Service Manual for Yale D818 (GC_GDC_GLC070_080LJ_LJ-BCS, GC_GDC_GLC100_120MJ_MJ-BCS) Forklift by www.heydownloads.com

PERKINSDIESELENGINES

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

GC/GLC070-120MG[B818];

GDP60-70CA(GP/GLP/GDP135-155CA)[A878];

GC/GLC/GDC135-155CA[A879];

GP135-280DA [A876]; GP070-120LJ /MJ[C813];

GC070-120LJ/MJ[C818,D818];

GDP80-120DB (GP170-280DB)[B876];

GDP130-160EB(GP300-360EB)[B877]

Maintenance

PARTNO.524150774 600YRM705

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SAFETYPRECAUTIONS MAINTENANCEANDREPAIR

• Whenliftingpartsorassemblies,makesureallslings,chains,orcablesarecorrectlyfastened,andthattheloadbeingliftedisbalanced.Makesurethecrane,cables,andchains havethecapacitytosupporttheweightoftheload.

• Donotliftheavypartsbyhand,usealiftingmechanism.

• Wearsafetyglasses.

• DISCONNECTTHEBATTERYCONNECTORbeforedoinganymaintenanceorrepairon electriclifttrucks.Disconnectthebatterygroundcableoninternalcombustionlifttrucks.

• Alwaysusecorrectblockstopreventtheunitfromrollingorfalling.SeeHOWTOPUTTHE LIFTTRUCKONBLOCKSinthe OperatingManual orthe PeriodicMaintenance section.

• Keeptheunitcleanandtheworkingareacleanandorderly.

• Usethecorrecttoolsforthejob.

• Keepthetoolscleanandingoodcondition.

• Alwaysuse YALEAPPROVED partswhenmakingrepairs.Replacementpartsmustmeet orexceedthespecificationsoftheoriginalequipmentmanufacturer.

• Makesureallnuts,bolts,snaprings,andotherfasteningdevicesareremovedbeforeusing forcetoremoveparts.

• AlwaysfastenaDONOTOPERATEtagtothecontrolsoftheunitwhenmakingrepairs,or iftheunitneedsrepairs.

• Besuretofollowthe WARNING and CAUTION notesintheinstructions.

• Gasoline,LiquidPetroleumGas(LPG),CompressedNaturalGas(CNG),andDieselfuelare flammable.Besuretofollowthenecessarysafetyprecautionswhenhandlingthesefuels andwhenworkingonthesefuelsystems.

• Batteriesgenerateflammablegaswhentheyarebeingcharged.Keepfireandsparksaway fromthearea.Makesuretheareaiswellventilated.

NOTE: Thefollowingsymbolsandwordsindicatesafetyinformationinthismanual:

WARNING

Indicatesaconditionthatcancausepropertydamage!

Indicatesaconditionthatcancauseimmediatedeathorinjury! CAUTION

PerkinsDieselEnginesTableofContents

General..................................................................................................................................................................1 GeneralSafetyRules............................................................................................................. ...........................1 Description............................................................................................................................................................2 EngineSerialNumberCodes............................................................................................................................5 EngineData......................................................................................................................................................5 EngineRemovalandInstallation...........................................................................................................................7 LiftEngine.........................................................................................................................................................7 CylinderHeadAssemblyRepair............................................................................................................................7 ValveCover.......................................................................................................................................................7 Remove.........................................................................................................................................................7 Install............................................................................................................................................................8 RockerArmAssembly.......................................................................................................................................8 Remove.........................................................................................................................................................8 Install............................................................................................................................................................8 Disassemble.................................................................................................................................................8 Inspect..........................................................................................................................................................9 Assemble......................................................................................................................................................9 ValveClearanceAdjustments...................................................................................................... .....................9 Four-CylinderEngines................................................................................................................................10 Six-CylinderEngines..................................................................................................................................10 ValveSprings..................................................................................................................................................10 CylinderHeadAssembly.................................................................................................................................12 Remove.......................................................................................................................................................12 Install..........................................................................................................................................................14 ValvesandValveSprings................................................................................................................................18 Remove.......................................................................................................................................................18 Inspect........................................................................................................................................................18 Install..........................................................................................................................................................19 ValveGuides...................................................................................................................................................19 Inspect........................................................................................................................................................19 Remove.......................................................................................................................................................20 Install..........................................................................................................................................................20 CylinderHeadandValveSeats.......................................................................................................................20 Inspect........................................................................................................................................................20 Repair.........................................................................................................................................................20 NewValveSeats,Install..............................................................................................................................20 PistonandConnectingRodAssembliesRepair..................................................................................................22 RodBearings..................................................................................................................................................22 Remove.......................................................................................................................................................23 Install..........................................................................................................................................................23 PistonandConnectingRodAssembly............................................................................................................24 ServiceNote...............................................................................................................................................24 Remove.......................................................................................................................................................24 Install..........................................................................................................................................................25 PistonRings....................................................................................................................................................26 Remove.......................................................................................................................................................26 Inspect........................................................................................................................................................26 Install..........................................................................................................................................................26 PistonandConnectingRod......................................................................................................... ...................27 Disassemble...............................................................................................................................................27 Inspect........................................................................................................................................................28 ©2006YaleMaterialsHandlingCorp. i

TABLEOFCONTENTS

TABLEOFCONTENTS(Continued)

TableofContentsPerkinsDieselEngines

HowtoSelectCorrectReplacements.........................................................................................................28 Install..........................................................................................................................................................29 PistonCoolingJets.........................................................................................................................................29 Remove.......................................................................................................................................................29 Install..........................................................................................................................................................30 CrankshaftAssemblyRepair....................................................................................................... ........................30 General...........................................................................................................................................................30 CrankshaftPulley............................................................................................................................................31 EngineAR,Remove...................................................................................................................................31 EnginesYGandYH,Remove....................................................................................................................31 Inspect........................................................................................................................................................32 EngineAR,Install............................................................................................................... ........................32 EnginesYGandYH,Install........................................................................................................................32 RearOilSeal...................................................................................................................................................33 Replace.......................................................................................................................................................33 MainBearings.................................................................................................................................................34 Remove.......................................................................................................................................................34 Inspect........................................................................................................................................................35 Install..........................................................................................................................................................35 ThrustWashers...............................................................................................................................................35 CrankshaftAxialMovement,Check............................................................................................................35 Remove.......................................................................................................................................................36 Install..........................................................................................................................................................36 Crankshaft.......................................................................................................................................................37 Remove.......................................................................................................................................................37 Inspect........................................................................................................................................................37 Install..........................................................................................................................................................37 Flywheel..........................................................................................................................................................39 Remove.......................................................................................................................................................39 RingGear,Replace....................................................................................................................................39 Install..........................................................................................................................................................39 FlywheelHousing............................................................................................................................................40 Remove.......................................................................................................................................................40 Install..........................................................................................................................................................40 TimingCaseandTimingGearsRepair...............................................................................................................41 General...........................................................................................................................................................41 TimingCaseCover..........................................................................................................................................41 Remove.......................................................................................................................................................41 Install..........................................................................................................................................................42 FrontOilSeal..................................................................................................................................................42 Remove.......................................................................................................................................................42 Install..........................................................................................................................................................42 CrankshaftPulleyWearSleeve..................................................................................................... ..................43 Install..........................................................................................................................................................43 IdlerGearandHub..........................................................................................................................................43 Remove.......................................................................................................................................................43 Install..........................................................................................................................................................44 AirCompressorDrive,Bendix.........................................................................................................................45 Disassemble...............................................................................................................................................45 Assemble....................................................................................................................................................46 FuelInjectionPumpGear...............................................................................................................................46 ii

TABLEOFCONTENTS(Continued)

PerkinsDieselEnginesTableofContents

Remove.......................................................................................................................................................47 Install..........................................................................................................................................................47 CamshaftGear................................................................................................................................................48 Remove.......................................................................................................................................................48 Install..........................................................................................................................................................48 CrankshaftGear..............................................................................................................................................49 Remove.......................................................................................................................................................49 Install..........................................................................................................................................................49 TimingCase..................................................................................................................... ...............................49 Remove.......................................................................................................................................................49 Install..........................................................................................................................................................50 CamshaftandTappets....................................................................................................................................51 Remove.......................................................................................................................................................51 Install..........................................................................................................................................................51 CylinderBlockAssemblyRepair.........................................................................................................................52 Description......................................................................................................................................................52 CylinderBlock.................................................................................................................. ...............................52 Disassemble...............................................................................................................................................52 Inspect........................................................................................................................................................53 Assemble....................................................................................................................................................53 CylinderBore(Four-CylinderEngines)...........................................................................................................53 CylinderLiner(Six-CylinderEngines).............................................................................................................54 Inspect........................................................................................................................................................54 CylinderLinerCondition,Check.................................................................................................................54 Remove.......................................................................................................................................................55 ServiceLiner,Install........................................................................................................... .........................55 PartiallyFinishedLiner,Install................................................................................................. ...................57 EngineTiming......................................................................................................................................................57 Description......................................................................................................................................................57 HowtoSetNumberOnePistontoTDConCompressionStroke...............................................................59 HowtoSetNumberOnePistontoTDConCompressionStroke(AlternateProcedure)...........................59 ValveTiming,Check...................................................................................................................................60 FuelInjectionPumpTiming,Check............................................................................................................61 Turbocharger-EngineYHRepair.................................................................................................... ...................62 General...........................................................................................................................................................62 Remove.......................................................................................................................................................62 Install..........................................................................................................................................................62 ImpellerandCompressorHousing,Clean..................................................................................................63 LubricationSystemRepair..................................................................................................................................64 General...........................................................................................................................................................64 OilFilter,Replace............................................................................................................................................64 FilterHead.......................................................................................................................................................64 RemoveandInstall.....................................................................................................................................64 OilSump.........................................................................................................................................................65 Remove.......................................................................................................................................................65 Install..........................................................................................................................................................65 OilPump.........................................................................................................................................................65 Remove.......................................................................................................................................................65 Inspect........................................................................................................................................................66 Install..........................................................................................................................................................67 ReliefValve.....................................................................................................................................................67 iii

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TableofContentsPerkinsDieselEngines

Remove.......................................................................................................................................................67 Disassemble...............................................................................................................................................68 Inspect........................................................................................................................................................68 Assemble....................................................................................................................................................68 Install..........................................................................................................................................................68 IdlerGearShaft,Replace................................................................................................................................69 Remove.......................................................................................................................................................69 Remove(Alternative)..................................................................................................................................69 Install..........................................................................................................................................................70 Install(Alternative)......................................................................................................................................70 Install(AlternativeforFour-CylinderEnginesOnly)....................................................................................71 FuelSystemRepair............................................................................................................... ..............................71 Description......................................................................................................................................................71 FuelInjectionPump........................................................................................................................................72 Remove.......................................................................................................................................................72 Install..........................................................................................................................................................73 CheckandAdjust........................................................................................................................................73 FuelSystemAirRemoval................................................................................................................................74 FuelFilter,Replace.........................................................................................................................................75 CanisterType..............................................................................................................................................75 QuickReleaseCanisterType......................................................................................................................76 FuelInjectors...................................................................................................................................................77 Remove.......................................................................................................................................................77 Inspect........................................................................................................................................................77 Install..........................................................................................................................................................77 FuelPump.......................................................................................................................................................78 Remove.......................................................................................................................................................78 Disassemble...............................................................................................................................................78 Assemble....................................................................................................................................................79 Install..........................................................................................................................................................80 Test.............................................................................................................................................................80 CoolingSystemRepair........................................................................................................................................80 General...........................................................................................................................................................80 Thermostat......................................................................................................................................................80 Remove.......................................................................................................................................................80 Install..........................................................................................................................................................81 Test.............................................................................................................................................................81 CoolantPump.................................................................................................................................................81 Remove.......................................................................................................................................................81 Disassemble...............................................................................................................................................82 Assemble....................................................................................................................................................83 Install..........................................................................................................................................................86 FanandFanDrive...........................................................................................................................................86 Remove.......................................................................................................................................................86 Install..........................................................................................................................................................87 OilCooler(Six-CylinderEngines)................................................................................................. ..................87 Remove.......................................................................................................................................................87 DisassembleandAssemble........................................................................................................................87 Install..........................................................................................................................................................88 OilCoolerBypassValve.............................................................................................................................88 ElectricalEquipmentRepair................................................................................................................................88 iv

TABLEOFCONTENTS(Continued)

PerkinsDieselEnginesTableofContents

DriveBelts.......................................................................................................................................................88 Adjustment..................................................................................................................................................88 Remove.......................................................................................................................................................89 Install..........................................................................................................................................................89 Alternator.........................................................................................................................................................89 Remove.......................................................................................................................................................89 Install..........................................................................................................................................................89 StarterMotor...................................................................................................................................................90 Remove.......................................................................................................................................................90 Install..........................................................................................................................................................90 ColdStartAid................................................................................................................... ...............................90 AirCompressor-EnginesYGandYH................................................................................................... .............90 General...........................................................................................................................................................90 Repair..............................................................................................................................................................90 Remove.......................................................................................................................................................90 Install..........................................................................................................................................................91 RotaryExhausterReplacement..........................................................................................................................92 Remove...........................................................................................................................................................92 Clean...............................................................................................................................................................92 Install...............................................................................................................................................................92 EngineSpecifications........................................................................................................... ...............................93 CylinderHeadAssembly.................................................................................................................................93 PistonandConnectingRods........................................................................................................ ...................96 CrankshaftAssembly............................................................................................................. .........................99 CrankshaftOverhaul.................................................................................................................................100 TimingCaseandDriveAssembly.................................................................................................................102 EngineBlockAssembly............................................................................................................ .....................103 Turbocharger.................................................................................................................................................106 LubricationSystem........................................................................................................................................106 FuelSystem..................................................................................................................... .............................107 CoolingSystem.............................................................................................................................................109 FlywheelandHousing...................................................................................................................................109 ElectricalEquipment.....................................................................................................................................110 TorqueSpecifications........................................................................................................... .............................110 CylinderHeadAssembly...............................................................................................................................110 PistonandConnectingRodAssemblies.......................................................................................................110 CrankshaftAssembly............................................................................................................. .......................110 TimingCaseandDriveAssembly.................................................................................................................111 Turbocharger.................................................................................................................................................111 LubricationSystem........................................................................................................................................111 FuelSystem..................................................................................................................... .............................111 CoolingSystem.............................................................................................................................................111 Flywheel........................................................................................................................................................111 AuxiliaryEquipment......................................................................................................................................111 SpecialTorqueSpecifications............................................................................................................................112 FlywheelandHousing...................................................................................................................................112 Turbocharger.................................................................................................................................................112 ElectricalEquipment.....................................................................................................................................112 AuxiliaryEquipment......................................................................................................................................112 SpecialTools*....................................................................................................................................................113 Troubleshooting.................................................................................................................................................118 v

TABLEOFCONTENTS(Continued)

Thissectionisforthefollowingmodels:

GC/GLC070-120MG[B818]; GDP60-70CA(GP/GLP/GDP135-155CA)[A878]; GC/GLC/GDC135-155CA[A879]; GP135-280DA[A876]; GP070-120LJ/MJ[C813]; GC070-120LJ/MJ[C818,D818]; GDP80-120DB(GP170-280DB)[B876]; GDP130-160EB(GP300-360EB)[B877]

TableofContentsPerkinsDieselEngines

General

Thissectionhasthedescriptionandrepairinstructions forthreemodelsoftheSeries1000Perkinsdieselengine.Thethreedieselenginesdescribedinthissection:

1004-42(AR).....................Fourcylinder,normally aspirated

1006-60(YG).....................Sixcylinder,normally aspirated

1006-60T(YH)...................Sixcylinder,turbocharged

GENERALSAFETYRULES

WARNING

Somesealsusedinthisenginearemadeofsyntheticmaterialscalledfluoroelastomers(acommercialnameisViton).Thesefluoroelastomerscan decomposeattemperaturesgreaterthan316 C (600 F)orbyburningandcausehydrofluoricacid toformonthesurfaceofthesealornearbyequipment.

Donottouchgaskets,sealsorO-ringswhichappearcharredorblackandstickyafterexposureto temperaturesgreaterthan316 C(600 F)orburning.Contactwiththisacidcancausesevereburns oftheskinandeyes.Burnscanbedelayedseveral hoursaftercontact.

Dothefollowingprocedurestopreventexposureto hydrofluoricacid:

•WeardisposableneopreneorPVCglovesanddiscardtheglovesafteruse.

•Washtheareawith10%calciumhydroxidesolutiontoneutralizeanyacidandthencleanwithwater.

Ifburnedsealby-producttouchestheskinoreyes:

•Immediatelyflushwithwaterforaminimumof15 minutes.

•Apply2.5%calciumgluconategeltoaffectedarea ofskin.

•Getmedicalhelpimmediatelyforsuspectedhydrogenfluorideorhydrofluoricacidburn.

WARNING

Disconnectthebatterycablesbeforedoinganydisassemblyandrepairoftheengineorpartsofthe

electricalsystem.PutaDONOTOPERATEtagin theoperator’sareaandonthebatteryconnectors.

Long-termexposuretousedengineoilcancause skinirritationorcancer.Washwithdetergentand water.

Exhaustfrominternalcombustionenginescontainscarbonmonoxideandotherharmfulchemicals.Carbonmonoxideisacolorless,odorless poisonandcancauseunconsciousnessordeath withoutwarning.Longtermexposuretoexhaust orchemicalsintheexhaustcancausecancer, birthdefects,andotherreproductiveharm.Avoid exposuretoengineexhaust.

Donotusedieselenginesindoorswheresootcan accumulate.

Ifenginesareoperatedinconfinedspaces,maintainadequateventilationorventexhausttotheoutside.Donotexceedapplicableaircontaminantlimits.

Followtheinspectionandmaintenanceschedule andproceduresinthismanual.Donotalterexhaust,ignition,orfuelsystems.

CAUTION

Disposaloflubricantsandfluidsmustmeetlocal environmentalregulations.

Disposal ofbatteriesmustmeetlocalenvironmentalregulations.

Thediodesandresistorsintheelectricalsystem canbedamagedifthefollowingcautionsarenot followed:

•Donotdisconnectthebatterywhentheengine isrunning.Thevoltagesurgecandamagethe diodesandresistors.

•DonotdisconnectanelectricwirebeforetheengineisstoppedandtheswitchesareOFF.

•Donotcauseashortcircuitbyconnectionofthe electricwirestothewrongterminals.Makesure acorrectidentificationismadeofthewirebefore itisconnected.

•Makesureabatteryisthecorrectvoltageandpolaritybeforeitisconnected.

600YRM705 General

•Donotcheckforcurrentflowbymakingaspark becausetheelectroniccomponentscanbedamaged.

CAUTION

Whensetscrewsorstudsarefittedintoholeswhich aretappedthroughthecylinderblock,asuitable sealantmust beusedtopreventleakage.

Microencapsulatedanaerobicsealant(M.E.A.S.) fastenershavebeenintroducedinsteadofjointing compoundsor othersealantswhenthefasteners arefittedin throughholesintooilorcoolantpassages.Theidentificationofthesefasteners,as

supplied,isbyared,blue,orothercolorsealant aroundthefastenerthreads.

WithM.E.A.S.sealedstuds,thesealedendmust befittedintothecylinderhead/cylinderblock,etc. Ensurethatthethreadedholeshavea1.59mm (0.0625in.)45 chamfer,toensurethatwhenthe newfastenersarefitted,theM.E.A.S.sealantisnot removed.Ifthefastenershavetoberemovedand fittedagain,thethreadsmustbecleanedanda suitablesealantused.

Observetheprevious WARNINGS and CAUTION beforerepairinganyequipment.

Description

Thecylinderheadiscastironandhasoneinletvalve andoneexhaustvalveforeachcylinder.Thevalve seatsandthevalveguidesarereplaceable.Thefuel injectors areinthecylinderhead.Theoverheadvalve assembly isactuatedbyacamshaftinsideoftheengine block.Ageartrain,turnedbythecrankshaft,turnsthe camshaft,coolantpump,injectionpump,andapowertakeoff(PTO)isavailableforadditionalequipment.The hydraulicpumpforthesteeringfunctionoracompressorisnor mallyturnedbythePTO.Thefuelpumpis actuatedbythecamshaft.SeeFigure1andFigure2.

Thecrankshaftinthesix-cylindermodelshaveseven mainbearings.Thecrankshaftinthefour-cylindermodelshave fivemainbearings.Themainbearinginthe centerofthecrankshaftisthethrustbearingandhas thrust washersonbothsidesofthebearing.

Thecylinderblockiscastiron.Thesix-cylinderengineshavecylinderlinersthatcanbereplacedduring overhaul.Thecylindersforthefour-cylinderengineare boreddirectlyintothecylinderblock.

AFastram™combustionchamberinthetopofeach piston isadesigntogiveanefficientmixoffuelandair. Thepistonsforthefour-cylinderARengineshavetwo recessesinthetopfaceforthevalves.Eachpistonhas

threepistonrings(twocompressionrings,andanoil controlring).Thetopcompressionringhasaspecial insertfor thegroovetoreducewear.Axiallocationof thefullyfloatingpistonpinisbycirclips.Thepistonpinis off-centertoreducethenoiselevel.Ajetforcoolingoil tothebottomofthepistonisinstalled.Thefour-cylinder ARengineshaveonlyonecoolingjetinstalledinthe numberonecylinder.

Thecoolingfanandthealternatorareturnedbyadrive belt.The coolingfanisnotconnectedtothecoolant pump.The coolantpumpisturnedbythegearforthe fuelinjectionpumpinthetiminggearcase.

Thetimingandquantityoffuelsenttothefuelinjectors iscontrolledbyathrottleandgovernorinthefuelinjection pump.Thestatictimingissetbythepositionof thefuel injectionpumpwhenitisinstalled.Thethrottle linkagemustbecorrectlyadjustedtocontrolthequantityof fuelsenttotheinjectors.Amechanicalgovernor isused tocontroltheenginespeed.

ALucas DP200seriesfuelinjectionpumpisusedonall engines.Specialtoolsareneededtorepairaninjection pumpandtheyarenormallysenttoanauthorizedrepair stationifrepairsarenecessary.

Description 600YRM705

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SIDEOFENGINE) 10.CRANKSHAFTPULLEY

600YRM705 Description

4.COOLANTPUMP 5.OILSUMP

11.TIMINGCASE

1.FILLCAPFORENGINEOIL 2.FUELFILTER 3.FUELINJECTIONPUMP

6.OILFILTER(CANBE INSTALLEDONEITHER SIDEOFENGINE) 7.FANDRIVE 8.ALTERNATOR 9.DIPSTICK,ENGINEOIL(CAN BEINSTALLEDONEITHER

Figure1.Engine1004-42AR

NOTE: ENGINE1006-60YGISSIMILARBUTWITHOUTTURBOCHARGER.

1.FILLCAPFORENGINEOIL

2.FUELFILTER(2)

3.FUEL INJECTIONPUMP 4.COOLANTPUMP 5.AIRCOMPRESSOR

Figure2.Engine1006-60TYH

11.DIPSTICK,ENGINEOIL

OOLER

Description 600YRM705

10.TURBOCHARGER

6.VIBRATIONDAMPER 7.OILFILTER(2) 8.OILSUMP 9.ALTERNATOR

12.FANDRIVE 13.OILC

14.TIMINGCASE

ENGINESERIALNUMBERCODES

Theenginenumberisonalabelonthesideortherear oftheengineblock.SeeFigure3.

1.PARTNUMBERS FORFUEL INJECTIONPUMP

2.ENGINESERIAL NUMBER

3.EMISSIONSLABEL

Figure3.SerialNumberLocations

Atypicalserialnumberhasthefollowingcode:

AR30126U510256B 12345

where:

1=Typeofengine;

AR=1004-42,(-424literengine)

YG=1006-60,YH=1006-60T(-606literengine)

2=Partslistnumber

3=Countryofmanufacture(U=manufacturedinthe UnitedKingdom)

4=Serialnumber

5=Yearofmanufacturer.Theletterindicatestheyear ofmanufacture.ThelettersI,O,Q,R,andZarenot used.

Ifpartsorservicearerequiredforyourengine,thecompleteenginenumbermustbegiventoyourdealer.

ENGINEDATA

Thespecificationsandtolerancedetailsforenginerepairareinachartattheendofthissection.

1004-42(AR)ENGINE(LowGovernedSpeed)

PowerRatingat2100 rpm...................................60.0kW(80.5bhp)

Numberofcylinders..........4

Firingorder.......................1 3 4 2

Boreandstroke................ 103×127mm (4.055×5.000in.)

Displacement....................4.23liter(258in. 3 )

CompressionRatio...........18.5:1

Minimumoilpressure.......207kPa(30psi) (at2400rpmandnormaloperatingtemperature) Governorspeed(noload)

Seethe PeriodicMaintenance sectionforyour modeloflifttruck.

IdleSpeed........................725to775rpm

Thermostat

Begintoopen............... Fullyopen..................... 77to85 C(170to185 F) 92to98 C(198to208 F)

Valveclearance(cold) Inlet.............................. Exhaust........................ 0.20mm(0.008in.) 0.45mm(0.018in.)

1004-42(AR)ENGINE(HighGovernedSpeed)

PowerRatingat2400 rpm....................................61.5kW(82.4bhp)

Numberofcylinders...........4

Firingorder........................1 3 4 2

Boreandstroke................. 103×127mm (4.055×5.000in.)

Displacement.....................4.23liter(258in. 3 )

CompressionRatio............18.5:1

Minimumoilpressure........207kPa(30psi) (at2400rpmandnormaloperatingtemperature) Governorspeed(noload)

Seethe PeriodicMaintenance sectionforyourmodel oflifttruck.

IdleSpeed.........................725to775rpm

Thermostat

Begintoopen................ Fullyopen...................... 77to85 C(170to185 F) 92to98 C(198to208 F)

Valveclearance(cold)

Inlet............................... Exhaust......................... 0.20mm(0.008in.) 0.45mm(0.018in.)

600YRM705 Description

1006-60(YG)ENGINE

PowerRatingat2200 rpm...................................79kW(106bhp)

Numberofcylinders..........6

Firingorder.......................1 5 3 6 2 4

Boreandstroke................ 100×127mm (3.937×5.000in.)

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

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

Minimumoilpressure.......280kPa(40psi)

(at2200rpmandnormaloperatingtemperature)

Governorspeed(noload)

Seethe PeriodicMaintenance sectionforyourmodel oflifttruck.

IdleSpeed........................ 700to775rpm

Thermostat

Begintoopen............... Fullyopen.....................

77to85 C(170to185 F) 92to98 C(198to208 F)

Valveclearance(cold) Inlet.............................. Exhaust........................

0.20mm(0.008in.) 0.45mm(0.018in.)

1006-60T(YH)ENGINE

PowerRatingat2300 rpm...................................106kW(142bhp)

Numberofcylinders..........6

Firingorder.......................1 5 3 6 2 4

Boreandstroke................ 100×127mm (3.937×5.000in.)

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

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

Minimumoilpressure.......280kPa(40psi) (at2300rpmandnormaloperatingtemperature)

Governorspeed(noload)

Seethe PeriodicMaintenance sectionforyourmodel oflifttruck.

IdleSpeed........................ 700to775rpm

Thermostat

Begintoopen............... Fullyopen.....................

Valveclearance(cold)

77to85 C(170to185 F) 92to98 C(198to208 F)

0.20mm(0.008in.) 0.45mm(0.018in.)

Description 600YRM705

Inlet.............................. Exhaust........................

EngineRemovalandInstallation

Seethe Frame sectionfortheprocedureforremoving theengineandtransmission.Seethe Transmission sectionfortheproceduretoseparatethetransmission fromtheengine.

LIFTENGINE

Therecanbeavariationinthemaximumweightof theenginedependinguponthecomponentsthatare attachedtoit.Thefollowingminimumliftingcapacity isneededforanenginewithoutcoolant,lubricants,or transmission:

four-cylinderengines500kg(1102lb)

six-cylinderengines600kg(1322lb)

Alwaysusealiftingdevicethatprovidesaverticallift abovetheengineliftbracketsasshowninFigure4. Never useasinglebrackettoliftanengine.

Makesuretheenginebracketsarecorrectlyfastened totheengine.Makesurethatthevalvecoverandother componentsarenotdamagedbytheliftingdevice.Use aliftingdevicetoliftandmovetheheavycomponents oftheengine:cylinderblock,cylinderhead,flywheel housing,flywheel,andcrankshaft.

1.ENGINELIFTBRACKETS

Figure4.LiftinganEngine

CylinderHeadAssemblyRepair

VALVECOVER

Remove

1. Disconnectthebreatherpipe.

2. Removethecapnutsandthesealingwashersfrom thetopofthevalvecover.SeeFigure5.

3. Liftthevalvecover,gasket,andsealfromthecylinderhead.Thevalvecoversealfitsbetweenthe valvecoverandtheinductionmanifold.

4. Whenthevalvecoverisinstalled,thecapnuts aretightenedontothenutsoftherockerbrackets. Whenthecapnutsareremoved,thenutsforthe rockerbracketscanbeloosened.Checkthatthe nutsfortherockerbracketsaretighteachtimethat thevalvecoverisremoved.

1.CAPNUTANDRUBBERSEAL

Figure5.ValveCover

600YRM705CylinderHeadAssemblyRepair

1. Checktheconditionofthevalvecovergasketand thesealwashersusedunderthecapnuts.Make surethatthesurfacesareclean.

2. Installthevalvecover,gasket,andsealonthecylinderhead.SeeFigure6.Installthesealwashers underthecapnuts.Tightenthecapnutsto30N•m (22lbfft).Donottightenthecapnutssothatthey arefastenedtothenutsfortherockerbrackets.

1.SEAL,OILFILLER

3. Connectthebreatherpipe.

1. Removethevalvecover.

2. Loosenthenutsevenlythatfastenthebracketsfor therockerarmshaftstothecylinderhead.Loosen thebracketsateachendofthecylinderheadfirst andloosenthebracketsinsequencetowardthe center.Removethenutsandwasherswhenthe pressureisremovedfromtherockerarms.Liftthe rockerarmassemblyfromthecylinderhead.

3. Removetherubbersealfromtheoilsupplyconnectionortheholefortheoilsupplyinthecylinder head.SeeFigure7.

Install

1. Installanewrubbersealintheholefortheoilsupply inthecylinderhead.SeeFigure7.

2. Checkthatthepushrodsfitcorrectlyinthesocketsforthetappets.Installtherockerarmassembly. Makesurethattheoilsupplyconnectionfitscorrectlyintotherubberseal.

3. Makesurethatthealignmentoftherockerarms andthepushrodsarecorrect.Installthenutsand washersonthestudsthatholdthebracketsforthe rockerarmshaftstothecylinderhead.Tightenthe nutsevenly.Begintighteningthenutsatthecenter oftherockerarmshaftandtighteninsequencetowardtheendsoftheshaft.Thefinaltorqueonthe nuts:

aluminumbrackets=40N•m(30lbfft) ironbrackets=75N•m(55lbfft).

4. Checkandadjustvalvetipclearances.SeeValve ClearanceAdjustments.

Disassemble

1. Removetheclipsfrombothendsoftherockerarm shaft.Makesurethattheendsoftherockerarm shaftarenotdamaged.Loosenthelocationscrew fortheoilsupplyconnection.

2. Makeanoteofthepositionofeachcomponenton therockerarmshaftsothattheycanbeassembled correctly.Removethecomponentsfromtherocker armshaft.

CylinderHeadAssemblyRepair600YRM705

Install

CAP 2.CAPNUT 3.RUBBERSEAL 4.GASKET 5.VALVECOVER

ROCKERARMASSEMBLY Remove

Figure6.ValveCover Figure7.RubberSealLocation

Inspect

1. Cleanandinspectallthecomponentsforwearand damage.Checktheclearanceoftherockerarms ontherockerarmshaft.Iftheclearanceisgreater than0.13mm(0.005in.),installanewbushingin therockerarmorinstallanewrockerarmshaftifit isworn.

2. Ifthebushingintherockerarmisworn,useapress toremovethebushing.

3. Useapresstoinstallanewbushingintherocker arm.Makesurethatthelubricationholeinthe bushingisalignedwiththeholeintherockerarm.

4. Useareamerinthebushingasnecessarytogive aclearanceontherockerarmshaftof0.03to 0.09mm(0.001to0.004in.).

Assemble

1. Makesurethatthelubricationholesintherocker armsandtherockerarmshaftareopenandclean.

2. Lubricatethecomponentswithcleanengineoilas theyareassembledontherockerarmshaft.Make surethecomponentsareassembledinthecorrect order.SeeFigure8.Makesurethatthelocation screwfortheoilsupplyconnectionisfittedcorrectly intherockerarmshaft.Installtheclipsattheends oftherockerarmshaft.

Thevalveclearanceismeasuredbetweenthetopofthe valvestemandtherockerarmasshowninFigure9.

Valveclearance(cold)

Numberonecylinderisattheendoftheenginewiththe fan.Theinletvalveisthefirstvalveinthesequence. SeeFigure10.

600YRM705CylinderHeadAssemblyRepair

Figure8.RockerArmAssembly VALVECLEARANCEADJUSTMENTS

Inlet Exhaust 0.20mm(0.008in.) 0.45mm(0.018in.)

Figure9.ValveClearanceAdjustment

Figure10.ValvePositions

Four-CylinderEngines

1. Turnthecrankshaftinthenormaldirectionofrotationuntiltheinletvalveofnumberfourcylinder hasjustopenedandtheexhaustvalveofthesame cylinderhasnotfullyclosed.Checktheclearance ofthevalvesofnumber one cylinder andadjust themasnecessary.

2. Turnthecrankshaftinthenormaldirectionofrotationuntiltheinletvalveofnumbertwocylinder hasjustopenedandtheexhaustvalveofthesame cylinderhasnotfullyclosed.Checkthevalveclearancesonnumber three cylinder andadjustthemas necessary.

3. Turnthecrankshaftinthenormaldirectionofrotationuntiltheinletvalveofnumberonecylinder hasjustopenedandtheexhaustvalveofthesame cylinderhasnotfullyclosed.Checkthevalveclearancesonnumber four cylinder andadjustthemas necessary.

4. Turnthecrankshaftinthenormaldirectionofrotationuntiltheinletvalveofnumberthreecylinder hasjustopenedandtheexhaustvalveofthesame cylinderhasnotfullyclosed.Checkthevalveclearancesonnumber two cylinder andadjustthemas necessary.

Six-CylinderEngines

1. Turnthecrankshaftinthenormaldirectionofrotationuntiltheinletvalveofnumbersixcylinder hasjustopenedandtheexhaustvalveofthesame cylinderhasnotfullyclosed.Checktheclearance ofthevalvesofnumber one cylinder andadjust themasnecessary.

3. Turnthecrankshaftinthenormaldirectionofrotationuntiltheinletvalveofnumberfourcylinder hasjustopenedandtheexhaustvalveofthesame cylinderhasnotfullyclosed.Checkthevalveclearancesonnumber three cylinder andadjustthemas necessary.

4. Turnthecrankshaftinthenormaldirectionofrotationuntiltheinletvalveofnumberonecylinder hasjustopenedandtheexhaustvalveofthesame cylinderhasnotfullyclosed.Checkthevalveclearancesonnumber six cylinder andadjustthemas necessary.

5. Turnthecrankshaftinthenormaldirectionofrotationuntiltheinletvalveofnumberfivecylinder hasjustopenedandtheexhaustvalveofthesame cylinderhasnotfullyclosed.Checkthevalveclearancesonnumber two cylinder andadjustthemas necessary.

6. Turnthecrankshaftinthenormaldirectionofrotationuntiltheinletvalveofnumberthreecylinder hasjustopenedandtheexhaustvalveofthesame cylinderhasnotfullyclosed.Checkthevalveclearancesonnumber four cylinder andadjustthemas necessary.

VALVESPRINGS

NOTE: Thisprocedureisnormallyforchangingthe valvespringsofasinglecylinderwhilethecylinder headisstillinstalledontheengine.Ifthevalvesand springsmustberemovedfromthecylinderheadfor repairs,seetheproceduresunderValvesandValve Springslaterinthissection.

SpecialTools:Valvespringcompressor Studadapter Setscrewadapter

1. Removethevalvecover.

2. Turnthecrankshaftinthenormaldirectionofrotationuntilthepistonforthecylinderisattopdead center(TDC).Theinletvalvewilljustopenandthe exhaustvalvewillnotbefullyclosedwhenthecylinderisatTDC.

3. Removetherockerarmassembly.

4. Installthespringcompressorandtheadapter.See Figure11.

CylinderHeadAssemblyRepair600YRM705

1.VALVESPRING COMPRESSOR 2.STUDADAPTER

3.SETSCREW ADAPTER

5. Compressthevalvespringsandremovetheretainers.Makesurethevalvespringsarecompressed paralleltothevalvestemsorthevalvestemscan bedamaged.

6. Releasethevalvespringcompressorandremove theretainercapandvalvesprings.

NOTE: Donotturnthecrankshaftwhilethevalve springsareremoved.

NOTE: Theouterdiameteroftheexhaustvalveguide is1mmlargerthantheinletvalveguide.Toprevent leakagepasttheinletvalvestemitisimportantthatthe largerexhaustvalvesealisnotfittedintotheinletguide. Thesealsarecolorcoded.

7. Installnewvalvestemsealsonthevalveguides. Makesurethatthebrownsealisinstalledonthe exhaustvalveandthegreensealontheinletvalves.

8. Installthenewvalvesprings.Makesuretheclosed dampercoilsofthevalvespringsaretowardthe cylinderhead.

9. Installtheretainercap.

10. Usethevalvespringcompressortocompressthe valvespringsandinstalltheretainers.Removethe valvespringcompressor.

11. Installtherockerarmassembly.

12. Checkthevalveclearances.SeeValveClearance Adjustments.

13. Installthevalvecover.

NOTE: Valvespringscanbechangedintwocylinders atatime.

ENGINEAR.WhenthepistonincylinderoneisatTDC, thepistonincylinderfourisalsoatTDC.WhenthepistonincylindertwoisatTDC,thepistonincylinderthree isalsoatTDC.

ENGINESYGandYH.Whenthepistonincylinderone isatTDC,thepistonincylindersixisalsoatTDC.When thepistonincylindertwoisatTDC,thepistonincylinder fiveisalsoatTDC.Whenthepistonincylinderthreeis atTDC,thepistonincylinderfourisalsoatTDC.

IftherockerarmassemblywasremovedbeforeTDC wasfound,installthevalvespringcompressorandcompressthevalvespringstoopenthevalve.Turnthe crankshaftbyhandinthenormaldirectionuntilthepistontouchesthevalve.Continuetoturnthecrankshaft, andatthesametime,releasethepressureonthevalve springcompressoruntilthepistonisatTDC.SeeFigure12. Figure12.FindTDCWithValveSpringCompressor

600YRM705CylinderHeadAssemblyRepair

Figure11.ValveSpringCompressor

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CYLINDERHEADASSEMBLY

Remove

1. Iftheengineisstillinthelifttruck,dothefollowing procedures:

a. Disconnectthebatteryterminals.

b. Drainthecoolingsystem.

c. Disconnectthesenderunitforthecoolanttemperaturegauge.

2. ENGINESARandYG.Removethehosefromthe airfilterattheinductionmanifold.ENGINEYH. Removeairfilterconnectionatthecompressorinlet oftheturbocharger.

3. Removethefuellinebetweenthecoldstartaidin theinductionmanifoldandthefuelfilter.Disconnecttheelectricalconnection.

4. ENGINEYH.Removetheboostcontrollinebetweenthefrontoftheinductionmanifoldandthe fuelinjectionpump.

5. Removetheinductionmanifold.SeeFigure13.For inductionmanifoldsfittedtoenginetypesAR:The tophalfoftheinductionmanifoldissealedtothe bottomhalfwithaliquidjointandfastenedtogether bysixcapscrews.

Thetophalfofthemanifoldmustberemovedto obtainaccesstofourofthemanifoldcapscrews, fittedinsidethemanifold.Thesecapscrewsretain thebottomhalfofthemanifoldtothecylinderhead.

6. ENGINEYH.Disconnectallconnectionstotheturbochargerandremovetheturbocharger.SeeTurbocharger-EngineYHRepair,Remove.

7. Removetheexhaustmanifold.Loosenthemanifold fastenersinthereverseordershowninFigure14.

8. Removethelowpressurefuellinesbetweenthe fuelinjectionpumpandthefuelfilter.Removethe fuelfilterbracketandthefuelfilters.

9. Removethehighpressurefuellines.Useaseparatewrenchtopreventmovementoftheoutletsof thefuelinjectionpumpwhenthefuellinesaredisconnected.Putplugsintheopenportsofthefuel injectionpump.

1.TOPHALF-INDUCTIONMANIFOLD

2.BOTTOMHALF-INDUCTIONMANIFOLD 3.CAPSCREWS

Figure14.ExhaustManifoldTighteningSequence

CylinderHeadAssemblyRepair600YRM705

Figure13.InductionManifold

10. Removethereturnfuellinefromthefuelinjectors.

11. Removethefuelinjectorsfromthecylinderhead. Keepthefuelinjectorscleanandpreventdamage tothenozzles.

12. ENGINESYGandYH.Ifanaircompressorisinstalled,removethecoolantpipebetweenthecylinderheadandthecompressor.Removethecoolant pipebetweenthebypassconnectionandthecompressor.

13. Loosenthehoseclampandremovethecoolantbypasshosefromthecylinderhead.Removethecapscrewsandremovethecoolantbypassconnection andthehose.

14. Disconnectthecoolanttemperaturesender.

15. ENGINEAR.Removetheoilcoolerifitisintegral withthecylinderblock.

16. Removethevalvecover.SeeValveCover,Remove.

17. Removetherockerarmassembly.SeeRockerArm Assembly,Remove.

18. Removethepushrods.

19. Loosenthecapscrewsforthecylinderheadevenly inareversesequencefromthesequenceshownin Figure15orFigure16.

20. Liftthecylinderheadfromtheengineblock.Donot useaprybarbetweenthecylinderheadandthe engineblockthatcancausedamagetothegasket surfaces.SeeFigure17.

21. Inspectthecapscrewsforthecylinderheadwitha straightedge.SeeFigure18.Checkthatthecapscrewsarestraightanddonothavedistortion.If thereisareductioninthediameterofthethread thathasnotbeeninengagementwiththecylinder block,thecapscrewmustbediscarded.

Four-CylinderEngines

600YRM705CylinderHeadAssemblyRepair

Figure15.CylinderHeadTighteningSequence,

Figure16.CylinderHeadTighteningSequence,Six-CylinderEngines

1.STRAIGHTEDGE

2.CAPSCREWMUSTBESTRAIGHTAND WITHOUTDISTORTION

3.THREADSMUSTBEINGOODCONDITIONAND NOTHAVEAREDUCEDDIAMETER

SpecialTools:Anglegaugetotightenthe capscrewsforthecylinderhead

1. Makesurethesurfacesofthecylinderheadandthe top oftheengineblockareclean.Makesurethat thereisnodirtorobjectsinthecylinders.

2. Installthegasketforthecylinderheadasshownin Figure19.Makesurethe"TOPFRONT"isinthe correctposition.Donotuseanygasketsealanton anyofthesurfaces.

Figure19.HeadGasketPosition

3. Usetwo1/2UNFstudsinpositions16and21on four-cycleenginesandpositions25and30onsixcycleengines.SeeFigure20andFigure21tohold thegasketinposition.Lowerthecylinderheadinto positionontheengineblock.SeeFigure22.

Figure20.CylinderHeadTighteningSequence,Six-CylinderEngines

CylinderHeadAssemblyRepair600YRM705

Figure17.CylinderHeadRemoval Figure18.CapscrewsInspection

Install

Figure21.CylinderHeadTighteningSequence, Four-CylinderEngines

mustbefurthertightenedinthesequenceshown inFigure20orFigure21accordingtothefollowing procedure:

Six-CylinderEngines

a. Theshortcapscrews(S)mustbetightened anadditional150 (2.5flats).

b. Themediumcapscrews(M)mustbetightenedanadditional180 (3.0flats).

c. Thelongcapscrews(L)mustbetightened anadditional210 (3.5flats).

Four-CylinderEngines

a. Theshortcapscrews(S)mustbetightened anadditional120 (2flats).

b. Themediumcapscrews(M)mustbetightenedanadditional120 (2flats).

c. Thelongcapscrews(L)mustbetightened anadditional150 (2.5flats).

d. Thefour1/2UNFcapscrewsinposition2,8, 13,and18mustbetightenedanadditional 180 (3flats).

NOTE: AspecialtoolshowninFigure23canbeused forthisproceduretomeasurethetighteningangles.If ananglegaugeisnotavailable,makeamarkinaline withoneofthecornersofthecapscrew.SeeFigure24 andFigure25.Makeanothermarkatthecorrectangle(counterclockwise)ontheedgeoftheflangeofthe cylinderheadforeachcapscrewandaccordingtothe lengthofeachcapscrew.Tighteneachcapscrewinthe correctsequenceuntilthetwomarksarealigned.

CAUTION

Therearethreelengthsofcapscrews.S=short,M =medium,L=long.Figure20andFigure21show theirpositionsintheengine.Makesurethatthe capscrewsareinstalledinthecorrectpositions.

4. Lubricatethecapscrewswithathincoatofoiland installthemintotheirholesinthecylinderhead. Whenthecylinderheadandgasketareheldinposition,removethetwostudsandinstallthetwocapscrewsinthosepositions.Thefour1/2UNFcapscrewsonthefour-cylinder(AR)enginesareinpositions2,8,13,and18.SeeFigure21.

5. Evenlytightenthecapscrewsinthesequence showninFigure20orFigure21.Thefinaltorque onthecapscrewsis110N•m(81lbfft)forthe six-cylinderenginesand45N•m(33lbfft)forthe four-cylinderengines.

6. Makesureallofthecapscrewsaretightenedtothe correcttorquedescribedinStep5.Thecapscrews

7. Installthepushrodsintheengine.Makesurethat theendofeachpushrodfitscorrectlyinthetappet socket.

8. InstalltherockerarmassemblyperRockerArmAssembly,Install.

9. AdjustthevalveclearancesperValveClearance Adjustments.

10. InstallthefuelinjectorsperFuelInjectors,Install.

11. Installthehighpressurefuellinesbetweenthefuel injectionpumpandthefuelinjectors.Useaseparatewrenchtopreventmovementoftheoutlets ofthefuelinjectionpumpwhenthefuellinesare connected.Tightentheconnectionnutsto22N•m (16lbfft).

600YRM705CylinderHeadAssemblyRepair

Figure22.CylinderHeadInstallation

EngineAR

Figure25.TightenCylinderHeadCapscrews, EngineYGandYH

12. Installthefuelfilterandbracket.Installthelowpressurefuellinesbetweenthefuelfilterandthe fuelinjectionpump.

13. Installthecoolantbypassconnection.Tightenthe capscrewsandthehoseclamp.

14. ENGINESYGandYH.Ifanaircompressorisinstalledontheengine,installthecoolantpipebetweenthecylinderheadandthecompressor.Installthepipebetweenthecoolantbypassandthe compressor.

15. Preparetoinstalltheinductionandexhaustmanifolds.Donotusesealantonthejointsofthemanifolds.

16. ENGINEAR.Installtheoilcoolerifitisintegralwith thecylinderblock.

17. ENGINEAR.Thefrontandreargasketshavetabs. Makesurethatthegasketsareinstalledwiththe tabsinstalledtowardtheoilsump.SeeFigure26.

1.GASKET

2.GASKET

3.LOCATIONTABS

Figure26.InductionandExhaustManifold Gaskets,EngineAR

NOTE: Somegasketsarenowmadeasasinglepiece.

18. ENGINESYGandYH.Thetwoendgasketsare thesame.Thecentergaskethastabs.Makesure thatthegasketsareinstalledwiththetabsinstalled towardtheoilsump.SeeFigure27.

CylinderHeadAssemblyRepair600YRM705

Figure23.AngleGauge Figure24.TightenCylinderHeadCapscrews,

1.GASKET

2.GASKET

3.LOCATIONTABS

Figure27.ManifoldGasketInstallation,Engines YGandYH

NOTE: Somereplacementexhaustmanifoldshave largeclearanceholesforthefasteners.Twoalignment bushingsaresuppliedwithareplacementmanifold (Figure28).Thesebushingsmustbeinstalledforthe replacementmanifold.Newalignmentbushingsare notnecessarywhentheoriginalmanifoldisinstalled.

19. Installtheexhaustmanifold.Tightenthecapscrews 44N•m(32lbfft)inthesequenceshowninFigure28.

21. ForinductionmanifoldsonenginesAR(seeFigure29),thetophalfoftheinductionmanifoldis sealedtothebottomhalfwithagasketandfastened togetherbysixcapscrews.

A. FANEND

1.BUSHING(SEENOTE)

Figure28.InductionManifoldInstallation,Engines YGandYH

20. Installtheinductionmanifold.Tightenthecapscrewsevenlyandgraduallyto44N•m(32lbfft).

1.TOPHALFOFMANIFOLD

2.BOTTOMHALFOFMANIFOLD

3.CAPSCREWS(INSIDEOFMANIFOLD)

4.CAPSCREWS(OUTSIDEOFMANIFOLD)

5.GASKET

Figure29.InductionManifoldInstallation,Engine AR

22. Thetophalfofthemanifoldmustberemovedto obtainaccesstofourofthemanifoldcapscrewsinsidethemanifold.Thesecapscrewsandthefour capscrewsontheoutsideofthemanifoldretainthe bottomhalfofthemanifoldcylindertothecylinder head.

CAUTION

Beforetheinletmanifoldcapscrewsareinstalled again,anylooseM.E.A.S.inthecylinderheadholes mustberemovedtoallowthemanifoldtobefully tightened.

Donotscratchordamagetheflangefacesofthe inletmanifold.

NOTE: Thecapscrewswhichretainthemanifoldtothe cylinderheadhaveM.E.A.S.appliedtothethreads.If thecapscrewsareremovedandinstalledagain,the threadsmustbecleanedandPOWERPARTthreadlock sealantused.

23. ENGINEYH.InstalltheturbochargerperTurbocharger-EngineYHRepair,Install.

24. Installthefuellinebetweenthefuelpumpandthe fuelfilter.

600YRM705CylinderHeadAssemblyRepair

25. Installthefuellinebetweenthefuelfilterandthe coldstartaid.Iftheengineisinthelifttruck,install theelectricalconnectiontothecoldstartaid.

26. ENGINEYH.Installtheboostcontrollinebetween theinductionmanifoldandthetopofthefuelinjectionpump.

27. Iftheengineisstillinthelifttruck,dothefollowing procedures:

a. Connectthesenderunitforthecoolanttemperaturegauge.

b. ENGINEYH.Installairfilterconnectionatthe compressorinletoftheturbocharger.ENGINESARandYG.Installthehosefromthe airfilterattheinductionmanifold.

c. Connectthehosesforthecoolantsystem.Fill thecoolingsystem.

d. Connectthebatteryterminals.

e. Iftheengineisreadytooperate,removethe airfromthefuelsystem.Seetheprocedure describedinFuelSystemAirRemoval.

28. Whentheenginecanbestarted,runitatlowspeed. Checkthatoilflowsfromtheholesintherocker arms.Iftheoilflowiscorrect,installthevalvecover. SeeValveCover,Install.

NOTE: Itisnotnecessarytotightenthecylinderhead capscrewsagainwiththeenginehotorafteralimited periodofservice.

VALVESANDVALVESPRINGS

SpecialTools:Valvespringcompressor Studadapter Setscrewadapter

Remove

1. Removethecylinderhead.SeeCylinderHeadAssembly,Remove.

2 Cleanthebottomfaceofthecylinderheadand checkthedepthoftheheadsofthevalvesbelow thefaceofthecylinderhead.SeeFigure30.

3. Checkthedepthofthevalvesbelowthefaceofthe cylinderheadbeforethevalvespringsareremoved.

Putthedialindicatorandfixtureorothermeasuringtoolonthefaceofthecylinderheadandsetthe gaugetozero.Carefullyputthedialindicatorover theheadofeachvalveandmakeanoteofthemeasurement.Themaximumservicedepthisshown intheEngineSpecifications.Ifavalveisbelowthe depthlimit,removethevalveandinstallanewvalve inthatposition.Ifthevalvedepthisstillbelowthe limit,thevalveseatmustbereplaced.SeeNew ValveSeats,Install.

4. Ifthevalveswillbeusedagain,makeamarkon eachvalveheadsothattheycanbeinstalledagain inthesamepositions.

5. Usethevalvespringcompressorandthecorrect adaptertocompressthevalvespringsandremove theretainers.Makesurethevalvespringsarecompressedparalleltothevalvestemsorthevalve stemscanbedamaged.SeeFigure31.

6. Releasethevalvestemcompressor.Removethe valvespringcap,valvesprings,seal,andseat washer.

7. RepeatStep5andStep6toremovetheother valves.

Inspect

1. Checkthevalvesforcracks.Checkthestemsofthe valvesforwearandthecorrectclearanceintheir valveguides.SeeValveGuides.

CylinderHeadAssemblyRepair600YRM705

Figure30.ValvesDepthCheck

1.CAP 2.COLLET(2) 3.SPRING

4.VALVESTEMSEAL 5.VALVE

CAUTION

Theouterdiameteroftheexhaustvalveguideis1 mmlargerthanthevalveguide.Topreventleakagepasttheinletvalvestemitisimportantthatthe largervalvesealisnotinstalledintotheinletguide. Thesealsarecolorcoded.

2. Installtheseatwasher.Installnewsealsonthe valveguides.Makesurethatthebrownsealisinstalledontheexhaustvalvesandthegreensealis installedontheinletvalves.

3. Installtheinnerandoutervalvespringsontheseat washer.Makesurethatthedampercoilsofthe valvespringsaretowardthecylinderhead.

4. Usethevalvespringcompressorandthecorrect adaptertocompressthevalvesprings.Installthe retainers.Makesurethevalvespringsarecompressedparalleltothevalvestemsorthevalve stemscanbedamaged.

5. Repeattheinstallationprocedureforeachvalve.

VALVEGUIDES

Inspect

2. Checkthattheseatfacesofthevalvesarenotbadly burned.Seatfacesofvalvesthataredamaged,but canberepaired,mustbecheckedforvalvedepth whentheyareinstalled.SeeFigure30.When newvalvesareinstalled,thevalvedepthmustbe checked.

3. Checkthattheloadonthevalvespringsiscorrect attheirinstalledlength.SeeEngineSpecifications.

4. Installnewvalvespringsduringacompleteoverhauloftheengine.

Install

1. Lubricatethevalvestemswithengineoilwhenthey areinstalledintheirvalveguides.

1. Checkthevalveguidesforwear.Themaximum clearancebetweenthevalvestemandtheboreof theguideis0.100mm(0.0039in.)forinletvalves and0.121mm(0.0048in.)forexhaustvalves.If theclearanceisgreaterthanthelimitwhenanew valveisinstalled,thevalveguidemustbereplaced.

2. Thefollowingprocedureisforcheckingthevalve guides(seeFigure32):

a. Putanewvalveintothevalveguide.

b. Installadialindicatoronthecylinderhead.

c. Lifttheheadofthevalveapproximately15mm (0.6in.)aboveitsseat.Movethevalvehead awayfromtheplungerofthedialindicatorand setthedialindicatortozero.

d. Movethevalvetowardthedialindicatorand makeanoteofthemovement.Ifthereading isequaltoorgreaterthanthemaximumclearance,anewvalveguidemustbeinstalled.

600YRM705CylinderHeadAssemblyRepair

Figure31.ValveComponents

1.MAGNETICBASE

2.DIALINDICATOR

3.VALVEHEAD

Figure32.ValveGuidesCheck

NOTE: Thepartiallyfinishedvalveguidesarereamed andthevalveseatsarecutinoneoperationwithaspecialtool.Thisisdonetoensuretheconcentricityofthe valveseattothevalveguideandprovideagoodseal betweentheguideanditsseat.Newvalvesandvalve seatinsertsmustbeinstalledeachtimeanewvalve guideisused.

Remove

Installthetoolforremovalandreplacementandthe adapteronthevalveguide.Pullthevalveguidefrom thecylinderhead.SeeFigure33.

Install

1. Makesuretheboreinthecylinderheadisclean.

2. Lubricatetheoutersurfaceofthenewvalveguide withengineoil.

3. Installthevalveguideonthespecialtool.SeeFigure34.Usethespecialtooltopullthevalveguide intothecylinderhead.Whenthevalveguideiscorrectlyinstalled,thevalveguidewillextend14.85to 15.15mm(0.585to0.596in.)abovetheseatofthe valvespring.

CYLINDERHEADANDVALVESEATS

Inspect

Thevalvesmustberemovedfromthecylinderhead beforethevalveseatscanbeinspectedandrepaired. Carefullycleanthecylinderhead.

1. Checkthecylinderheadforcracks.Carefullycheck theareasaroundthevalveseatsandaroundthe holesforthefuelinjectors.

2. Useastraightedgeandspacergaugestocheckthe cylinderheadfordistortionacrossandalongitsface thatjoinstheengineblock.SeetheEngineSpecifications.Ifthedistortionismorethanthespecifications,thefacecanbemachined.Removeonlythe minimummetalsothatthethicknessofthecylinder headwillnotbelessthan102.48mm(4.035in.)afterthecylinderheadhasbeenmachined.

NOTE: Afterthecylinderheadhasbeenmachined,the valveseatsmustbecheckedforthecorrectdepth.See ValvesandValveSprings,Inspect.Ifthedepthofthe valveseatsmustbeincreased,usetheminimumlimit toallowforlaterwear.

3. Checkthevalveseatsforwearanddamage.Before anyworkisdoneonthevalveseats,makesurethe valveguidesaregood.SeeValveGuides,Inspect forinspectionandreplacement.

4. Damagedvalveseatscanberepairedwithacuttertool.SeeFigure35.Ifthevalveseatcannotbe repairedsothatthevalvedepthiswithinthespecifications,thevalveseatmustbereplaced.

Repair

SpecialTools:Cutterforinletvalveseats Cutterforexhaustvalveseats Valveguidesreamer

1. Installthecorrectcutterintothevalveseatthatisto berepaired.Carefullyturnthecutterinaclockwise direction.Removeonlytheminimummetaltorepair thevalveseat.Keepthevalveseatasnarrowas possible.

2. Whenthevalveseathasbeencut,removethecutterandpilot.Cleantheportareaandremoveany particles.

3. Checkthevalvedepth.SeeValvesandValve Springs,Inspect.Ifthevalveseatisbadlydamagedorworn,replacethevalveseatasdescribed inthefollowingparagraphs.

NewValveSeats,Install

1. Removethevalveguide.Cleantheboreandinstall anewvalveguide.SeeValveGuidesforinspection andreplacement.

CylinderHeadAssemblyRepair600YRM705

4.VALVEGUIDE 5.MAXIMUM CLEARANCE

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COMPLETE MANUAL

2. Usetheboreofthenewvalveguideasapilotand useamillingmachinetoremovetheoldvalveseat. SeetheEngineSpecifications.Cleantheparticles fromtheportandtheareawherethenewvalveseat willbeinstalled.

3. Ifthebottomfaceofthecylinderheadhasbeen machined,thebackfaceofthenewvalveseatmust bemachinedsothatitwillnotextendabovethe surfaceofthecylinderhead.Ifthebackfaceofthe valveseatismachined,makesurethattheouter edgeofthebackfacedimensionsarewithinthe EngineSpecifications.

4. Usetheboreofthevalveguideasapilot.Usea presstoinstallthevalveseatintothecylinderhead. Makesurethevalveseatisfullyinsertedintothe cylinderhead.

5. Useacuttertocutthevalveseatatthecorrectangle.CheckthevalvedepthasshowninFigure30. MakesurethatthedimensionsarewithintheEngineSpecifications.

1.14.85to15.15mm(0.585to0.596in.)ABOVE SEATOFVALVESPRING

Figure34.ValveGuideInstallation

Figure35.ValveSeatsCutter

600YRM705CylinderHeadAssemblyRepair

Figure33.ValveGuideRemoval

PistonandConnectingRodAssembliesRepair

Theconnectingrodsareforgedfromsteel.Thepiston heightiscontrolledbythelengthoftheconnectingrod. Eachpistonandconnectingrodismatchedtoacylinderduringassemblytomakesurethepistonheightis correctforcombustionefficiencytomeetemissionstandards.

Themanufacturerusessixlengthgradesofconnecting rodsduringassemblytogivethecorrectpistonheight. Thesesixheightgradesaremadebymachiningthe small-endbushingasmallamountoff-center.Connectingrodsforservicereplacementareavailableintwo heightgrades.

Thecombustionchamberismachinedintothetopof thepiston.SeeFigure36andFigure37.Thepistons havetwocompressionringsandanoilcontrolring.The grooveforthetopcompressionringhasahardmetal inserttoreducewearinthegroove.Thepistonskirt hasalayerofgraphitetoreducewear.

Someengineshavetwosteeldowelsthatareinstalled intothebearingcaptokeepthealignmentwiththeconnectingrod.Twocapscrewsfastenthebearingcapto theconnectingrod.SeeFigure38.

Someengineshavegrooves(serrations)thataremachinedinthejointfacesoftheconnectingrodandbearingcaptokeepalignmentbetweenthetwoparts.The bearingcapisfastenedtotheconnectingrodwithtwo nutsandspecialbolts.SeeFigure39.

1.LOCATIONDOWELS

Figure38.ConnectingRodAssemblywith LocationDowels

1.SERRATIONS

Figure39.ConnectingRodAssemblywith Serrations

PistonandConnectingRodAssembliesRepair600YRM705

Figure36.Piston,EngineAR RODBEARINGS Figure37.Piston,EnginesYGandYH

Remove

1. Draintheengineoilfromthesump.Removetheoil sump.SeeOilSump,Remove.

2. Removethesuctionpipeandoilstrainer.See Figure40.Removethecapscrewthatholdsthe brackettothemainbearingcap.Removethetwo capscrewsfromtheflangeofthesuctionpipeand removethesuctionpipeandscreen.Cleanthe facesofbothflanges.

5. Removethelowerbearinghalffromthebearing cap.Keepthebearinghalfwithitscap.

6. Carefullypushtheconnectingrodupthecylinder borejustenoughtopermitaccesstotheupper bearinghalf.Removetheupperbearinghalffrom theconnectingrod.Keepthebearinghalvestogether.

Install

1. Cleanthebearingsurfacesoftheconnectingrod andthecrankshaft.Makesurethattheprotrusion forthelocationdowelsis3.0to4.5mm(0.12to 0.18in.)abovethecapfaces.Cleanthebearing halvesandlubricatethemwithcleanengineoil.

2. Installtheupperbearinghalfintotheconnecting rod.Makesurethatthelocationtabisinstalled correctlyintoitspositionintheconnectingrod.See Figure41.

1.SUPPORTBRACKET,MAINBEARINGCAP

2.CAPSCREWS,FLANGE,SUCTIONPIPE

Figure40.SumpScreenRemoval

3. Turnthecrankshaftuntiltheconnectingrodtobe removedisatthelowestpositiononthecrankshaft.

CAUTION

Donotpermittheconnectingrodstohitthecooling jetsforthepistons.Ifacoolingjetishit,thealignmentmustbecheckedandthecoolingjetreplaced ifnecessary.

4. Connectingrodswithcapscrews.Loosenthecapscrewsforthebearingcapapproximatelyfourturns. Lightlyhittheheadsofthecapscrewswithasoft hammertoseparatetheconnectingrodfromthe bearingcap.Removethecapscrewsandthebearingcap.

Connectingrodswithnuts.Removethenutsand removethebearingcap.

1.POSITIONOFLOCATIONTABINBEARING HALFANDCONNECTINGROD

Figure41.RodBearingsPosition

3. Installthebearingcapontheconnectingrod.Make surethattheassemblynumberonthebearingcap isthesameasthenumberontheconnectingrod. Makesurethatthetwoassemblynumbersareon thesamesideoftheconnectingrodasshownin Figure42.

600YRM705PistonandConnectingRodAssembliesRepair

4. Connectingrodswithnuts.Installandtightenthe nutsevenlytoatorqueof125N•m(92lbfft).Make surethatthecrankshaftturnsfreely.

Connectingrodswithcapscrews.Installandtighten thecapscrewsevenlytoatorqueof155N•m (114lbfft).Makesurethatthecrankshaftturns freely.

5. Looselyassemblethebracketofthesuctionpipe tothemainbearingcap.Installanewgasketand fastentheflangesofthesuctionlinetotheoil pump.Makesurethatthesuctionpipeisaligned correctlyandthentightenthecapscrewthatholds thebrackettothemainbearingcap.

6. Installtheoilsump.SeeOilSump,Install.

PISTONANDCONNECTINGROD ASSEMBLY

ServiceNote

Ifapistonmustbereplaced,makesurethatthepiston hasthesameheightgrade.AnHoranLisstamped intothetopofthepiston.SeeFigure43.Aproduction pistondoesnothaveanHoranLmark.Thepiston heightmustbecheckedafterinstallation.SeetheproceduredescribedinInstallation.

1. Iftheengineisstillinthelifttruck,draintheengine oilandthecoolant.

2. Removethecylinderheadassemblyasdescribed inCylinderHeadAssembly,Remove.Removethe carbonfromthetopsoftheboresofthecylinder liners.

3. Removetheoilsump.SeeOilSump,Remove.

4. Removethesuctionlineandoilstrainer.See Figure40.Removethecapscrewthatholdsthe brackettothemainbearingcap.Removethetwo capscrewsfromtheflangeofthesuctionlineand removethesuctionlineandscreen.Cleanthe facesofbothflanges.

5. RemovethebearingcapandrodbearingsasdescribedunderRodBearings,Remove.Markthe bearingcapsandrodbearingssothattheycanbe installedagainintheiroriginalpositions.

CAUTION

Donotpermittheconnectingrodstohitthecooling jetsforthepistons.Ifacoolingjetishit,thealignmentmustbecheckedandthecoolingjetreplaced ifnecessary.

6. Pushthepistonandconnectingrodoutofthetop ofthecylinderliner.

7. Inspectthebearingsurfacesonthecrankshaftfor damage.

PistonandConnectingRodAssembliesRepair600YRM705

Figure42.BearingCapPosition,ConnectingRod Figure43.PistonGradeMark

Remove

Install

SpecialTools:Pistoninstallationtool(pistonring compressor)

Pistonheighttool

Dialindicatorgauge

1. Make sureallofthepartsareclean.Lubricatethe partswithengineoilastheyareinstalled.

2. Turn thecrankshaftuntilthepositionfortheconnectingrodtobeinstalledisatthelowestposition onthecrankshaft.

3. Installtheupperbearinghalfintotheconnecting rod.Makesurethatthelocationtabisinstalled correctlyintoitspositionintheconnectingrod.See Figure41.

4. Put thepistoninstallationtoolatthetopofthecylinder.SeeFigure44.Thetoolhasaborewithataper to compressthepistonringswhenthepistonand connectingrodassemblyisinstalled.Makesure thesmallerendofthetaperistowardthecylinder block.

5. Putthespacesinthethreepistonringssothatthey are120 apart.Puttheconnectingrodthroughthe pistoninstallationtoolandpermitthepistontoenter thetool.Thepistonandconnectingrodmustbe turnedsothattheconnectingroddoesnothitthe coolingjetforthepiston.

onthepistonmustbeturnedtowardtheendofthe enginewiththecoolingfan.SeeFigure45.

6. Whentheconnectingrodhaspassedthecooling jetduringinstallation,thearrowor"FRONT"mark

Figure45.PistoninBorePosition

7. Lubricatethelowerhalfoftherodbearingandinstallitintothebearingcap.

8. Installthebearingcapontheconnectingrod.Make surethattheassemblynumberonthebearingcap isthesameasthenumberontheconnectingrod. Makesurethatthetwoassemblynumbersareon thesamesideoftheconnectingrodasshownin Figure42.

9. Connectingrodswithnuts.Installandtightenthe nutsevenlytoatorqueof125N•m(92lbfft).Make surethatthecrankshaftturnsfreely.

Connectingrodswithcapscrews.Installandtighten thecapscrewsevenlytoatorqueof155N•m (114lbfft).Makesurethatthecrankshaftturns freely.

10. Measuretheheightofthepistonabovethetopof theengineblockwithadialindicatorgauge.The crankshaftmustbeturnedsothatthepistonisat TDCintheengineblock.Putthedialindicatoron thetopoftheengineblockandmeasuretheheight ofthepistonabovethefaceoftheengineblock. SeeFigure46.

Thecorrectheightofthepistonabovetheengine blockis0.36to0.50mm(0.014to0.020in.). The topsofthepistonsmustnotbechangedormachined.

600YRM705PistonandConnectingRodAssembliesRepair

Figure44.PistonInstallationTool

Figure46.PistonHeightAboveEngineBlock Measurement

11. Looselyassemblethebracketofthesuctionpipeto themainbearingcap.Installanewgasketandfastentheflangesofthesuctionpipetotheoilpump. Makesurethatthesuctionpipeisalignedcorrectly andtightenthecapscrewthatholdsthebracketto themainbearingcap.

12. Installtheoilsump.SeeOilSump,Install.

13. Installthecylinderhead.SeeCylinderHeadAssembly,Install.

PISTONRINGS

Remove

1. Checkthatthepistonringscanmovefreelyintheir groovesandarenotbroken.

2. Removethepistonringswitharingexpander.Increasethediameterofthepistonringsonlyenough toremovethemwithoutdamagingthepiston.

Inspect

1. Checkthepistonforwearanddamage.

2. Cleanthecarbonfromthetopofthecylinderliners. Fitthepistonringsinthetoppartofthecylinderliner andmeasuretheclearanceattheendsofthering. SeeFigure47.Thespringmustbeinstalledinthe oilcontrolringwhenitsendclearanceismeasured. Theclearancemeasurementsforthepistonrings areshownintheEngineSpecifications.

3. Installnewpistonringsonthepistonandcheckthe clearanceinthegrooveswithaspacergauge.See Figure48.Iftheclearancebetweenthepistonrings andthepistonaregreaterthanthespecifications, thepistonmustbereplaced.SeetheEngineSpecifications.Theclearanceinthetopgrooveofthe pistonsfortheseenginescannotbecheckedbecauseithasataper.

Install

Installthepistonringswitharingexpander.Increase thediameterofthepistonringsonlyenoughtoremove themwithoutdamagingthepiston.

1. Installthespringfortheoilcontrolringinthebottom grooveofthepiston.SeeFigure49.Installthelatch pininsidebothendsofthespring.SeeFigure50 andFigure51.Installtheoilcontrolringoverthe springsothattheendspaceintheoilcontrolring is180 tothelatchpin.

PistonandConnectingRodAssembliesRepair600YRM705

Figure47.PistonRingEndClearanceCheck Figure48.PistonRingClearanceCheck

Figure49.SpringInstallationforOilControlRing

1.TOPRING 2.SECONDRING

3.OILCONTROL RINGANDSPRING

Figure50.PistonRingsInstallation,EnginesYG andYH

2. Installthecastironringwiththetaperintothesecondgrooveofthepiston.Makesurethattheword "TOP"orthemanufacturer’ssymbolistowardthe topofthepiston.Newpistonringshaveagreen identificationmarkwhichmustbeontheleftofthe clearanceattheendsoftheringwhentheringis installedonthepistonandthepistonisupright.

CAUTION

Makesurethattheword"TOP"orthemanufacturer’ssymbolistowardthetopofthepiston.New pistonringshavearedidentificationmarkwhich mustbeontheleftoftheclearancespaceatthe endsoftheringwhentheringisinstalledonthe pistonandthepistonisupright.

3. EnginesYGandYH.Installthebarrelfaceringwith themolybdenuminsertintothetopgrooveofthe piston.

EnginesAR.Installtheparallelfaceringwiththe molybdenuminsertintothetopgrooveofthepiston.

1.TOPRING

Figure51.PistonRingsInstallation,EngineAR

4. Checkthattheopengapofthepistonringsare spaced120 apartbeforeinstallingthepiston.

PISTONANDCONNECTINGROD

Disassemble

1. RemovethepistonringsasdescribedinPiston Rings,Remove.

2. Makeamarkonthepistontoindicatethecylinder numberasshownontheconnectingrod.Makethe markonthesamesideofthepistonasthenumber ontheconnectingrod.SeeFigure52.

3. Removethesnapringsthatholdthepistonpinin thepiston.Pushthepistonpinfromthepistonwith yourthumb.Ifthepistonpinistight,heatthepiston andconnectingrodto40to50 C(104to122 F)to makeremovalofthepistonpineasier.

Figure52.MarkingPiston

600YRM705PistonandConnectingRodAssembliesRepair

2.SECONDRING

3.OILCONTROL RINGANDSPRING

Inspect

1. Cleanandinspectallthecomponentsforwearand damage.Checkthealignmentoftheconnecting rodwithatestmandrel.SeeFigure53.

CAUTION

Donotuseareamertomachinethepartiallyfinishedbushing.Specialequipmentandtrainedpersonnelareneeded.

5. Useapresstoinstallapartiallymachinedbushing intheconnectingrod.Makesurethatthelubricationholeinthebushingisalignedwiththelubricationholeintheconnectingrod.

NOTE: Thesmallendiswedgeshaped.Afterthesmall endbushinghasbeeninstalled,machinethebushing totheshapeofthesmallendandremoveanysharp edges.

6. Machinethepartiallyfinishedbushingtoobtainthe correctconnectingrodgrade.

CAUTION

NOTE: THELARGEANDSMALLBORESINTHE CONNECTINGRODMUSTBESQUAREANDPARALLELWITHEACHOTHERWITHINTHELIMITSOF ±0.25mm(0.010in.).THEMEASUREMENTISMADE AT127mm(5.0in.)ONEACHSIDEOFTHEAXIS OFTHECONNECTINGROD.IFTHEBUSHINGIS INSTALLEDINTHESMALLENDOFTHECONNECTINGROD,THELIMITSAREREDUCEDTO±0.06mm (0.0025in.).

Figure53.ConnectingRodAlignmentCheck

2. Checktheclearanceofthebushingintheconnectingrodwiththepistonpin.Iftheclearanceis greaterthan0.043mm(0.0017in.)orisdamaged, installanewbushing.

NOTE: Connectingrodkitsareavailablewithanew small-endbushinginstalledandfinishedtothecorrect grade.RefertoHowtoSelectCorrectReplacementsto identifythecorrectrodgrade.

Apartiallyfinishedsmall-endbushing,whichcanbeinstalledintheoriginalconnectingrodandmachinedto obtaincorrectlengthgradeisalsoavailable.

3. Ifthebushingintheconnectingrodisworn,usea presstoremovethebushing.

4. Cleantheparentboreoftheconnectingrodand removeanysharpedges.

Donotusealetterstamptomarktheconnecting rod.

7. Checkthatthegradeletterontheconnectingrod iscorrect.Ifnecessary,deletetheletterandetcha newletteronthesideoftherod.

HowtoSelectCorrectReplacements

CAUTION

Itisimportantthatthepistondoesnotcontactthe cylinderhead.Ensurethatthepistonheightabove thecylinderblockiscorrect.

Checkthattheconnectingrodsarefittedinthecorrectcylinder.Recordthepositionoftheconnectingrodanditsrelevantcylinderwhenitisremoved fromtheengine.

Tocheckthatthepistonheightabovethecylinderblock iscorrect,theenginemayhaveuptosixlengthgrades (FtoL)ofconnectingrodsfitted.

Identificationofthelengthgradeisbyaletterorcolor whichismarkedonthesideofeachconnectingrod. SeeFigure54.TheletterFisthelongestgradeofconnectingrodandletterListheshortestgrade.Thedifferencebetweengradesis0.046mm(0.0018in.).

PistonandConnectingRodAssembliesRepair600YRM705

makesurethatthemarkonthepistonisaligned withthemarkontheconnectingrodasshownin Figure52.Makesurethatthepistonandconnectingrodareinstalledinthesamecylinderagain.

4. Ifanewpistonorconnectingrodisbeinginstalled, makesurethatindexslotintheconnectingrodfor therodbearingisonthesamesideofthepistonas thebossforthepistonpin.SeeFigure55.

1.CONNECTING ROD

Figure54.RodBearingsPosition

Ifthegrade letterorcoloronthesideoftheconnectingrodcannotbeseen,thelengthcanbecheckedby themeasurementofthedimension(x)showninFigure54.Beforethelengthoftheconnectingrodismeasured,checkthattheboresofthebigendandthesmall endaresquareandparallel,seeFigure53.Thelength ischecked withthebigendbearingremovedandthe originalsmallendbushfitted.Thedimensionsforeach gradeare listedinthetablebelow.

F Red

165.728to165.761mm

G Orange 165.682to165.715mm

H White 165.637to165.670mm

J Green 165.591 to165.624mm

K Purple 165.545to165.578mm

L Blue 165.499to165.532mm

Install

1. Makesurethatthepartsareclean.Lubricatethe partswithengineoilastheyareassembled.

2. Installanewsnapringintooneofthegroovesto holdthepistonpin.

3. Turnthepistonforaccesstoinstalltheconnecting rod.Installtheconnectingrodinpositioninthepiston.Iftheoriginalpistonistobeinstalledagain,

1.INDEXSLOTFOR

BEARING

2.IBOSSFOR

PISTONPIN

Figure55.PistonandConnectingRodOrientation

5. Installthepistonpintofastentheconnectingrodto thepiston.Ifthepistonpinistight,heatthepiston to40to50 C(104to122 F)tomakeinstallationof thepistonpineasier.

6. Installtheothersnapringtoholdthepistonpinin thepiston.

7. InstallthepistonringsasdescribedunderPiston Rings,Install.

PISTONCOOLINGJETS

Remove

Releasethevalveassemblyandremovethepiston coolingjet.ThecrankshafthasbeenremovedinFigure56toshowthepistoncoolingjet.TheARengines haveonlyonecoolingjetanditisinstalledinthenumberonecylinder.

600YRM705PistonandConnectingRodAssembliesRepair

Length Letter Color Code Length

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ofthecoolingjet.SeeFigure57andFigure58for checkingthealignmentofthecoolingjet.

1.ALIGNMENTDOWEL

Figure56.PistonCoolingJet

Install

1. Checkthattheballassemblymovesfreelyagainst thespringpressureinthevalveassemblyandthat thejettubeisnotdamaged.Replaceanydamaged orwornparts.

2. Installthecoolingjet.Makesurethattheassemblyisinstalledcorrectlyonthealignmentdowelin thecylinderblock.Tightenthevalveassemblyto 20N•m(15lbfft).

3. Checkthealignmentofthecoolingjet.Inserta 1.70mm(0.067in.)rodintothenozzleofthecoolingjet.Thelengthoftherodmustextendoutof thetopofthecylinder.Ifarodofthecorrectdiameterisnotavailable,grindoneendofathickerrod tothe1.70mm(0.067in.)diameterforalengthof 16.00mm(0.630in.)sothatitwillfitintothenozzle

Figure57.PistonCoolingJetAlignment,Engines YGandYH

Figure58.PistonCoolingJetAlignment,Engine AR

CrankshaftAssemblyRepair

GENERAL

Thecrankshaftisforgedfromchrome-molybdenum steel.Thefour-cylinderengineshavefivemainjournals andthesix-cylinderengineshavesevenmainjournals. Thecentermainbearingisthethrustbearingthat controlstheaxialmovementofthecrankshaft.The thrustbearinghasthrustwashersonbothsidesofthe bearing.Themainbearingsareanalloyoftinand aluminum.Thecentermainbearinginthesix-cylinder

enginesisaleadandbronzealloy.Themainbearing capsaremadeofcastironorspheroidalgraphite(SG) iron.Thefrontandrearoilssealsarelipsealswith anadditionaldustsealoutsideofthemainlipandoil returngroovesonthefaceofthemainlip.

ENGINEAR.Thecrankshaftpulley,usuallyfittedwithoutadamperisheldinpositionbyaplainthrustblock andthreesetscrews.Thenoseofthecrankshaftisserratedforlocation.SeeFigure59.

CrankshaftAssemblyRepair600YRM705

1.THRUSTBLOCK 2.CAPSCREWS

3.CRANKSHAFT PULLEY

Figure59.CrankshaftPulleyArrangement,Engine AR

ENGINESYGandYH.Thelocationofthefrontpulley isbyakeyinthecrankshaftnoseandthepulleyisheld inpositionbyataperedringsarrangement.SeeFigure60.

Abalancerunitisfittedtocertainfour-cylinderengines whichhaverigidmountingsorwhicharepartofthe chassisorframe.Thepurposeofthebalancerunitisto reducetheeffectoftheout-of-balanceforces.

CRANKSHAFTPULLEY

EngineAR,Remove

1. Removethedrivebelts.

2. Removethethreecapscrewswhichholdthepulleytothecrankshaft.SeeFigure59.Removethe thrustblockandpulley.

3. Cleanthepartsandcheckfordamage.Replace anydamagedparts.

EnginesYGandYH,Remove

1. Removethedrivebelts.

2. Removethethreecapscrewswhichholdthepulleytothecrankshaft.SeeFigure61.Removethe thrustblock.Ifthecrankshaftpulleywillnotslide fromthecrankshaft,DONOTuseapullertoremove thepulley.Holdawoodblockagainsttheinnerhub ofthepulleyandlightlyhitthewoodblockwitha hammer.SeeFigure62.Thisactionwillloosenthe innerringandouterringsothatthepulleycanbe removedfromthecrankshaftasshowninFigure61.

1.CRANKSHAFT PULLEY

Figure60.CrankshaftPulleyArrangement, EnginesYGandYH

Anintegraldamper,witharubberinsertisbuiltintothe pulleyofsix-cylinderenginesandsomefour-cylinder engines.Six-cylinderengineshaveaviscousdamper whichisfastenedtothefrontorrearfaceofthepulley. SeeFigure60.Alldampersaredesignedforthesuppressionoftorsionalvibrationsintheenginecrankshaft.

Figure 61.CrankshaftPulleyArrangement, EnginesYGandYH

600YRM705CrankshaftAssemblyRepair

2.VISCOUSDAMPER 3.TAPEREDRING

1.SPACERRING 2.INNERRING 3.OUTERRING 4.THRUSTBLOCK 5.O-RING

3. Ifaseparatedamperisconnectedtothecrankshaftpulley,removethecapscrewsandremovethe damper.

1. Whenanintegralpulleyanddamperisfitted,the assemblyshouldbereplacedif(seeFigure63):

• Therubberinsertbetweenthehubandtheouter ringissplit.

• Therubberinsertisdamagedbyoilorsolvents.

• Thereismovementofthepulleyorouterringon thehub.

CAUTION

Donotuseexcessiveforcetoleverthedamper awayfromtheengine.

3. Removeanypaintordirtinfourpositions90 apart onthefaceofthedamper,abovetherubberinsert. SeeFigure63.Usealevertomovethedamper forwardandeliminatethecrankshaftend-float.Fit adialtestindicatoronthefrontcoverofthetiming case.Measurethealignmentofthedamperfaceat fourlocations,90 apart.Themaximumpermissibledifferencebetweenthemaximumandminimum figuresobtainedis0.18mm(0.007in.).

4. Removeanypaintordirtfromthecircumference ofthedamper.Fitadialtestindicatoronthefront coverofthetimingcase.

5. Rotatethecrankshaftslowlyonecompleterevolutionandmeasureforrun-outonthecircumferenceofthedamperwiththedialtestindicator.The maximumpermissibledifferencebetweenthemaximumandminimumfiguresobtainedin0.12mm (0.005in.).

6. Ifthealignmentortherun-outisinexcessofthe permissiblelimit,renewthepulley.

7. Aviscousdampermustberenewedifthereisimpactdamagetotheoutercasingorifthereisleakageoftheviscousfluidfromthecoverplate.See Figure60.Checktheareaaroundtheholesforthe damperfastenersfordamage.

EngineAR,Install

1. Putthepulleyintopositiononthecrankshaft.See Figure59.Lubricatelightlythethreadsofthethree capscrews.Installthethrustblockandthethree capscrews.Tightenthethreecapscrewsevenlyto 115N•m(85lbfft).Checkeachcapscrewagainfor thecorrecttorque.

2. Installthedrivebelts.SeeDriveBelts.

EnginesYGandYH,Install

2. Checktheareaaroundtheholesforthedamper fastenersforcracksorwear.

1. Ifyourenginehasaseparatedamperthatis connectedtothecrankshaftpulleyanditwas removed,installitonthecrankshaftpulley.Ifaviscousdamperisused,installthedamperinposition onthefaceofthepulley.Installtheclampringor thewashersandtightenthecapscrewsgradually andevenlyto35N•m(26lbfft).IfM12capscrews areused,tightenthemto75N•m(55lbfft).

CrankshaftAssemblyRepair600YRM705 Figure62.CrankshaftPulleyInstallation,Engines YGandYH

Inspect

Figure63.CrankshaftPulley

1.RUBBERINSERT2.PULLEY

2. Cleantheendofthecrankshaftandthepartsof thecrankshaftpulley.Donotuseadegreasingsolution.SeeFigure61.Donotmakeanychanges totheinnerringortheouterring.

3. Putthecrankshaftpulleyonthecrankshaftsothat thekeyisengaged.Pushthepulleyontothecrankshaft.

NOTE: Iftheringsarenotinstalledcorrectly,thecrankshaftpulleywillbeverydifficulttoremoveagain.

4. Installthespacerring,innerring,andtheouterring inthecorrectorder.

5. LightlylubricatetheO-ringandthethrustfacesof thecapscrewswithengineoil.Putthethrustblock andthecapscrewsinposition.

6. Graduallyandevenlytightenthecapscrewstopush thecrankshaftpulleyonthecrankshaft.Tightenthe capscrewsto115N•m(85lbfft).

7. Installthedrivebelts.SeeDriveBelts.

REAROILSEAL

Replace

SpecialTools:Replacementtoolforoilseal.

1. Removethedrivecomponentsfromtherearofthe engine.

2. Removetheflywheelandhousing.SeeFlywheel, Remove.

3. Removethecapscrewsandremovethesealhousingandsealassembly.Cleantheparts.

4. Inspecttheoilsealforwearanddamage.Ifthere isanyquestionabouttheconditionoftheoilseal, replacetheoilseal.

5. Checkthattheoilsealareaandoutercircumferenceofthecrankshaftflangearenotwornordamaged.

6. Presstheoilsealfromthehousing.

7. Lubricatetheoilsealwithengineoilandcarefully presstheoilsealintooneofthepositionsinthe housing.Thespringinthesealgoestowardthe

housing.Theinstallationtoolhastwosidesandwill installtheoilsealinthehousingineitherposition1 orposition2.

8. Therearethreepositionsinwhichtheoilsealcan beinstalledinthesealhousing.SeeFigure64.

• Position"1"isusedwhenanewsealisfirstfitted inservice.

• Position"2"isusedwhenanewsealisfittedin serviceandthecrankshaftflangeisworninposition"1".

• Position"3"canbeusedwithanewsealinservice,ifawetclutchisnotusedandthecrankshaft isneworthecrankshaftpalmareahasbeencorrected.Checkthatthesealisfittedsquareinthe housing.

Ifallpositionshavebeenused,thecrankshaft musthaveanewsurfacegroundonthecrankshaft flange.SeetheEngineSpecificationsforthesize limits.

Figure64.OilSealPositions

9. Makesurethatthetwopositiondowelsareinstalled intheengineblock.Useanewgasket.Donotuse gasketcompoundonanyofthesurfaces.

10. Makesurethelipofthesealislubricatedwith engineoilwhereittouchesthecrankshaftflange. Thislubricationoftheoilsealisnecessarytopreventdamagetotheoilsealwhentheengineisfirst started.

11. Installanewgasketonthesealhousing.Puttheoil sealandhousingonthesealguide.Carefullypush theoilsealassemblyintopositiononthecrankshaft flangeandontothedowels.SeeFigure65.

600YRM705CrankshaftAssemblyRepair

Figure65.OilSealInstallation

12. Removethesealguide.Installthecapscrews.See Figure66.Tightenthecapscrewsandthetwospecialcapscrewsto22N•m(16lbfft).

Thefrontmainbearingcanbedifficulttoreplacewhen thetimingcaseisontheengine.Theoilpumpisinstalledonthefrontbearingcap.Aspecialwrenchcan berequiredtoapplythecorrecttorquetothecapscrews forremovalandinstallation.Ifawrenchisnotavailable toinstallthecapscrewsonthemainbearingcap,the timingcasemustberemoved.Theoilpumpwillberemovedwiththecapforthefrontmainbearing.Thesuctionpipe,oilstrainer,deliverypipe,andreliefvalvemust beremoved.

Remove

1. Draintheengineoilandremovetheoilsump.

2. Removethenecessarycomponentsforaccessto thebearingcapforthebearingthatmustbereplaced.

3. Removethecapscrewsandremovethebearing cap.Removethelowerhalfofthebearingfromthe bearingcap.

4. Useathinflexibletooltopushonthesideofthe upperbearinghalfthatisoppositefromthelocationtab.Pushonthebearinghalfsothatitbegins torotateoutoftheengineblock.Carefullyrotate crankshaftsothatbearingwillrotateoutoftheengineblock.

5. Checkthatthebearingjournalonthecrankshaftis cleanandingoodcondition.SeeFigure67.

1.SPECIALCAPSCREWS

Figure66.OilSealInstallation

MAINBEARINGS

NOTE: Thefollowingprocedureisforreplacementof themainbearingswithoutremovingthecrankshaftfrom theengine.

Iftherearmainbearingmustbereplaced,theflywheel, flywheelhousing,rearoilsealhousing,andbridge piecemustberemoved.

1.BEARING REMOVALTOOL 2.LOCATIONSLOTS 3.BEARINGGROOVE

Figure67.MainBearingRemoval

CrankshaftAssemblyRepair600YRM705

2.OILSEALAND

3.GASKET 4.DOWEL(2)

1.SEALGUIDE

HOUSING

Inspect

Inspectthebearingsforwearandotherdamage.Ifa bearingiswornordamaged,replacebothhalvesofthe shellbearingsandchecktheconditionoftheotherbearings.

Install

NOTE: Onlytheupperhalfofthebearinghaslubrication holesanditmustbeinstalledintotheengineblock.

1. Lubricatetheupperbearinghalfwithengineoil.Installtheplainendofthebearingbetweenthecrankshaftjournalandthesideofthebearinghousing thathasthelocationslot.Carefullyslidethebearinghalfintothebearinghousinguntilthelocation tabfitsintothelocationslot.

2. Lubricatethelowerbearinghalfwithengineoiland installitintothebearingcap.Makesurethelocation tabisinstalledcorrectlyintothelocationslot.

3. Makesurethatthelocationthimblesareinstalledin eitherthebearingcaporthebearinghousingofthe engineblock.Makesurethattheorientationofthe locationslotsforthebearinghalvesarecorrectas showninFigure68.Installthebearingcap.

4. Makesurethecapscrewsareingoodcondition. Installthecapscrewsintothebearingcap.Tighten thecapscrewsgraduallyandevenly.Tightenthe capscrewstoafinaltorqueof265N•m(195lbfft).

5. Makesurethatthecrankshaftrotatesfreely.Ifthe thrustwashershavebeenremovedandinstalled again,theaxialmovementofthecrankshaftmust bechecked.SeeThrustWashersinthefollowing paragraphs.

6. Installthecomponentsthatwereremovedforaccesstothemainbearing.

7. Installtheoilsump.

1.LOCATIONSLOTSFORMAINBEARINGHALVES Figure68.MainBearingCapOrientation THRUSTWASHERS

CrankshaftAxialMovement,Check

Theaxialmovementofthecrankshaftiscontrolledby twohalfthrustwashersinstalledoneachsideofthe centermainbearing.SeeFigure69.Theaxialclearancecanbecheckedwithaspacergaugeinsertedbetweenthecrankshaftandthethrustwasher.SeeFigure70.Adialindicatorcanbeusedtochecktheaxialmovementfromtheendofthecrankshaftasshown inFigure71.Thenormalaxialmovementis0.05to 0.38mm(0.002to0.015in.).Themaximumaxialmovementpermittedis0.51mm(0.020in.).

600YRM705CrankshaftAssemblyRepair

Figure69.ThrustWashers

Figure70.AxialClearanceMeasurementWith SpacerGauge

3. Removethecapscrewsforthecentermainbearing cap.Removethebearingcap,lowerbearinghalf, andthelowerhalvesofthethrustwashers.

4. Useathinflexibletooltopushtheupperhalves ofthethrustwashersfromtheirpositionsnextto themainbearinghousing.SeeFigure72.Usea smallprybarasnecessarytomovethecrankshaft toloosenatightthrustwasher.

Figure71.AxialMovementMeasurementWithDial Indicator

Iftheaxialmovementisgreaterthanthespecifications, oversizethrustwasherscanbeinstalledononeside orbothsidesofthemainbearing.Theoversizethrust washersare0.019mm(0.00075in.)largerthanthe standardthrustwashers.

Remove

1. Draintheengineoilfromthesump.Removetheoil sump.SeeOilSump,Remove.

1. Lubricatethethrustwasherswithengineoil.Slide theupperhalvesofthethrustwashersintotheir positionsintheengineblock.Makesurethatthe sidesofthethrustwasherswiththegroovesare againstthecrankshaft.

2. Installthelowerhalvesofthethrustwashersinto themainbearingcap.Makesurethatthelocation tabsareintheircorrectpositions.

3. Makesurethatthelocationthimblesareinstalled ineitherthebearingcaporthebearinghousingof theengineblock.Makesurethattheorientationof thelocationslotsforthebearinghalvesarecorrect asshowninFigure68.Lubricatethebearingand thrustwasherswithengineoil.Installthebearing cap.

4. Inspectthecapscrews,reuseifingoodcondition. Installthecapscrewsintothebearingcap.Tighten thecapscrewsgraduallyandevenly.Tightenthe capscrewstoafinaltorqueof265N•m(195lbfft).

5. Makesurethatthecrankshaftrotatesfreely.Check theaxialmovementofthecrankshafttomakesure thatitiswithinthespecifications.

CrankshaftAssemblyRepair600YRM705

Figure72.ThrustWasherUpperHalfRemoval Install

6. Looselyassemblethebracketofthesuctionline tothemainbearingcap.Installanewgasketand fastentheflangesofthesuctionlinetotheoilpump. Makesurethatthesuctionlineisalignedcorrectly andtightenthecapscrewthatholdsthebracketto themainbearingcap.

7. Installtheoilsump.SeeOilSump,Install.

CRANKSHAFT

Remove

1. Removetheenginefromthelifttruck.Seethe Frame section.Seethe Transmission sectionfor separatingtheenginefromthetransmission.

2. Removetheoilsump.SeeOilSump,Remove.

3. Removethefan,drivebelts,fandrivepulleyand housing,andthecoolantpump.

4. Removethecrankshaftpulley.SeeCrankshaftPulley.

5. Removethealternatoranditsmountbracket.

6. Removethetimingcasecover.SeeTimingCase Cover,Remove.

7. Removethefuelinjectionpump.SeeFuelInjection Pump,Remove.

8. Removethetiminggearsandthetimingcase.See thesectionTimingCaseandTimingGearsRepair.

9. Removetheflywheelandtheflywheelhousing. SeeFlywheel,Remove.

10. Removetherearoilsealhousing.SeeRearOil Seal,Replace.

11. Iftheengineisnotalreadyinapositionwiththe crankshaftfacingup,turntheenginetothatposition.Removethesuctionpipeandoilstrainer. SeeFigure40.Removethecapscrewthatholds thebrackettothemainbearingcap.Removethe twocapscrewsfromtheflangeofthesuctionpipe andremovethesuctionpipeandscreen.Cleanthe facesofbothflanges.Removetheoilpump,deliverytube,andreliefvalve.SeeOilPumpandRelief Valve.

12. Removethebridgepieceovertherearmainbearing.Makeanoteifthereisaroundrubberseal ateachendofthebridgepiecewhereitjoinsthe

crankcase.Someengineshaverubbersealsand otherengineshavesealant.

13. Removethebearingcapsandlowerbearinghalves fromtheconnectingrods.Makeanarrangement sothatthepartsforeachconnectingrodwillbeassembledagainintheiroriginalpositions.Carefully pushthepistonsintotheirboresasmallamount sothattheconnectingrodsareseparatedfromthe crankshaft.

CAUTION

Makesurethecoolingjetsforthepistonsarenot damagedormovedoutofalignment.Ifacooling jetishit,thealignmentmustbecheckedandthe coolingjetreplacedifnecessary.

14. Makesurethatthemainbearingcapsaremarked withtheirpositionnumber.Removethemainbearingcaps,lowerbearinghalves,andtheupperand lowerthrustwashers.Keepallthepartsinanarrangementsothatthepartscanbeinstalledintheir originalpositions.

15. Liftthecrankshaftfromthecylinderblock.Remove theupperbearinghalvesandputeachofthemwith theirlowerbearinghalf.

Inspect

Checkthecrankshaftforwearandotherdamage.The maximumwearandout-of-roundonthebearingjournalsis0.04mm(0.0016in.).

Thebearingjournalsonstandardcrankshaftscanbe groundtothefollowingdiameterssmallerthantheoriginalsize:

0.25mm(0.010in.)

0.50mm(0.020in.)

0.75mm(0.030in.)

Specialbearingsareavailableforthesesizes.

Thecrankshaftmustbereplacedifthesurfacemustbe groundmorethan0.75mm(0.030in.).

Theareaonthecrankshaftflangefortherearoilseal canbemachinedtoremovewearmarksiftheoilseal hasbeenusedinallthreepositions.SeetheEngine Specifications.Theminimumdiameterofthisareais 133.27mm(5.247in.).

Install

1. Makesurethatalloftheoilpassagesareclean.

600YRM705CrankshaftAssemblyRepair

2. Makesureallofthebearingsandbearingcapsare clean.Installtheupperbearinghalvesintotheirpositionsintheconnectingrodsandthehousingsfor themainbearings.Makesurethatthepositiontags ofthebearingsfitintotheirpositionslots.Lubricate thebearingswithengineoil.

3. Installthecrankshaftinpositiononthemainbearings.

4. Lubricatethethrustwasherswithengineoil.Slide theupperhalvesofthethrustwashersintotheir positionsintheengineblock.Makesurethatthe sidesofthethrustwasherswiththegroovesare againstthecrankshaft.

5. Installthelowerhalvesofthethrustwashersinto themainbearingcap.Makesurethatthelocation tagsareintheircorrectpositions.

6. Makesurethatthelocationthimblesareinstalled ineitherthebearingcaporthebearinghousingof theengineblock.Makesurethattheorientationof thelocationslotsforthebearinghalvesarecorrect asshowninFigure68.Lubricatethebearingand thrustwasherswithengineoil.Installthebearing cap.

7. Makesurethemainbearingcapsareinstalledaccordingtotheirpositionnumbersshownonthecap. Theserialnumbersonthemainbearingcapswill alsobeinalignment.Theserialnumberonthe mainbearingcapsmustbethesameasthenumberonthebottomfaceoftheengineblock.(The thirdandfifthbearingcapsonsix-cylinderengines arenotmarkedwithaserialnumber.)

8. Inspectthecapscrews,reuseifingoodcondition.Installthecapscrewsintothemainbearing cap.Tightenthecapscrewsgraduallyandevenly. Tightenthecapscrewstoafinaltorqueof265N•m (195lbfft).Repeatthisstepforallfivemainbearings.

9. Whenthebridgepieceisputintoposition,inject liquidgasketsealant(Loctite® 5900)intotheupper grooveateachendofthebridgepiece.SeeFigure73.Injectthesealantuntiltheuppergrooveis fullandthesealantleavesthelowergrooveatthe frontandrearofthebridgepiece.Makesureallof thegroovesarecompletelyfullofsealant.

1.LOWERGROOVE

Figure73. BridgePieceandSealant

NOTE: Many engineshavecapscrewsinsteadofthe twostudsshowninthebridgepieceinFigure74.These capscrewsfastentheoilsumptothebridgepiece.Use sealantonthethreadsofeitherthestudsorthecapscrews.

10. Useastraightedgetomakesurethebridgepiece isalignedwiththerearfaceoftheengineblock. SeeFigure74.Tightenthecapscrewsto16N•m (12lbfft).

11. Installtheconnectingrodstothecrankshaft.See RodBearings,Install.Installtheupperbearinghalf intotheconnectingrod.Makesurethatthelocationtabisinstalledcorrectlyintoitspositioninthe connectingrod.SeeFigure41.Makesurethatthe assemblynumberonthebearingcapisthesame asthenumberontheconnectingrod.Makesure thatthetwoassemblynumbersareonthesame sideoftheconnectingrodasshowninFigure42.

CrankshaftAssemblyRepair600YRM705

2.UPPERGROOVE Figure74.BridgePieceAlignment

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12. Connectingrodswithnuts.Installandtightenthe nutsevenlytoatorqueof125N•m(92lbfft).Make surethatthecrankshaftturnsfreely.Connecting rodswithcapscrews.Installandtightenthecapscrewsevenlytoatorqueof155N•m(114lbfft). Makesurethatthecrankshaftturnsfreely.

13. Installtheoilpump,deliverypipe,andreliefvalve. Looselyassemblethebracketofthesuctionpipe tothemainbearingcap.Installanewgasketand fastentheflangesofthesuctionlinetotheoilpump. Makesurethatthesuctionpipeisalignedcorrectly andtightenthecapscrewthatholdsthebracketto themainbearingcap.

14. Installtherearoilsealhousing.SeeRearOilSeal, Replace.

15. Installtheflywheelandtheflywheelhousing.See Flywheel,Install.

16. Installthetiminggearsandthetimingcase.See TimingCaseandTimingGearsRepair.

17. Installthefuelinjectionpump.SeeFuelInjection Pump,Install.

18. Installthetimingcasecover.SeeTimingCase Cover,Install.

19. Installthealternatoranditsmountbracket.

20. Installthecrankshaftpulley.SeeCrankshaftPulley.

21. Installthecoolantpump,fandrivepulleyandfan housing,drivebelts,andthefan.

22. Installtheoilsump.SeeOilSump,Install.

23. Installtheengineintothelifttruck.Seethe Frame sectionandthe Transmission sectionforthelift truck.

FLYWHEEL

Thesteelflywheelhasahardenedsteelstarterring. Thestarterringhas126teeth.

Remove

1. Removetwooppositecapscrewsfromtheflywheel andtemporarilyinstalltwostudstohelpcontrolthe flywheelwhentheothercapscrewsareremoved.

2. Removetheothercapscrewsthatfastentheflywheeltothecrankshaft.Removetheflywheel.

3. Checktheflywheelandringgearfordamage. RingGear,Replace

WARNING

Weareyeprotectionforthisoperationtoprevent eyeinjuryfrommetalchips.Youwillbeusinga hammerandchiseltobreaktheringgear.

1. Beforetheringgearisremoved,checktheposition ofthechamferontheteeth.

2. Useahammerandchiseltobreaktheringgear. Makesurethatyoudonotdamagetheflywheel.

3. Theringgearmustbeheatedbeforeitcanbeinstalledontheflywheel.Useanoventhathasatemperaturecontrol.Makesurethattheringgearisnot heatedtomorethan250 C(482 F).

4. Makesurethatthechamferontheringgearteeth isinthecorrectdirection.Installtheringgearon theflywheel.

Install

1. Makesurethesurfacesofthecrankshaftandflywheelarecleansothatthetwopartswillfittogether correctly.

2. Installtheflywheelovertheguidestuds.Install fourcapscrews.Removethetwostudsandinstall theremainderofthecapscrews.Tightenthecapscrewsinacrosspatternto105N•m(77lbfft).

3. Checktheflywheelrun-outwithadialtestindicator. SeeFigure75.Thismustbelessthan0.30mm (0.012in.)totalindicatorreading.

4. Checkthealignmentoftheflywheelface.SeeFigure76.Theerrorinalignmentmustnotbemore than0.003mm(0.0001in.)totalindicatorreading forevery25mm(1.0in.)oftheflywheelradiusfrom thecrankshaftaxistotheindicatorplunger.During thischeck,keepthecrankshaftpressedtowardthe fronttoremovetheeffectofcrankshaftend-float.

600YRM705CrankshaftAssemblyRepair

FLYWHEELHOUSING

Remove WARNING

Theflywheelhousingisheavy,useliftequipment orgethelptoassistwiththeliftoperationbefore removaloftheflywheelhousingfasteners.

1. Removethestarter.

2. Releasethehousingsetscrewsandwithasoftface hammer,hitcarefullythehousingtoremoveitfrom thedowels.

Install

1. Ensurethattherearfaceofthecylinderblockand thefacesofthehousingarecleanandfreefrom damage.Ensurethatthelocationdowelsarefitted correctly.Ifafeltsealisinstalledtotherearflange ofthesump,replacetheseal.

2. Fitthehousingontothedowelsandtightenlightly thesetscrews.

3. Checkthehousingconcentricitywithadialtestindicator.SeeFigure77.Therun-outlimitisgiven inthedataanddimensions.Ifanyadjustmentis necessary,itmustbemadeonthehousingandthe concentricitycheckedagain.

4. Tightenthesetscrewstothetorquerecommended intheSpecialTorqueSpecifications.

5. Checkthehousingalignment.SeeFigure78.The maximumtoleranceisgiveninthedataanddimensions.Anynecessaryadjustmentmustbemadeon thehousingandnotonthecylinderblock.

6. Installtheflywheelandthestartermotor.

CrankshaftAssemblyRepair600YRM705

Figure75.FlywheelRun-OutCheck Figure76.FlywheelFaceAlignment Figure77.FlywheelHousingConcentricityCheck

TimingCaseandTimingGearsRepair

GENERAL

Thetimingcasecanbeeithercastaluminumorcast iron.Thetiminggearsaresteel.

Thegeartrainincludesthecrankshaftgear,idlergear, gearforthefuelinjectionpump,camshaftgear,and PTOgear.Thetimingcasecoverisaluminumandhas thefrontoilsealforthecrankshaft.Thetimingcase coverhasanoiseshieldonitsfrontsurface.

SeeDescriptionforadditionalinformationontiming gearsandenginetiming.

Thecamshaftismadefromcastiron.Thelobesonthe camshaftforthefuelpumparehardened.

TIMINGCASECOVER

Remove

1. Drainthecoolant.Removethefan.SeeFigure79.

2. Removethedrivebeltsandalternator.

3. Removethecrankshaftpulley.SeeCrankshaftPulley.

4. Removethefandrivepulleyifadditionalclearance isneeded.

5. Removethecoolantpump.SeeCoolantPump,Remove.

Figure79.TimingCaseCover

600YRM705TimingCaseandTimingGearsRepair

Figure78.FlywheelHousingAlignmentCheck

2.CYLINDERBLOCK 3.STUD 4.GASKET

1.CAPSCREW

5.TIMINGCASE COVER

6. Removethecapscrewsandnutsthatholdthetimingcasecovertothetimingcase.Removethetimingcasecoverandthesoundshield.

Install

SpecialTools:Alignmenttool,frontoilseal

1. Use anewgasketandinstallthetimingcasecover onthetimingcase.SeeFigure79.Usetwocapscrewstoholdthetimingcasecoverinposition.Installthespecialtoolonthecrankshaft.Usethespecialwasherandthecapscrewsforthecrankshaft pulleytoholdthealignmenttoolinposition.The purposeofthespecialtoolistomakesurethatthe frontoilsealevenlyfitsthecircumferenceoftheseal surfaceofthecrankshaftpulley.SeeFigure80.

6. Installthealternatoranddrivebeltsandadjustthe tension.SeeDriveBelts.

7. Installthefan.Fillthecoolingsystem.

FRONTOILSEAL

Remove

1. Removethefananddrivebelts.

2. Removethecrankshaftpulley.

3. Useaprybartoremovethefrontoilsealfromthe timinggearcover.Puttheprybarbehindthemain lipofthefrontoilseal.Makesurethattheedgeof thehousingfortheoilsealisnotdamagedduring removal.

Install

SpecialTools:Installationtoolforfrontoilseal Pressureplate Fastenerplate Sleeve Sealadapter

NOTE: Thefrontoilsealisnormallyinstalledtoadepth of9.3mm(0.366in.)fromthefrontfaceoftheoilseal housingtotheflatfrontfaceoftheoilseal.Ifthecrankshaftpulleyiswornatthislocation,awearsleevecan be installed.SeeFigure82.

1. Cleantheoilsealhousing.Inspecttheoilsealfor damage.Donotinstallafrontoilsealthathasa scratchoranydamageonthelipoftheseal.

CAUTION

Thecorrectalignmentofthetimingcasecoveris importantandmustbedonecarefully.Thefrontoil sealcanleakandthegearsforthecoolantpump canfailifthealignmentisnotcorrect.

2. Whenthetimingcasecoverisalignedwiththe crankshaft,installthecapscrewsandnutsinthe timingcasecover.Tightenthecapscrewsandnuts to22N•m(16lbfft).Removethealignmenttool.

3. Installthecoolantpump.SeeCoolantPump,Install.

4. Installcrankshaftpulley.SeeCrankshaftPulley.

5. Installthefandrivepulleyifitwasremoved.

2. Lubricatetheoutercircumferenceoftheoilseal withengineoilandinstallthefrontoilsealintothe oilsealhousing.Makesurethatthelipoftheseal istowardtheinsideofthecoverforthetiminggear caseandthefrontoilsealisparalleltotheboreof theoilsealhousing.

3 Putthereplacementtoolforthefrontoilsealonthe crankshaftasshowninFigure81.Usethefastener platetofastentheinstallationtooltothecrankshaft. Installthesealadaptersothatthe10.5mmmark istowardthefrontoilseal.Putthesleeveandthe pressureplateintopositionandfastenittothestud ofthefastenerplateasshowninFigure81.

TimingCaseandTimingGearsRepair600YRM705

Figure80.FrontOilSealAlignmentTool

1.REPLACEMENT TOOLFORFRONT OILSEAL

2.PRESSUREPLATE

3.FASTENERPLATE

4.SLEEVE

5.SEALADAPTER

Figure81.FrontOilSealInstallation

4. Installarodthroughtheholeintheendofthetool sothatthetoolwillnotturn.Turnthenutonthe pressureplatewithawrenchandthefrontoilseal willbepushedintothehousing.Pushthesealinto thecorrectdepth.Removetheinstallationtool.

5. Lubricatethesealareaofthecrankshaftpulleywith engineoil.Installthecrankshaftpulley.SeeCrankshaftPulley.

6. Installthedrivebeltsandadjustthebelttension.

7. Installthefan.

CRANKSHAFTPULLEYWEARSLEEVE

Install

Torenewaworncrankshaftpulley,awearsleeveisfittedoverthespigot.SeeFigure82.

1. Removethecrankshaftpulley.SeeCrankshaftPulley,Removal.

NOTE: Fullinstructionsandaspecialtooltoinstallthe wearsleeveareineachservicekit.

2. Installthewearsleeve,inaccordancewiththemanufacturer’sinstructions.

Itisnotnecessarytoremovetheflangeofthewear sleeveafterithasbeenfitted.

Anewfrontoilsealmustbeusedwhenawear sleeveisfitted.

Thedimension,topressthenewoilsealintothe timingcase,withorwithoutawearsleevefitted,is 9.3mm(0.366in.),fromthefrontfaceofthetiming case.

3. Installthecrankshaftpulley.SeeCrankshaftPulley, Installation.

Figure82.CrankshaftPulleyWearSleeve IDLERGEARANDHUB

Remove

1. Removethetimingcasecover.SeeTimingCase Cover,Remove.

2. Turnthecrankshaftuntilthemarkedteethofthe crankshaftgear,thecamshaftgear,andthegear forthefuelinjectionpumparealignedasshownin Figure83.Themarkedteethontheidlergearwill notnecessarilybealignedwiththemarkedteethof theotherthreegearsbecauseofthedifferentspeed ofrotationoftheidlergear.

CAUTION

Makesurethatthecrankshaftisnotturnedwhile theidlergearisremoved.Apistoncanhitanddamageavalve.Thevalvetimingandthefuelinjection pumptimingwillbelostifthecrankshaftisturned.

3. Removethethreecapscrews,removetheplateof theidlergear,andremovetheidlergear.See Figure84.Makeanoteofthepositionoftheoil hole.Thegearforthefuelinjectionpumpwillturn asmallamountinthecounterclockwisedirectionas theteethbecomedisengagedfromtheidlergear.

600YRM705TimingCaseandTimingGearsRepair

1.SPIGOT 2.WEARSLEEVE 3.FLANGE 4.OILSEAL

Figure83.TimingMarksAlignment

1.PLATE 2.THRUSTWASHER 3.IDLERGEAR

WASHER

Figure84.IdlerGearComponents

4. Inspecttheidlergearandbushingsforwearand damage.Theidlergearandbushingsareavailable asanassemblyorasseparateparts.

5. Ifthebushingsmustbereplaced,useapullerto removethemfromtheidlergear.Ifapullerisnot available,grindoneofthefacesfromthebushings anduseapresstoremovethemfromtheidlergear. Useapresstoinstallnewbushings.Thebores andfacesofthebushingswillneedmachiningto correctlyfitthehub.SeetheEngineSpecifications, IdlerGearandHubforthemeasurements.

6. Forenginesthatusetheidlergearassemblywith needlerollerbearings-removethethreecapscrews,removetheplateoftheidlergear.Remove thefrontthrustwasher,thefrontspacer,andthe gear.Removethetwoneedlerollerbearings.If thesearetobeusedagain,theyshouldbefitted intheiroriginalpositions.Removetherearthrust washerandtherearspacer.Removethehub.See Figure85.

1.PLATE

2.THRUSTWASHER

3.FRONTSPACER

4.IDLERGEAR

5.NEEDLE BEARINGS

6.REARTHRUST WASHER

7.REARSPACER

8.HUB

Install

1. Usethethreecapscrewsfortheidlergeartomake surethatthehubfortheidlergearisinthecorrect positionwiththelubricationholeatthetop.

2. Lubricatethebushingsintheidlergearwithengine oil.Alignthetimingmarksontheidlergearwith themarksonthecrankshaftgearandthecamshaft gear.Turnthegearforthefuelinjectionpumpclockwiseasnecessarytoalignthetimingmarkswhen theteethoftheidlergearengagetheothergears. Makesureallofthealignmentmarksarealigned asshowninFigure83.

3. Installtheplatefortheidlergearandthethreecapscrews.Tightenthecapscrewsto44N•m(32lbfft).

4. Checktheclearancebetweenthebushingsofthe idlergearandtheplateoftheidlergear.Thecorrect clearanceis0.10to0.20mm(0.004to0.008in.).A maximumservicelimitis0.38mm(0.015in.).See Figure86.

TimingCaseandTimingGearsRepair600YRM705

GEAR

5.PTOGEAR

1.CAMSHAFTGEAR 2.CRANKSHAFT

3.IDLERGEAR 4.GEARFORFUEL INJECTIONPUMP

7.REARTHRUST

8.CAPSCREW

4.TIMINGMARKS 5.HUB 6.OILHOLE

Figure85.IdlerGearwithNeedleBearings Components

5. Forenginesthatusetheidlergearassemblywith needlerollerbearings-inspectthecomponentsfor wearandotherdamageandreplacethemasnecessary.Lightlylubricatethecomponentswithclean lubricatingoilbeforeassemblyontothehub.See Figure84.Positiontheidlergearhubwiththelubricationholetothetop.SeeFigure85.Puttherear spacerinpositiononthehub.Puttherearthrust washerinpositionontherearspacer.Putbearings inpositiononthehubinthesamepositionasthey wereremoved.Lightlylubricatetheboreandthrust washerfacesofthegearwithcleanlubricatingoil andputthegearinpositiononthebearings.Put thefrontspacerinpositiononthehubthenputthe frontthrustwasherinpositiononthespacer.Put theplateinposition.TheplatehasTOPstamped onthefrontfaceastheholesintheplatearenot equallyspaced.Fitthesetscrewsandtightenthem to44N•m(33lbfft).

6. CheckthetiminggearclearancesasshowninFigure89.Theminimumclearancesforallgearsis 0.08mm(0.003in.).

7. Installthetimingcasecover,coolantpump,crankshaftpulley,fandrivepulley,drivebelts,andfan. SeeTimingCaseCover,Install.

AIRCOMPRESSORDRIVE,BENDIX

Disassemble

CAUTION

Donotturntheenginecrankshaftnorthecrankshaftfortheaircompressor.Ifeithercrankshafts aremoved,theaircompressormustbetimedtothe engine.

1. SetthenumberonepistontoTDCasdescribedin theEngineTimingsection.

2. RemovethetimingcasecoverasdescribedinTimingCaseCover,Remove.

3. Removethethreecapscrewsshown.SeeFigure87.Removethecoverplate.Removetheidler gearandtheneedlebearingsfromtheidlerhub.

1.O-RING

2.CAPSCREW

3.BRACKET

4.DRIVEGEAR,AIR COMPRESSOR

5.TIMINGCASE

6.COVER,TIMING CASE

7.NEEDLEBEARING

8.CAPSCREW(3)

9.IDLERHUB

10.COVERPLATE

11.IDLERGEAR

12.ENGINEIDLER GEAR

Figure87.BendixCompressorDrive

4. Removethethreecapscrewswhichfastentheidler hubtothebracket.Removetheidlergearhub.See Figure88.

600YRM705TimingCaseandTimingGearsRepair

Figure86.IdlerGearHubClearanceCheck

1.TIMINGCASE

HUB

Figure88.BendixCompressorDrive

5. RemoveanddiscardtheO-ring.SeeFigure87.

6. Inspectthepartsforwearordamage.

Assemble

1. InstalltheO-ring.SeeFigure87.

2. Checkthatthefourcapscrewswhichfastentheidler hubbracket(4)tothetimingcasearetightenedto 35N•m(26lbfft).SeeFigure88.

3. Installthehubintothetimingcase.SeeFigure87 andFigure88.Installthethreecapscrewsand tightenthemto60N•m(44lbfft).Installtheneedle bearingassemblyonthehub.

4. Lubricatetheboreoftheidlergearwithcleanengineoilandinstalltheidlergearontheneedlebearings.SeeFigure87.Installthecoverplateand tightenthreecapscrewsto22N•m(16lbfft).

5. Checktheclearancebetweenthebushingsofthe idlergearandtheplateoftheidlergear.Thecorrect clearanceis0.10to0.20mm(0.004to0.008in.).A maximumservicelimitis0.38mm(0.015in.).See Figure86.

6. Checkthetiminggearclearancesasshownin Figure89.Theminimumclearanceis0.08mm (0.003in.).

Figure89.TimingGearClearancesCheck

7. InstallthetimingcasecoverasdescribedinTiming CaseCover,Install.

FUELINJECTIONPUMPGEAR

Thefuelinjectionpumphasatimingplatefastenedto thefrontfaceofthegearforthefuelinjectionpump.See Figure90.Thistimingplateisinstalledbythemanufacturerafterthefuelinjectiontiminghasbeenaccurately settoTDC,numberonecylinderonthecompression stroke.ThetimingplateisfastenedbytwoM5special capscrews.

Figure90.FuelInjectionPumpGearRemoval

TimingCaseandTimingGearsRepair600YRM705

2.BRACKET,IDLER

3.CAPSCREWS(3) 4.CAPSCREWS(4) 5.IDLERGEAR

1.M5SPECIAL CAPSCREWS 2.TIMINGPLATE 3.CAPSCREWS(4)

Remove

CAUTION

DonotloosenthetwoM5specialcapscrews.Ifthis timingplateismoved,thefuelinjectionpumpmust betimedagain.

Donotloosennorremovethelargenutfromthe shaftofthefuelinjectionpump.Thehubispermanentlyfastenedtotheshaft.Ifthehubisremoved, specialequipmentandspecialtrainingisrequired tocorrectlyinstallthehubagain.

SpecialTools:Lucasfuelinjectionpumptimingpin

1. Removethetimingcasecover.SeeTimingCase Cover,Remove.

CAUTION

Makesuretheshaftofthefuelinjectionpumpisnot locked.

2. SetthenumberonepistontoTDConthecompressionstroke.Turnthecrankshaftuntilthemarked teethofthecrankshaftgear,thecamshaftgear,and thegearforthefuelinjectionpumparealignedas showninFigure90.Themarkedteethontheidler gearwillnotnecessarilybealignedwiththemarked teethoftheotherthreegearsbecauseofthedifferentspeedofrotationoftheidlergear.

CAUTION

DONOTturnthecrankshaftwhileremovingthe camshaftgear.Apistoncanhitanddamagea valve.

3. Installthetimingpinuntilthesmallendofthepin ispushedfullyintotheholeinthebodyofthefuel injectionpump.SeeFigure91.

4. Removethefourcapscrewsfromthefuelpump gearandremovethegearfromthehub.

5. Inspectthegearforwearanddamage,replaceif necessary.

1.TIMINGPIN

Figure91.FuelInjectionPumpGearRemoval Install

CAUTION

Makesuretheshaftofthefuelinjectionpumpisnot locked.

1. Thegearforthefuelinjectionpumpcanonlybeinstalledinoneposition.ThelettersCandMaretowardthefrontoftheengine.Makesurethenumber onepistonissettoTDConthecompressionstroke.

2. Ifthetimingpinwasremovedduringservice,install itintheholeinthebodyofthefuelinjectionpump. SeeFigure92.Leavethetimingpininposition sothatthegearforthefuelinjectionpumpcanbe installed.

1.GEARFORFUEL INJECTIONPUMP

2.IDLERGEAR 3.TIMING PIN

Figure 92.FuelInjectionPumpGearInstallation

3. Installthegearforthefuelinjectionpumpoverthe timing pinsothatitengagescorrectlywiththeidler gear.

NOTE: Ifanewgearisinstalled,installtheoriginaltimingplateontothefrontfaceofthenewgear.Installthe twoM5specialcapscrewslooselyandinstallthegear

600YRM705TimingCaseandTimingGearsRepair

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onthehub.Ifthegearandtimingplateareinstalledcorrectly,thefourthreadedholesinthehubcanbeseen throughtheslotsinthegear.

4. Installthefourcapscrewslooselyinthecentersof theslotsofthegear.

NOTE: Ifanewgearisinstalled,carefullyrotatethe gearcounterclockwisetoremoveanyclearancebetweenthegearandtheidlergear.SeeFigure91.Do notrotatethecrankshaftoritwillbenecessarytoset TDCagain.

5. Tightenthefourcapscrewsto28N•m(21lbfft). Removethetimingpinfromthefuelinjectionpump.

6. Ifanewgearhasbeeninstalled,checktheclearanceasshowninFigure89.

7. Installthetimingcasecover,coolantpump,crankshaftpulley,fandrivepulley,drivebelts,andfan. SeeTimingCaseCover,Install.

CAMSHAFTGEAR

Remove SpecialTools:Gearpullerwithadapters

1. Removethetimingcasecover.SeeTimingCase Cover,Remove.

2. Turnthecrankshaftuntilthemarkedteethofthe crankshaftgear,thecamshaftgear,andthegear forthefuelinjectionpumparealignedasshownin Figure93.Themarkedteethontheidlergearwill notnecessarilybealignedwiththemarkedteethof theotherthreegearsbecauseofthedifferentspeed ofrotationoftheidlergear.

CAUTION

Makesurethatthecrankshaftisnotturnedwhile thecamshaftgearisremoved.Apistoncanhitand damageavalve.

3. Removethecapscrewandwasher.Useapuller andadaptertopullthegearfromthecamshaft. MakesurethattheWoodruffkeyinthecamshaft isnotlost.Inspectthecamshaftgearforwearand damage.SeeFigure94.

1.CAMSHAFTGEAR

2.CRANKSHAFT GEAR

3.IDLERGEAR

4.GEARFORFUEL INJECTIONPUMP

5.PTOGEAR

Figure93.TimingMarksAlignment

Figure94.CamshaftGearRemoval

Install

CAUTION

Ifthecrankshaftorthecamshaftmustbeturned topermitthealignmentofthemarksonthetiminggears,apistoncanhitanddamageavalve. Therockerarmassemblymustbeloosenedsothat thevalvesareclosedwhenthecrankshaftorthe camshaftisturned.

1. MakesurethattheWoodruffkeyisinstalledcorrectlyintheendofthecamshaft.

2. Removetheidlergear.SeeIdlerGearandHub, Remove.

TimingCaseandTimingGearsRepair600YRM705

3. Installthecamshaftgearontheshaftwiththe markedteethtowardthefrontandthekeyway correctlyaligned.Useasofthammertopushthe gearontothecamshaft.Makesurethatthetiming marksarealignedcorrectlyasthegearteethare engaged.SeeFigure93.

4. Installtheidlergearwiththemarkedteethcorrectly aligned.SeeIdlerGearandHub,Install.Ifthe camshafthastobeturnedandavalvehitsapiston, disengagetherockerassembly.

5. Installthecapscrewandwasherandtightenthe capscrewtopressthegearintoposition.Tighten thecapscrewto78N•m(58lbfft).

6. Ifnewgearshavebeeninstalled,checkthetiming gearclearancesasshowninFigure89.Theminimumclearancesforallgearsis0.08mm(0.003in.).

7. Installthetimingcasecover,coolantpump,crankshaftpulley,fandrivepulley,drivebelts,andfan. SeeTimingCaseCover,Install.

CRANKSHAFTGEAR

Remove

1. Removethetimingcasecover.SeeTimingCase Cover,Remove.

CAUTION

Makesurethatthecrankshaftisnotturnedwhile theidlergearorthecrankshaftgearisremoved.A pistoncanhitanddamageavalve.

3. RemovetheidlergearSeeIdlerGearandHub,Remove.

4. Thecrankcasegearispressedontothecrankshaft. Sometimesapullerwillremovethecrankcasegear. Sometimesthegearfitssotightlyonthecrankshaft thatthecrankshaftmustberemovedfromtheengineso thatthegearcanberemoved.

Install

1. Putthecrankshaftgearinapanofhotoil.Make surethatthetemperaturecanbecontrolled. DO NOT heatthecrankshaftgearmorethan180 C (356 F).Useboilingwaterifacontainerofhotoil andatemperaturecontrolisnotavailable.DONOT useanopenflametoheatthegear.

2. Alignthegearwiththekeyonthecrankshaftand withthetimingmarksonthegearawayfromthe engine.Pushthegearontothecrankshaft.

3. Installtheidlergear.SeeIdlerGearandHub,Install.

4. CheckthetiminggearclearancesasshowninFigure89.Theminimumclearancesforallgearsis 0.08mm(0.003in.).

5. Installthetimingcasecover,coolantpump,crankshaftpulley,fandrivepulley,drivebelts,andfan. SeeTimingCaseCover,Install.

TIMINGCASE

Remove

1. Removethefan.

2. Removethedrivebelts.

3. Removethecrankshaftpulley.SeeCrankshaftPulley.

4. Removethefandriveassembly.SeeFanandFan Drive,Remove.

5. Drainthecoolantandremovethecoolantpump. SeeCoolantPump,Remove.

6. Removethealternatoranditsmountbracket,and thefrontsupportplate.

7. Removetheaircompressor.SeeAirCompressor -EnginesYGandYH,Remove.Removethecompressordrive.SeeAirCompressorDrive,Bendix, Disassemble.

8. Removethetimingcasecover.SeeTimingCase Cover,Remove.

9. Turnthecrankshaftuntilthemarkedteethofthe crankshaftgear,thecamshaftgear,andthegear forthefuelinjectionpumparealignedasshownin Figure93.Themarkedteethontheidlergearwill notnecessarilybealignedwiththemarkedteethof

600YRM705TimingCaseandTimingGearsRepair

theotherthreegearsbecauseofthedifferentspeed ofrotationoftheidlergear.

10. Removethefuelinjectionpump.SeeFuelInjection Pump,Remove.

11. Removetheidlergearandthecamshaftgear.See IdlerGearandHub,RemoveandCamshaftGear, Remove.

12. Removethecapscrewsthatholdthetimingcaseto theengineblock.Removethecapscrewsthathold theoilsumptothetiminggearcase.

13. Removethetiminggearcase,gasket,andhubfor theidlergear.Donotpermitthehubtofalland becomedamaged.

Install

1. Inspecttheoilsumpgasketfordamage.Ifthegasketisdamaged,removetheoilsumpandinstall after thetimingcasehasbeeninstalled.Adamaged sectionofthegasketcanbecutandanewsection canbeinstalledinitsplace,buttheworkmustbe carefullydonetopreventoilleaks.

2. Iftheoilsumphasbeenremoved,installthehub fortheidlergearonthefrontoftheengineblock. Usethethreecapscrewsfortheidlergeartohold thehubinposition.Makesurethattheoilholein thehubistowardthetopoftheengine.

3. Makesurethatthethrustwasherforthecamshaft isinthecorrectposition.

4. Installanewgasketforthetimingcasetotheengineblock.Cutthebottomendsofthegasketto correctlyfitthespace.Usegasketcompoundat thebottomendsofthegasket.

5. Putthetimingcaseintopositionontheengine block.Iftheoilsumpwasnotremoved,installthe hubfortheidlergear.Usethefourcapscrewsfor theidlergeartoholdthehubinposition.Make surethattheoilholeinthehubistowardthetop oftheengine.Installthefourcapscrewsthathold thehuboftheidlergeartotheengineblock.See Figure95.

6. Installthealternatoranditsfrontsupportplatein positionandinstalltheremainderofthecapscrews intothetimingcase.Ifthefrontsupportplatehas beenseparatedfromthealternatorbracket,make

surethatthesupportplateisevenwiththemachinedfaceoftheengineblockwherethealternatorbracketisinstalled.TightentheM8capscrews to22N•m(16lbfft).TightentheM10capscrewsto 44N•m(32lbfft).

1.CAPSCREWSFOR HUB

Figure95.IdlerGearHubInstallation

NOTE: Ifa newtimingcaseisbeinginstalled,remove thetwostudsfromthetimingcaseandcleanthe threadsthatfitintothetimingcase.Applyliquidsealant tothethreadsofthestudsandinstallthemintothenew timingcase.

7. Install thecamshaftgear.Installthecapscrew andwasherandtightenthecapscrewtopressthe gearintoposition.Tightenthecapscrewto95N•m (70lbf ft).

8. Lubricatethebushingsintheidlergearwithengine oil.Alignthetimingmarksontheidlergearwiththe marksonthecrankshaftgearandthecamshaft gear.Removethethreecapscrewsfromthehub forthe idlergearandinstalltheidlergear.Make surethatthetimingmarksarealignedasshownin Figure93.

9. Installthefuelinjectionpump.SeeFuelInjection Pump, Install.

10. Ifnew gearshavebeeninstalled,checkthetiming gearclearancesasshowninFigure89.Theminimumclearancesforallgearsis0.08mm(0.003in.).

11. Ifthe oilsumpwasremoved,installit.Makesure thatanyjointsinthegasketsarefittedtopreventoil leaks.

TimingCaseandTimingGearsRepair600YRM705

2.HUBFORIDLER GEAR

12. Installthetimingcasecover,coolantpump,crankshaftpulley,fandrive,alternator,drivebelts,and fan.SeeTimingCaseCover,Install.

CAMSHAFTANDTAPPETS

Remove

NOTE: Theremovalandinstallationofthecamshaft andtappetsrequiredisassemblyofmanycomponents oftheengine.Theengineisnormallyremovedfromthe lifttruckforthisoperation.Seethe Frame sectionfor procedurestoremovetheengine.Seethe Transmission sectionforprocedurestoseparatetheenginefrom thetransmission.

1. Draintheengineoilandcoolant.

2. Removethetimingcase.SeeTimingCase,Remove.

3. Removethevalvecover,rockerarmassembly,and pushrods.SeeRockerArmAssembly,Remove.

4. Removethefuelpump.

5. Turntheenginesothattheoilsumpisupandremovetheoilsump.

6. Removethethrustwasherforthecamshaft.See Figure96.

Figure97.CamshaftRemovalandInstallation

8. Removethetappets.

9. Inspectthecamshaftandthetappetsforwearand damage.SeetheEngineSpecificationsforthe measurements.Replaceanywornordamaged parts.

Install

1. Makesureallofthepartsareclean.Lubricatethe partswithengineoilastheyareassembled.

2. Installthetappetsintheirpositions.

3. Carefullyinstallthecamshaft.SeeFigure97.

4. Installthethrustwasherforthecamshaft.Make surethethrustwasherfitscorrectlyonthedowel. SeeFigure96.

5. Useanewgasketandinstallthetimingcase.See TimingCase,Install.

6. Checktheaxialclearanceofthecamshaft.Adial indicatorcanbeusedtochecktheaxialmovementfromtheendofthecamshaft.Thenormal axialmovementis0.10to0.41mm(0.004to 0.016in.).Themaximumaxialmovementpermittedis0.53mm(0.021in.).

7. Turnthecamshaftuntilthecamforthefuelpumpis attheminimumliftposition.Installthefuelpump.

7. Carefullyremovethecamshaft.SeeFigure97.

8. Turntheenginetotheuprightposition.Turnthe crankshaftuntilthekeyslotinthecrankshaftistowardthetop.Installthetiminggears.SeeCrankshaftGear,Install.

9. Installthefuelinjectionpump.

600YRM705TimingCaseandTimingGearsRepair

CAMSHAFT 2.POSITIONDOWEL Figure96.CamshaftThrustWasher

1.THRUSTWASHER,

10. Installthepushrodsandtherockerarmassembly. SeeRockerArmAssembly,Install.

11. Adjustthevalveclearances.SeeValveClearance Adjustments.

12. Installtheoilpump.

DESCRIPTION

13. Installthetimingcasecover.SeeTimingCase Cover,Install.Installtheoilsump.

14. Installtheengine.Whentheenginecanbeoperated,removetheairfromthefuelsystembefore operation.

CylinderBlockAssemblyRepair

11. Removethestartermotor.SeeStarterMotor,Remove.

Thecylinderblockismadeofcastiron.Thefour-cylinderengineshavethecylindersboreddirectlyintothe cylinderblock.Thesix-cylinderengineshaveremovablecylinderlinerspressedintothecylinderblock.A bushingisinstalledinthefrontofthecylinderblockfor thefrontjournalofthecamshaft.Theothercamshaft journalsdonothavebushingsandrundirectlyinthe cylinderblock.

CYLINDERBLOCK

Disassemble

1. Removetheenginefromthelifttruck.Seethe Frame sectionforprocedurestoremovetheengine.Seethe Transmission sectionforprocedurestoseparatetheenginefromthetransmission.

2. Removethefan,drivebelts,fandrive,andthe coolantpump.

3. ENGINESYGandYH.Iftheenginehasanaircompressor,removeit.

4. Removethecrankshaftpulley.SeeCrankshaftPulley.

5. Removethealternatoranditsmountbracket.

6. Removethetimingcasecover.SeeTimingCase Cover,Remove.

7. Removethefuelinjectionpump.SeeFuelInjection Pump,Remove.

8. Removethefuelinjectors,fuellines,fuelfilter,and fuelpump.SeetheFuelSystemRepairsection.

9. ENGINESYGandYH.Removetheoilcooler.See OilCooler(Six-CylinderEngines).

10. ENGINEYH.Removetheturbocharger.SeeTurbocharger-EngineYHRepair,Remove.

12. Removethetiminggearsandthetimingcase.See TimingCaseandTimingGearsRepair.

13. Removetheoilfilterandtheoilsump.SeeOil Sump,Remove.

14. Removethecylinderheadassembly.SeeCylinder HeadAssembly,Remove.

15. Removetheflywheelandtheflywheelhousing. SeeFlywheel.

16. Removetherearoilsealhousing.SeeRearOil Seal,Replace.

17. Iftheengineisnotalreadyinapositionwiththe crankshaftfacingup,turntheenginetothatposition.Removethesuctionlineandoilstrainer. SeeFigure115.Removethecapscrewthatholds thebrackettothemainbearingcap.Removethe twocapscrewsfromtheflangeofthesuctionline andremovethesuctionlineandscreen.Cleanthe facesofbothflanges.Removetheoilpump,deliverypipeandreliefvalve.SeethesectionsOil Pump,RemoveandReliefValve,Remove.

18. Removethebridgepieceovertherearmainbearing.

CAUTION

Makesurethecoolingjetsforthepistonsarenot damaged ormovedoutofalignment.Ifacooling jetishit,thealignmentmustbecheckedandthe coolingjetreplacedifnecessary.

19. Remove thebearingcapsandlowerbearinghalves fromtheconnectingrods.Makeanarrangement sothat thepartsforeachconnectingrodwillbeassembledagainintheiroriginalpositions.Carefully pushthepistonsintotheirboresasmallamount

CylinderBlockAssemblyRepair600YRM705

sothattheconnectingrodsareseparatedfromthe crankshaft.

20. Makesurethatthemainbearingcapsaremarked withtheirpositionnumber.Removethemainbearingcaps,lowerbearinghalves,andtheupperand lowerthrustwashers.Keepallthepartsinanarrangementsothatthepartscanbeinstalledintheir originalpositions.

21. Liftthecrankshaftfromthecylinderblock.Remove theupperbearinghalvesandputeachofthemwith theirlowerbearinghalf.

22. Carefullyremovethepistonsandconnectingrod assembliesfromtheengine.

23. Removethecamshaftandtappets.SeeCamshaft andTappets,Remove.

24. Removethecoolingjetsforthepistons.

Inspect

1. Makesurealloftheoilandcoolantpassagesinthe engineblockareclean.

2. Checktheengineblockforcracksanddamage.

NOTE: Thetopfaceofthecylinderblockforthe six-cylinderenginescannotbemachinedbecausethe cylinderlinersandpistonswillnotfit.Thetopfaceof thecylinderblockforthefour-cylinderenginescannot bemachinedbecausethepistonsandconnectingrods arematchedforeachcylinder.

3. Checkthefrontbushingforthecamshaftforwear. Ifanewbushingmustbeinstalled,useapullerto removetheoldbushing.Makesuretheoilholefor thenewbushingisawayfromtheenginewhenitis installed.Makesuretheoilholeisalignedwiththe passageinthecylinderblockwhenitisinstalled. Useapresstoinstallanewbushingandalignitin positioninthecylinderblock.

Assemble

1. Makesureallthepartsareclean.

2. Removethescrewplugsfromthecylinderblock andcleanthethreads.Applyasealanttothe threadsoftheplugsandinstalltheminthecylinder block.

3. Installthecoolingjetsforthepistons.SeePiston CoolingJets,Install.

4. Installthecrankshaftandtherearoilsealassembly. SeeCrankshaftAssemblyRepairsection.

5. Installtheflywheelhousingandflywheel.SeeFlywheelsection.

6. Installthetappetsandthecamshaft.SeeCamshaft andTappets,Install.

7. Installthereliefvalve,oilpump,suctionline,andoil strainer.

8. Installthetimingcaseandthetiminggears.See TimingCaseandTimingGearsRepair.

9. Installthecylinderheadassembly.SeeCylinder HeadAssembly,Install.

10. Installthestartermotor.

11. Installthefuelpump.

12. ENGINEYH.Installtheturbocharger.SeeTurbocharger-EngineYHRepair,Install.

13. Installtheoilfilterassemblyandtheoilsump.See OilSump,Install.

14. Installtheoilcooler.SeeOilCooler(Six-Cylinder Engines).

15. Installthefuelinjectors,fuellines,fuelfilter,andfuel injectionpump.SeeFuelSystemRepairsection.

16. Installthecoolantpump,fandrivepulley,andfan. SeeCoolingSystemRepairsection.

17. Installthealternatorandmountbrackets.

18. Installthedrivebeltsandadjustthetension.See DriveBelts.

19. Installtheengineintothelifttruck.

20. Removetheairfromthefuelsystembeforeoperatingtheengine.SeeFuelSystemAirRemoval.

CYLINDERBORE(FOUR-CYLINDER ENGINES)

Toensurethebestperformanceduringthelifeofthe engine,itisimportantthatwornordamagedcylinder boresarecorrected.

Theconditionofacylinderboreisdecidedby:

• Theamountandlocationofanypolishedareas.

• Wear.

• Damagetothecylinderwall.

600YRM705CylinderBlockAssemblyRepair

NOTE: Itwillnotbenecessarytocorrecttheboreif:

• Thehonedfinishcanstillbeclearlyseen.

• Theengineperformanceandoilconsumptionisacceptable.

1. Inspectthesurfaceofthecylinderboreforcracks anddeepscratches.

2. Checktheborewallforareaswherethehonedfinishhasbeenpolishedaway.Checkespeciallythe areaaroundthetopofthelinerborejustbelowthe carbonring.Inthisarea,thrustfromthetoppiston ringisatitsmaximum.

CAUTION

Donotuse"Flex-hone"torepaircylinderbores.

Anenginecanhavehighoilconsumptionwithvery littlewearofthecylinderbores,ifthesurfacesof theboresare glazed.

Specialisttrainingandequipmentisneededtomachinethefinishofacylinderbore.

3. Ifnecessary,thecylinderborescanbeboredand honed0.50mm(0.0195in.)1.00mm(0.039in.) oversizein diameterandoversizepistonsinstalled.

4. Toobtainoversizecylinderborestheymustbe boredandthendiamondhoned,siliconcarbide basehonedandsiliconcarbideplateauhonedto thefinishedsizetoconformtothedimensionsin theEngineDatasection.Specialisttrainingand equipment isneededtomachineboreacylinder bore.Forfurtherinformationcontactyournearest Perkinsdistributor.

CYLINDER LINER(SIX-CYLINDER ENGINES)

Inspect

Forthebestperformanceduringthelifeoftheengine, itisimportantthatwornordamagedcylinderlinersare replaced.Ifachangeoflinerbecomesnecessary,transitionfitlinersandpartiallyfinishedlinersareavailable. Theconditionofacylinderlinerisdecidedby:

• Theamountandlocationofanypolishedareas.

• Wear.

• Damagetothelinerwall.

NOTE: Itwillnotbenecessarytoreplacethelinersif:

• Thehonedfinishcanstillbeclearlyseen.

• Theengineperformanceandoilconsumptionisacceptable.

CylinderLinerCondition,Check

1. Inspectthelinersurfaceforcracksanddeep scratches.

2. Checkthelinerwallforareaswherethehonedfinishhasbeenpolishedaway.SeeFigure98andFigure99.Checkespeciallytheareaaroundthetop ofthelinerborejustbelowthecarbonring.Inthis area,thrustfromthetoppistonringisatitsmaximum.

CylinderBlockAssemblyRepair600YRM705

Figure98.CylinderLinerWearCheck

Figure99.WheretoMeasureCylinderLinerfor WearCheck

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