Fan Drive ........................................................................................................................................ 87

Remove....................................................................................................................................................... 87

Install......................................................................................................................................................... 87

Oil Cooler (Six-Cylinder Engines) ................................................................................................................ 88

Remove....................................................................................................................................................... 88

Disassemble and Assemble ....................................................................................................................... 88

Install......................................................................................................................................................... 88

Oil Cooler Bypass Valve ............................................................................................................................ 88

Electrical Equipment Repair............................................................................................................................. 89

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Drive Belts ..................................................................................................................................................... 89

Adjustment ................................................................................................................................................ 89

Remove....................................................................................................................................................... 90

Install......................................................................................................................................................... 90Alternator....................................................................................................................................................... 90

Remove....................................................................................................................................................... 90

Install......................................................................................................................................................... 90

Starter Motor ................................................................................................................................................. 90

Remove....................................................................................................................................................... 90

Install......................................................................................................................................................... 90

Cold Start Aid ................................................................................................................................................ 90

Air Compressor - Engines YG and YH.............................................................................................................. 9

General........................................................................................................................................................... 9

Repair ............................................................................................................................................................. 9

Remove....................................................................................................................................................... 9

Install......................................................................................................................................................... 9

Rotary Exhauster Replacement ........................................................................................................................ 93Remove ........................................................................................................................................................... 93

Clean .............................................................................................................................................................. 93

Install ............................................................................................................................................................. 93

Engine Specifications......................................................................................................................................... 94

Cylinder Head Assembly ............................................................................................................................... 94

Piston and Connecting Rods ......................................................................................................................... 9

Crankshaft Assembly .................................................................................................................................. 100

Crankshaft Overhaul .............................................................................................................................. 102

Timing Case and Drive Assembly............................................................................................................... 104

Engine Block Assembly ............................................................................................................................... 105

Turbocharger ................................................................................................................................................ 108

Lubrication System ..................................................................................................................................... 108

Fuel System ................................................................................................................................................. 109Cooling System ............................................................................................................................................. 11

Flywheel and Housing.................................................................................................................................. 11

Electrical Equipment................................................................................................................................... 11

Torque Specifications ....................................................................................................................................... 11

Cylinder Head Assembly ............................................................................................................................. 11

Piston and Connecting Rod Assemblies ..................................................................................................... 11

Crankshaft Assembly .................................................................................................................................. 11

Timing Case and Drive Assembly............................................................................................................... 11

Turbocharger ................................................................................................................................................ 11

Lubrication System ..................................................................................................................................... 11

Fuel System ................................................................................................................................................. 11

Cooling System ............................................................................................................................................ 11

Flywheel ....................................................................................................................................................... 11

Auxiliary Equipment ................................................................................................................................... 11

Special Torque Specifications .......................................................................................................................... 11

Flywheel and Housing................................................................................................................................. 11

Turbocharger ................................................................................................................................................ 11

Electrical Equipment................................................................................................................................... 11

Auxiliary Equipment ................................................................................................................................... 11

Special Tools* ................................................................................................................................................... 11

Troubleshooting................................................................................................................................................ 120

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This section is for the following models:

H3.50-5.00XL (H70-110XL) [G005];

S3.50-5.50XL (S70-120XL) [D004];H6.00-7.00XL (H135-155XL, H135-155XL 2) [F006];

S6.00-7.00XL (S135-155XL, S135-155XL2) [B024];

H13.00-16.00XL (H300-360XL) [D019];

H8.00-12.00XL (H165-280XL) [E007];

H3.50-5.50XM (H70-120XM) [K005];

H8.00-12.00XM (H170-280HD) [F007];

H13.00-16.00XM (H300-360HD) [E019];

H10.00-12.00XM-12EC (H360HD-EC) [E019];

H3.50-5.50XM (H70-120XM) [E004, F004]

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600 SRM 705 Genera

General

This section has the description and repair instruc-

tions for three models of the Series 1000 Perkins

diesel engine. The three diesel engines described in

this section:

1004-42 (AR)..................... Four cylinder, normally

aspirated

1006-60 (YG).....................Six cylinder, normally

aspirated

1006-60T (YH) ..................Six cylinder, turbocharged

GENERAL SAFETY RULES

WARNING

Some seals used in this engine are made of

synthetic materials called fluoroelastomers(a commercial name is Viton). These fluo-

roelastomers can decompose at temperatures

greater than 316 C (600 F) or by burning and

cause hydrofluoric acid to form on the surface

of the seal or nearby equipment.

Do not touch gaskets, seals or O-rings which

appear charred or black and sticky after ex-

posure to temperatures greater than 316 C

(600 F) or burning. Contact with this acid can

cause severe burns of the skin and eyes. Burns

can be delayed several hours after contact.

Do the following procedures to prevent expo-

sure to hydrofluoric acid:

Wear disposable neoprene or PVC gloves and

discard the gloves after use.

Wash the area with 10% calcium hydroxide

solution to neutralize any acid and then clean

with water.

If burned seal by-product touches the skin or

eyes:

Immediately flush with water for a minimum

of 15 minutes.

Apply 2.5% calcium gluconate gel to affected

area of skin.

Get medical help immediately for suspected

hydrogen fluoride or hydrofluoric acid burn.

WARNING

Disconnect the battery cables before doing any

disassembly and repair of the engine or parts of

the electrical system. Put a DO NOT OPERATE

tag in the operators area and on the battery

connectors.

Long-term exposure to used engine oil can

cause skin irritation or cancer. Wash with

detergent and water.

Exhaust from internal combustion engine

contains carbon monoxide and other harmfu

chemicals. Carbon monoxide is a colorless

odorless poison and can cause unconscious

ness or death without warning. Long term

exposure to exhaust or chemicals in the ex

haust can cause cancer, birth defects, and

other reproductive harm. Avoid exposure to

engine exhaust.

Do not use diesel engines indoors where soocan accumulate.

If engines are operated in confined spaces

maintain adequate ventilation or vent exhaus

to the outside. Do not exceed applicable ai

contaminant limits.

Follow the inspection and maintenance sched

ule and procedures in this manual. Do not alte

exhaust, ignition, or fuel systems.

CAUTIONDisposal of lubricants and fluids must meet local environmental regulations.

Disposal of batteries must meet local environ

mental regulations.

The diodes and resistors in the electrical sys

tem can be damaged if the following caution

are not followed:

Do not disconnect the battery when the en

gine is running. The voltage surge can dam

age the diodes and resistors.

Do not disconnect an electric wire before the

engine is stopped and the switches are OFF.

Do not cause a short circuit by connection

of the electric wires to the wrong terminals

Make sure a correct identification is made o

the wire before it is connected.

Make sure a battery is the correct voltage and

polarity before it is connected.

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Description 600 SRM 705

Do not check for current flow by making a

spark because the electronic components can

be damaged.

CAUTIONWhen setscrews or studs are fitted into holes

which are tapped through the cylinder block, a

suitable sealant must be used to prevent leak-

age.

Micro encapsulated anaerobic sealant

(M.E.A.S.) fasteners have been introduced

instead of jointing compounds or other

sealants when the fasteners are fitted in

through holes into oil or coolant passages. The

identification of these fasteners, as supplied,

is by a red, blue, or other color sealant around

the fastener threads.

With M.E.A.S. sealed studs, the sealed end must

be fitted into the cylinder head/cylinder block,

etc. Ensure that the threaded holes have a1.59 mm (0.0625 in.) 45 chamfer, to ensure that

when the new fasteners are fitted, the M.E.A.S.

sealant is not removed. If the fasteners have to

be removed and fitted again, the threads must

be cleaned and a suitable sealant used.

Observe the previous WARNINGS and CAUTION

before repairing any equipment.

Description

The cylinder head is cast iron and has one inlet

valve and one exhaust valve for each cylinder. The

valve seats and the valve guides are replaceable.

The fuel injectors are in the cylinder head. The

overhead valve assembly is actuated by a camshaft

inside of the engine block. A gear train, turned by

the crankshaft, turns the camshaft, coolant pump,

injection pump, and a power-takeoff (PTO) is avail-

able for additional equipment. The hydraulic pump

for the steering function or a compressor is normally

turned by the PTO. The fuel pump is actuated by the

camshaft. SeeFigure 1and Figure 2.

The crankshaft in the six-cylinder models have seven

main bearings. The crankshaft in the four-cylinder

models have five main bearings. The main bearing

in the center of the crankshaft is the thrust bearing

and has thrust washers on both sides of the bearing.

The cylinder block is cast iron. The six-cylinder en-

gines have cylinder liners that can be replaced during

overhaul. The cylinders for the four-cylinder engine

are bored directly into the cylinder block.

A Fastram combustion chamber in the top of each

piston is a design to give an efficient mix of fuel and

air. The pistons for the four-cylinder AR engineshave two recesses in the top face for the valves. Each

piston has three piston rings (two compression rings,

and an oil control ring). The top compression ring has

a special insert for the groove to reduce wear. Axial

location of the fully floating piston pin is by circlips.

The piston pin is off-center to reduce the noise level.

A jet for cooling oil to the bottom of the piston is in-

stalled. The four-cylinder AR engines have only one

cooling jet installed in the number one cylinder.

The cooling fan and the alternator are turned by a

drive belt. The cooling fan is not connected to the

coolant pump. The coolant pump is turned by the

gear for the fuel injection pump in the timing gear

case.

The timing and quantity of fuel sent to the fuel in-

jectors is controlled by a throttle and governor in

the fuel injection pump. The static timing is set by

the position of the fuel injection pump when it is in-

stalled. The throttle linkage must be correctly ad-

justed to control the quantity of fuel sent to the in-

jectors. A mechanical governor is used to control the

engine speed.

A Lucas DP200 series fuel injection pump is used on

all engines. Special tools are needed to repair an in-

jection pump and they are normally sent to an autho-rized repair station if repairs are necessary.

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600 SRM 705 Description

1. FILL CAP FOR ENGINE OIL2. FUEL FILTER3. FUEL INJECTION PUMP4. COOLANT PUMP5. OIL SUMP

6. OIL FILTER (CAN BEINSTALLED ON EITHERSIDE OF ENGINE)

7. FAN DRIVE8. ALTERNATOR

9. DIPSTICK, ENGINE OIL (CANBE INSTALLED ON EITHERSIDE OF ENGINE)

10. CRANKSHAFT PULLEY11. TIMING CASE

Figure 1. Engine 1004-42 AR

3

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Description 600 SRM 705

1006-60 (YG) ENGINE

Power Rating at 2200

rpm................................... 79 kW (106 bhp)

Number of cylinders........ 6

Firing order ..................... 1 5 3 6 2 4

Bore and stroke ...............100 127 mm

(3.937 5.000 in.)

Displacement................... 6 liter (365 in.3)

Compression Ratio ..........17.25:1

Minimum oil pressure..... 280 kPa (40 psi)

(at 2200 rpm and normal operating temperature)

Governor speed (no load)

See the Periodic Maintenance section for your

model of lift truck.

Idle Speed ........................700 to 775 rpm

Thermostat

Begin to open ..............

Fully open....................

77 to 85 C (170 to 185 F)

92 to 98 C (198 to 208 F)

Valve clearance (cold)

Inlet .............................

Exhaust .......................

0.20 mm (0.008 in.)

0.45 mm (0.018 in.)

1006-60T (YH) ENGINE

Power Rating at 2300

rpm................................... 106 kW (142 bhp)

Number of cylinders........ 6

Firing order ..................... 1 5 3 6 2 4

Bore and stroke ............... 100 127 mm

(3.937 5.000 in.)

Displacement................... 6 liter (365 in. 3)

Compression Ratio .......... 17.25:1

Minimum oil pressure..... 280 kPa (40 psi)

(at 2300 rpm and normal operating temperature)

Governor speed (no load)

See the Periodic Maintenancesection for your

model of lift truck.

Idle Speed ........................ 700 to 775 rpm

Thermostat

Begin to open ..............

Fully open....................

77 to 85 C (170 to 185 F)

92 to 98 C (198 to 208 F)


Inlet .............................

Exhaust .......................

0.20 mm (0.008 in.)

0.45 mm (0.018 in.)

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600 SRM 705 Cylinder Head Assembly Repai

Engine Removal and Installation

See the Framesection for the procedure for remov-

ing the engine and transmission. See the Transmis-

sionsection for the procedure to separate the trans-

mission from the engine.

LIFT ENGINE

There can be a variation in the maximum weight of

the engine depending upon the components that are

attached to it. The following minimum lifting capac-

ity is needed for an engine without coolant, lubri-

cants, or transmission:

four-cylinder engines 500 kg (1102 lb)

six-cylinder engines 600 kg (1322 lb)

Always use a lifting device that provides a vertical lift

above the engine lift brackets as shown inFigure 4.Never use a single bracket to lift an engine.

Make sure the engine brackets are correctly fastened

to the engine. Make sure that the valve cover and

other components are not damaged by the lifting de-

vice. Use a lifting device to lift and move the heavy

components of the engine: cylinder block, cylinder

head, flywheel housing, flywheel, and crankshaft.

1. ENGINE LIFT BRACKETS

Figure 4. Lifting an Engine

Cylinder Head Assembly Repair

VALVE COVER

Remove

1. Disconnect the breather pipe.

2. Remove the cap nuts and the sealing washers

from the top of the valve cover. SeeFigure 5.

3. Lift the valve cover, gasket, and seal from the

cylinder head. The valve cover seal fits betweenthe valve cover and the induction manifold.

4. When the valve cover is installed, the cap nuts

are tightened onto the nuts of the rocker brack-

ets. When the cap nuts are removed, the nuts for

the rocker brackets can be loosened. Check that

the nuts for the rocker brackets are tight each

time that the valve cover is removed.

1. CAP NUT AND RUBBER SEAL

Figure 5. Valve Cover

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Cylinder Head Assembly Repair 600 SRM 705

Install

1. Check the condition of the valve cover gasket and

the seal washers used under the cap nuts. Make

sure that the surfaces are clean.

2. Install the valve cover, gasket, and seal on the

cylinder head. See Figure 6. Install the seal

washers under the cap nuts. Tighten the cap

nuts to 30 Nm (22 lbf ft). Do not tighten the

cap nuts so that they are fastened to the nuts for

the rocker brackets.

1. SEAL, OIL FILLERCAP

2. CAP NUT

3. RUBBER SEAL4. GASKET5. VALVE COVER

Figure 6. Valve Cover

3. Connect the breather pipe.

ROCKER ARM ASSEMBLY

Remove

1. Remove the valve cover.

2. Loosen the nuts evenly that fasten the brackets

for the rocker arm shafts to the cylinder head.

Loosen the brackets at each end of the cylinder

head first and loosen the brackets in sequence

toward the center. Remove the nuts and wash-

ers when the pressure is removed from the rockerarms. Lift the rocker arm assembly from the

cylinder head.

3. Remove the rubber seal from the oil supply con-

nection or the hole for the oil supply in the cylin-

der head. SeeFigure 7.

Figure 7. Rubber Seal Location

Install

1. Install a new rubber seal in the hole for the oilsupply in the cylinder head. SeeFigure 7.

2. Check that the push rods fit correctly in the sock-

ets for the tappets. Install the rocker arm assem-

bly. Make sure that the oil supply connection fits

correctly into the rubber seal.

3. Make sure that the alignment of the rocker arms

and the push rods are correct. Install the nuts

and washers on the studs that hold the brackets

for the rocker arm shafts to the cylinder head.

Tighten the nuts evenly. Begin tightening the

nuts at the center of the rocker arm shaft and

tighten in sequence toward the ends of the shaft.

The final torque on the nuts:

aluminum brackets = 40 Nm (30 lbf ft)

iron brackets = 75 Nm (55 lbf ft).

4. Check and adjust valve tip clearances. SeeValve

Clearance Adjustments.

Disassemble

1. Remove the clips from both ends of the rocker

arm shaft. Make sure that the ends of the rocker

arm shaft are not damaged. Loosen the location

screw for the oil supply connection.

2. Make a note of the position of each component on

the rocker arm shaft so that they can be assem-

bled correctly. Remove the components from the

rocker arm shaft.

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Inspect

1. Clean and inspect all the components for wear

and damage. Check the clearance of the rocker

arms on the rocker arm shaft. If the clearance is

greater than 0.13 mm (0.005 in.), install a new

bushing in the rocker arm or install a new rockerarm shaft if it is worn.

2. If the bushing in the rocker arm is worn, use a

press to remove the bushing.

3. Use a press to install a new bushing in the rocker

arm. Make sure that the lubrication hole in the

bushing is aligned with the hole in the rocker

arm.

4. Use a reamer in the bushing as necessary to giv

a clearance on the rocker arm shaft of 0.03 t

0.09 mm (0.001 to 0.004 in.).

Assemble

1. Make sure that the lubrication holes in throcker arms and the rocker arm shaft are open

and clean.

2. Lubricate the components with clean engine oi

as they are assembled on the rocker arm shaft

Make sure the components are assembled in th

correct order. SeeFigure 8. Make sure that th

location screw for the oil supply connection is fit

ted correctly in the rocker arm shaft. Install the

clips at the ends of the rocker arm shaft.

Figure 8. Rocker Arm Assembly

VALVE CLEARANCE ADJUSTMENTS

The valve clearance is measured between the top of

the valve stem and the rocker arm as shown inFig-

ure9.


Inlet

Exhaust

0.20 mm (0.008 in.)

0.45 mm (0.018 in.)

Number one cylinder is at the end of the engine withthe fan. The inlet valve is the first valve in the se-

quence. SeeFigure 10.

Figure 9. Valve Clearance Adjustment

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Figure 10. Valve Positions

Four-Cylinder Engines

1. Turn the crankshaft in the normal direction of ro-

tation until the inlet valve of number four cylin-

der has just opened and the exhaust valve of the

same cylinder has not fully closed. Check the

clearance of the valves of number one cylinder

and adjust them as necessary.

2. Turn the crankshaft in the normal direction of ro-tation until the inlet valve of number two cylin-



valve clearances on number three cylinder and

adjust them as necessary.


tation until the inlet valve of number one cylin-



valve clearances on number four cylinder and ad-

just them as necessary.


tation until the inlet valve of number three cylin-



valve clearances on number two cylinder and ad-


Six-Cylinder Engines

1. Turn the crankshaft in the normal direction of

rotation until the inlet valve of number six cylin-



clearance of the valves of number one cylinder

and adjust them as necessary.


tation until the inlet valve of number two cylin-



valve clearances on number five cylinder and ad-



tation until the inlet valve of number four cylin-



valve clearances on number three cylinder and

adjust them as necessary.


tation until the inlet valve of number one cylin-



valve clearances on number six cylinder and ad-



tation until the inlet valve of number five cylin-



valve clearances on number two cylinder and ad-



tation until the inlet valve of number three cylin-



valve clearances on number four cylinder and ad-


VALVE SPRINGS

NOTE: This procedure is normally for changing the

valve springs of a single cylinder while the cylinder

head is still installed on the engine. If the valves and

springs must be removed from the cylinder head for

repairs, see the procedures under Valves and Valve

Springs later in this section.

Special Tools: Valve spring compressor

Stud adapter

Setscrew adapter

1. Remove the valve cover.

2. Turn the crankshaft in the normal direction of

rotation until the piston for the cylinder is at top

dead center (TDC). The inlet valve will just open

and the exhaust valve will not be fully closed

when the cylinder is at TDC.

3. Remove the rocker arm assembly.

4. Install the spring compressor and the adapter.

SeeFigure 11.

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1. VALVE SPRINGCOMPRESSOR

2. STUD ADAPTER

3. SETSCREWADAPTER

Figure 11. Valve Spring Compressor

5. Compress the valve springs and remove the re-tainers. Make sure the valve springs are com-

pressed parallel to the valve stems or the valve

stems can be damaged.

6. Release the valve spring compressor and remove

the retainer cap and valve springs.

NOTE: Do not turn the crankshaft while the valve

springs are removed.

NOTE: The outer diameter of the exhaust valve guide

is 1 mm larger than the inlet valve guide. To prevent

leakage past the inlet valve stem it is important that

the larger exhaust valve seal is not fitted into the

inlet guide. The seals are color coded.

7. Install new valve stem seals on the valve guides.

Make sure that the brown seal is installed on

the exhaust valve and the green seal on the inlet

valves.

8. Install the new valve springs. Make sure the

closed damper coils of the valve springs are to-

ward the cylinder head.

9. Install the retainer cap.

10. Use the valve spring compressor to compress the

valve springs and install the retainers. Remove

the valve spring compressor.

11. Install the rocker arm assembly.

12. Check the valve clearances. SeeValve Clearance

Adjustments.

13. Install the valve cover.

NOTE:Valve springs can be changed in two cylinder

at a time.

ENGINE AR. When the piston in cylinder one is a

TDC, the piston in cylinder four is also at TDC. Whe

the piston in cylinder two is at TDC, the piston in

cylinder three is also at TDC.

ENGINES YG and YH. When the piston in cylinde

one is at TDC, the piston in cylinder six is also a

TDC. When the piston in cylinder two is at TDC, th

piston in cylinderfive is also at TDC. When the piston

in cylinder three is at TDC, the piston in cylinder fou

is also at TDC.

If the rocker arm assembly was removed before TDC

was found, install the valve spring compressor and

compress the valve springs to open the valve. Turn

the crankshaft by hand in the normal direction unti

the piston touches the valve. Continue to turn th

crankshaft, and at the same time, release the pres

sure on the valve spring compressor until the piston

is at TDC. SeeFigure 12.

Figure 12. Find TDC With Valve SpringCompressor

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CYLINDER HEAD ASSEMBLY

Remove

1. If the engine is still in the lift truck, do the fol-

lowing procedures:

a. Disconnect the battery terminals.

b. Drain the cooling system.

c. Disconnect the sender unit for the coolant

temperature gauge.

2. ENGINES AR and YG. Remove the hose from

the air filter at the induction manifold. ENGINE

YH. Remove air filter connection at the compres-

sor inlet of the turbocharger.

3. Remove the fuel line between the cold start aid

in the induction manifold and the fuel filter. Dis-connect the electrical connection.

4. ENGINE YH. Remove the boost control line be-

tween the front of the induction manifold and the

fuel injection pump.

5. Remove the induction manifold. SeeFigure 13.

For induction manifolds fitted to engine types

AR: The top half of the induction manifold is

sealed to the bottom half with a liquid joint and

fastened together by six capscrews.

The top half of the manifold must be removed to

obtain access to four of the manifold capscrews,fitted inside the manifold. These capscrews re-

tain the bottom half of the manifold to the cylin-

der head.

6. ENGINE YH. Disconnect all connections to the

turbocharger and remove the turbocharger. See

Turbocharger - Engine YH Repair,Remove.

7. Remove the exhaust manifold. Loosen the mani-

fold fasteners in the reverse order shown inFig-

ure14.

8. Remove the low pressure fuel lines between thefuel injection pump and the fuel filter. Remove

the fuel filter bracket and the fuel filters.

9. Remove the high pressure fuel lines. Use a sep-

arate wrench to prevent movement of the outlets

of the fuel injection pump when the fuel lines are

disconnected. Put plugs in the open ports of the


1. TOP HALF - INDUCTION MANIFOLD2. BOTTOM HALF - INDUCTION MANIFOLD3. CAPSCREWS

Figure 13. Induction Manifold

Figure 14. Exhaust Manifold TighteningSequence

10. Remove the return fuel line from the fuel injec-

tors.

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11. Remove the fuel injectors from the cylinder head.

Keep the fuel injectors clean and prevent damage

to the nozzles.

12. ENGINES YG and YH. If an air compressor is

installed, remove the coolant pipe between the

cylinder head and the compressor. Remove thecoolant pipe between the bypass connection and

the compressor.

13. Loosen the hose clamp and remove the coolant

bypass hose from the cylinder head. Remove the

capscrews and remove the coolant bypass connec-

tion and the hose.

14. Disconnect the coolant temperature sender.

15. ENGINE AR. Remove the oil cooler if it is inte-

gral with the cylinder block.

16. Remove the valve cover. See Valve Cover, Re-move.

17. Remove the rocker arm assembly. See Rocker

Arm Assembly, Remove.

18. Remove the push rods.

19. Loosen the capscrews for the cylinder head

evenly in a reverse sequence from the sequence

shown inFigure 15or Figure 16.

20. Lift the cylinder head from the engine block. D

not use a pry bar between the cylinder head and

the engine block that can cause damage to th

gasket surfaces. SeeFigure 17.

21. Inspect the capscrews for the cylinder head with

a straightedge. See Figure 18. Check that thcapscrews are straight and do not have distor

tion. If there is a reduction in the diameter of th

thread that has not been in engagement with the

cylinder block, the capscrew must be discarded.

Figure 15. Cylinder Head Tightening SequenceFour-Cylinder Engines

Figure 16. Cylinder Head Tightening Sequence, Six-Cylinder Engines

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Figure 17. Cylinder Head Removal

1. STRAIGHTEDGE2. CAPSCREW MUST BE STRAIGHT AND

WITHOUTDISTORTION3. THREADS MUST BE IN GOOD CONDITION AND

NOT HAVE A REDUCED DIAMETER

Figure 18. Capscrews Inspection

Install

Special Tools: Angle gauge to tighten the

capscrews for the cylinder head

1. Make sure the surfaces of the cylinder head and

thetop of the engine block are clean. Make surethat there is no dirt or objects in the cylinders.

2. Install the gasket for the cylinder head as shown

in Figure 19. Make sure the "TOP FRONT" is

in the correct position. Do not use any gasket

sealant on any of the surfaces.

Figure 19. Head Gasket Position

3. Use two 1/2 UNF studs in positions 16 and 21

on four-cycle engines and positions 25 and 30 onsix-cycle engines. SeeFigure 20andFigure 21to

hold the gasket in position. Lower the cylinder

head into position on the engine block. SeeFig-

ure22.

Figure 20. Cylinder Head Tightening Sequence, Six-Cylinder Engines

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Figure 21. Cylinder Head Tightening Sequence,Four-Cylinder Engines

Figure 22. Cylinder Head Installation

CAUTION

There are three lengths of capscrews. S = short,M = medium, L = long. Figure 20and Figure 21

show their positions in the engine. Make sure

that the capscrews are installed in the correct

positions.

4. Lubricate the capscrews with a thin coat of oil

and install them into their holes in the cylinder

head. When the cylinder head and gasket are

held in position, remove the two studs and in-

stall the two capscrews in those positions. The

four 1/2 UNF capscrews on the four-cylinder (AR)

engines are in positions 2, 8, 13, and 18. SeeFig-

ure21.

5. Evenly tighten the capscrews in the sequence

shown in Figure 20 or Figure 21. The final torque

on the capscrews is 110 Nm (81 lbf ft) for the

six-cylinder engines and 45 Nm (33 lbf ft) for

the four-cylinder engines.

6. Make sure all of the capscrews are tightened to

the correct torque described inStep 5. The cap-

screws must be further tightened in the sequence

shown inFigure 20orFigure 21according to th

following procedure:

Six-Cylinder Engines

a. The short capscrews (S) must be tightene

an additional 150 (2.5 flats).

b. The medium capscrews (M) must be tightened an additional 180 (3.0 flats).

c. The long capscrews (L) must be tightene


Four-Cylinder Engines

a. The short capscrews (S) must be tightene

an additional 120 (2 flats).

b. The medium capscrews (M) must be tight

ened an additional 120 (2 flats).

c. The long capscrews (L) must be tightene


d. The four 1/2 UNF capscrews in position 2

8, 13, and 18 must be tightened an additional 180 (3 flats).

NOTE:A special tool shown in Figure 23can be used

for this procedure to measure the tightening angles

If an angle gauge is not available, make a mark in

a line with one of the corners of the capscrew. Se

Figure 24andFigure 25. Make another mark at th

correct angle (counterclockwise) on the edge of th

flange of the cylinder head for each capscrew and ac

cording to the length of each capscrew. Tighten each

capscrew in the correct sequence until the two mark

are aligned.

7. Install the push rods in the engine. Make sur

that the end of each push rod fits correctly in th

tappet socket.

8. Install the rocker arm assembly perRocker Arm

Assembly, Install.

9. Adjust the valve clearances perValve Clearanc

Adjustments.

10. Install the fuel injectors per Fuel Injectors, In

stall.

11. Install the high pressure fuel lines between thefuel injection pump and the fuel injectors. Us

a separate wrench to prevent movement of th

outlets of the fuel injection pump when the fue

lines are connected. Tighten the connection nut

to 22 Nm (16 lbf ft).

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Figure 23. Angle Gauge

Figure 24. Tighten Cylinder Head Capscrews,

Engine AR

Figure25. Tighten Cylinder Head Capscrews,

EngineYG and YH

12. Install the fuel filter and bracket. Install the low-

pressure fuel lines between the fuel filter and the


13. Install the coolant bypass connection. Tighten

the capscrews and the hose clamp.

14. ENGINES YG and YH. If an air compressor is

installed on the engine, install the coolant pipe

between the cylinder head and the compressor.

Install the pipe between the coolant bypass andthe compressor.

15. Prepare to install the induction and exhaust

manifolds. Do not use sealant on the joints of

the manifolds.

16. ENGINE AR. Install the oil cooler if it is integral

with the cylinder block.

17. ENGINE AR. The front and rear gaskets have

tabs. Make sure that the gaskets are installed

with the tabs installed toward the oil sump. See

Figure 26.

1. GASKET2. GASKET

3. LOCATION TABS

Figure 26. Induction and Exhaust Manifold

Gaskets, Engine AR

NOTE:Some gaskets are now made as a single piece.

18. ENGINESYG and YH. The two end gaskets are

the same. The center gasket has tabs. Make

sure that the gaskets are installed with the tabs

installed toward the oil sump. SeeFigure 27.

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1. GASKET2. GASKET

3. LOCATION TABS

Figure 27. Manifold Gasket Installation,

Engines YG and YH

NOTE: Some replacement exhaust manifolds have

large clearance holes for the fasteners. Two align-

ment bushings are supplied with a replacement man-

ifold (Figure 28). These bushings must be installed

for the replacement manifold. New alignment bush-

ings are not necessary when the original manifold is

installed.

19. Install the exhaust manifold. Tighten the cap-

screws 44 Nm (32 lbf ft) in the sequence shown

inFigure 28.

A. FAN END

1. BUSHING (SEE NOTE)

Figure 28. Induction Manifold Installation,Engines YG and YH

20. Install the induction manifold. Tighten the cap

screws evenly and gradually to 44 Nm (32 lbf ft)

21. For induction manifolds on engines AR (see Fig

ure29), the top half of the induction manifold i

sealed to the bottom half with a gasket and fas

tened together by six capscrews.

1. TOP HALF OF MANIFOLD2. BOTTOM HALF OF MANIFOLD3. CAPSCREWS (INSIDE OF MANIFOLD)4. CAPSCREWS (OUTSIDE OF MANIFOLD)5. GASKET

Figure 29. Induction Manifold Installation,

Engine AR

22. The top half of the manifold must be removed to

obtain access to four of the manifold capscrewinside the manifold. These capscrews and th

four capscrews on the outside of the manifold re

tain the bottom half of the manifold cylinder t

the cylinder head.

CAUTION

Before the inlet manifold capscrews are in

stalled again, any loose M.E.A.S. in the cylin

der head holes must be removed to allow the

manifold to be fully tightened.

Do not scratch or damage the flange faces o

the inlet manifold.

NOTE: The capscrews which retain the manifol

to the cylinder head have M.E.A.S. applied to the

threads. If the capscrews are removed and installe

again, the threads must be cleaned and POWER

PART threadlock sealant used.

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23. ENGINE YH. Install the turbocharger per Tur-

bocharger - Engine YH Repair,Install.

24. Install the fuel line between the fuel pump and

the fuel filter.

25. Install the fuel line between the fuel filter and

the cold start aid. If the engine is in the lift truck,

install the electrical connection to the cold start

aid.

26. ENGINE YH. Install the boost control line be-

tween the induction manifold and the top of the


27. If the engine is still in the lift truck, do the fol-

lowing procedures:

a. Connect the sender unit for the coolant tem-

perature gauge.

b. ENGINE YH. Install air filter connection

at the compressor inlet of the turbocharger.

ENGINES AR and YG. Install the hose from

the air filter at the induction manifold.

c. Connect the hoses for the coolant system. Fill

the cooling system.

d. Connect the battery terminals.

e. If the engine is ready to operate, remove the

air from the fuel system. See the procedure

described inFuel System Air Removal.

28. When the engine can be started, run it at low

speed. Check that oil flows from the holes in the

rocker arms. If the oil flow is correct, install the

valve cover. SeeValve Cover,Install.

NOTE: It is notnecessary to tighten the cylinder head

capscrews again with the engine hot or after a limited

period of service.

VALVES AND VALVE SPRINGS

Special Tools: Valve spring compressor

Stud adapterSetscrew adapter

Remove

1. Remove the cylinder head. See Cylinder Head

Assembly, Remove.

2. Clean the bottom face of the cylinder head and

check the depth of the heads of the valves below

the face of the cylinder head. SeeFigure 30.

3. Check the depth of the valves below the face of

the cylinder head before the valve springs are re-

moved. Putthe dial indicator and fixture or othermeasuring tool on the face of the cylinder head

and set the gauge to zero. Carefully put the dial

indicator over the head of each valve and make a

note of the measurement. The maximum service

depth is shown in theEngine Specifications. If a

valve is below the depth limit, remove the valve

and install a new valve in that position. If the

valve depth is still below the limit, the valve seat

must be replaced. SeeNew Valve Seats, Install.

4. If the valves will be used again, make a mark

on each valve head so that they can be installed

again in the same positions.

5. Use the valve spring compressor and the correct

adapter to compress the valve springs and re-

move the retainers. Make sure the valve springs

are compressed parallel to the valve stems or the

valve stems can be damaged. SeeFigure 31.

6. Release the valve stem compressor. Remove the

valve spring cap, valve springs, seal, and seat

washer.

7. Repeat Step 5 and Step 6 to remove the other

valves.

Inspect

1. Check the valves for cracks. Check the stems of

the valves for wear and the correct clearance in

their valve guides. SeeValve Guides.

Figure 30. Valves Depth Check

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1. CAP2. COLLET (2)3. SPRING

4. VALVE STEM SEAL5. VALVE

Figure 31. Valve Components

2. Check that the seat faces of the valves are notbadly burned. Seat faces of valves that are dam-

aged, but can be repaired, must be checked for

valve depth when they are installed. See Fig-

ure30. When new valves are installed, the valve

depth must be checked.

3. Check that the load on the valve springs is cor-

rect at their installed length. See Engine Speci-

fications.

4. Install new valve springs during a complete over-

haul of the engine.

Install

1. Lubricate the valve stems with engine oil when

they are installed in their valve guides.

CAUTIONThe outer diameter of the exhaust valve guide

is 1 mm larger than the valve guide. To prevent

leakage past the inlet valve stem it is importan

that the larger valve seal is not installed into

the inlet guide. The seals are color coded.

2. Install the seat washer. Install new seals on th

valve guides. Make sure that the brown seal i

installed on the exhaust valves and the greenseal is installed on the inlet valves.

3. Install the inner and outer valve springs on th

seat washer. Make sure that the damper coils o

the valve springs are toward the cylinder head.

4. Use the valve spring compressor and the correc

adapter to compress the valve springs. Instal

the retainers. Make sure the valve springs ar

compressed parallel to the valve stems or th

valve stems can be damaged.

5. Repeat the installation procedure for each valve

VALVE GUIDES

Inspect

1. Check the valve guides for wear. The maximum

clearance between the valve stem and the bore o

the guide is 0.100 mm (0.0039 in.) for inlet valve

and 0.121 mm (0.0048 in.) for exhaust valves

If the clearance is greater than the limit when a

new valve is installed, the valve guide must b

replaced.

2. The following procedure is for checking the valvguides (seeFigure 32):

a. Put a new valve into the valve guide.

b. Install a dial indicator on the cylinder head

c. Lift the head of the valve approximatel

15 mm (0.6 in.) above its seat. Move th

valve head away from the plunger of the dia

indicator and set the dial indicator to zero.

d. Move the valve toward the dial indicato

and make a note of the movement. If th

reading is equal to or greater than the maximum clearance, a new valve guide must b

installed.

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1. MAGNETIC BASE2. DIAL INDICATOR3. VALVE HEAD

4. VALVE GUIDE5. MAXIMUM

CLEARANCE

Figure 32. Valve Guides Check

NOTE: The partially finished valve guides are

reamed and the valve seats are cut in one operation

with a special tool. This is done to ensure the con-

centricity of the valve seat to the valve guide and

provide a good seal between the guide and its seat.

New valves and valve seat inserts must be installed

each time a new valve guide is used.

Remove

Install the tool for removal

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