GM ENGINES 4.3 litre V-6 5.7 litre V-8SAFETY PRECAUTIONS MAINTENANCE AND REPAIR ‘When lifting parts or assemblies, make sure that all slings, chains or cables are correctly fastened and that the load being lifted is balanced, Make sure that the crane, cables and chains have the capacity to support the weight of the load, Do not lift heavy parts by hand. Use a lifting mechanism, Wear safety glasses. DISCONNECT THE BATTERY CONNECTOR before doing any ‘maintenance or repair on electric lift tricks. Disconnect the battery ground cable on internal combustion lift trucks. Always use correct blocks to prevent the unit from rolling or falling. See “How To Put The Lift Truck On Blocks” in the OPERATING MANUAL or the PERIODIC MAINTENANCE section. Keep the unit and working area clean and in order. Use the correct tools for the job. Keep the tools clean and in good condition, Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer, Make sure that all nuts, bolts, snap rings and other fastening devices are removed before using force to remove parts. Always fasten a DO NOT OPERATE sign to the controls of the unit when making repairs or if the unit needs repairs. Make sure you follow the DANGER, WARNING and CAUTION notes in the instructions, Gasoline, Liquid Petroleum Gas (LPG), and Diesel are flammable fuels. Make sure that you follow the necessary safety precautions when handling these fuels and when working on these fuel systems. Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area has ventilation.CONTENTS GM 4.3 LITRE V-6 AND 5.7 LITRE V-8 ENGINES 4.544 DESCRIPTION .. 5 : ENGINE, REMOVAL AND INSTALLATION ........ CYLINDER HEAD . Removal And Disassembly Cleaning And Inspection Repairs, Valve Guides and Seats . . Studs For The Rocker Arms . ‘Valve Springs ASSEMBLY AND INSTALLATION CYLINDER BLOCK, CLEANING AND INSPECTION PISTON BORE PREPARATION .. ENGINE MOUNTS ... LUBRICATION SYSTEM Oil Pump, Removal and Disassembly . . Cleaning and Inspection Oil Pump, Assembly and Installation TIMING COVER, TIMING SPROCKETS, CAMSHAFT AND CAM FOLLOWERS ‘Timing Cover, Removal ........ Installation . . Timing Sprockets, Removal. Timing Sprockets, Installation . Camshaft, Removal... Camshaft, Inspection . . Camshaft, Installation Hydraulic Valve Lifters, Removal Hydraulic Valve Lifters, Disassembly Hydraulic Valve Lifters, Cleaning And Inspection . Hydraulic Valve Lifters, Assembly .. CRANKSHAFT Removal . Inspection and Repair ..... eee sevens How To Check The Clearance Between The Main Bearings And Their Journals Installation . ; PISTON AND CONNECTING ROD ASSEMBLIES ..... Connecting Rod Bearings, Replacement . . @HYSTER COMPANY 1993Piston And Connecting Rod Assemblies, Removal. Disassembly ..... Piston, Cleaning And Inspection ....... Cylinder Bores, Inspection And Repair Piston Rings ........ Assembly .. Piston And Connecting Rod Assemblies, Installation FLYWHEEL AND FLYWHEEL HOUSING Flywheel Repair For V~ Flywheel For V-6 Engines, Installation . Flywheel Housing, H3.50-5.00XL (H70-110xL) . Engine Adapter, H6.00-7.00XL (H135-155XL) Ring Gear Replacement (Flywheel) For V-8 Engines... Flywheel For V-8 Engines, Flywheel Housing. COOLANT PUMP ... FAN MOUNT CHECKS AND ADJUSTMENTS . Valve Clearance Adjustment ENGINE SPECIFICATIONS ... Engine Data ...... Cylinder head... Hydraulic Valve Lifter Camshaft Pistons ... Crankshaft... Connecting Rods Cooling System Lubrication System 6 Engines . ‘TORQUE SPECIFICATIONS FOR CAPSCREWS AND BOLTS . TROUBLESHOOTING ‘This section is for the following models: 113.50-5.00XL (H70-I10XL), $3.50-5.50XL (S70-120XL) H6.00-7.00XL (H135-155XL), $6.00-7.00XL (S135-155XL), H1150-275H, P1S0-200B, M200-400H ‘@HYSTER COMPANY 1993, 2 12 13 B 4 4 15 15 15 15 15 15 16 16 a 7 18 18 18 18 18 19 19 19 20 20 20GM 4.3 LITRE V-6 AND 5.7 LITRE V-8 ENGINES This section has the description and the repair instruc- tions for the GM 4.3 litre V-6 and the 5.7 Litre V-8 en- gines. Checks and Adjustments, Troubleshooting pro- cedures and Specifications are also included in this sec- tion. DESCRIPTION The arrangement of the cylinders is in a "V” shape. The cylinder block is made of cast iron, The V-8 engine has five main bearings for the crankshaft. The V-6 engine has four main bearing: The cylinder head is cast iron and has an intake valve and an exhaust valve for each cylinder. The valve mech- anism is actuated by push rods and rocker arms from the camshaft, ‘The camshaft has five bearings on the V-8 and four bearings on the V-6, The camshaft is driven by a chain from the crankshaft. Hydraulic cam followers are used to actuate the push rods. ‘The pistons are made of cast aluminum and have two compression rings and one oil control ring. ENGINE, REMOVAL AND INSTALLATION ‘The Removal and Installation procedures for the engine is in the section for THE FRAME for each model of lift truck, See the sections for the TRANSMISSION to sep- arate the transmission from the engine. CYLINDER HEAD Removal And Disassembly (See FIGURE 1.) A warninc Disconnect the battery cables before making repairs to the engine. 1. Drain the coolant from the engine. 2. Disconnect and remove the coolant hose from the housing for the thermostat. 3. Remove the air cleaner, carburetor, distributor, intake ‘manifold and the exhaust manifolds. Loosen the drive belts and remove the bracket for the fan mount from the cylinder heads. 4, Remove the rocker arm cover. ‘5. Remove the capserews that hold the cylinder head to the block. Loosen the capscrews in the reverse order of the tightening sequence shown in FIGURE 5. Remove the cylinder head and the gasket. 6, Remove the nuts and balls for the rocker arms, Re- ‘move the rocker arms. Keep the parts for each rocker arm assembly together. 7. Use a valve spring compressor and remove the valves and springs. Put the valves in a rack so that they can be installed in their original positions. 4. CYLINDER HEAD 2. CY-INDER BLOCK 3. CAM FOLLOWER 4, PUSH ROD 5. ROCKER ARM 6. CAMSHAFT FIGURE 1. CYLINDER HEAD Cleaning And Inspection Clean the carbon from the ports and chambers in the cyl- inder heed. Clean the carbon and oil from the valves, push rods and rocker arms. Inspect the cylinder head for cracks in the ports and chambers. Inspect the valves for cracks in the heads or damaged stems. Repairs, Valve Guides and Seats Measure the clearance between the valve stem and the Buide as shown in FIGURE 2. The maximum clearance for the imake valves is 0.094 mm (0.0037 in) The maxi- mum clearance for the exhaust valves is 0.119 mm (0.0047 in). Ifthe clearance is more than the maximumamount, oversize valves must be installed, Use a reamer of the correct size when installing oversize valves. Use normal service procedures when grinding the valve seats. See the Specifications for dimensions. 1. VALVE STEM 2. DIAL INDICATOR FIGURE 2. VALVE STEM CLEARANCE ‘Studs For The Rocker Arms Replace a stud that has damaged threads or is loose in the cylinder head. New studs are available in the following oversizes: 0.003 inch and 0.013 inch, 1. Remove the old stud, Install a spacer, flat washer, and nut to the damaged stud. Use a wrench to remove the damaged stud. See FIGURE 3. FIGURE 3. REMOVE A STUD FOR A ROCKER ARM Acaution Do not attempt to install an oversize stud without reaming the stud hole to the new size. Installation of an oversize stud without reaming the stud hole can cause cracks in the cylinder head. 2. Use a reamer of the correct size for the new oversize stud. Apply SAE 90 lubricant to the new stud during in- stallation. Install the new stud as shown in FIGURE 4. 1. REAMER 2. INSTALLATION TOOL ROCKER ARM Valve Springs (See FIGURE 38.) Use a special tool to check the tension of the valve springs. Compress the spring to the correct height and ccheck the tension, See Specifications for the correct ten- sion. Replace valve springs that are not within 44 N (10 Ib) of specifications,ASSEMBLY AND INSTALLATION 1. Install each valve in the correct port. Install the shim and valve springs. Compress the spring and install the oil seal in the lower groove. On the exhaust valves, install the valve rotators. Install the valve retainer cap and retainers. Measure the height of the valve spring as shown in FIGURE 38, Measure from the top ofthe shim to the top of the retainer cap. Install shims to get the cor- rect height shown in Specifications. The installed height of the valve spring must not be less than the minimum height. 2. Clean the surface of the cylinder head and the top of, the cylinder block. Make sure the threads in the block are clean. 3. Install the cylinder head gasket and cylinder head. If a steel gasket is used, use a sealant on both sides of the gasket, Do not use a sealant when a steel and asbestos, ‘gasket is used. Make sure the cylinder head is aligned with the pins in the block. 4, Use a sealant on the threads of the capscrews for the cylinder head. Install the capscrews and tighten them in steps until the final torque is reached. The final torque is 88 N.m (65 lbs ft). Use the tightening sequence shown in FIGURE 5 FAN END V-6 ENGINE ® 00008 FIGURE 5. TIGHTENING SEQUENCE, CYLINDER HEAD 5. Install the intake manifold and gaskets. Tighten the capscrews in the sequence shown in FIGURE 6. On the V-6 engines, tighten the capscrews to 47 N.m (35 Iby ft). On the V-8 engines, tighten the capscrews to 41 Num (30 Ibe ft. V-8 ENGINE FIGURE 6. TIGHTENING SEQUENCE, INLET MANIFOLD 6. Install the push rods, making sure they are in the seat of the cam follower. Lubricate the rocker arms and rock- ‘er arm balls with a molybdenum grease. Install the rock- cer arms, balls and nuts. Tighten the nuts and adjust the valve clearance as described in Checks and Adjust- ments, 7. Use a aew gasket and install each valve cover. On the ‘V-6 engines, tighten the capscrews to 10 Nm (7 Iby ft). (On the V-8 engines, tighten the capscrews to 5 N.m (4 Iby ft. 8. Install the exhaust manifolds. Use new gaskets when they are required, Do not use a sealant on the gaskets. On the V-8 engines, tighten all of the capscrews for the ex- 3haust manifolds to 27 N.m (20 Ib; ft). On the V-6 en- ines, tighten the capscrews at the center port to 35 N.m (26 tbs ft). Tighten the capscrews at the outer ports to 27 Nam (20 by ft). FIGURE 7. VALVE COVERS 9. Install the coolant hose to the housing for the thermo- stat, Fill the coolant system with coolant, See PERIOD- IC MAINTENANCE. CYLINDER BLOCK, CLEANING AND INSPECTION After the engine is disassembled, clean the cylinder block in solvent, Make sure all of the oil passages are clean. Remove the gaskets from the surface of the block. Inspect the bores for the pistons for wear or damage. Measure the bores and check the dimensions shown in Specifications. Repair the cylinder block as necessary. NOTE; It is important that the piston bores are prepared correctly before new piston rings are installed. Incorrect preparation can cause the parts to wear quickly. 4 PISTON BORE PREPARATION Use a hone in the piston bores when installing new rings. Use the hone as follows: 1. Use a hone with a 280 grit stone, Make sure the stone is clean and will rot damage the bore. 2. Move the hone quickly (approximately 60 times per ‘minute) up and down in the bore. Make sure the hone ‘makes a cross pattern of 45 to 60 degrees. Use the hone until the entire lergth of the bore has this patter. 3, After using the hone, clean the cylinder block with hot ‘water and detergert, Make sure all metal particles are re- moved from the block. Dry the bores and lubricate them with engine oil. ENGINE MOUNTS If the engine mount was removed from the cylinder block, tighten the capscrews for the mount as follows: H3,50-5.00XL (H70-I10XL), 31 N.m (23 Iby ft); H6.00-7.00XL (H135—155XL), 50 N.m (37 Iby ft); H1S0-275H, 50 N.m (37 Iby ft). LUBRICATION SYSTEM Oil Pump, Removal and Disassembly (See FIGURE 8.) 1. Remove the oil sump. 2, Remove the capscrew at the mount for the pump. Re- ‘move the oil pump and shaft. 3, Remove the cover forthe oil pump. Put marks on the ‘gear teeth to show their correct location during assem- bly. 4, Do not remove the tube and screen assembly unless it is damaged. The tube and screen must be replaced as an assembly. Cleaning and Inspection Clean the parts ofthe oil pump in solvent and dry with ‘compressed air. Inspect the gears, shaft and body of the ump for wear or damage. If any of the parts are worn or damaged the oil pump must be replaced, Separate parts are not available, il Pump, Assembly and Installation (See FIGURE 8.) NOTE: There are some variations in the oil pumps installed during the years of manufacture of these en-ines, but the design is the same. The repair procedures are the same. See the PARTS MANUAL for each oil pump. 1. Use a sealant when replacement of the tube and screen assembly is necessary. Do not damage the tube during installation, Make sure that the surface of the screen as- sembly is parallel to the bottom surface of the cylinder block. HOUSING . COVER |. RETAINER PIN . SPRING. RELIEF VALVE 6. CAPSCREW ‘AND WASHER 7. SCREEN 9. RETAINER 8. CAPSCREW 10. SHAFT FIGURE 8. OIL PUMP 2. Install the gears in the body of the pump. Make sure to align the identification marks. Make sure that the smooth side of the idler gear is toward the cover. Install the cover for the oil pump and tighten the capscrews to 5 Nam (40 tbs in). Turn the shaft forthe oil pump and check for smooth operation. 3, Install the oil pump assembly to the engine. Make sure the shaft is aligned with the slot in the distributor shaft Tighten the capscrew at the mount on the bearing cap to 47 N.m (35 Ib ft). 4, Install new gasket(s) and the oil sump. Use a sealant on the gasket(s). Tighten the capscrews for the ol as follows: 1/4-20 capscrews, 10 N.m (7 Ib ft); 5/16-18 capserews, 19 N.m (14 Iby fi). 1. OIL SUMP 2. GASKET 3. SEAL 4. PLATE V-8 ENGINE FIGURE 9. OIL SUMP. TIMING COVER, TIMING SPROCKETS, CAMSHAFT AND CAM FOLLOWERS Timing Cover, Removal 1, Remove the fan assembly and belts. If installed, re- move the drive shaft atthe crankshaft pulley. 2, Remove the crankshaft pulley and vibration damper. Use a tocl that pulls on the center of the vibration damp- er, Do net pull on the outside diameter of the vibration damper. 3, Remove the timing cover. 4, Carefully remove the oil seal from the cover. Installation (See FIGURE 10.) 1. Install a new oil seal in the cover. Make sure the open side of the seal is toward the inside of the cover. 2. Use a sealant on the new gasket for the cover. During. installation of the cover, use a special tool to align the oil seal with the crankshaft. The vibration damper will damage the oil seal if tis not installed correctly. Tighten the capscrews for the cover to 9 N.m (7 Iby ft). 3. Use a special tool to install the vibration damper. Tighten the capscrew for the damper to 81 N.m (60 Ib fi,4, Install the crankshaft pulley, drive shaft, belts and fan assembly. TIMING COVER GASKET TOOL FOR VIBRATION DAMPER |. VIBRATION, DAMPER FIGURE 10. TIMING COVER Timing Sprockets, Removal Remove the timing cover, Remove the capscrews for the camshaft sprocket. Use a puller to remove the crank- shaft sprocket. Make sure the timing chain is removed with the sprockets. Timing Sprockets, Installation (See FIGURE 11.) 1. Install the chain on the camshaft sprocket. Install the camshaft sprocket and the crankshaft sprocket. Make sure the marks are aligned as shown in FIGURE 11. Tighten the capscrews to the camshsft sprocket to 27 Nam (20 Ibe ft). 2. Lubricate the chain and sprockets with engine oil. Install the timing cover. 6 No. 1 CYLINDER No. 6 CYLINDER ATTDG, FIGURE 11. TIMING MARKS Camshaft, Removal 1. Remove the intake manifold, push rods and cam fol- lowers. Remove the fuel pump. 2. Remove the timing cover. Align the timing marks and then remove the timing chain and sprockets. 3. Carefully remove the camshaft from the cylinder block. Al of the camshaft bearings are the same size, Do not damage bearings or camshaft during removal. 4, If necessary, use a special tool as shown in FIGURE 12. to remove the camshaft bearings, Remove the front and rear bearings last. 1. TOOL FOR CAMSHAFT BEARINGS FIGURE 12. CAMSHAFT BEARINGS Camshatt, Inspection Measure the diameter of each bearing surface on the ‘camshaft, Do the measurement at different positions onthe surface of the bearing to see if they are round. If the difference of the readings for each bearing is more than 0.025 mm (0.001 in), replace the camshaft Camshaft, Installation 1. Use a special tool as shown in FIGURE 12. to install the camshaft bearings. Install the front and rear bearings first. Make sure the oil holes in the bearings are aligned with the oil holes in the block. Use a sealant on the rear ‘camshaft plug and install the plug in the block. Make sure the plug is even with or 0.80 mm (0,08 in) below the surface of the block. 2. Lubricate the camshaft lobes with a molybdenum lu- bricant. Lubricate the camshaft bearings with engine oil, Carefully install the camshaft in the cylinder block. and cover as de- 3, Install the timing sprockets, cl scribed in Timing Cover. 4, Lubricate the cam followers with a molybdenum lu- bricant. Install the cam folowers in the block, Install the push rods and adjust the valve mechanism as described in Checks and Adjustments. Hydraulic Valve Lifters, Removal 1. The hydraulic valve lifters normally do not need re- pair unless varnish or dirty engine oil has caused them to malfunction. The hydraulic valve lifters must be clean to operate correctly. If a hydraulic valve lifter must be disassembled, make sure the small parts are handled carefully to prevent loss or damage. 2. The push rods must be removed as described under “Cylinder Head, Removal”. Remove the side cover from the cylinder block. 3, Remove the hydraulic valve lifters and put them in a rack so that they can be installed again in the same posi- tion in the engine. Hydraulic Valve Lifters, Disassembly 1. See FIGURE 13. Hold the plunger (2) down with a push rod. Use the blade of a small screwdriver to remove the retainer for the push rod seat (7). 2. Remove the push rod seat (3) and the metering valve ©). 3, Remove the plunger (2), check ball assembly (5), and the plunger spring (4). a) ; ‘ RE. ’ 5 LIFTER BODY © PLUNGER 6 . PUSH ROD SEAT }. SPRING: T CHECK BALL ASSEMBLY METERING VALVE RETAINER, PUSH ROD SEAT FIGURE 13. HYDRAULIC VALVE LIFTER Nogsene 4, See FIGURE 14. Use a small screwdriver as a prybar to remove the check ball retainer from the plunger. FIGURE 14. REMOVE THE CHECK BALL. ‘ASSEMBLY Hydraulic Valve Lifters, Cleaning And Inspection Clean all parts in a cleaning solvent and inspect them carefully. If any parts are damaged or wor, the com- plete hydraulic valve lifter must be replaced. If the body of the hydraulic valve lifter is wor, also inspect the bore in the cylinder block. If the bottom of the hydraulic valve lifter is wom or damaged, inspect the camshaft lobe for wear and damage. The bottom of the lifter must be convex for correct rotation during engine operation, 7Hydraulic Valve Lifters, Assembly 1. Assemble the check ball assembly, Put the check ball ‘on the small hole inthe bottom of the plunger. Install the check ball spring in the seat of the check ball retainer. Put the check ball retainer over the check ball so that the check ball spring is on the check ball. Carefully press the check ball retainer into position in the plunger. See FIGURE 15. 3. See FIGURE 13. Put the plunger spring (9) over the check ball retainer (5) and slide the lifter body (1) over the spring and plunger. \ FIGURE 15. INSTALL THE CHECK BALL ‘ASSEMBLY 4, Fill the assembly with SAE 10 engine oil. Put a3 mm (fg inch) drift into the plunger and push the plunger un- til the holes for oil are aligned. See FIGURE 16. Now puta 1.6 mm (!/16 inch) drift through the holes to hold the plunger. Remove the 3 mm (1/g inch) drift and fill the assembly again with SAE 10 oil 5. Install the metering valve (3) and push rod seat (2). ‘See FIGURE 13. Install the retainer, push rod seat (6). Push down the push rod seat to loosen the 1.6 mm (1/16 inch) drift and remove the drift, The hydraulic valve lift er is now ready for installation. 8 1/8" DRIFT PIN OIL FEED HOLE 116" PIN FIGURE 16. ASSEMBLY, HYDRAULIC VALVE LIFTER CRANKSHAFT Removal (See FIGURE 17.) 1. OIL SEAL, 2. THRUST BEARING 3. MAIN BEARING CAP 4 CRANKSHAFT FIGURE 17. CRANKSHAFT 1, Remove the oil pan, oil pump and flywheel. On V-6 engines, remove the rear seal retainer, 2. Use a special tool to remove the vibration damper. 3. Remove the caps for the connecting rods.4, Remove the caps for the main bearings. Make sure that there are identification marks on the caps during re- moval. 5, Carefully remove the crankshaft. Inspection and Repair 1, Clean the crankshaft with solvent and dry it with com- pressed air. 2. Inspect the crankshaft for cracks or other damage. 3, Inspect the crankshaft for wear and damage. See FIGURE 18. Use a micrometer to measure the journals for the bearings of the crankshaft. Do the measurement at different positions to see if the surface of the bearing is round, The correct sizes are given in the ENGINE SPECIFICATIONS. FIGURE 18, CRANKSHAFT INSPECTION 4, If the crankshaft journals must be repaired, they can be ground to the following diameters smaller (under- size) than the original size: 0.25 mm (0.010 in) 0.50 mm (0.020 in) NOTES ABOUT MAIN BEARINGS: Main bearings are an insert bearing that does not use shims for adjust- ment. Main bearings are available in a standard size and the following undersizes: 0.001 in, 0.002 in, 0.009 in, 0.010 in, and 0.020 in, Ifa bearing on a journal is worn, both the upper and lower half of the bearing must be re- placed. ‘When the crankshaft is assembled by the manufacturer, the main bearings are specially selected to obtain close tolerances. For this reason, you can find one-half of a standard size insert with one-half of a 0.001 in under- size insert. This combination will decrease the clearance 0.0005 in from using a full standard bearing. ‘When a production crankshaft can not be fitted with this ‘method, the main journal is then ground 0.009 in under- size. Only those main bearing journals that can not be fitted with standard, 0.001 in or 0.002 in undersize main bearing will be ground. A 0,009 in and a 0.010 in under- size bearings will be selected as described to obtain close tolerances. ‘A production crankshaft that has been ground will have the following identification: ‘+ The crankshaft journal that has been ground will have a “9” marked in the metal of the crankshaft next to the journal. A spot of light green paint is also added to the crankshaft. © The main bearing cap is also marked with green paint, How To Check The Clearance Between The Main Bearings And Their Journals 1. Use PlastigageR or equivalent to check the clearance. ‘The procedure is similar for both connecting rod bear- ings and main bearings. Ifthe engine has been removed from the lft truck put the engine so that the crankshaft is up. The weight of the crankshaft is against the upper bearing half and the total clearance can be measured cor- rectly. Ifthe engine is still in the lift truck, the crankshaft ‘must have a support to remove any additional clearance between the upper bearing half and its journal. 2. All main bearing caps must be installed and their capscrews tightened to the specifications. 3. Check the rear main bearing first. Remove the cap for the rear main bearing. The procedure for checking the clearance of the other bearings is similar. 4, Clean the oil from the bearing half and journal to be checked. Put a piece of Plastigage across the full width of the bearing journal as shown in FIGURE 21, Do not rotate the crankshaft when the Plastigage is between the main bearing and its journal.5. Install the main bearing cap and tighten the capscrews. (See TORQUE SPECIFICATIONS FOR CAPSCREWS AND BOLTS.) The capscrews must be tightened to their final torque or there will be an error in the measurement. 66. Remove the main bearing cap. The Plastigage will be ‘compressed and wider and will adhere to either the bear- ing or its journal. Use the scale on the envelope for the Plastigage to measure the width of the plastic at its wid- est point. The scale will indicate the clearance in milli- ‘metres or thousandths of an inch. See FIGURE 22. 7. Ifthe clearance is greater than the specifications, se- lect a new undersize bearing set and install it. Measure the clearance again. If the clearance can not meet speci- fications with the available undersize bearings, the bear- ing journal must be ground to a new undersize. If the bearing journal is already at the maximum undersize, the crankshaft must be replaced. 8, Ifthe clearance is within specifications, lubricate the bearing with engine oil and install the main bearing and bearing cap. Tighten the capscrews on the main bearing cap to the correct specifications. 9. Turn the crankshaft to make sure it rotates smoothly. FAN END a 1. MEASURE CLEARANCE FIGURE 19. MEASURE THE AXIAL CLEARANCE OF THE CRANKSHAFT 10 10, Check the axial clearance between the rear main bearing and the thrust surface. Push the crankshaft for- ward, See FIGURE 19. Measure the clearance between the crankshaft and the thrust surface of the rear bearing. The correct clearance is 0.05 t0 0.15 mm (0.002 to 0.006, inch). Installation 1. On engines with a two-piece rear seal, install the seal halves so that the lips are towards the fan end of the en- gine. Apply engine oil to the seal during installation, Do ‘not get any oil on the ends of the seal. NOTE: With the use of special tools, the main bearings and the rear crankshaft seal (two-piece) can be replaced without removing the crankshaft. 2. Install the main bearings in the cylinder block and the bearing caps. Lubricate the bearings with engine oil and carefully install the crankshaft in the cylinder block. 3. Install the bearing caps. Make sure the arrows on the bearing caps are towards the front (fan end) of the en- gine. Push the crankshaft forward and measure the clearance at the front side of the rear main bearing. The correct clearance is (.05-0.15 mm (0.002-0.006 (See FIGURE 19.) 4. On the V-6 engine, tighten the capscrews for the bear- ing caps to 70 N.m (52 Iby ft). On the V-8 engines, tight- en the capscrews for all of the bearing caps except the rear bearing cap to 95 N.m (70 lby ft). Tighten the cap- serews for the rear bearing cap to 14 N.m (10 Iby ft). Move the crankshaft forward and backward to align the rear main bearing. Tighten the capscrews forall bearing, ‘caps to 95 Num (70 Iby ft). 5. Install the connecting rods, oil pump and oil pan. Install the flywheel and other parts. 6. On late mode! engines with a one-piece seal, install the seal in the retainer, Use a sealant between the seal re- tainer and the cylirder block, then install the seal retain- er (See FIGURE 20,)3, SEAL RETAINER 4. ENGINE BLOCK 1. CRANKSHAFT 2. OIL SEAL FIGURE 20. REAR SEAL PISTON AND CONNECTING ROD ASSEMBLIES Connecting Rod Bearings, Replacement NOTE: Connecting rod bearings are insert bearings that do not use shims for adjustment. These bearings are available in a standard size and the following under- sizes: 0.001 in, 0,002 in, 0.010 in, and 0.020 in. Ifa bear- ing on a journal is worn, both the upper and lower half of the bearing must be replaced. 1, Remove the oil sump and the oil pump. 2. Before the cap for the connecting rod is removed, mark the connecting rod and cap with the cylinder num- bber so that the parts will be installed again in their origi- nal positions. Remove the cap for the connecting rod bearing and the lower bearing half. 3. Push the connecting rod away from the crankshaft and remove the upper bearing half. Wipe the oil from the bearing halves and the bearing journal. 4, Use a micrometer to measure the bearing journal. The bearing journal must be within the following specifica- tions: Out-of-round less than 0.0254 mm (0.001 in) ‘Taper less than 0.0254 mm (0,001 in) If the bearing journals are not within specifications, the crankshaft must be removed and the bearing journal ground to an undersize. If the bearing journal can not be repaired so that the bearing journal is a correct under- size, the crankshaft must be replaced. See the ENGINE SPECIFICATIONS, Crankshaft. 5. If the bearing journal is within specifications, mea- sure the clearance between the new bearing and the crankshaft. Use Plastigage® or equivalent to check the clearance: a, Puta piece of Plastigage across the full width of. the bearing journal as shown in FIGURE 21. Do not rotate the crankshaft when the Plastigage is between the bearing and its journal. FIGURE 21. PLASTIGAGE® ON A BEARING JOURNAL b. Remove the bearing cap. The Plastigage will be compressed and wider and will adhere to either the bearing or its journal, Use the scale on the en- vvelope for the Plastigage to measure the width of the plastic at its widest point, The scale will indi- cate the clearance in millimetres or thousandths of an inch. See FIGURE 22. FIGURE 22. MEASURE THE PLASTIGAGE® ON ABEARING JOURNAL . Ifthe clearance is greater than the specifications, select a new undersize bearing set and install it ‘Measure the clearance again. Ifthe clearance can not meet specifications with the available under size bearings, the bearing joumal must be ground uto a new undersize. If the bearing journal is al- ready at the maximum undersize, the crankshaft must be replaced, 4. If the clearance is within specifications, lubricate the bearing with engine oil and install the bearing and bearing cap. Tighten the nuts on the bearing cap. (See TORQUE SPECIFICATIONS FOR CAPSCREWS AND BOLTS.) 6, When all of the rod bearings have been replaced, use the following procedure to check the side clearances be- tween the connecting rods and the crankshaft: a. Use a hammer to lightly hit the connecting rod parallel to the crankshaft journal to make sure there is a clearance. b. Measure the clearance between the caps for the connecting rods and the crankshaft. See FIGURE 23. FIGURE 23. MEASURE THE SIDE CLEARANCE, CONNECTING RODS Piston And Connecting Rod Assemblies, Removal 1, Remove the oil sump and the oil pump. 2. Remove the cylinder head as described in Cylinder Head, Removal, 3. If the engine has been in service for many hours, a ridge can be worn in the top of the cylinder. This ridge ‘can be removed with a ridge reamer tool. Turn the crank- shaft to lower the piston to the bottom of the stroke in its cylinder. Puta cloth on top of the piston fora collector of ‘metal particles, Remove the ridge at the top of the cylin- der. 4, Clean the carbon from the top of each cylinder. 5, Put an identification mark on the top of each piston, 2 6, Remove the caps and bearings from each connecting rod. Keep the caps and bearings with their original pis- ton assemblies. Mark the caps so that they will be in- stalled again in their original positions. Do not mix the parts. 7. Push the connecting rod and piston from the cylinder. ‘Temporarily install the bearing cap on the connecting rod to keep the parts together. Disassembly Acaution ‘The pistons are aluminum alloy and can be damaged if they are hit with a hard object. The grooves for the piston rings are machined to close tolerances. Use a tool made to clean the grooves of the piston rings. Do not use a wire brush to clean a piston. 1, Remove the piston rings from the pistons. Use a press to remove the piston pins from the piston. See FIGURE 24. FIGURE 24, PISTON PIN REMOVAL 2. Use solvent to clean the pistons and connecting rods. Use compressed airto dry the parts. Make sure that the holes for oil passages are clean,Piston, Cleaning And Inspection Inspect the pistons for wear, cracks, and damage, Re- place a piston that is worn or damaged NOTE: Ifthe cylinder bore must be repaired the piston must be changed to the correct oversize. Check the Clearance of the piston in its cylinder after the surface of the cylinder bore has been finished with a hone. (Check the clearance of the piston pin in the piston. The normal clearance is shown in the ENGINE SPECIFI- CATIONS. The piston pin will normally fall from the hole inthe piston by its own weight. The piston pin is a press fit in the connecting rod. The piston and piston pin are a matched set and must be replaced as a unit if the clearances are greater than the specifications. Cylinder Bores, Inspection And Repair Inspect the cylinder bores for wear and damage. Mea- sure the cylinder bores in several positions as shown in FIGURE 25. Measure the cylinder bore at right angles to the centerline to find any distortion from wear. A cyl- inder that is out-of-round greater than 0.05 mm (0.002 in) must be repaired. SN. = FIGURE 25. MEASURE THE CYLINDER BORE Measure the cylinder bore in positions from top to bot- tom to find any taper from wear. A normal wear pattern for a cylinder bore is shown in FIGURE 26. A cylinder that has a taper [measurement “A” that is 0.127 mm (0.005 in) greater than measurement “B”] must have a new bore. A tool called a hone can be used to remove a small amount of taper from a cylinder bore. Use a boring machine to repair a badly worn cylinder. The boring ma- cchine will make a more accurate cylinder bore. The hone is then used to finish the surface of the cylinder bore. 8 FIGURE 26. PATTERN FOR NORMAL. CYLINDER WEAR BORE GAUGE POINT FIGURE 27. GAUGE POINTS FOR PISTON AND CYLINDER BORE, ‘Acylinder bore that has been repaired with a hone or a boring machine must be fitted with a piston that is the correct size. Measure the outer diameter of the piston and the inner diameter of the cylinder bore as shown in FIGURE 27. Using different oversize pistons in the en- gine does not affect the dynamic balance of the engine. Replacement pistons from standard size to 0.030 inch oversize normally have the same weight. The clearance specifications between a piston and its cylinder bore is, shown in the ENGINE SPECIFICATIONS. BPiston Rings NOTE: Check the clearance of the piston rings in the cylinder after the surface of the cylinder has been fin- ished with a hone. New piston rings are available for the following piston sizes: standard size, and 0,005 in, 0.010 in, 0.020 in, and 0.030 in oversize. The piston rings must match the size of the piston on which they are installed. Check the side clearance and the end clearance of the piston rings as described in the following para- ‘graphs, Each compression ring has a mark on one surface. This mark must be toward the top of the cylinder when the piston ring is installed. The No. 1 compression ring nor- mally has a chrome or molybdenum surface. ‘The oil control ring has three pieces. There are two thin steel rings separated by a spacer. FIGURE 28. CHECK THE CLEARANCE BETWEEN THE PISTON RING AND THE GROOVE 1. Measure the clearance between the piston ring and the groove in the piston as shown in FIGURE 28, The clear- ances are shown in the ENGINE SPECIFICATIONS. Replace the piston if the clearances are greater than the specifications. 14 2. Measure the end clearance of each piston ring as shown in FIGURE 29, The end clearances are shown in the ENGINE SPECIFICATIONS. Install the piston ring into the cylinder where it will be used. Use a thickness ‘gauge to measure the amount of end clearance, Replace the piston ifthe clearances are greater than the specifica- tions. FIGURE 29. CHECK THE END CLEARANCE OF ‘THE PISTON RINGS Assembly NOTE: There are notches cast in the top ofall pistons to indicate the correct assembly and installation. The pis- tons must always be installed with this notch toward the fan end of the engine. See FIGURE 31. ‘The connecting rods have a notch cast in the bearing {journal as shown in FIGURE 30. This notch must be op- posite the notch on the top of the piston when the piston and connecting rod are assembled. NOTCHES ON ROD ‘OPPOSITE NOTCH IN PISTON, FIGURE 30, CONNECTING ROD IDENTIFICATION 1. Assemble the connecting rod to the piston. Make sure the orientation of the connecting rod and piston are cor- rect as described in the NOTE above. Use a press to in- stall the piston pin into the piston and connecting rod,Lubricate the piston pin with engine oil during installa- tion, 2. Check the clearances of the piston rings as described in “Piston Rings”. Install the piston rings on the piston as shown in FIGURE 31. FAN END OF ENGINE A~ POSITION OF THE GAP FOR THE SPACER OF THE OIL RING B— POSITION OF THE GAP FOR THE ‘OIL RING C~ POSITION OF THE GAP FOR THE ‘SECOND COMPRESSION RING D ~ POSITION OF THE GAP FOR THE FIRST COMPRESSION RING. FIGURE 31. ARRANGEMENT OF THE PISTON. RINGS ON THE PISTON Piston And Connecting Rod Assemblies, Installation 1. Lubricate the assembly with engine oil during instal- lation, Arrange the piston rings on the piston as shown in FIGURE 31. Install a ring compressor on the piston. 2, Make sure that the notch in the piston is toward the fan end of the engine. Install the piston and connecting rod assemblies in the cylinder bores. 3. Install the bearings and the caps for the connecting rods. Tighten the nuts. (See TORQUE SPECIFICA- TIONS FOR CAPSCREWS AND BOLTS.) Check the side clearance of each connecting rod after the bearing cap is installed, See the procedure in the paragraphs un- der “Connecting Rod Bearings, Replacement”. 4, Install the cylinder head as described in “Cylinder Head, Installation”. 5. Install the oil sump and the oil pump. FLYWHEEL AND FLYWHEEL HOUSING Flywheel Repair For V-6 Engines 1. Replace the ring gear on the flywheel. During remov- al or installation, do not heat the gear to more than 230°C (450°F). 2. During installation, push the ring gear fully against the flywheel. 3. The bearing in the flywheel can be replaced. Push the old bearing from the flywheel and push in a new bear- ing. Flywheel For V-6 Engines, Installation H3.50-5.00XL (H70-110XL) When irstalling the flywheel on these units, refer to the section on the HYDRAULIC PUMP DRIVE AS- SEMBLY, 1H6.00-7.00XL (HI35-1SSXL) Make sure the dowel pin is installed in the crankshaft. Install the flywheel. Units with a manual transmission: make sure the O- ring is installed between the flywheel and the crank- shaft. Use a sealant (Hyster Part No, 246108) on the heads of the capscrews. Tighten the capscrews for the flywheel to 79 N.m (58 Iby ft). Units with a powershift transmission: tighten the cap- serews to 79 Nam (58 Ib ft). Flywheel Housing, H3.50-5.00XL (H70-110XL) ‘The flywheel housing on these units has the parts for the hydraulic pump drive assembly. When doing any ser- vice to the housing, refer to the section for the HY- DRAULIC PUMP DRIVE ASSEMBLY. Engine Adapter, H6.00-7.00XL (H135-155XL) (See FIGURE 32.) ‘The engine adapter is used on engines with a manual transmission. When the seal in the adapter is replaced, use a sealant (Hyster Part No, 246108) between the seal and the adapter. When installing the adapter on the en- ine, make sure the O-rings are installed under the ‘washers. Tighten the capscrews for the adapter to 47 Nam (35 Iby ft). 1s. ENGINE ADAPTER ENGINE FLYWHEEL . PILOT BEARING. . SEAL CAPSCREW WASHER O-RING O-RING FIGURE 32. ENGINE ADAPTER ting Gear Replacement (Flywheel) For V-8 Engines (See FIGURE 33.) 1. During removal or installtion, do not heat the gear to more than 230°C (450°F). 2. During installation, push the ring gear fully against the flywheel. 3. The bearing in the flywheel can be replaced. Push the old bearing from the flywheel and push in a new bear- ing. 4, When used, make sure the dowel pin is installed in the crankshaft, When installing the flywheel, tighten the ccapscrews to 81 N.m (60 Iby ft). 16 1 ASS ISG ee FLYWHEEL SEAL (O-RING (EARLIER PRODUCTION ‘SEALANT (LATER PRODUCTION) CAPSCREW BEARING. DOWEL FIGURE 33. FLYWHEEL MOUNT Flywheel For V-8 Engines, Flywheel Housing (See FIGURE 34.) The flywheel housing must be checked for alignment during its installation. Check the alignment as follows: 1. Install the dowel pins in the cylinder block. Install the flywheel housing or the cylinder block. Tighten the cap- serews for the housing to 31 Nam (23 Iby ft). 2. Install a dial indicator on the crankshaft so that it indi- cates on the flywheel housing as shown in FIGURE 33. Rotate the crankshaft and check the movement of the needle. Ifthe total movement of the needle is 0.38 mm (0.015 in) or less, the housing can be installed without adjustment. Follow the procedures in step 1 when instal- ling the housing. If the total movement of the needle is more that 0.38 mm (0.015 in), adjust the housing as de- scribed in step 3. 3. Remove the flywheel housing. Rotate the dowel pins so that the position of the housing is moved toward thedirection of minimum needle movement, Install the housing and check the alignment as described in step 2. If the housing can not be adjusted to specifications, check that the dowel pins are installed correctly. 1. DIAL INDICATOR 2. FLYWHEEL HOUSING. 3. DOWEL PINS 4_ CRANKSHAFT FIGURE 34. ADJUST THE FLYWHEEL HOUSING, V-8 ENGINE ONLY 4, On units with a manual transmission, a seal is installed in the flywheel housing. When the seal in the flywheel housing is replaced, use a sealant (Hyster Part No. 246108) between the seal and the flywheel housing. ‘When installing the flywheel housing, tighten the cap- serews to 31. Num (23 Iby ft). COOLANT PUMP If any arts of the coolant pump are worn or damaged, replace the coolant pump. Parts for the coolant pump are not available separately. During installation, apply a sealant to the gasket for the coolant pump. Tighten the capscrews for the coolant pump to 41 N.m (30 Iby ft). ‘Adjust che tension of the belt as described in the PE- RIODIC MAINTENANCE section. FAN MOUNT (See FIGURE 35.) ‘The fan mount has the shaft and bearings for the fan, On some units the mount has an idler pulley for adjustment of the fan belt. When the fan is installed, tighten the bolts 10 20 Nm (15 Ib fd). 87.78 mm (45 inj I V-8 ENGINE 1. FAN SHAFT. 2. INNER SNAP RING 6. SNAP RING 3. SNAP RING 7. IDLER PULLEY 4, FAN MOUNT 8. IDLER BRACKET 5. BEARING 9. FAN BOLTS FIGURE 35. FAN MOUNT ”‘CHECKS AND ADJUSTMENTS Valve Clearance Adjustment (See FIGURE 36.) 1, Disconnect the negative cable at the battery. Remove the valve covers, 2. Rotate the engine until the mark on the vibration ‘damper or crankshaft pulley is aligned with the "0" tim- ing mark on the timing tab. Make sure the valves for the No. 1 cylinder are closed. Ifthe valves are moving as the timing mark is reached, the engine is in the wrong position. 3. When the engine is in the No. | firing position, adjust the valves for the following cylinders: ‘V-6; Inlet Valves for Numbers. 1, 2, 3 and Exhaust Valves for Numbers. 1, 5,6 ‘V-8: Inlet Valves for Numbers. 1, 2, 5, 7 and Exhaust ‘Valves for Numbers. 1, 3, 4,8 4, Adjust the valve clearance by loosening the nut for the rocker arm until the push rod is loose. Tighten the nut for the rocker are until there is no clearance at the push rod. Check the clearance by rotating the push rod while tight- ening the nut, When there is no clearance at the push rod, tighten the nut for the rocker arm one full turn, The ad tional turn of the nut will put the push rod in the seat of the cam follower. 5. After the valves are adjusted in step 3, rotate the en- gine one full tum, Make sure the timing marks are aligned, On V-6 engines, the valves on the No. 4 cylin- der will be closed. On V-8 engines, the valves on the No. 6 cylinder will be closed. When the engine isin this position, adjust the valves for the following cylinders: V-6: Inlet Valves for Numbers. 4, 5, 6 and Exhaust ‘Valves for Numbers. 2, 3, 4, V-8: Inlet Valves for Numbers. 3, 4, 6, 8 and Exhaust ‘Valves for Numbers. 2, 5, 6, 7 6. Install the valve covers. Connect the battery cable. Start the engine and check for correct operation. FIGURE 36. ADJUST THE VALVE CLEARANCE ENGINE SPECIFICATIONS Engine Data Firing order 1-8-43-6-5-7-2 , Bore 101.58 to 101.71 mm GM 43 litre V6 (8.9995 to 4.0045 in) Number of cylinders eI Stroke 88.39 mm (3.480 in) Firing order 165432 Displacement 5.7 litre (350 in3)Governor Bore 101.58 to 101.71 mm speed See the PERIODIC (3.9995 to 4.0045 in) MAINTENANCE section Stroke 88.39 mm (3.480 in) Pao Displacement 43 litre (262.4 in? Governor speed See the PERIODIC Cylinder head MAINTENANCE section for each model of lift truck GM 5.7 litre V-8 Number of cylinders 8 18 Valve seat specifications: See FIGURE 37, Valve seat width (inlet valves) 0.78 to 1.57 mm (0.031 t0 0.062 in)Valve seat width (exhaust valves): 1.57 t0 2.36 mm (0.062 t0 0.093 in) 1. CYLINDER HEAD. 2. MINIMUM THICKNESd ‘OF VALVE HEAD IS 0.80 mm (0.031 in) FIGURE 37. VALVE SEAT SPECIFICATIONS. FOR INLET AND EXHAUST VALVES. Clearance between inlet valve and guide: (0.02 to 0.09 mm (0.001 to 0.0037 in) Clearance between exhaust valve and guide 0.02 to 0.12 mm (0.001 to 0.0047 in) ‘Valve spring, free length (See FIGURE 38. 52.8 mm (2.08 in) Valve spring force (installed and valve is closed): 347 0 383 N@ 43 mm (78 t0 86 pounds @ 1.69 in) ‘Valve spring force (installed and valve is open): 880 10 930 N@ 31.75 mm (194 to 206 pounds @ 1.25 in) Hydraulic Valve Lifter 12 t0 90 seconds with 50 Ib load Leak rate: 21.3868 to 21.4046 mm (0.8420 to 0.8427 in) Body diameter Plungertravel: 3.175 mm (0.125 in) Clearance in bore: 0.0635 mm (0,0025 in) Lifter bore diameter: 21.425 to 21.450 mm. (0.8435 to 0.8445 in) A. VARIATION FROM VERTICAL — Production ~ Service limit Jess than 1.5 mm (0.06 in) 2.5 mm (0.984 in) B. INSTALLATION HEIGHT: ‘THE VALVE SPRINGS NEED A MINIMUM FORCE OF 347 to 383 N (76 to 86 Ibf) TO COMPRESS THEM TO AHEIGHT OF 43 mm (1.69 in) FIGURE 38. VALVE SPRING SPECIFICATIONS Camshaft ‘Variation from front to rear of a cam lobe: Taper with larger dimension away from No. 1 piston Bearing journals, diameter (All engines) 47.45 10 47.48 mm, (1.8682 to 1.8692 in) Bearing journals, clearance 0.01778 t0 0.9685 mm (0.0007 to 0.0027 in Variation of a bearing journal in either diameter or axial direction: ‘0.03 mm (0.001 in) ‘Axial Clearance (All Engines) (0.10 to 0.30 mm (0.004 to 0.0012 in) »Lobe lift (V-6) Inlet 9.06 mm (0.357 in) Exhaust 9.90 mm (3.90 in) Lobe lift (V-8) Inlet 6.60 mm (0.260 in) Exhaust 6.94 mm (0.2733 in) Pistons Piston diameter (see gauge points in FIGURE 27.) (Cylinder Bore Out-of- round (see FIGURE 25.): (0.0508 mm (0.002 in) Maximum cylinder taper: 0,025 mm (0.001 in) Clearance at bottom of cylinder: (0,068 mm (0.0027 in) Piston ring to groove clearance for piston rings (see FIGURE 28,) ‘Compression rings No. I and No. 2: (0.030 to 0.081 mm (0.0012 to 0.0032 in) Oil ring to groove clearance: (0.051 10 0.18 mm (0.002 to 0.007 in) Piston ring end clearance (see FIGURE 29.) ‘Compression rings No. I and No. 2: (0.25 to 0.76 mm (0.010 to 0.030 in) il ring (0.38 to 1.40 mm (0.015 to 0.055 in) Piston pin to piston clearance: 0.006 to 0.011 mm (0,00025 to 0.00045 in) Piston pin to connecting rod clearance: Press fit Crankshaft Diameter of main bearing journal Number 1 62.16 to 62.21 mm (2.4474 to 2.4493 in) Number 2, 3,4 62.15 to 62.20 mm (2.4471 to 2.4490 in) Number 5 62.15 t0 62.19 mm (2.4471 to 2.4488 in) Out-of-round of main bearing journal (maximum) Production Limit 0.0051 mm (0.0002 in) Service Limit 0.0254 mm (0.001 in) ‘Taper of main bearing journal (maximum) Production Limit 0.0051 mm (0.0002 in) —Service Limit 0.0254 mm (0.001 in) Clearance between journals and main bearings Number 1 (0.020 to 0.050 mm (0.0008 to 0.0020 in) Number 2, 3,4 0.027 to 0.058 mm (0.0011 to 0.0023 in Number 5 (0.043 t0 0.081 mm (0.0017 to 0.0032 in Available undersize main bearings: 0.0254 mm (-0.001 in) 0.0508 mm (~0.002 in) 0.2285 mm (~0.009 in 0.25 mm (-0.010 in) 0.50 mm (-0.020 in) 20 Axial Clearance (crankshaft to thrust surface main bearing): 0.15 to 0.254 mm (0,006 to 0.010 in) Connecting Rods v6 Diameter of connecting rod journals: 57.12 to 57.14 mm (2.2487 to 2.2497 in) v-8 Diameter of connecting rod journals: ‘53.31 to 53.33 mm (2.0988 to 2.0998 in) Out-of-round of bearing journal (maximum) = Production Limit 0.0127 mm (0.0005 in) = Service Limit 0.0254 mm (0.001 in) ‘Taper of bearing journal (maximum) = Production Limit 9.0127 mm (0.0005 in) ~Service Limit 0,0254 mm (0.001 in) Clearance between crankshaft joumals and connecting rod bearings 0.03 to 0.08 mm (0.0013 to 0.0035 in) Available undersize connecting rod bearings: ~0.0254 mm (-0.001 in) 0.0508 mm (-0.002 in) ~0.254 mm (-0.010 in) ~0.508 mm (-0.020 in) Side clearance of connecting rod to crankshaft: 1,20 10 0.35 mm (0.008 to 0.014 in) Cooling System ‘Thermostat: 82°C (80°F) Lubrication System Oil pressure @ 2500 rpm 170 to 241 kPa (2510 35 psi) Minimum oil pressure @ idle rpm. 48 kPa (7 psi) Oil pressure switch “ON” @ 20 10 39 kPa (2.910 5.7 psi) Acaution Fuel System Note: Lift trucks that have the V-6 en- gine with fuel injection have an electric fuel pump. and a fuel shut-off valve. Do not close the fuel shut- off valve when the engine is running. This action can cause high pressure at the fuel pump and break the connector hose.TORQUE SPECIFICATIONS FOR CAPSCREWS AND BOLTS Cylinder Head... Inlet Manifold To Cylinder Head Exhaust manifold : Exhaust Manifold To Inlet Manifold Main Bearing Cap Connecting Rod Cap Vibration Damper Flywheel Housing Flywheel! . : Chain Control Block For Hydraulic Pump Drive Camshaft Thrust Plate Cooling Fan To Pulley . Coolant Pump To Engine Block Thermostat Housing . Rocker Arm Cover Side Cover To Engine Block Oil Pump To Crankcase ll Screen Support To Crankcase il Sump To Crankcase (1/;-20) il Sump To Crankcase (*/16-18) . il Sump To Timing Cover ll Pump Cover Oil Pressure Switch ‘Alternator pulley . Distributor Mount Bolt Motor Mount to Engine ..... Motor Mount to Frame . 88 N.m (65 lby ft) = 54 Num (40 iby ft) 41/Nm (30 Ib) 61 N.m (45 Ibs ft) 95 N.m (70 lo #) +44 Nam (32 lb, ft) 80 Nam (60 lby ft) 44 Nam (365 Ib ft) 80 N.m (60 iy ft) 19 Num (14 Iby ft) with adhesive sealant 10 N.m (7 log) 24 Nam (18 lby ft) 10 Num (7 Iby ft) 27 Nam (20 ly ft) 8 Num (6 loft) 40 Num (7 Iby ft) 30 Num (22 Iby ft) 50 N.m (37 Iby ft) 10 Nam (7 lyf) 419 Nam (14 log) 8 Nam (6 ib ft) 14 Nam (10 lb) «27 N.m (20 Ib ft 61 N.m (45 lby ft) 34 Nim (25 Ibs ft) 44 Nim (35 by ft) 53 N.m (39 Iby ft) aTROUBLESHOOTING PROBLEM POSSIBLE CAUSE When the ignition switch isin the "START" position, the starter does not operate. The battery has a problem. The battery is not fully charged. ‘The connections at the battery are loose or they have corrosion. The ignition switch has a problem. ‘The starter system has a problem. ‘There are damaged parts in the engine. The engine will not start. The fuel tank is emply. The battery is not fully charged. The valves are worn or damaged. The piston rings are worn or have damage The ignition system has a problem. The fuel system has a problem. The ignition timing is wrong, The choke system has a problem. The engine does not run smoothly. The valves are not adjusted correctly. ‘The head gasket has a leak. The cylinder head has cracks. There is a leak in the intake system. The spark plugs have a problem. “The ignition system has problems. (See the sections for the electrical components in the SERVICE MANUAL for more information. ‘The engine does not have enough power. The air fiteris dirty. ‘The fuel is the wrong type. ‘The ignition timing is not correct. ‘The valve mechanism needs adjustment or is worn. ‘The piston assemblies are worn or damaged. ‘The spark plugs are the wrong type or they are not installed correctly, The valve timing is not correct. ‘The exhaust system has restrictions. 2TROUBLESHOOTING PROBLEM POSSIBLE CAUSE ‘There is noise inside the engine. ‘The main bearings are worn or damaged. The bearings for the connecting rods are worn or damaged. ‘The pistons are worn or damaged. The engine is too hot. There is not enough oil in the engine. The flywheel is loose. A connecting rod is bent. ‘There is a leak in the exhaust system. A valve lifter has a problem. The valves are not adjusted correctly. There is noise in the engine during acceleration, The spark plugs are dirty The spark plugs are the wrong type The ignition timing ‘s not correct. The fuel is the wrong type. There is too much carbon in the combustion chamber. The engine is too hot. The carburetor is not adjusted correctly. The engine gets too hot. There is not enough coolant in the cooling system. ‘The belt for the water pump is worn or not adjusted correctly ‘The thermostat has damage. ‘The cooling system has restrictions. The water pump has damage. The radiator is dity The exhaust system has restrictions. The bearings in the engine are damaged. There is not enough oil in the engine. The oil in the engine is the wrong type ‘The oil pump has damage. ‘The connecting rods have damage. ‘The camshatt is worn or damaged, The passages for ol have restrictions. The bearings are not installed correctly The oil in the engine is dirty. 2BHyster Easy Language Program HYSTER tecunicat pusuications 600 SRM 104 9/93 (12/89) (2/87) (4/86) (7/78)