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Hyster 599805 09 93 srm0104 GM ENGINE V8 350 (5.7L) PDF
Hyster 599805 09 93 srm0104 GM ENGINE V8 350 (5.7L) PDF
• 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.
• 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.
• 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 instmctions.
• 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
DESCRIPTION
ENGINE, REMOVAL AND INSTALLATION
CYLINDER HEAD
Removal And Disassembly
Cleaning And Inspection
Repairs, Valve Guides and Seats
Studs For The Rocker Arms 2
Valve Springs 2
ASSEMBLY AND INSTALLATION 3
CYLINDER BLOCK, CLEANING AND INSPECTION 4
PISTON BORE PREPARATION 4
ENGINE MOUNTS 4
LUBRICATION SYSTEM 4
Oil Pump, Removal and Disassembly 4
Cleaning and Inspection 4
Oil Pump, Assembly and Installation 5
TIMING COVER, TIMING SPROCKETS, CAMSHAFT AND CAM FOLLOWERS 5
Timing Cover, Removal 5
Installation 5
Timing Sprockets, Removal 6
Timing Sprockets, Installation 6
Camshaft, Removal 6
Camshaft, Inspection 6
Camshaft, Installation 7
Hydraulic Valve Lifters, Removal 7
Hydraulic Valve Lifters, Disassembly 7
Hydraulic Valve Lifters, Cleaning And Inspection 7
Hydraulic Valve Lifters, Assembly 8
CRANKSHAFT 8
Removal 8
Inspection and Repair 9
How To Check The Clearance Between The Main Bearings And Their Journals .. 9
Installation 10
PISTON AND CONNECTING ROD ASSEMBLIES 11
Connecting Rod Bearings, Replacement 11
1. Drain the coolant from the engine. Inspect the cylinder head for cracks in the ports and
chambers. Inspect the valves for cracks in the heads or
2. Disconnect and remove the coolant hose from the damaged stems.
housing for the thermostat.
Repairs, Valve Guides and Seats
3. Remove the air cleaner, carburetor, distributor, intake
Measure the clearance between the valve stem and the
manifold and the exhaust manifolds. Loosen the drive
belts and remove the bracket for the fan mount from the guide as shown in FIGURE 2. The maximum clearance
for the intake valves is 0.094 mm (0.0037 in). The maxi¬
cylinder heads.
mum clearance for the exhaust valves is 0.119 mm
4. Remove the rocker arm cover. (0.0047 in). If the clearance is more than the maximum
1
amount, oversize valves must be installed. Use a reamer
of the correct size when installing oversize valves. Use
A CAUTION
normal service procedures when grinding the valve Do not attempt to install an oversize stud without
seats. See the Specifications for dimensions.
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.
©r
11700
1. VALVE STEM
2. DIAL INDICATOR
REAMER
FIGURE 2. VALVE STEM CLEARANCE
INSTALLATION TOOL
11700
2
ASSEMBLY AND INSTALLATION 5. Install the intake manifold and gaskets. Tighten the
capscrews in the sequence shown in FIGURE 6. On the
1. Install each valve in the correct port. Install the shim V-6 engines, tighten the capscrews to 47 N.m (35 lbf ft).
and valve springs. Compress the spring and install the On the V-8 engines, tighten the capscrews to 41 N.m
oil seal in the lower groove. On the exhaust valves, (30 lbf ft).
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 of the shim
to the top of the retainer cap. Install shims to get the cor¬ 0 CD © ©
rect height shown in Specifications. The installed height
of the valve spring must not be less than the minimum 4 FAN END INITIAL SEQUENCE
height.
6. Install the push rods, making sure they are in the seat
FAN END of the cam follower. Lubricate the rocker arms and rock¬
V-6 ENGINE er arm balls with a molybdenum grease. Install the rock¬
er arms, balls and nuts. Tighten the nuts and adjust the
valve clearance as described in Checks and Adjust¬
0 0 0 ments.
©00© 7. Use a new gasket and install each valve cover. On the
V-6 engines, tighten the capscrews to 10 N.m (7 lbf ft).
On the V-8 engines, tighten the capscrews to 5 N.m (4
© 000 0 © lbf ft).
8. Install the exhaust manifolds. Use new gaskets when
FIGURE 5. TIGHTENING SEQUENCE,
CYLINDER HEAD 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 lbf ft). On the V-6 en¬ PISTON BORE PREPARATION
gines, tighten the capscrews at the center port to 35 N.m
Use a hone in the piston bores when installing new rings.
(26 lbf ft). Tighten the capscrews at the outer ports to 27
Use the hone as follows:
N.m (20 lbf ft).
1. Use a hone with a 280 grit stone. Make sure the stone
is clean and will not damage the bore.
2. Move the hone quickly (approximately 60 times per
minute) up and down in the bore. Make sure the hone
V-6 ENGINE makes a cross pattern of 45 to 60 degrees. Use the hone
untilthe entire length of the bore has this pattern.
3. After using the hone, clean the cylinder block with hot
water and detergent. 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 (H70-110XL), 31 N.m (23 lbf ft);
V-8 ENGINE
H6.00-7.00XL (H135-155XL), 50 N.m (37 lbf ft);
H150-275H, 50 N.m (37 lbf ft).
LUBRICATION SYSTEM
Oil Pump, Removal and Disassembly
(See FIGURE 8.)
11700
3. Remove the cover for the oil pump. Put marks on the
9. Install the coolant hose to the housing for the thermo¬ gear teeth to show their correct location during assem¬
stat. Fill the coolant system with coolant. See PERIOD¬ bly.
IC MAINTENANCE.
4. Do not remove the tube and screen assembly unless it
is damaged. The tube and screen must be replaced as an
CYLINDER BLOCK, CLEANING AND assembly.
INSPECTION
Cleaning and Inspection
After the engine is disassembled, clean the cylinder
block in solvent. Make sure all of the oil passages are Clean the parts of the oil pump in solvent and dry with
clean. Remove the gaskets from the surface of the block. compressed air. Inspect the gears, shaft and body of the
pump for wear or damage. If any of the parts are worn or
Inspect the bores for the pistons for wear or damage. damaged the oil pump must be replaced. Separate parts
Measure the bores and check the dimensions shown in are not available.
Specifications. Repair the cylinder block as necessary.
Oil Pump, Assembly and Installation
NOTE: It is important that the piston bores are prepared
(See FIGURE 8.)
correctly before new piston rings are installed. Incorrect NOTE: There are some variations in the oil pumps
preparation can cause the parts to wear quickly. installed during the years of manufacture of these en-
4
gines, but the design is the same. The repair procedures as follows: 1/4-20 capscrews, 10 N.m (7 lbf ft); 5/16-18
are the same. See the PARTS MANUAL for each oil capscrews, 19 N.m (14 lbf ft).
pump.
11699
V-8 ENGINE
FIGURE 9. OIL SUMP
2. Install the gears in the body of the pump. Make sure to 4. Carefully remove the oil seal from the cover.
align the identification marks. Make sure that the Installation (See FIGURE 10.)
smooth side of the idler gear is toward the cover. Install
1. Install a new oil seal in the cover. Make sure the open
the cover for the oil pump and tighten the capscrews to 5
side of the seal is toward the inside of the cover.
N.m (40 lbf in). Turn the shaft for the oil pump and check
for smooth operation. 2. Use a sealant on the new gasket for the cover. During
installation of the cover, use a special tool to align the oil
3. Install the oil pump assembly to the engine. Make sure seal with the crankshaft. The vibration damper will
the shaft is aligned with the slot in the distributor shaft. damage the oil seal if it is not installed correctly. Tighten
Tighten the capscrew at the mount on the bearing cap to the capscrews for the cover to 9 N.m (7 lbf ft).
47 N.m (35 % ft).
3. Use a special tool to install the vibration damper.
4. Install new gasket(s) and the oil sump. Use a sealant Tighten the capscrew for the damper to 81 N.m (60 lbf
on the gasket(s). Tighten the capscrews for the oil sump ft).
5
4. Install the crankshaft pulley, drive shaft, belts and fan
assembly. No. 1 CYLINDER
AT T.D.C.
to 0
No. 6 CYLINDER
AT T.D.C.
1. TIMING FIGURE 11. TIMING MARKS
COVER
2. GASKET
3. TOOL FOR Camshaft, Removal
VIBRATION 1. Remove the intake manifold, push rods and cam fol¬
DAMPER lowers. Remove the fuel pump.
4. VIBRATION
DAMPER 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. All of the camshaft bearings are the same size. Do
not damage bearings or camshaft during removal.
6
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 1. LIFTER BODY
sure the plug is even with or 0.80 mm (0.03 in) below the 2. PLUNGER
surface of the block. 3. PUSH ROD SEAT
4. SPRING
2. Lubricate the camshaft lobes with a molybdenum lu¬ 5. CHECK BALL ASSEMBLY
bricant. Lubricate the camshaft bearings with engine 6. METERING VALVE
7018
7. RETAINER, PUSH ROD SEAT
oil. Carefully install the camshaft in the cylinder block.
FIGURE 13. HYDRAULIC VALVE LIFTER
3. Install the timing sprockets, chain and cover as de¬
scribed in Timing Cover. 4. See FIGURE 14. Use a small screwdriver as a prybar
to remove the check ball retainer from the plunger.
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.
7
Hydraulic Valve Lifters, Assembly
1. Assemble the check ball assembly. Put the check ball 1/8" DRIFT PIN
on the small hole in the 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
OIL FEED HOLE
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.
1/16" PIN
FIGURE 16. ASSEMBLY, HYDRAULIC VALVE
LIFTER
CRANKSHAFT
32
5. Install the metering valve (3) and push rod seat (2). 1. Remove the oil pan, oil pump and flywheel. On V-6
See FIGURE 13. Install the retainer, push rod seat (6). engines, remove the rear seal retainer.
Push down the push rod seat to loosen the 1.6 mm (Vl6
2. Use a special tool to remove the vibration damper.
inch) drift and remove the drift. The hydraulic valve lift¬
er is now ready for installation. 3. Remove the caps for the connecting rods.
8
4. Remove the caps for the main bearings. Make sure both the upper and lower half of the bearing must be re¬
that there are identification marks on the caps during re¬ placed.
moval.
When the crankshaft is assembled by the manufacturer,
5. Carefully remove the crankshaft. the main bearings are specially selected to obtain close
tolerances. For this reason, you can find one-half of a
Inspection and Repair
standard size insert with one-half of a 0.001 in under-
1. Clean the crankshaft with solvent and dry it with com¬ size insert. This combination will decrease the clearance
pressed air. 0.0005 in from using a full standard bearing.
2. Inspect the crankshaft for cracks or other damage. When a production crankshaft can not be fitted with this
method, the main journal is then ground 0.009 in under-
3. Inspect the crankshaft for wear and damage. See
size. Only those main bearing journals that can not be
FIGURE 18. Use a micrometer to measure the journals
fitted with standard, 0.001 in or 0.002 in undersize main
for the bearings of the crankshaft. Do the measurement
bearing will be ground. A 0.009 in and a 0.010 in under¬
at different positions to see if the surface of the bearing is
size bearings will be selected as described to obtain
round. The correct sizes are given in the ENGINE
close tolerances.
SPECIFICATIONS.
A production crankshaft that has been ground will have
the following identification:
9741
FIGURE 18. CRANKSHAFT INSPECTION between the upper bearing half and its journal.
9
5. Install the main bearing cap and tighten the 10. Check the axial clearance between the rear main
capscrews. (See TORQUE SPECIFICATIONS FOR bearing and the thrust surface. Push the crankshaft for¬
CAPSCREWS AND BOLTS.) The capscrews must be ward. See FIGURE 19. Measure the clearance between
tightened to their final torque or there will be an error in the crankshaft and the thrust surface of the rear bearing.
the measurement. The correct clearance is 0.05 to 0.15 mm (0.002 to 0.006
inch).
6. 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
Installation
Plastigage to measure the width of the plastic at its wid¬ 1. On engines with a two-piece rear seal, install the seal
est point. The scale will indicate the clearance in milli¬ halves so that the lips are towards the fan end of the en¬
metres or thousandths of an inch. See FIGURE 22. gine. Apply engine oil to the seal during installation. Do
7. If the clearance is greater than the specifications, se¬ not get any oil on the ends of the seal.
lect a new undersize bearing set and install it. Measure
NOTE: With the use of special tools, the main bearings
the clearance again. If the clearance can not meet speci¬
and the rear crankshaft seal (two-piece) can be replaced
fications with the available undersize bearings, the bear¬
without removing the crankshaft.
ing journal must be ground to a new undersize. If the
bearing journal is already at the maximum undersize, 2. Install the main bearings in the cylinder block and the
the crankshaft must be replaced. bearing caps. Lubricate the bearings with engine oil and
8. If the clearance is within specifications, lubricate the carefully install the crankshaft in the cylinder block.
bearing with engine oil and install the main bearing and
3. Install the bearing caps. Make sure the arrows on the
bearing cap. Tighten the capscrews on the main bearing
bearing caps are towards the front (fan end) of the en¬
cap to the correct specifications.
gine. Push the crankshaft forward and measure the
9. Turn the crankshaft to make sure it rotates smoothly. clearance at the front side of the rear main bearing. The
correct clearance is 0.05-0.15 mm (0.002-0.006 in).
(See FIGURE 19.)
s m rear bearing cap to 95 N.m (70 lbf ft). Tighten the cap-
screws for the rear bearing cap to 14 N.m (10 lbf ft).
Move the crankshaft forward and backward to align the
rear main bearing. Tighten the capscrews for all bearing
caps to 95 N.m (70 lbf ft).
10
size, the crankshaft must be replaced. See the ENGINE
SPECIFICATIONS, Crankshaft.
11
to a new undersize. If the bearing journal is al¬ 6. Remove the caps and bearings from each connecting
ready at the maximum undersize, the crankshaft rod. Keep the caps and bearings with their original pis¬
must be replaced. ton assemblies. Mark the caps so that they will be in¬
stalled again in their original positions. Do not mix the
d. If the clearance is within specifications, lubricate
parts.
the bearing with engine oil and install the bearing
and bearing cap. Tighten the nuts on the bearing 7. Push the connecting rod and piston from the cylinder.
cap. (See TORQUE SPECIFICATIONS FOR Temporarily install the bearing cap on the connecting
CAPSCREWS AND BOLTS.) rod to keep the parts together.
6. When all of the rod bearings have been replaced, use Disassembly
the following procedure to check the side clearances be¬
tween the connecting rods and the crankshaft: A CAUTION
The pistons are aluminum alloy and can be damaged
a. Use a hammer to lightly hit the connecting rod if they are hit with a hard object. The grooves for the
parallel to the crankshaft journal to make sure piston rings are machined to close tolerances. Use a
there is a clearance. tool made to clean the grooves of the piston rings. Do
b. Measure the clearance between the caps for the not use a wire brush to clean a piston.
connecting rods and the crankshaft. See 1. Remove the piston rings from the pistons. Use a press
FIGURE 23. to remove the piston pins from the piston. See
FIGURE 24.
12
Piston, Cleaning And Inspection
1/2 In
Inspect the pistons for wear, cracks, and damage. Re¬
place a piston that is worn or damaged.
2 1/4'
GAGE
POINT
Measure the cylinder bore in positions from top to bot¬ A cylinder bore that has been repaired with a hone or a
tom to find any taper from wear. A normal wear pattern boring machine must be fitted with a piston that is the
for a cylinder bore is shown in FIGURE 26. A cylinder correct size. Measure the outer diameter of the piston
that has a taper [measurement "A" that is 0.127 mm and the inner diameter of the cylinder bore as shown in
(0.005 in) greater than measurement "B"] must have a FIGURE 27. Using different oversize pistons in the en¬
new bore. A tool called a hone can be used to remove a gine does not affect the dynamic balance of the engine.
small amount of taper from a cylinder bore. Use a boring Replacement pistons from standard size to 0.030 inch
machine to repair a badly worn cylinder. The boring ma¬ oversize normally have the same weight. The clearance
chine will make a more accurate cylinder bore. The hone specifications between a piston and its cylinder bore is
is then used to finish the surface of the cylinder bore. shown in the ENGINE SPECIFICATIONS.
13
Piston Rings 2. Measure the end clearance of each piston ring as
shown in FIGURE 29. The end clearances are shown in
NOTE: Check the clearance of the piston rings in the
the ENGINE SPECIFICATIONS. Install the piston ring
cylinder after the surface of the cylinder has been fin¬
into the cylinder where it will be used. Use a thickness
ished with a hone. New piston rings are available for the
gauge to measure the amount of end clearance. Replace
following piston sizes: standard size, and 0.005 in,
the piston if the clearances are greater than the specifica¬
0.010 in, 0.020 in, and 0.030 in oversize. The piston
tions.
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.
The oil control ring has three pieces. There are two thin
steel rings separated by a spacer.
0
A593
Assembly
NOTE: There are notches cast in the top of all 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
'V
A595
14
Lubricate the piston pin with engine oil during installa¬ FLYWHEEL AND FLYWHEEL HOUSING
tion.
Flywheel Repair For V-6 Engines
2. Check the clearances of the piston rings as described
1. Replace the ring gear on the flywheel. During remov¬
in "Piston Rings". Install the piston rings on the piston
al or installation, do not heat the gear to more than
as shown in FIGURE 31.
230°C (450°F).
_
H6.00-7.00XL (H135-155XL)
SECOND COMPRESSION RING
D - POSITION OF THE GAP FOR THE
FIRST COMPRESSION RING
FIGURE 31. ARRANGEMENT OF THE PISTON
_ Make sure the dowel pin is installed in the crankshaft.
Install the flywheel.
RINGS ON THE PISTON
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
Piston And Connecting Rod Assemblies, heads of the capscrews. Tighten the capscrews for the
Installation
flywheel to 79 N.m (58 lbf ft).
1. Lubricate the assembly with engine oil during instal¬ Units with a powershift transmission: tighten the cap-
lation. Arrange the piston rings on the piston as shown in screws to 79 N.m (58 lbf ft).
FIGURE 31. Install a ring compressor on the piston.
Flywheel Housing, H3.50-5.00XL (H70-110XL)
2. Make sure that the notch in the piston is toward the fan
end of the engine. Install the piston and connecting rod The flywheel housing on these units has the parts for the
assemblies in the cylinder bores. hydraulic pump drive assembly. When doing any ser¬
vice to the housing, refer to the section for the HY¬
3. Install the bearings and the caps for the connecting DRAULIC PUMP DRIVE ASSEMBLY.
rods. Tighten the nuts. (See TORQUE SPECIFICA¬
TIONS FOR CAPSCREWS AND BOLTS.) Check the
Engine Adapter, H6.00-7.00XL (H135-155XL)
(See FIGURE 32.)
side clearance of each connecting rod after the bearing
cap is installed. See the procedure in the paragraphs un¬ The engine adapter is used on engines with a manual
der "Connecting Rod Bearings, Replacement". transmission. When the seal in the adapter is replaced,
use a sealant (Hyster Part No. 246108) between the seal
4. Install the cylinder head as described in "Cylinder and the adapter. When installing the adapter on the en¬
Head, Installation". gine, make sure the O-rings are installed under the
washers. Tighten the capscrews for the adapter to 47
5. Install the oil sump and the oil pump. N.m (35 lbf ft).
15
12009
11696
1. FLYWHEEL 5
2. SEAL
3. O-RING (EARLIER PRODUCTION
1. ENGINE ADAPTER SEALANT (LATER PRODUCTION)
2. ENGINE 4. CAPSCREW
3. FLYWHEEL 5. BEARING
4. PILOT BEARING 6. DOWEL
5. SEAL
6. CAPSCREW FIGURE 33. FLYWHEEL MOUNT
7. WASHER
8. O-RING
9. O-RING Flywheel For V-8 Engines, Flywheel Housing
(See FIGURE 34.)
FIGURE 32. ENGINE ADAPTER
The flywheel housing must be checked for alignment
during its installation. Check the alignment as follows:
Ring Gear Replacement (Flywheel) For V-8 1. Install the dowel pins in the cylinder block. Install the
Engines (See FIGURE 33.) flywheel housing on the cylinder block. Tighten the cap-
screws for the housing to 31 N.m (23 lbf ft).
1. During removal or installtion, do not heat the gear to
2. Install a dial indicator on the crankshaft so that it indi¬
more than 230°C (450°F).
cates on the flywheel housing as shown in FIGURE 33.
2. During installation, push the ring gear fully against Rotate the crankshaft and check the movement of the
the flywheel. needle. If the total movement of the needle is 0.38 mm
(0.015 in) or less, the housing can be installed without
3. The bearing in the flywheel can be replaced. Push the adjustment. Follow the procedures in step 1 when instal¬
old bearing from the flywheel and push in a new bear¬ ling the housing. If the total movement of the needle is
ing. more that 0.38 mm (0.015 in), adjust the housing as de¬
scribed in step 3.
4. When used, make sure the dowel pin is installed in the
crankshaft. When installing the flywheel, tighten the 3. Remove the flywheel housing. Rotate the dowel pins
capscrews to 81 N.m (60 lbf ft). so that the position of the housing is moved toward the
16
direction of minimum needle movement. Install the COOLANT PUMP
housing and check the alignment as described in step 2.
If any parts of the coolant pump are worn or damaged,
If the housing can not be adjusted to specifications,
replace the coolant pump. Parts for the coolant pump are
check that the dowel pins are installed correctly.
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 lbf ft).
Adjust the tension of the belt as described in the PE¬
RIODIC MAINTENANCE section.
1. DIAL INDICATOR
2. FLYWHEEL HOUSING
3. DOWEL PINS
4. CRANKSHAFT esos
V-8 ENGINE
4. On units with a manual transmission, a seal is 1. FAN SHAFT
installed in the flywheel housing. When the seal in the 2. INNER SNAP RING 6. SNAP RING
flywheel housing is replaced, use a sealant (Hyster Part 3. SNAP RING 7. IDLER PULLEY
4. FAN MOUNT 8. IDLER BRACKET
No. 246108) between the seal and the flywheel housing. 5. BEARING 9. FAN BOLTS
When installing the flywheel housing, tighten the cap-
screws to 3 1 N.m (23 lbf ft). FIGURE 35. FAN MOUNT
17
CHECKS AND ADJUSTMENTS aligned. On V-6 engines, the valves on the No. 4 cylin¬
der will be closed. On V-8 engines, the valves on the
Valve Clearance Adjustment No. 6 cylinder will be closed. When the engine is in this
(See FIGURE 36.) position, adjust the valves for the following cylinders:
1. Disconnect the negative cable at the battery. Remove V-6: Inlet Valves for Numbers. 4, 5, 6 and Exhaust
the valve covers. Valves for Numbers. 2, 3, 4,
2. Rotate the engine until the mark on the vibration
V-8: Inlet Valves for Numbers. 3, 4, 6, 8 and Exhaust
damper or crankshaft pulley is aligned with the "0" tim¬
Valves for Numbers. 2, 5, 6, 7
ing mark on the timing tab. Make sure the valves for the
No. 1 cylinder are closed. If the valves are moving as the 6. Install the valve covers. Connect the battery cable.
"0" timing mark is reached, the engine is in the wrong Start the engine and check for correct operation.
position.
3. When the engine is in the No. 1 firing position, adjust
11695
the valves for the following cylinders:
ENGINE SPECIFICATIONS
Engine Data Firing order 1-8—4-3-6-5-7-2
Bore 101.58 to 101.71 mm
GM 4.3 litre V-6 (3.9995 to 4.0045 in)
Number of cylinders Stroke 88..39 mm (3.480 in)
Firing order 1-6-5ÿ4-3-2
Displacement 5.7 litre (350 in3)Governor
Bore 101.58 to 101.71 mm See the PERIODIC
speed
(3.9995 to 4.0045 in)
MAINTENANCE section
Stroke 88..39 mm (3.480 in) for each model of lift truck
Displacement 4.3 litre (262.4 in3
Governor speed See the PERIODIC Cylinder head
MAINTENANCE section
Valve seat specifications: See FIGURE 37.
for each model of lift truck
Valve seat width (inlet valves):
GM 5.7 litre V-8 0.78 to 1.57 mm
Number of cylinders (0.031 to 0.062 in)
18
Valve seat width (exhaust valves):
1.57 to 2.36 mm
(0.062 to 0.093 in)
1. CYLINDER HEAD
2. MINIMUM THICKNESS
OF VALVE HEAD IS
0.80 mm (0.031 in)
Camshaft
Hydraulic Valve Lifter
Variation from front to rear of a cam lobe:
Leak rate: 12 to 90 seconds - Taper with larger dimension away from No. 1 piston
with 50 lb load Bearing journals, diameter (All engines)
47.45 to 47.48 mm
Body diameter 21.3868 to 21.4046 mm (1.8682 to 1.8692 in)
(0.8420 to 0.8427 in)
Bearing journals, clearance
0.01778 to 0.9685 mm
Plunger travel: 3.175 mm (0.125 in) (0.0007 to 0.0027 in)
Clearance in bore: 0.0635 mm (0.0025 in) Variation of a bearing journal in either diameter or axial
direction: 0.03 mm (0.001 in)
Lifter bore diameter: 21.425 to 21.450 mm Axial Clearance (All Engines)
(0.8435 to 0.8445 in) 0.10 to 0.30 mm (0.004 to 0.0012 in)
19
Lobe lift (V-6) Axial Clearance (crankshaft to thrust surface main bearing):
Inlet 9.06 mm (0.357 in) 0.15 to 0.254 mm (0.006 to 0.010 in)
Exhaust 9.90 mm (3.90 in)
Lobe lift (V-8) Connecting Rods
Inlet 6.60 mm (0.260 in)
V-6
Exhaust 6.94 mm (0.2733 in)
Diameter of connecting rod journals:
57.12 to 57.14 mm (2.2487 to 2.2497 in)
Pistons
Piston diameter (see gauge points in FIGURE 27.) V-8
Diameter of connecting rod journals:
Cylinder Bore Out-of- round (see FIGURE 25.):
53.31 to 53.33 mm (2.0988 to 2.0998 in)
0.0508 mm (0.002 in)
Maximum cylinder taper: 0.025 mm (0.001 in) Out-of-round of bearing journal (maximum)
- Production Limit 0.0127 mm (0.0005 in)
Clearance at bottom of cylinder: - Service Limit 0.0254 mm (0.001 in)
0.068 mm (0.0027 in)
Taper of bearingjournal (maximum)
Piston ring to groove clearance for piston rings (see - Production Limit 0.0127 mm (0.0005 in)
FIGURE 28.)
- Service Limit 0.0254 mm (0.001 in)
Compression rings No. 1 and No. 2:
0.030 to 0.081 mm (0.0012 to 0.0032 in) Clearance between crankshaft journals and connecting rod
Oil ring to groove clearance: bearings 0.03 to 0.08 mm (0.0013 to 0.0035 in)
0.051 to 0.18 mm (0.002 to 0.007 in)
Available undersize connecting rod bearings:
Piston ring end clearance (see FIGURE 29.) -0.0254 mm (-0.001 in)
Compression rings No. 1 and No. 2: -0.0508 mm (-0.002 in)
0.25 to 0.76 mm (0.010 to 0.030 in) -0.254 mm (-0.010 in)
Oil ring 0.38 to 1.40 mm (0.015 to 0.055 in) -0.508 mm (-0.020 in)
Piston pin to piston clearance:
0.006 to 0.011 mm (0.00025 to 0.00045 in)
Side clearance of connecting rod to crankshaft:
0.20 to 0.35 mm (0.008 to 0.014 in)
Piston pin to connecting rod clearance:
Press fit
Cooling System
Crankshaft Thermostat: 82°C(180°F)
Diameter of main bearing journal
Number 1 62.16 to 62.21 mm (2.4474 to 2.4493 in) Lubrication System
Number 2, 3, 4 62.15 to 62.20 mm (2.4471 to 2.4490 in)
Number 5 62.15 to 62.19 mm (2.4471 to 2.4488 in) Oil pressure @ 2500 rpm
170 to 241 kPa
Out-of-round of main bearingjournal (maximum)
(25 to 35 psi)
- Production Limit 0.005 1 mm (0.0002 in)
- Service Limit 0.0254 mm (0.001 in) Minimum oil pressure @ idle rpm
Taper of main bearingjournal (maximum) 48 kPa (7 psi)
- Production Limit 0.005 1 mm (0.0002 in)
Oil pressure switch "ON" @
- Service Limit 0.0254 mm (0.001 in) 20 to 39 kPa
Clearance between journals and main bearings (2.9 to 5.7 psi)
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 to 0.081 mm (0.0017 to 0.0032 in
A CAUTION
Fuel System Note: Lift trucks that have the V-6 en¬
Available undersize main bearings:
gine with fuel injection have an electric fuel pump
-0.0254 mm (-0.001 in)
and a fuel shut-off valve. Do not close the fuel shut-
-0.0508 mm (-0.002 in)
-0.2285 mm (-0.009 in off valve when the engine is running. This action can
-0.25 mm (-0.010 in) cause high pressure at the fuel pump and break the
-0.50 mm (-0.020 in) connector hose.
20
TORQUE SPECIFICATIONS FOR CAPSCREWS AND BOLTS
.......
Vibration Damper 80 N.m 60 lb, ft)
Flywheel Housing 44 N.m 35 lb, ft)
Flywheel 80 N.m 60 lb, ft)
Chain Control Block For Hydraulic Pump Drive 19 N.m 14 lb, ft) with adhesive sealant
Camshaft Thrust Plate 10 N.m 7 lb, ft)
Cooling Fan To Pulley 24 N.m 18 lb, ft)
Coolant Pump To Engine Block 10 N.m 7 lb, ft)
Thermostat Housing 27 N.m 20 lb, ft)
Rocker Arm Cover 8 N.m 6 lb, ft)
Side Cover To Engine Block 10 N.m 7 lb, ft)
Oil Pump To Crankcase 30 N.m 22 lb, ft)
Oil Screen Support To Crankcase 50 N.m 37 lb, ft)
Oil Sump To Crankcase (1/4-20) 10 N.m 7 lb, ft)
Oil Sump To Crankcase (1/-|6-18) 19 N.m 14 lb, ft)
Oil Sump To Timing Cover 8 N.m 6 lb, ft)
Oil Pump Cover 14 N.m 10 lb, ft)
Oil Pressure Switch 27 N.m 20 Ibf ft)
Alternator pulley 61 N.m 45 lb, ft)
Distributor Mount Bolt 34 N.m 25 lb, ft)
Motor Mount to Engine 44 N.m 35 lb, ft)
Motor Mount to Frame 53 N.m 39 lb, ft)
21
TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE
When the ignition switch is in the "START" The battery has a problem.
position, the starter does not operate. 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 empty.
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 filter is 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.
22
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 The spark plugs are dirty.
acceleration. The spark plugs are the wrong type.
The ignition timing is 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 dirty.
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 camshaft is worn or damaged.
The passages for oil have restrictions.
The bearings are not installed correctly.
The oil in the engine is dirty.
23
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