Hyster H8.00-12.00XM Operating instructions

Hyster G007 (H8.00-12.00XM Europe) Forklift

PERKINS TIER 2DIESEL
ENGINES
1100 (VK)
H8.00-12.00XM (H170-280HD) [F007, G007];
H13.00-16.00XM (H300-360HD) [E019, F019];
H10.00-12.00XM-12EC (H360HD-EC) [E019, F019]
PART NO. 1541323 600 SRM 1068

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 Manual or 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 WARNING and CAUTION notes 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:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!

Perkins Tier 2 Diesel Engines Table of Contents
TABLE OF CONTENTS
General ................................................................................................................................................................. 1
General Safety Rules....................................................................................................................................... 1
Description ........................................................................................................................................................... 2
Engine Serial Number Codes.......................................................................................................................... 4
Engine Data ..................................................................................................................................................... 4
Engine Removal and Installation ....................................................................................................................... 5
Cylinder Head Assembly Repair ......................................................................................................................... 5
Valve Cover ...................................................................................................................................................... 5
Remove......................................................................................................................................................... 5
Install........................................................................................................................................................... 6
Rocker Arm Assembly ..................................................................................................................................... 6
Remove......................................................................................................................................................... 6
Disassemble................................................................................................................................................. 6
Inspect.......................................................................................................................................................... 6
Assemble...................................................................................................................................................... 6
Install........................................................................................................................................................... 6
Valve Clearance Adjustments ......................................................................................................................... 7
Valve Springs ................................................................................................................................................... 8
Cylinder Head Assembly................................................................................................................................. 9
Remove......................................................................................................................................................... 9
Install......................................................................................................................................................... 11
Valves and Valve Springs .............................................................................................................................. 14
Remove....................................................................................................................................................... 14
Inspect........................................................................................................................................................ 14
Install......................................................................................................................................................... 15
Valve Guides .................................................................................................................................................. 15
Inspect........................................................................................................................................................ 15
Remove....................................................................................................................................................... 15
Install......................................................................................................................................................... 15
Cylinder Head and Valve Seats .................................................................................................................... 16
Inspect........................................................................................................................................................ 16
Repair......................................................................................................................................................... 17
New Valve Seats, Install ........................................................................................................................... 17
Piston and Connecting Rod Assemblies Repair ............................................................................................... 17
Rod Bearings.................................................................................................................................................. 18
Remove....................................................................................................................................................... 18
Install......................................................................................................................................................... 18
Piston and Connecting Rod Assembly .......................................................................................................... 19
Service Note............................................................................................................................................... 19
Remove....................................................................................................................................................... 19
Install......................................................................................................................................................... 20
Piston Rings ................................................................................................................................................... 21
Remove....................................................................................................................................................... 21
Inspect........................................................................................................................................................ 21
Install......................................................................................................................................................... 22
Piston and Connecting Rod ........................................................................................................................... 22
Disassemble............................................................................................................................................... 22
Inspect........................................................................................................................................................ 22
How to Select Correct Replacements ....................................................................................................... 23
Install......................................................................................................................................................... 24
Piston Cooling Jets ........................................................................................................................................ 24
©2004 HYSTER COMPANY i

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Table of Contents Perkins Tier 2 Diesel Engines
TABLE OF CONTENTS (Continued)
Remove....................................................................................................................................................... 24
Install......................................................................................................................................................... 25
Crankshaft Assembly Repair ............................................................................................................................ 25
General........................................................................................................................................................... 25
Crankshaft Pulley.......................................................................................................................................... 26
Remove....................................................................................................................................................... 26
Inspect........................................................................................................................................................ 26
Install......................................................................................................................................................... 26
Rear Oil Seal.................................................................................................................................................. 27
Remove....................................................................................................................................................... 27
Install......................................................................................................................................................... 27
Main Bearings................................................................................................................................................ 28
Remove....................................................................................................................................................... 28
Inspect........................................................................................................................................................ 29
Install......................................................................................................................................................... 29
Thrust Washers.............................................................................................................................................. 29
Crankshaft Axial Movement, Check ........................................................................................................ 29
Remove....................................................................................................................................................... 30
Install......................................................................................................................................................... 30
Crankshaft ..................................................................................................................................................... 31
Remove....................................................................................................................................................... 31
Inspect........................................................................................................................................................ 31
Install......................................................................................................................................................... 32
Flywheel ......................................................................................................................................................... 33
Remove....................................................................................................................................................... 33
Ring Gear, Replace .................................................................................................................................... 33
Install......................................................................................................................................................... 33
Flywheel Housing .......................................................................................................................................... 34
Remove....................................................................................................................................................... 34
Install......................................................................................................................................................... 34
Timing Case and Timing Gears Repair ............................................................................................................ 35
General........................................................................................................................................................... 35
Timing Case Cover ........................................................................................................................................ 35
Remove....................................................................................................................................................... 35
Install......................................................................................................................................................... 36
Front Oil Seal................................................................................................................................................. 36
Remove....................................................................................................................................................... 36
Install......................................................................................................................................................... 36
Crankshaft Pulley Wear Sleeve .................................................................................................................... 37
Install......................................................................................................................................................... 37
Idler Gear and Hub ....................................................................................................................................... 37
Remove....................................................................................................................................................... 37
Install......................................................................................................................................................... 38
Air Compressor Drive, Bendix ...................................................................................................................... 39
Disassemble ............................................................................................................................................... 39
Assemble .................................................................................................................................................... 39
Fuel Injection Pump Gear ............................................................................................................................. 40
Remove....................................................................................................................................................... 40
Install......................................................................................................................................................... 41
Camshaft Gear............................................................................................................................................... 41
Remove....................................................................................................................................................... 41
ii

Perkins Tier 2 Diesel Engines Table of Contents
TABLE OF CONTENTS (Continued)
Install......................................................................................................................................................... 42
Crankshaft Gear ............................................................................................................................................ 42
Remove....................................................................................................................................................... 42
Install......................................................................................................................................................... 43
Timing Case ................................................................................................................................................... 43
Remove....................................................................................................................................................... 43
Install......................................................................................................................................................... 43
Camshaft and Tappets .................................................................................................................................. 44
Remove....................................................................................................................................................... 44
Install......................................................................................................................................................... 45
Cylinder Block Assembly Repair....................................................................................................................... 45
Description ..................................................................................................................................................... 45
Cylinder Block ............................................................................................................................................... 45
Disassemble............................................................................................................................................... 45
Inspect........................................................................................................................................................ 46
Assemble.................................................................................................................................................... 46
Cylinder Liner................................................................................................................................................ 47
Inspect........................................................................................................................................................ 47
Cylinder Liner Condition, Check.............................................................................................................. 47
Remove....................................................................................................................................................... 48
Service Liner, Install................................................................................................................................. 49
Partially Finished Liner, Install............................................................................................................... 50
Engine Timing.................................................................................................................................................... 51
Description ..................................................................................................................................................... 51
How to Set Number One Piston to TDC on Compression Stroke ........................................................... 52
How to Set Number One Piston to TDC on Compression Stroke (Alternate Procedure)...................... 53
HowtoSetNumberOnePistonto4 After TDC on Compression Stroke ............................................. 54
Valve Timing, Check.................................................................................................................................. 55
Fuel Injection Pump Timing, Check......................................................................................................... 56
Turbocharger ...................................................................................................................................................... 56
General........................................................................................................................................................... 56
Remove ........................................................................................................................................................... 56
Install ............................................................................................................................................................. 57
Impeller and Compressor Housing, Clean ................................................................................................... 57
Waste-Gate Valve Check ............................................................................................................................... 58
Closed Circuit Breather System (CCB) ........................................................................................................ 59
CCB Assembly, Remove ............................................................................................................................ 59
Closed Circuit Drain Valve, Remove ........................................................................................................ 59
CCB Assembly, Install .............................................................................................................................. 59
Closed Circuit Drain Valve, Install .......................................................................................................... 59
Lubrication System Repair................................................................................................................................ 60
General........................................................................................................................................................... 60
Oil Filter, Replace.......................................................................................................................................... 60
Oil Filter Head............................................................................................................................................... 60
Remove....................................................................................................................................................... 60
Install......................................................................................................................................................... 60
Oil Filter Head Bypass Valve........................................................................................................................ 61
Remove and Install ................................................................................................................................... 61
Oil Sump ........................................................................................................................................................ 61
Remove....................................................................................................................................................... 61
Install......................................................................................................................................................... 61
iii

Table of Contents Perkins Tier 2 Diesel Engines
TABLE OF CONTENTS (Continued)
Oil Pump ........................................................................................................................................................ 62
Remove....................................................................................................................................................... 62
Inspect........................................................................................................................................................ 62
Install......................................................................................................................................................... 63
Relief Valve .................................................................................................................................................... 64
Remove....................................................................................................................................................... 64
Disassemble ............................................................................................................................................... 64
Inspect........................................................................................................................................................ 64
Assemble .................................................................................................................................................... 64
Install......................................................................................................................................................... 64
Idler Gear Shaft, Replace.............................................................................................................................. 64
Remove....................................................................................................................................................... 65
Remove (Alternative) ................................................................................................................................ 65
Install......................................................................................................................................................... 66
Install (Alternative) .................................................................................................................................. 66
Fuel System Repair............................................................................................................................................ 67
Description ..................................................................................................................................................... 67
Fuel Injection Pump ...................................................................................................................................... 69
Remove....................................................................................................................................................... 69
Install......................................................................................................................................................... 71
Fuel System Air Removal.............................................................................................................................. 72
Fuel Filter, Replace ....................................................................................................................................... 74
Fuel Injectors ................................................................................................................................................. 74
Remove....................................................................................................................................................... 75
Inspect........................................................................................................................................................ 75
Install......................................................................................................................................................... 75
Fuel Lift Pump............................................................................................................................................... 76
Remove....................................................................................................................................................... 76
Disassemble ............................................................................................................................................... 76
Assemble .................................................................................................................................................... 76
Install......................................................................................................................................................... 77
Test............................................................................................................................................................. 77
Cooling System Repair ...................................................................................................................................... 78
General........................................................................................................................................................... 78
Thermostat..................................................................................................................................................... 78
Remove....................................................................................................................................................... 78
Install......................................................................................................................................................... 79
Test............................................................................................................................................................. 79
Coolant Pump ................................................................................................................................................ 79
Remove....................................................................................................................................................... 79
Disassemble ............................................................................................................................................... 80
Assemble .................................................................................................................................................... 82
Install......................................................................................................................................................... 84
Fan and Fan Drive ........................................................................................................................................ 85
Remove....................................................................................................................................................... 85
Install......................................................................................................................................................... 85
Oil Cooler ....................................................................................................................................................... 85
Remove....................................................................................................................................................... 85
Disassemble and Assemble....................................................................................................................... 86
Install......................................................................................................................................................... 86
Electrical Equipment Repair............................................................................................................................. 87
iv

Perkins Tier 2 Diesel Engines Table of Contents
TABLE OF CONTENTS (Continued)
Drive Belts ..................................................................................................................................................... 87
Alternator....................................................................................................................................................... 87
Remove....................................................................................................................................................... 87
Install......................................................................................................................................................... 87
Electronic Control Module (ECM) ................................................................................................................ 88
Remove....................................................................................................................................................... 88
Inspect........................................................................................................................................................ 88
Install......................................................................................................................................................... 88
Voltage Load and Protection Module (VLPM).............................................................................................. 89
Remove....................................................................................................................................................... 89
Install......................................................................................................................................................... 89
Engine Speed and Timing Sensor................................................................................................................. 89
Remove....................................................................................................................................................... 89
Install......................................................................................................................................................... 90
Pressure Sensors (Engine Oil and Air Intake)............................................................................................. 90
Remove....................................................................................................................................................... 90
Install......................................................................................................................................................... 91
Temperature Sensor ...................................................................................................................................... 91
Remove....................................................................................................................................................... 91
Install......................................................................................................................................................... 92
Starter Motor ................................................................................................................................................. 92
Remove....................................................................................................................................................... 92
Install......................................................................................................................................................... 92
Cold Start Aid ................................................................................................................................................ 92
Air Compressor .................................................................................................................................................. 92
General........................................................................................................................................................... 92
Repair ............................................................................................................................................................. 93
Remove....................................................................................................................................................... 93
Install......................................................................................................................................................... 93
Rotary Exhauster Replacement ........................................................................................................................ 94
Remove ........................................................................................................................................................... 94
Clean .............................................................................................................................................................. 94
Install ............................................................................................................................................................. 94
Engine Specifications......................................................................................................................................... 95
Cylinder Head Assembly............................................................................................................................... 95
Piston and Connecting Rods ......................................................................................................................... 98
Crankshaft Assembly .................................................................................................................................... 99
Crankshaft Overhaul .............................................................................................................................. 100
Timing Case and Drive Assembly............................................................................................................... 102
Engine Block Assembly ............................................................................................................................... 103
Turbocharger................................................................................................................................................ 104
Lubrication System ..................................................................................................................................... 105
Cooling System ............................................................................................................................................ 107
Flywheel and Housing................................................................................................................................. 107
Electrical Equipment................................................................................................................................... 107
Torque Specifications ....................................................................................................................................... 108
Cylinder Head Assembly............................................................................................................................. 108
Piston and Connecting Rod Assemblies ..................................................................................................... 108
Crankshaft Assembly .................................................................................................................................. 108
Timing Case and Drive Assembly............................................................................................................... 108
Turbocharger................................................................................................................................................ 108
v

Table of Contents Perkins Tier 2 Diesel Engines
TABLE OF CONTENTS (Continued)
Lubrication System ..................................................................................................................................... 108
Fuel System ................................................................................................................................................. 108
Cooling System ............................................................................................................................................ 109
Flywheel ....................................................................................................................................................... 109
Auxiliary Equipment................................................................................................................................... 109
Special Torque Specifications .......................................................................................................................... 109
Flywheel and Housing................................................................................................................................. 109
Electrical Equipment................................................................................................................................... 109
Auxiliary Equipment................................................................................................................................... 109
Special Tools ..................................................................................................................................................... 110
Troubleshooting................................................................................................................................................ 115
Turbocharger Troubleshooting ........................................................................................................................ 117
This section is for the following models:
H8.00-12.00XM (H170-280HD) [F007, G007];
H13.00-16.00XM (H300-360HD) [E019, F019];
H10.00-12.00XM-12EC (H360HD-EC) [E019, F019]
vi

600 SRM 1068 General
General
This section has the description and repair instruc-
tions for the VK model of the Series 1100 Perkins
diesel engine. All VK models are six-cylinder, tur-
bocharged.
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(600F) 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 percent calcium hy-
droxide solution to neutralize any acid and
thencleanwithwater.
If burned seal by-product touches the skin or
eyes:
• Immediately flush with water for a minimum
of 15 minutes.
• Apply 2.5 percent calcium gluconate gel to af-
fected 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 operator’s 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 engines
contains carbon monoxide and other harmful
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 soot
can accumulate.
If engines are operated in confined spaces,
maintain adequate ventilation or vent exhaust
to the outside. Do not exceed applicable air
contaminant limits.
Follow the inspection and maintenance sched-
ule and procedures in this manual. Do not alter
exhaust, ignition, or fuel systems.
CAUTION
Disposal of lubricants and fluids must meet lo-
cal 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 cautions
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 of
the wire before it is connected.
• Verify the battery is the correct voltage and
polarity before it is connected.
• Do not check for current flow by making a
spark because the electronic components can
be damaged.
1

Description 600 SRM 1068
CAUTION
When 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 a
1.59 mm (0.0626 in.), 45 chamfer so that the
M.E.A.S. sealant is not removed. If the fasten-
ers have to be removed and fitted again, the
threads must be cleaned and a suitable sealant
used.
Observe the previous WARNINGS and CAUTIONS
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
valveassemblyisactuatedbyacamshaftinsideof
the engine block. A gear train, turned by the crank-
shaft, turns the camshaft, coolant pump, injection
pump, and a power-takeoff (PTO) which is available
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. See Figure 1.
The crankshaft has seven 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 and has cylinder liners
that can be replaced during overhaul.
A Fastram™ combustion chamber in the top of each
piston is designed to give an efficient mix of fuel and
air. Each piston has three piston rings (two compres-
sion rings and an oil control ring). The top compres-
sion 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 installed.
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, speed adjustment, and quantity of fuel
sent to the fuel injectors is controlled electronically
by the Electronic Control Module (ECM).
A Bosch VP30 series fuel injection pump is used on all
1100 VK engines. Special tools are needed to repair
an injection pump, and they are normally sent to an
authorized repair station if repairs are necessary.
2

600 SRM 1068 Description
1. FILL CAP FOR ENGINE OIL
2. FUEL FILTER
3. FUEL INJECTION PUMP
4. COOLANT PUMP
5. AIR COMPRESSOR
6. VIBRATION DAMPER
7. OIL FILTERS
8. OIL SUMP
9. ALTERNATOR
10. TURBOCHARGER
11. DIPSTICK, ENGINE OIL
12. FAN DRIVE
13. OIL COOLER
14. TIMING CASE
Figure 1. Engine
3

Description 600 SRM 1068
ENGINE SERIAL NUMBER CODES
The engine number is on a label on the left side of the
engine block. See Figure 2.
1. PART NUMBERS
FOR FUEL
INJECTION PUMP
2. ENGINE SERIAL
NUMBER
3. EMISSIONS LABEL
Figure 2. Serial Number Locations
A typical serial number has the following code:
VK U 090001 H
1234
where:
1=Typeofengine:VK=1100
2 = Country of manufacture (U = manufactured in
the United Kingdom)
3 = Serial number
4 = Year of manufacture. The letter indicates the
year of manufacture. The letters I, O, Q, R, and Z
are not used.
If parts or service are required for your engine,
the complete engine number must be given to your
dealer.
ENGINE DATA
The specifications and tolerance details for engine re-
pairareinachartattheendofthissection.
1100 (VK)
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................... 6.00 liter (366 in.3)
Compression ratio ........... 17.25:1
Minimum oil pressure
(at maximum speed
and normal operating
temperature)
Governor speed (no
load) ................................. 280 kPa (41 psi)
See the Periodic Maintenance section for your
model of lift truck.
Idle Speed ........................ 725 to 775 rpm
Thermostat
Begin to open ..............
Fully open.................... 80 to 84 C (176 to 183 F)
96 C(205F)
Valve clearance (hot or cold)
Inlet .............................
Exhaust ....................... 0.20 mm (0.008 in.) 0.45 mm (0.018 in.)
4

600 SRM 1068 Cylinder Head Assembly Repair
Engine Removal and Installation
See the Frame section for the procedure for remov-
ing the engine and transmission. See the Transmis-
sion section for the procedure to separate the trans-
mission from the 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:
1100 (VK) engines 600 kg (1323 lb)
Always use a lifting device that provides a vertical lift
above the engine lift brackets as shown in Figure 3.
Never use a single bracket to lift an engine.
Verify the engine brackets are correctly fastened to
the engine. Verify that the valve cover and other com-
ponents are not damaged by the lifting device. 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 3. Lifting an Engine
Cylinder Head Assembly Repair
VALVE COVER
Figure 4. Valve Cover
Legend for Figure 4
1. VALVE COVER
2. OIL FILLER CAP SEAL
3. OIL SEPARATOR ASSEMBLY SEAL
4. VALVE COVER GASKET
5. CAPSCREW ASSEMBLY
Remove
1. Disconnect the breather pipe.
2. Remove the capscrews and sealing washers from
thevalvecover. SeeFigure4.
3. Lift the valve cover and gasket from the cylinder
head. The valve cover gasket fits between the
valve cover and the induction manifold.
5

Cylinder Head Assembly Repair 600 SRM 1068
Install
1. Check the condition of the valve cover gasket,
bolts, and seal washers. Replace components as
necessary. Verify that the surfaces are clean.
2. Install the valve cover and gasket on the cylinder
head. See Figure 4.
3. Install the valve cover bolts. Torque to 9 N•m
(80 lbf in) in sequence shown in Figure 5.
Figure 5. Valve Cover Torque Sequence
4. 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
towards the center. Remove the nuts and wash-
ers when the pressure is removed from the rocker
arms. 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. See Figure 6.
Disassemble
1. Remove the clips from both ends of the rocker
arm shaft. Verify 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.
Figure 6. Rubber Seal Location
Inspect
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
0.09 mm (0.0035 in.), install a new rocker arm, or
install a new rocker arm shaft if it is worn.
Assemble
1. Verify that the lubrication holes in the rocker
arms and the rocker arm shaft are open and
clean.
2. Lubricate the components with clean engine oil
as they are assembled on the rocker arm shaft.
Verify the components are assembled in the cor-
rect order. See Figure 7. Verify that the loca-
tion screw for the oil supply connection is fitted
correctly in the rocker arm shaft and torqued to
4 N•m (35 lbf in). Install the clips at the ends of
the rocker arm shaft.
Install
1. Verify that the rocker arm assembly is clean and
dry.
2. Install a new rubber seal in the hole for the oil
supply in the cylinder head. See Figure 6.
3. Check that the push rods fit correctly in the sock-
ets for the tappets. Install the rocker arm assem-
bly over the four studs, insert the oil supply con-
nection into the oil supply hole in the cylinder
head.
6

600 SRM 1068 Cylinder Head Assembly Repair
Figure 7. Rocker Arm Assembly
CAUTION
Loosen any tappet adjustment screws that may
tighten during the following procedure.
4. Verify that the alignment of the rocker arms
and the push rods is 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 towards the ends of the
shaft. The final torque on the nuts is 75 N•m
(55 lbf ft).
5. Check and adjust valve tip clearances. See Valve
Clearance Adjustments.
VALVE CLEARANCE ADJUSTMENTS
The valve clearance is measured between the top of
the valve stem and the rocker arm as shown in Fig-
ure 8.
Valve clearance (hot or cold)
Inlet
Exhaust 0.20 mm (0.008 in.) 0.45 mm (0.018 in.)
Number one cylinder is at the front of the engine.
The inlet valve is the first valve in the sequence. See
Figure 9.
1. Turn the crankshaft in the normal direction of
rotation until the inlet valve of number six cylin-
der has just opened and the exhaust valve of the
same cylinder has not fully closed. Check the
clearances of the valves of number one cylinder
and adjust them as necessary.
Figure 8. Valve Clearance Adjustment
Figure9. ValvePositions
NOTE: The torque for the locking nut is 27 N•m
(21 lbfft).
2. Turn the crankshaft in the normal direction of ro-
tation until the inlet valve of number two cylin-
der has just opened and the exhaust valve of the
same cylinder has not fully closed. Check the
valve clearances on number five cylinder and ad-
just them as necessary.
7

Cylinder Head Assembly Repair 600 SRM 1068
3. 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
valve clearances on number three cylinder and
adjust them as necessary.
4. Turn the crankshaft in the normal direction of ro-
tation until the inlet valve of number one cylin-
der has just opened and the exhaust valve of the
same cylinder has not fully closed. Check the
valve clearances on number six cylinder and ad-
just them as necessary.
5. Turn the crankshaft in the normal direction of ro-
tation until the inlet valve of number five cylin-
der has just opened and the exhaust valve of the
same cylinder has not fully closed. Check the
valve clearances on number two cylinder and ad-
just them as necessary.
6. Turn the crankshaft in the normal direction of ro-
tation until the inlet valve of number three cylin-
der has just opened and the exhaust valve of the
same cylinder has not fully closed. Check the
valve clearances on number four cylinder and ad-
just them as necessary.
NOTE: After valve adjustments, lubricate the rocker
assembly with clean engine oil.
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.
SeeFigure10.
1. VALVE SPRING
COMPRESSOR
2. STUD ADAPTER
3. SETSCREW
ADAPTER
Figure 10. Valve Spring Compressor
5. Compress the valve springs and remove the re-
tainers. Verify the valve springs are compressed
parallel to the valve stems, or the valve stems can
be damaged.
NOTE: Do not turn the crankshaft while the valve
springs are removed.
6. Release the valve spring compressor and remove
the retainer cap and valve springs.
NOTE: The outer diameter of the exhaust valve guide
is 1 mm (0.039 in.) larger than the inlet valve guide.
To prevent leakage past the inlet valve stem it is im-
portant 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.
Verify that the brown seal is installed on the
exhaust valve and the green seal on the inlet
valves.
8. Install the new valve springs. The springs can be
fitted with either end toward 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. See Valve Clearance
Adjustments.
13. Install the valve cover.
8

600 SRM 1068 Cylinder Head Assembly Repair
NOTE: Valvespringscanbechangedintwocylinders
at a time.
When the piston in cylinder one is at TDC, the piston
in cylinder six is also at TDC. When the piston in
cylinder two is at TDC, the piston in cylinder five is
also at TDC. When the piston in cylinder three is at
TDC,thepistonincylinderfourisalsoatTDC.
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 until
the piston touches the valve. Continue to turn the
crankshaft and, at the same time, release the pres-
sure on the valve spring compressor until the piston
isatTDC.SeeFigure11.
Figure 11. Find TDC With Valve Spring
Compressor
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. If equipped, remove closed circuit breather unit.
3. Remove the Machine Interface Connector (MIC)
connection from the mounting bracket if the
mounting bracket is attached to the cylinder
head.
4. Remove the air intake hose.
5. Removethefuellinebetweenthecoldstartaid
in the induction manifold and the fuel filter. Dis-
connect the electrical connection and electrical
connectors from sensors.
6. Disconnect all connections to the turbocharger
and remove turbocharger. See Turbocharger, Re-
move.
7. Remove the induction manifold capscrews.
8. Remove the induction manifold and gasket from
the cylinder head. Discard the gasket.
9. Remove exhaust manifold fasteners and the ex-
haust manifold.
10. Remove the low pressure fuel lines between the
fuel injection pump and the fuel filter. Remove
the fuel filter bracket and the fuel filters.
11. Removethehighpressurefuellines. Useasep-
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
fuel injection pump.
12. Remove the fuel injectors from the cylinder head.
Keep the fuel injectors clean and prevent damage
to the nozzles.
13. If an air compressor is installed, remove the
coolant pipe between the cylinder head and the
compressor. Remove the coolant pipe between
the bypass connection and the compressor.
9

Cylinder Head Assembly Repair 600 SRM 1068
14. 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.
15. Disconnect the coolant temperature sender.
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
showninFigure12.
Figure 12. Cylinder Head Tightening Sequence
20. Lift the cylinder head from the engine block. Do
not use a pry bar between the cylinder head and
theengineblock,thatcancausedamagetothe
gasket surfaces. See Figure 13.
Figure 13. Cylinder Head Removal
21. Inspect the capscrews for the cylinder head with
a straightedge. See Figure 14. Check that the
capscrews are straight and do not have distor-
tion. If there is a reduction in the diameter of the
thread that has not been in engagement with the
cylinder block, the capscrew must be discarded.
1. STRAIGHTEDGE
2. CAPSCREW MUST BE STRAIGHT AND
WITHOUT DISTORTION
3. THREADS MUST BE IN GOOD CONDITION AND
NOT HAVE A REDUCED DIAMETER
Figure 14. Capscrews Inspection
10