Hyster K005 (H3.50-5.50XM, H4.00XM-5, H4.00XM-6, H4.00XMS-6 Europe) Forklift Service Repair Workshop Manual

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) [F006]; S6.00-7.00XL (S135-155XL) [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

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 Diesel Engines Table of Contents TABLE OF CONTENTS General ................................................................................................................................................................. 1 General Safety Rules ....................................................................................................................................... 1 Description ........................................................................................................................................................... 2 Engine Serial Number Codes .......................................................................................................................... 5 Engine Data ..................................................................................................................................................... 5 Engine Removal and Installation ....................................................................................................................... 7 Lift Engine ....................................................................................................................................................... 7 Cylinder Head Assembly Repair ......................................................................................................................... 7 Valve Cover ...................................................................................................................................................... 7 Remove ......................................................................................................................................................... 7 Install ........................................................................................................................................................... 8 Rocker Arm Assembly ..................................................................................................................................... 8 Remove ......................................................................................................................................................... 8 Install ........................................................................................................................................................... 8 Disassemble ................................................................................................................................................. 8 Inspect .......................................................................................................................................................... 8 Assemble ...................................................................................................................................................... 9 Valve 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 ........................................................................................................................................................ 19 Remove ....................................................................................................................................................... 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 ....................................................................................................................................................... 24 Install ......................................................................................................................................................... 25 Piston Rings ................................................................................................................................................... 26 Remove ....................................................................................................................................................... 26 Inspect ........................................................................................................................................................ 26 Install ......................................................................................................................................................... 26 Piston and Connecting Rod ........................................................................................................................... 27 Disassemble ............................................................................................................................................... 27 Inspect ........................................................................................................................................................ 28 ©2003 HYSTER COMPANY i

Table of Contents Perkins Diesel Engines TABLE OF CONTENTS (Continued) How to Select Correct Replacements ....................................................................................................... 28 Install ......................................................................................................................................................... 29 Piston Cooling Jets ........................................................................................................................................ 29 Remove ....................................................................................................................................................... 29 Install ......................................................................................................................................................... 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 ....................................................................................................................................................... 34 Inspect ........................................................................................................................................................ 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 .................................................................................................................................... 39 Install ......................................................................................................................................................... 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 ii

Perkins Diesel Engines Table of Contents TABLE OF CONTENTS (Continued) Remove ....................................................................................................................................................... 47 Install ......................................................................................................................................................... 47 Camshaft Gear ............................................................................................................................................... 48 Remove ....................................................................................................................................................... 48 Install ......................................................................................................................................................... 48 Crankshaft Gear ............................................................................................................................................ 49 Remove ....................................................................................................................................................... 49 Install ......................................................................................................................................................... 49 Timing Case ................................................................................................................................................... 49 Remove ....................................................................................................................................................... 49 Install ......................................................................................................................................................... 50 Camshaft and Tappets .................................................................................................................................. 51 Remove ....................................................................................................................................................... 51 Install ......................................................................................................................................................... 51 Cylinder Block Assembly Repair....................................................................................................................... 52 Description ..................................................................................................................................................... 52 Cylinder Block ............................................................................................................................................... 52 Disassemble ............................................................................................................................................... 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 ............................................................................................................... 57 Engine Timing .................................................................................................................................................... 58 Description ..................................................................................................................................................... 58 How to Set Number One Piston to TDC on Compression Stroke ........................................................... 59 How to Set Number One Piston to TDC on Compression Stroke (Alternate Procedure) ...................... 60 Valve Timing, Check.................................................................................................................................. 60 Fuel Injection Pump Timing, Check......................................................................................................... 61 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 ......................................................................................................................................................... 67 Relief Valve .................................................................................................................................................... 67 iii

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Hyster K005 (H3.50-5.50XM, H4.00XM-5, H4.00XM-6, H4.00XMS-6 Europe) Forklift Service Repair Workshop Manual

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