GM Engines: 4.3 LITER V-6

GM ENGINES
4.3 LITER V-6

H3.50-5.00XL (H70-110XL) [G005];
S3.50-5.50XL (S70-120XL) [D004];
H6.00-7.00XL (H135-155XL) [F006, G006];
S6.00-7.00XL (S135-155XL) [B024, C024];
H3.50-5.50XM (H70-120XM) [K005, L005];
S3.50-5.50XM (S70-120XM) [E004, F004]
PART NO. 897800 600 SRM 590

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair

on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,
or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!
GM Engines Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
Engine Removal and Installation ..................................................................................................................... 2
Cylinder Head Repair ........................................................................................................................................ 2
Remove and Disassemble .............................................................................................................................. 2
Clean and Inspect .......................................................................................................................................... 2
Valve Guides and Seats, Repairs .................................................................................................................. 3
Valves, Repair ................................................................................................................................................ 3
Valve Seats, Repair........................................................................................................................................ 4
Valve Springs ................................................................................................................................................. 4
Rocker Arm Studs (Early Models) ................................................................................................................ 6
Rocker Arm Studs (Late Models) .................................................................................................................. 6
Assemble and Install ..................................................................................................................................... 7
Cylinder Block Cleaning and Inspection .......................................................................................................... 10
Piston Bore Preparation .................................................................................................................................... 10
Engine Mounts Installation .............................................................................................................................. 11
Lubrication System Repair................................................................................................................................ 11
Oil Pump, Remove and Disassemble ............................................................................................................ 11
Clean and Inspect .......................................................................................................................................... 11
Oil Pump, Assemble and Install ................................................................................................................... 12
Oil Sump, Install ........................................................................................................................................... 12
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters ...................................................................... 13
Timing Cover.................................................................................................................................................. 13
Remove....................................................................................................................................................... 13
Install ......................................................................................................................................................... 15
Timing Sprockets ........................................................................................................................................... 15
Remove....................................................................................................................................................... 15
Install ......................................................................................................................................................... 15
Camshaft ........................................................................................................................................................ 16
Remove....................................................................................................................................................... 16
Inspect........................................................................................................................................................ 16
Install ......................................................................................................................................................... 16
Balance Shaft................................................................................................................................................. 17
Remove....................................................................................................................................................... 17
Install ......................................................................................................................................................... 18
Hydraulic Valve Lifters ................................................................................................................................. 18
Remove....................................................................................................................................................... 18
Disassemble ............................................................................................................................................... 19
Clean and Inspect...................................................................................................................................... 19
Assemble .................................................................................................................................................... 19
Install ......................................................................................................................................................... 20
Crankshaft Repair ............................................................................................................................................. 21
Remove ........................................................................................................................................................... 21
Inspect and Repair......................................................................................................................................... 21
How to Check Clearance Between Main Bearings and Their Journals ..................................................... 22
Install ............................................................................................................................................................. 23
Piston and Connecting Rod Assemblies Repair ............................................................................................... 24
Connecting Rod Bearings, Replace ............................................................................................................... 24
Piston and Connecting Rod Assemblies, Remove ........................................................................................ 25
Disassemble ................................................................................................................................................... 25
Piston, Clean and Inspect ............................................................................................................................. 26
©2005 HYSTER COMPANY i

Table of Contents GM Engines
TABLE OF CONTENTS (Continued)

Cylinder Bores, Inspect and Repair.............................................................................................................. 26
Piston Rings ................................................................................................................................................... 27
Assemble ........................................................................................................................................................ 28
Piston and Connecting Rod Assemblies, Install .......................................................................................... 28
Flywheel and Flywheel Housing Repair........................................................................................................... 29
Flywheel, Repair............................................................................................................................................ 29
Flywheel, Install ............................................................................................................................................ 29
H3.50-5.00XL (H70-110XL), S3.50-5.50XL (S70-120XL), S6.00-7.00XL (S135-155XL) ........................ 29
H6.00-7.00XL (H135-155XL) .................................................................................................................... 29
Flywheel Housing H3.50-5.00XL (H70-110XL), H3.50-5.50XM (H70-120XM), S3.50-5.50XL
(S70-120XL), S6.00-7.00XL (S135-155XL) ................................................................................................... 29
Engine Adapter H6.00-7.00XL (H135-155XL) ............................................................................................. 29
Coolant Pump Repair......................................................................................................................................... 30
Thermostat Replacement .................................................................................................................................. 30
Fan Mount Repair (Early Models) .................................................................................................................... 30
Fan Mount Assembly Repair (Late Models) ..................................................................................................... 30
Drive Belt Installation....................................................................................................................................... 32
Valve Clearance Adjustment (Early Models).................................................................................................... 33
Valve Clearance Adjustment (New Models) ..................................................................................................... 34
Compression Check............................................................................................................................................ 34
Engine Specifications......................................................................................................................................... 35
Engine Data ................................................................................................................................................... 35
Cylinder Head ................................................................................................................................................ 35
Hydraulic Valve Lifter ................................................................................................................................... 36
Camshaft ........................................................................................................................................................ 36
Pistons ............................................................................................................................................................ 36
Crankshaft ..................................................................................................................................................... 37
Connecting Rods ............................................................................................................................................ 37
Balance Shaft................................................................................................................................................. 38
Cooling System .............................................................................................................................................. 38
Lubrication System ....................................................................................................................................... 38
Torque Specifications ......................................................................................................................................... 38
Troubleshooting.................................................................................................................................................. 39
This section is for the following models:
H3.50-5.00XL (H70-110XL) [G005];

S3.50-5.50XL (S70-120XL) [D004];
H6.00-7.00XL (H135-155XL) [F006, G006];
S6.00-7.00XL (S135-155XL) [B024, C024];
H3.50-5.50XM (H70-120XM) [K005, L005];
S3.50-5.50XM (S70-120XM) [E004, F004]
ii
600 SRM 590 Description
General
NOTE: This SRM applies to different model years of The diodes and resistors in the electrical sys-
the GM 4.3 liter, V-6 engine. While there can be tem can be damaged if the following cautions
physical differences in the parts, many of the proce- are not followed:
dures will apply to all of the models. If the different • Do not disconnect the battery when the en-
parts require separate procedures, all the procedures gine is running. The voltage surge can dam-
will be given. age the diodes and resistors.
• Do not disconnect an electric wire before the
engine is stopped and the switches are OFF.
CAUTION • Do not cause a short circuit by connection
Changes to the engines have occurred at each of the electric wires to the wrong terminals.
model year. Do not install parts from one model Make sure a correct identification of the wire
year engine into another model year engine. is made before it is connected.
Installation of the wrong parts will cause poor • Make sure a battery is the correct voltage and
performance, wear, and failure of the engine. polarity before it is connected.
• Do not check for current flow by making a
CAUTION spark because the electronic components can
Disconnect the battery cables before doing any be damaged.
disassembly and repair of the engine or parts This SRM has the description and the repair instruc-
of the electrical system. tions for the GM 4.3 liter, V-6 engine. Checks and
Adjustments, Troubleshooting procedures, and Spec-
ifications are also included.
Description
The cylinder block is made of cast iron. The arrange- The piston is a low-friction, lightweight design with
ment of the cylinders is in a V shape, with three cylin- a flat top and barrel-shaped skirt. The piston pins
ders on each bank. From the front, cylinders on the are offset to reduce piston slap. They have a floating
right bank are numbered 1, 3, and 5 and cylinders on fit in the piston and are retained by a press fit in
the left bank are numbered 2, 4, and 6. the connecting rod. The connecting rods are forged
steel and are machined with the rod cap installed for
The cylinder heads are cast iron and have one in- proper clearances and alignment.
take valve and one exhaust valve for each cylinder. A
spark plug is located between the valves in the side The balance shaft is cast iron and mounted in the
of the cylinder head. The valve guides and seats are crankcase above and in-line with the camshaft. The
integral to the cylinder head. balance shaft is driven by a gear from the camshaft.
The crankshaft is supported by four main bearings. The valve mechanism is actuated by push rods and
The number four bearing at the rear of the engine rocker arms from the camshaft. The rocker arm piv-
is the end thrust bearing. The bearings are retained ots on a ball to open the valve. Later model engines
by bearing caps that are matched with the block for have hydraulic valve lifters that keep all parts of the
proper alignment and clearances. valve train in constant contact. Each lifter acts as an
automatic adjuster and maintains zero lash in the
The camshaft is steel and is supported by four bear- valve train, eliminating the need for periodic valve
ings pressed into the engine block. The camshaft is adjustment.
driven by a chain from the crankshaft. A spiral gear
machined into the camshaft near the rear journal When the engine has a gasoline fuel system, it has
drives a shaft assembly which operates the oil pump electronic fuel injection with an electronic engine
drive shaft assembly. control system. When the engine has a LPG fuel
system, it uses an LPG carburetor with the Micro-
The pistons are made of cast aluminum and have two processor Spark Timing System (MSTS).
compression rings and one oil control ring assembly.
1
Cylinder Head Repair 600 SRM 590
Engine Removal and Installation

The Removal and Installation procedures for the engine are in the Frame section for each model of lift truck.
See the Transmission sections to separate the transmission from the engine.
Cylinder Head Repair

REMOVE AND DISASSEMBLE
WARNING
Disconnect the battery cables before making
repairs to the engine.
1. Drain cooling system.
2. Disconnect and remove coolant hose from hous-

ing for thermostat.
3. Remove air cleaner, distributor, throttle body, in-

take manifold, and exhaust manifolds. Remove
drive belt(s) and remove brackets for drive belt
tensioner and alternator.
4. Remove spark plugs.
5. Remove rocker arm cover. See Figure 1.
NOTE: For year 2002 or later model engines, go to

Step 10.
6. Remove nuts and balls for rocker arms. Remove

rocker arms and push rods. Keep parts for each 1. ROCKER COVER 5. CYLINDER HEAD
2. NUT 6. HEAD GASKET
rocker arm assembly together. Mark assemblies 3. BALL 7. GASKET
so they can be installed in their original posi- 4. ROCKER ARM
tions.
Figure 1. Cylinder Head
7. Remove rocker arm studs.
CLEAN AND INSPECT
8. Remove capscrews that hold cylinder head to
block. Remove capscrews in the reverse order 1. Clean carbon from valve ports and combustion
of the tightening sequence shown in Figure 12. chambers in cylinder head.
Remove cylinder head and gasket.
2. Clean carbon and oil from valves, push rods, and
9. Use a valve spring compressor and remove valve rocker arms.
stem keys, caps, springs, and oil seals. Discard
oil seals. Remove valves. Organize valves and 3. Clean valve guides.
springs so they can be installed in their original
4. Clean surfaces of cylinder head where gaskets fit.
positions.
5. Inspect cylinder head for cracks in ports, combus-
10. Remove valve rocker arms. See Figure 2.
tion chambers, and external surfaces.
11. Remove valve rocker arm supports.
6. Measure cylinder head for warping with a
12. Remove valve push rods. straight edge and feeler gauge. Refer to Engine
Specifications for tolerances.
2
600 SRM 590 Cylinder Head Repair
valve faces and seats within the specifications. Make

sure all of the lapping compound is removed from the
valve and valve seat when the process is completed.
Valves with minor pits in the valve faces can be ma-

chined to the proper angle. There are many different
types of equipment for repairing valve faces. Follow
the instructions of the manufacturer of the equip-
ment that you are using. Valves must be machined
to the proper specifications. See Figure 4.
1. VALVE ROCKER ARM

2. VALVE ROCKER ARM SUPPORT
3. PUSH ROD
Figure 2. Remove Valve Rocker Arm and Push

Rod (Year 2002 or Later Engine Models)
7. Inspect valves for burned or damaged areas in

seat surfaces. Inspect for cracks and damaged
1. VALVE STEM
or worn valve stems. Valve stems with excessive 2. DIAL INDICATOR
guide clearance must be repaired or replaced.
Refer to Engine Specifications. Figure 3. Valve Steam Clearance
VALVE GUIDES AND SEATS, REPAIRS

Measure the clearance between the valve stem and
the guide as shown in Figure 3. See Engine Speci-
fications for maximum clearances. If the clearance
is more than the maximum amount, oversize valves
or new valve guides must be installed. Use a reamer
of the correct size when installing new valve guides.
Use normal service procedures when grinding the
valve seats. See the Engine Specifications for dimen-
sions.
VALVES, REPAIR
NOTE: SEAT WIDTH DIMENSION APPLIES TO THE
NOTE: Before any work is performed on the valve
46 FACE ONLY.
faces and seats, make sure the clearance of the valve
stems in their valve guides is within specifications. 1. CYLINDER HEAD
A correction for minimum wear and damage to the Figure 4. Valve Seat Specifications for Inlet
valve and seat can be done by a process called lap- and Exhaust Valves
ping. When the valve seats are lapped, keep the
3
Replace a valve if any of the following conditions are valve seats. Follow the instructions of the manufac-
present: turer of the equipment that you are using.
• Valve stem is worn below specifications.
• Valve stem is bent. The valve seats are ground at three different angles:
• Valve face is warped. 30 , 46 , and 60 . This method makes a valve seat
• Any part of the valve is cracked. that is the proper width and produces the correct con-
• Any wear or damage to the valve face that cannot tact line between the valve and valve seat. The spec-
be removed by resurfacing and still meet the specifications for the valve seats are shown in the Engine
ifications shown in Figure 5. Specifications section and in Figure 4.
• If the contact line is too high, it can be made lower
by using a 30 stone.
• If the contact line is too low, it can be raised using
the 46 stone.
• If the seat is too narrow, it can be made wider using
a 46 stone.
• If the seat is too wide, it can be made narrower
using a 60 stone.
The correct dimensions for the valve seat widths and

valve/valve seat overlap are shown in Figure 6. The
valve seat widths are the dimensions of the 46 face
only. The valve/valve seat overlap is the distance
from the edge of the seat to the outside edge of the
valve.
Figure 5. Valve Head Measurements VALVE SPRINGS

VALVE SEATS, REPAIR Measure the length of the valve springs. The correct
length is 51.6 mm (2.03 in.).
NOTE: Before any work is done on the valve faces and
seats, make sure the clearance of the valve stems in
their valve guides is within specifications.
WARNING
Be careful when testing the valve springs.
These springs can come loose with enough
CAUTION force to cause an injury. Always use equip-
The exhaust valve seats in these cylinder heads ment that was designed to test springs. Always
are induction-hardened. Removal of too much wear eye and face protection while testing
valve seat material will damage the valve seats valve springs.
which will require replacement of the cylinder
head. Use a special tool to check the tension of the valve
springs. Compress the spring to the correct height
Damaged valve seats can be resurfaced with a tool and check the tension. For the correct specifications,
that is designed to repair valve seats. There are see Figure 7. Replace valve springs that are not
many different types of equipment for repairing within specifications.
4
A. EXHAUST VALVE B. INLET VALVE

1. CYLINDER HEAD 2. VALVE
Figure 6. Valve Seat Widths and Valve/Valve Seat Overlap

Legend for Figure 7
A. VARIATION FROM VERTICAL: LESS THAN
1.6 mm (0.063 in.)
B. FREE LENGTH: 51.6 mm (2.03 in.)
C. SPRING COMPRESSED TO 338 to 374 N (76 to
84 lbf) AT 43 mm (1.69 in.)
D. INSTALLED HEIGHT
EARLY MODELS : 42.92 to 43.43 mm (1.690 to
1.710 in.)
LATE MODELS:
INTAKE: 45.2 mm (1.78 in.)
EXHAUST: 45.2 to 43.43 mm (1.780 to 1.710 in.)
Figure 7. Valve Spring Specifications
5
ROCKER ARM STUDS (EARLY MODELS)

CAUTION
These studs are pressed into the head. Disposal of lubricants and fluids must meet lo-
cal environmental regulations.
Replace a stud that has damaged threads or is loose
in the cylinder head. New studs are available in the Drain the cooling system before replacing the studs.
following oversizes: 0.003 in. and 0.013 in. The studs for late model engines have threads that
hold them to the cylinder head. See Figure 10. A stud
1. To remove old stud, install spacer, flat washer,
that has damaged threads must be replaced with a
and nut to damaged stud. Use a wrench to re-
new stud. If the threads in the head are damaged, a
move damaged stud. See Figure 8.
thread repair kit can be used. If the damaged threads
cannot be repaired with a thread repair kit, then the
CAUTION head must be replaced.
Do not attempt to install an oversized stud
without reaming the stud hole to the new
size. Installation of an oversized stud without
reaming the stud hole can cause cracks in the
cylinder head.
2. Use a reamer of the correct size for new oversized

stud. Apply SAE 90 lubricant to new stud during
installation. Install new stud as shown in Fig-
ure 9.
NOTE: EARLY MODELS ONLY.
Figure 8. Rocker Arm Stud Removal
ROCKER ARM STUDS (LATE MODELS)

NOTE: EARLY MODELS ONLY.
WARNING 1. REAMER 2. INSTALLATION
DO NOT remove a stud from the cylinder head TOOL
when the engine is hot. Some of the studs fit
into coolant passages and can release pressure Figure 9. Rocker Arm Stud Installation
and hot coolant when removed. The steam and
boiling coolant can cause burns.
6
Legend for Figure 11

A. VARIATION FROM VERTICAL: LESS THAN
1.6 mm (0.063 in.)
B. FREE LENGTH: 51.6 mm (2.03 in.)
C. SPRING COMPRESSED TO 338 to 374 N (76 to
84 lbf) AT 43 mm (1.69 in.)
D. INSTALLED HEIGHT
EARLY MODELS : 42.92 to 43.43 mm (1.780 to
1.710 in.)
LATE MODELS:
INTAKE: 45.2 mm (1.78 in.)
EXHAUST: 45.2 to 43.43 mm (1.690 to 1.710 in.)
2. Clean surface of cylinder head and top of cylinder

block. Make sure threads in block are clean.
NOTE: LATE MODELS ONLY.
3. Install cylinder head gasket and cylinder head.
1. STUD Make sure cylinder head is aligned with pins in
block.
Figure 10. Studs With Threads
4. Use a sealant on threads of capscrews for cylin-
ASSEMBLE AND INSTALL der head. Install capscrews as follows:
1. Install each valve in correct port. Install oil seal a. On 1995 and earlier engines, tighten cap-
in lower groove. Install shim, damper, spring, screws in three steps. Tighten all capscrews
shield, and cap or rotator. Using a spring com- to one torque specification, then use the next
pressor, compress assembly and install retainers. specification: 34 N•m (25 lbf ft), 61 N•m
Measure height of valve spring as shown in Fig- (45 lbf ft), and 90 N•m (65 lbf ft). Use se-
ure 11. Measure from top of shim to top of re- quence shown in Figure 12.
tainer cap. Install shims to get correct height
shown in Figure 11. The installed height of valve
spring must not be less than minimum height.
A. FAN END
Figure 12. Cylinder Head Tightening Sequence
b. On 1996 model and later engines, tighten all

capscrews to 30 N•m (22 lbf ft). Use se-
quence shown in Figure 12. Next, tighten
capscrews 11, 7, 3, 2, 6, 10 an additional 55
Figure 11. Valve Spring Specifications degrees. Tighten capscrews 12 and 13 an ad-
ditional 65 degrees. Tighten capscrews 1, 4,
8, 5, 9 an additional 75 degrees.
7
5. Apply RTV sealant (Hyster part number 280472) 8. Install valve push rods. See Figure 15.
to front and rear surfaces between intake mani-
fold and engine block. See Figure 13. The bead
of sealant must be 5 mm (0.2 in.) thick and ex-
tend up sides of heads 13 mm (0.5 in.) to seal and
retain gaskets.
1. EXTEND BEAD 13 mm (0.5 in.) UP HEADS

(FRONT AND REAR).
2. REAR
3. FRONT
A. EARLY MODELS C. FAN END
Figure 13. Intake Manifold Sealant Locations B. LATE MODELS
6. Install gaskets and intake manifold. Tighten Figure 14. Inlet Manifold Tightening Sequence
capscrews in sequence shown in Figure 14.
Tighten capscrews on early models to 48 N•m
(35 lbf ft). On later models tighten capscrews on
first pass to 3 N•m (27 lbf in). Tighten capscrews
on second pass to 12 N•m (106 lbf in). Tighten
capscrews on final pass to 15 N•m (133 lbf in).
NOTE: For year 2002 or later model engines, perform

Step 8 through Step 18. For 2001 and earlier model
engines, perform Step 7 and Step 14 through Step 18.
NOTE: Install parts as marked during removal.
7. Install push rods, making sure they are in the

seat of the valve lifter. Lubricate rocker arms
and rocker arm balls with a molybdenum grease.
Install rocker arms, balls, and nuts. The ear-
lier and later models have different procedures to
tighten rocker arms and adjust valves. The pro-
cedures are described in Valve Clearance Adjust-
ment (Early Models) and Valve Clearance Ad-
justment (New Models). Figure 15. Install Valve Push Rod
8
Legend for Figure 17

CAUTION
Be sure that the arrow on the valve rocker arm 1. VALVE PUSH ROD SOCKET
2. ROLLER PIVOT
support is in the up position. See Figure 16. 3. VALVE STEM TIP
4. ROCKER ARM BOLT
9. Install valve rocker arm supports.
11. See Figure 18. Install the valve rocker arm as-
semblies as follows:
a. Finger start the rocker arm bolt at location 1
in Figure 18.
b. Finger start the rocker arm bolt at location 2
in Figure 18.
c. Finger start the rocker arm bolt at location 3
in Figure 18.
d. Finger start the remaining three valve
rocker arm bolts.
Figure 16. Install Valve Rocker Arm Supports
10. Apply a molybdenum grease or equivalent to the

following valve rocker arm contact surfaces: See
Figure 17.
• Valve push rod socket
• Roller pivot
• Valve stem tip
1. BOLT AT LOCATION 1
Figure 18. Install Valve Rocker Arm Assemblies
12. Rotate the crankshaft balancer to position the

crankshaft balancer alignment mark 57 to 63 de-
grees clockwise or counterclockwise from the en-
gine front cover alignment tab. See Figure 19.
NOTE: Once the valve rocker arm assemblies are in-

stalled and properly torqued, no additional valve lash
adjustment is required.
13. Tighten the valve rocker arm bolts to 30 N•m

(22 lbf ft). See Figure 17.
14. Use new gasket and install valve covers. Tighten

Figure 17. Lubricate Valve Rocker Arm capscrews to 12 N•m (107 lbf in).
Surfaces
9
Piston Bore Preparation 600 SRM 590
15. Install spark plugs.
16. Install throttle body, air cleaner, and distributor.

Install brackets for drive belt tensioner and al-
ternator. Install drive belt(s).
17. Install exhaust manifolds. Tighten capscrews in

two steps; first to 15 N•m (133 lbf in), then to
31 N•m (274 lbf in). If used, bend lock tabs
against heads of capscrews.
18. Install coolant hose to housing for thermostat.

Fill coolant system with coolant. See the Peri-
odic Maintenance section for your lift truck.
1. CRANKSHAFT BALANCER ALIGNMENT MARK

2. ENGINE FRONT COVER ALIGNMENT TAB
Figure 19. Rotate Crankshaft Balancer
Cylinder Block Cleaning and Inspection

away from all personnel. Wear protective gog-
WARNING gles or a face shield to prevent injury to the
Cleaning solvents can be flammable and toxic eyes.
and can cause skin irritation. When using
cleaning solvents, always follow the solvent After the engine is disassembled, clean cylinder block
manufacturer’s recommended safety proce- in solvent and dry with compressed air. Make sure
dures. all oil passages are clean. Remove gaskets from sur-
face of block.
WARNING Inspect bores for pistons for wear or damage. Mea-
Compressed air can move particles so they sure bores and check dimensions shown in Engine
cause injury to the user or to other personnel. Specifications. Repair cylinder block, as necessary.
Make sure the path of the compressed air is
Piston Bore Preparation

NOTE: It is important that the piston bores are pre- 2. Move hone quickly (approximately 60 times per
pared correctly before new piston rings are installed. minute) up and down in bore. Make sure hone
Incorrect preparation can cause the parts to wear makes a cross pattern of 45 to 60 degrees. Use
quickly. hone until entire length of bore has this pattern.
Use a hone in the piston bores when installing new 3. After using the hone, clean cylinder block with
rings. Use the hone as follows: hot water and detergent. Make sure all metal
particles are removed from block. Dry bores and
1. Use a hone with a 280-grit stone. Make sure lubricate them with engine oil.
stone is clean and will not damage bore.
10
600 SRM 590 Lubrication System Repair
Engine Mounts Installation

If the engine mount was removed from the cylinder S/H3.50-5.00XL (S/H70-110XL) 31 N•m
block, install and tighten capscrews for mount as fol- (23 lbf ft)
lows.
S/H6.00-7.00XL 50 N•m
(S/H135-155XL) (37 lbf ft)
H3.50-5.50XM (H70-120XM) 52 N•m
(38 lbf ft)
Lubrication System Repair

OIL PUMP, REMOVE AND DISASSEMBLE
1. Remove oil sump.
2. Remove capscrew at mount for pump. Remove

oil pump and shaft. See Figure 20.
3. Remove cover for oil pump. Put marks on gear

teeth to show their correct location during assem-
bly.
4. Do not remove tube and screen assembly unless

it is damaged. The tube and screen must be re-
placed as an assembly.
5. Remove retaining pin, pressure regulator spring,

and pressure regulator valve from pump cover.
CLEAN AND INSPECT
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the solvent
manufacturer’s recommended safety proce-
dures.
WARNING 1. CAPSCREW 7. HOUSING

Compressed air can move particles so they 2. SCREEN 8. SPRING
3. DRIVEN GEAR 9. RELIEF VALVE
cause injury to the user or to other personnel. 4. DRIVE GEAR 10. COVER
Make sure the path of the compressed air is 5. RETAINER 11. PIN
away from all personnel. Wear protective gog- 6. SHAFT
gles or a face shield to prevent injury to the
eyes. Figure 20. Oil Pump
Clean parts of oil pump in solvent and dry with com-

pressed air. Inspect gears, shaft, and body of pump
for wear or damage.
11
Lubrication System Repair 600 SRM 590
OIL PUMP, ASSEMBLE AND INSTALL a. Install new gasket(s) and oil sump. See Fig-
ure 22. Use a sealant on gasket(s) in the fol-
NOTE: There are some variations in the oil pumps in- lowing locations: at front cover to block joint
stalled during the years of manufacture of these en- and rear seal retainer to block joint. The
gines, but the design is the same. The repair proce- sealant must extend 25 mm (1 in.) in both
dures are the same. See the Parts Manual for each directions at each of the four corners.
oil pump.
1. Install NEW pressure regulator valve and spring

into pump cover. Install retaining pin.
2. Install gears in body of pump. Make sure to align

identification marks. Install cover for oil pump
and tighten capscrews to 12 N•m (106 lbf in).
Turn shaft for oil pump and check for smooth op-
eration.
3. Use a sealant when replacement of tube and

screen assembly is necessary. The tube and
screen assembly must have a good press fit into
the oil pump body. Do not damage tube during
installation. Make sure surface of screen assem-
bly is parallel to bottom surface of cylinder block.
See Figure 21.
A. EARLY MODELS C. FAN END

B. LATE MODELS
1. OIL SUMP 3. PLATE
Figure 21. Oil Pump Tube and Screen 2. GASKET
Installation
Figure 22. Oil Sump
4. Install oil pump shaft and NEW retainer.
b. Tighten capscrews for oil sump as follows:
5. Install oil pump assembly to engine. Make sure 1/4-20 capscrews, 10 N•m (89 lbf in); 5/16-18
shaft is aligned with slot in distributor shaft. On capscrews, 19 N•m (168 lbf in).
early models (1995 and older engines), tighten
capscrew at mount to 47 N•m (35 lbf ft). On 2. Install oil sump on late models (1996 and later
late models (1996 and later), tighten capscrew to engines) as follows:
90 N•m (66 lbf ft).
a. Apply an RTV sealant to surfaces of engine
OIL SUMP, INSTALL block as shown in Figure 23.
1. Install oil sump on early models (1995 and earlier

engines) as follows:
12
600 SRM 590 Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters
b. Install gasket and oil sump. Make sure ver-

tical surfaces at back of engine block and oil
sump are even.
c. Tighten capscrews and nuts for oil sump

in sequence shown in Figure 24 to 25 N•m
(221 lbf in).
Figure 24. Oil Sump Installation
A. FAN END
Figure 23. Oil Sump Installation
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters

TIMING COVER vibration damper. Do not pull on outside diame-
ter of vibration damper.
Remove
3. Remove crankshaft position sensor from timing
NOTE: For model H3.50-5.50XM (H70-120XM), refer cover. See Figure 26.
to the section Cooling System 700 SRM 740.
4. Remove capscrews and stud for timing cover. Re-
1. Remove fan assembly and belts. move timing cover from engine. See Figure 27.
2. Remove crankshaft pulley and vibration damper. 5. Remove crankshaft position sensor reluctor ring
See Figure 25. Use a tool that pulls on center of from crankshaft. See Figure 28.
13
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters 600 SRM 590
1. TIMING COVER 1. TIMING COVER 2. ENGINE

2. VIBRATION DAMPER
3. TOOL FOR REMOVING VIBRATION DAMPER Figure 27. Timing Cover
Figure 25. Timing Cover
1. CRANKSHAFT POSITION SENSOR RELUCTOR

RING
1. CRANKSHAFT POSITION SENSOR BOLT 2. CRANKSHAFT
2. CRANKSHAFT POSITION SENSOR
3. TIMING COVER Figure 28. Crankshaft Position Sensor
Reluctor Ring
Figure 26. Crankshaft Position Sensor
14
Install TIMING SPROCKETS

NOTE: The plastic timing cover can be used only Remove
once. When the engine has a plastic timing cover,
always install a new one. 1. Remove timing cover. On late models, remove
ring for crankshaft position sensor. See Fig-
1. Install crankcase position sensor reluctor ring on ure 30.
crankshaft. See Figure 28. Make sure open side
of seal is toward inside of cover. 2. Check timing chain for wear. If timing chain
can be moved back and forth more than 16 mm
2. Use a sealant on sump gasket in the following (0.63 in.), install a new chain.
locations: at front cover to block joint and rear
seal retainer to block joint. The sealant must 3. Remove capscrews for camshaft sprocket. Use a
extend 25 mm (1 in.) in both directions at each of puller to remove crankshaft sprocket. Make sure
the four corners. During installation of the cover, timing chain is removed with sprockets.
use a special tool to align oil seal with crankshaft.
The vibration damper will damage the oil seal if Install
it is not installed correctly. Tighten capscrews for
cover to 12 N•m (106 lbf in). See Figure 27. 1. Install crankshaft sprocket. Install timing chain
on camshaft sprocket. Install camshaft sprocket
3. Install crankshaft position sensor. Tighten with chain. Make sure marks are aligned as
crankshaft position sensor bolt to 8 N•m shown in Figure 30. The number 4 cylinder will
(71 lbf in). See Figure 26. be at top dead center (TDC) on the compression
stroke. Tighten capscrews to camshaft sprocket
4. Lubricate lips of seal with clean engine oil before to 28 N•m (21 lbf ft). On late models, install ring
vibration dampener is installed. Use a special for crankshaft position sensor.
tool to pull vibration damper onto crankshaft.
See Figure 29. Tighten capscrew for damper to 2. Lubricate chain and sprockets with new engine
95 N•m (70 lbf ft). oil. Install timing cover as described in section
for Timing Cover.
5. Install crankshaft pulley, belts, and fan assem-
bly.
1. SPECIAL TOOL 2. VIBRATION

DAMPER
Figure 29. Timing Cover 1. TIMING MARKS 3. CAMSHAFT

2. TIMING CHAIN SPROCKET
Figure 30. Timing Marks
15
CAMSHAFT on the surface of the bearing to see if they are round.

If the difference of the readings for each bearing is
Remove more than 0.025 mm (0.001 in.), replace camshaft.
Check for a bent camshaft or excessive camshaft
1. Remove intake manifold, push rods, lifter guides, runout. If runout exceeds 0.065 mm (0.0026 in.), the
and valve lifters. camshaft is bent and should be replaced.
2. Remove timing cover as described in section Tim-
ing Cover. Align timing marks. Remove timing
chain, sprockets, and camshaft retainer.
3. Install two or three 5/16-18 capscrews that are

100 to 125 mm (4 to 5 in.) long into camshaft.
See Figure 31. These capscrews will make the
camshaft easier to control. Carefully remove
camshaft from cylinder block. All camshaft bear-
ings are the same size. Do not damage bearings
or camshaft during removal.
1. TOOL FOR CAMSHAFT BEARINGS
Figure 32. Camshaft Bearings
Install
1. Use a special tool as shown in Figure 32 to install
camshaft bearings. See Figure 33. Install front
and rear bearings first. Make sure oil holes in
bearings are aligned with oil holes in block. Use
a sealant on rear camshaft plug and install plug
in block. Make sure plug is even with or 0.80 mm
(0.03 in.) below surface of block.
NOTE: LATE MODEL SHOWN, OTHER MODELS SIM-
ILAR. 2. Lubricate camshaft lobes with a molybdenum lu-
bricant. Lubricate camshaft bearings with en-
Figure 31. Camshaft gine oil. Install two or three 5/16-18 capscrews
that are 100 to 125 mm (4 to 5 in.) long into
4. If necessary, use a special tool as shown in Fig- camshaft. See Figure 31. These capscrews will
ure 32 to remove camshaft bearings. Remove make camshaft easier to control. Carefully in-
front and rear bearings last. stall camshaft in cylinder block.
Inspect 3. Lubricate and install retainer for camshaft.
Tighten capscrews to 14 N•m (125 lbf in).
Inspect entire camshaft for any signs of wear or dam-
age. Measure diameter of each bearing surface on 4. Install gear for the balance shaft as described in
camshaft. Do the measurement at different positions procedures for Balance Shaft.
16
1. RETAINER 2. CAMSHAFT
Figure 33. Camshaft and Retainer
5. Install timing sprockets, chain, and cover as de-

scribed in procedures for Timing Cover.
6. Lubricate valve lifters with a molybdenum lu-

bricant. Install lifters in block. Install push
rods and adjust valve mechanism as described in
Valve Clearance Adjustment (Early Models) and
Valve Clearance Adjustment (New Models).
BALANCE SHAFT
1. SPROCKET, 3. DRIVEN GEAR,
CAMSHAFT BALANCE SHAFT
Remove 2. DRIVE GEAR, 4. BALANCE SHAFT
CAMSHAFT 5. RETAINER
1. Remove intake manifold.
Figure 34. Balance Shaft Components
2. Remove retainer for lifters.
3. Remove timing cover as described in section Tim-

ing Cover. Remove timing chain and sprocket
from camshaft.
4. Remove driven gear from balance shaft. Remove

retainer. See Figure 34.
5. Use a soft-faced hammer to remove balance

shaft. See Figure 35.
NOTE: The balance shaft and front bearing are ser-

viced as a unit.
6. Use a special tool to remove rear bearing.

A. FRONT
Figure 35. Balance Shaft Removal
17
Install
1. Lubricate rear bearing with new engine oil. Use
a special tool to push rear bearing into block. See
Figure 34 and Figure 36.
1. ALIGNMENT OF TIMING MARKS

2. DRIVEN GEAR, BALANCE SHAFT
3. DRIVE GEAR, CAMSHAFT
Figure 37. Balance Shaft Timing Marks

A. FRONT
7. Install timing cover as described in section Tim-
1. HAMMER 2. BEARING DRIVER
ing Cover.
Figure 36. Balance Shaft Installation
8. Make sure all lifters and guides for lifters are
2. Lubricate front bearing with new engine oil. Use properly installed. Install retainer for lifters.
a driver to install balance shaft into engine block. Tighten bolts for retainer to 16 N•m (142 lbf in).
3. Install retainer for balance shaft. Tighten screws 9. Install intake manifold as described in the sec-
for retainer to 14 N•m (125 lbf in). tion Cylinder Head Repair, Assemble and Install.
4. Install driven gear onto balance shaft. Tighten HYDRAULIC VALVE LIFTERS
bolt to 20 N•m (177 lbf in), plus an additional 35
degrees of rotation. Rotate balance shaft by hand Remove
to make sure there is clearance between retainer
and shaft. If the balance shaft does not rotate 1. The hydraulic valve lifters normally do not need
freely, check that retaining ring on the front bear- repair unless they become dirty, causing them to
ing is in its seat. malfunction or the roller does not operate prop-
erly. The hydraulic valve lifters must be clean to
5. Temporarily install drive gear on camshaft. operate correctly. If a hydraulic valve lifter must
Turn camshaft until timing mark on drive gear be disassembled, make sure small parts are han-
is straight up. Remove drive gear and rotate bal- dled carefully to prevent loss or damage.
ance shaft until mark on driven gear is straight
down. Install drive gear on camshaft. Make 2. Remove air bonnet, distributor, and intake man-
sure timing marks are in the position shown in ifold.
Figure 37. 3. The push rods must be removed as described in
6. Install timing chain and sprocket on camshaft. Cylinder Head Repair, Remove and Disassemble.
Make sure timing marks are in the position 4. Remove hydraulic valve lifters. Put lifters in a
shown in Figure 30. Tighten capscrews that at- rack so they can be installed in their original po-
tach sprocket to camshaft to 28 N•m (21 lbf ft). sitions.
18
Disassemble
CAUTION
The internal parts of a lifter are a precise fit
to each lifter body. When servicing the lifters,
make sure the parts from one lifter are not
mixed with another lifter. If any part of the
lifter or roller is worn or damaged, the lifter
must be replaced.
1. Hold plunger down with a push rod. See Fig-

ure 38. Use blade of a small screwdriver to re-
move retainer for push rod seat.
Figure 39. Check Ball Assembly Removal
Clean and Inspect

Clean all parts in a cleaning solvent and inspect them
carefully. If any parts are damaged or worn, the com-
plete hydraulic valve lifter must be replaced. If the
body of the hydraulic valve lifter is worn, also inspect
bore in cylinder block. If roller of hydraulic valve
lifter is worn or damaged, inspect camshaft lobe for
wear and damage.
Assemble
1. CHECK BALL 5. RETAINER 1. Assemble check ball assembly. Put check ball on
ASSEMBLY 6. SPRING
2. PLUNGER 7. LIFTER BODY small hole in bottom of plunger. Install check
3. METERING VALVE 8. RETAINER ball spring in seat of check ball retainer. Put
4. PUSH ROD SEAT check ball retainer over check ball so check ball
spring is on check ball. Carefully press check ball
Figure 38. Hydraulic Valve Lifter retainer into position in plunger. See Figure 40.
2. Remove push rod seat and metering valve. 2. Put plunger spring over check ball retainer and
slide lifter body over spring and plunger. See
3. Remove plunger, check ball assembly, and
Figure 38.
plunger spring.
3. Fill assembly with SAE 10 engine oil. Put a 3 mm
4. Use a small screwdriver as a pry bar to remove
(0.125 in.) drift into plunger and push plunger
check ball retainer from plunger. See Figure 39.
until holes for oil are aligned. See Figure 41.
Now put a 1.6 mm (0.0625 in.) drift through holes
to hold plunger. Remove 3 mm (0.125 in.) drift
and fill assembly again with SAE 10 oil.
19
(0.063 in.) drift and remove drift. The hydraulic

valve lifter is now ready for installation.
Install
1. Lubricate all roller and lifter surfaces with new
engine oil. Install lifters in their original posi-
tions. Make sure guides are in correct positions.
See Figure 42.
2. Install retainer. Tighten capscrews to 16 N•m

(142 lbf in).
3. Install push rods. Adjust valves. The old and

new models use different procedures to tighten
rocker arms and adjust valves. The procedures
are described in Valve Clearance Adjustment
Figure 40. Check Ball Assembly Installation (Early Models) and Valve Clearance Adjustment
(New Models).
4. Install intake manifold and distributor.
1. 3 mm (0.120 in.) 3. 1.6 mm (0.063 in.)

DRIFT PIN PIN
2. OIL FEED HOLE 1. ROCKER ARM 5. LIFTER
2. CYLINDER HEAD 6. RETAINER
Figure 41. Hydraulic Valve Lifter Assembly 3. CYLINDER BLOCK 7. GUIDE
4. CAMSHAFT 8. PUSH ROD
4. Install metering valve and push rod seat. See
Figure 42. Cylinder Head
Figure 38. Install retainer for push rod seat.
Push down push rod seat to loosen 1.6 mm
20
600 SRM 590 Crankshaft Repair
Crankshaft Repair
REMOVE bearing is round. The correct sizes are given in
the Engine Specifications section.
1. Remove oil pan, oil pump, and flywheel. Remove
rear seal retainer (late models).
2. Remove timing cover as described in the proce-

dure Timing Cover, Remove.
3. Mark caps for connecting rods so they can be in-

stalled in their correct locations. Remove caps
and bearing inserts for connecting rods. Make
sure all parts from each rod assembly remain to-
gether.
4. Mark caps for main bearings so they can be in-

stalled in their correct locations. Remove caps
for main bearings. Make sure all parts from each
bearing assembly remain together.
5. Remove crankshaft with extreme care to prevent

damage to journals and thrust flanges of crank-
shaft.
INSPECT AND REPAIR
WARNING
Commercial cleaning solvents can be
flammable and toxic and can cause severe
skin irritation. When using commercial Figure 43. Crankshaft Inspection
cleaning solvents, always comply with the
5. If crankshaft journals must be repaired, they can
solvent manufacturer’s recommended safety
be ground to the following diameters smaller (un-
precautions.
dersize) than the original size:
Compressed air can move particles so they 0.254 mm (0.010 in.)
cause injury to the user or to other personnel. 0.508 mm (0.020 in.)
NOTES ABOUT MAIN BEARINGS: Main bear-
ings are an insert bearing that do not use shims for
gles or a face shield to prevent injury to the
adjustment. Main bearings are available in a stan-
eyes.
dard size and the following undersizes: 0.0254 mm
1. Clean crankshaft with solvent and dry it with (0.001 in.), 0.0508 mm (0.002 in.), 0.2286 mm
compressed air. Make sure oil passages are not (0.009 in.), 0.254 mm (0.010 in.), and 0.508 mm
plugged. (0.020 in.). If a bearing on a journal is worn, both
the upper and lower half of the bearing must be
2. Inspect crankshaft for cracks or other damage. replaced.
3. Inspect bearing journals and thrust surfaces for When the crankshaft is assembled by the manu-
scratches or damage caused by a lack of lubrica- facturer, the main bearings are specially selected
tion. to obtain close tolerances. For this reason, you can
find one-half of a standard size insert with one-half
4. Inspect crankshaft for wear and damage. See of a 0.0254 mm (0.001 in.) undersize insert. This
Figure 43. Use a micrometer to measure jour- combination will decrease the clearance 0.0127 mm
nals for bearings of crankshaft. Do measurement (0.0005 in.) from using a full standard bearing.
at different positions to see if the surface of the
21
Crankshaft Repair 600 SRM 590
When a production crankshaft cannot be fitted 6. Remove main bearing cap. The Plastigage® will
with this method, the main journal is then ground be compressed and wider and will adhere to ei-
0.2286 mm (0.009 in.) undersize. Only those main ther the bearing or its journal. Use scale on en-
bearing journals that cannot be fitted with standard, velope for Plastigage® to measure width of plas-
0.0254 mm (0.001 in.), or 0.0508 mm (0.002 in.) un- tic at its widest point. The scale will indicate
dersize main bearing will be ground. A 0.2286 mm the clearance in millimeters or thousandths of an
(0.009 in.) and a 0.254 mm (0.010 in.) undersize inch. See Figure 47.
bearings will be selected as described to obtain close
tolerances. 7. If the clearance is greater than the specifications,
select a new undersize bearing set and install
A production crankshaft that has been ground will it. Measure clearance again. If clearance can-
have the following identification: not meet specifications with the available under-
• The crankshaft journal that has been ground will size bearings, bearing journal must be ground to
have a 9 marked in the metal of the crankshaft next a new undersize. If bearing journal is already
to the journal. A spot of light green paint is also at maximum undersize, crankshaft must be re-
added to the crankshaft. placed.
• The main bearing cap is also marked with green
paint. 8. If clearance is within specifications, lubricate
bearing with engine oil and install main bearing
HOW TO CHECK CLEARANCE BETWEEN and bearing cap. Tighten capscrews on main
MAIN BEARINGS AND THEIR JOURNALS bearing cap to correct specifications.
1. Use Plastigage® or equivalent to check clearance. 9. Turn crankshaft to make sure it rotates
The procedure is similar for both connecting rod smoothly.
bearings and main bearings. If engine has been 10. Check axial clearance between rear main bearing
removed from lift truck, put engine so crankshaft and thrust surface. Push crankshaft forward.
is up. The weight of the crankshaft is against the See Figure 44. Measure clearance between
upper bearing half and the total clearance can be crankshaft and thrust surface of rear bearing.
measured correctly. If the engine is still in the See Engine Specifications for correct clearances.
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 rear main bearing first. Remove cap for

rear main bearing. The procedure for checking
the clearance of the other bearings is similar.
4. Clean oil from bearing half and journal to be

checked. Put a piece of Plastigage across full
width of bearing journal as shown in Plastigage®
on Bearing Journal. Do not rotate crankshaft
when Plastigage is between main bearing and its
journal.
5. Install main bearing cap and tighten capscrews.

See Torque Specifications. The capscrews must A. FAN END
be tightened to their final torque or there will be 1. MEASURE CLEARANCE
an error in the measurement.
Figure 44. Measuring Crankshaft Axial
Clearance
22
600 SRM 590 Crankshaft Repair
INSTALL 4. Tighten capscrews for bearing caps to 70 N•m

(52 lbf ft). Move crankshaft forward and back-
1. On engines with a two-piece rear seal, install seal ward to align rear main bearing. Tighten cap-
halves so lips are toward fan end of engine. Apply screws for all bearing caps to 106 N•m (78 lbf ft).
sealant to ends of seal halves. Apply engine oil On late model engines, tighten capscrews for
to seal during installation. Do not get any oil on bearing caps to 20 N•m (177 lbf in) on the first
ends of seal. pass. Move crankshaft forward and backward to
align rear main bearing. Tighten capscrews for
NOTE: With the use of special tools, the main bear-
all bearing caps an additional 73 degrees on the
ings and the rear crankshaft seal (two-piece) can be
final pass.
replaced without removing the crankshaft.
5. Install connecting rods, oil pump, and oil pan.
2. Install main bearings in cylinder block and bear-
Install flywheel and other parts.
ing caps. Lubricate bearings with engine oil and
carefully install crankshaft in cylinder block. 6. On late model engines with a one-piece seal, in-
stall seal in retainer. Use new gasket and install
3. Install bearing caps. Make sure arrows on bear-
seal retainer. See Figure 45. Tighten screws and
ing caps are toward front (fan end) of engine.
nut to 15 N•m (133 lbf in).
Push crankshaft forward and measure clearance
at front side of rear main bearing. The correct
clearance is 0.050 to 0.20 mm (0.002 to 0.008 in.).
See Figure 44.
A. SEAL REMOVAL NOTCHES

1. CRANKSHAFT 5. GASKET
2. OIL SEAL 6. STUD
3. SEAL RETAINER 7. SCREW
4. ENGINE BLOCK 8. NUT
Figure 45. One-Piece Rear Seal
23
Piston and Connecting Rod Assemblies Repair 600 SRM 590
Piston and Connecting Rod Assemblies Repair

CONNECTING ROD BEARINGS, REPLACE envelope for Plastigage® to measure width of
plastic at its widest point. The scale will in-
NOTE: Connecting rod bearings are insert bearings dicate the clearance in millimeters or thou-
that do not use shims for adjustment. These bearings sandths of an inch. See Figure 47.
are available in a standard size and the following un-
dersizes: 0.025 mm (0.001 in.), 0.051 mm (0.002 in.),
0.254 mm (0.010 in.), and 0.508 mm (0.020 in.). If
a bearing on a journal is worn, both the upper and
lower half of the bearing must be replaced.
1. Remove oil sump and oil pump.
2. Mark caps for connecting rods so they can be in-

stalled in their correct locations and positions.
3. Push connecting rod away from crankshaft and

remove upper bearing half. Wipe oil from bearing
halves and bearing journal. Make sure all parts
from each rod assembly remain together. Figure 46. Plastigage® on Bearing Journal
4. Use a micrometer to measure bearing journal.
The bearing journal must be within the following
specifications:
Out-of-round less than 0.0254 mm (0.001 in.)
Taper less than 0.0254 mm (0.001 in.)
If bearing journals are not within specifications,

crankshaft must be removed and bearing journal
ground to an undersize. If bearing journal cannot
be repaired so bearing journal is a correct under-
size, crankshaft must be replaced. See Engine
Specifications, Crankshaft.
5. If bearing journal is within specifications, mea-

sure clearance between new bearing and crank- Figure 47. Measuring Plastigage® on Bearing
shaft. Use Plastigage® or equivalent to check Journal
clearance:
d. If clearance is greater than specifications, se-
a. Put a piece of Plastigage® across the full lect a new undersize bearing set and install
width of the bearing journal as shown in it. Measure clearance again. If clearance
Figure 46. Do not rotate crankshaft when cannot meet specifications with available
Plastigage® is between bearing and its jour- undersize bearings, bearing journal must
nal. be ground to a new undersize. If bearing
journal is already at maximum undersize,
b. Install bearing cap and tighten bearing cap crankshaft must be replaced.
nuts first to 27 N•m (240 lbf in) and then an
additional 70 degrees. e. If clearance is within specifications, lubricate
bearing with engine oil and install bearing
c. Remove bearing cap. The Plastigage® will be and bearing cap. First tighten nuts on bear-
compressed and wider and will adhere to ei- ing caps to 27 N•m (240 lbf in). After this
ther the bearing or its journal. Use scale on step, tighten nuts an additional 70 degrees.
24
600 SRM 590 Piston and Connecting Rod Assemblies Repair
6. When all rod bearings have been replaced, use 7. Push connecting rod and piston from cylinder.
the following procedure to check side clearances Temporarily install bearing cap on connecting
between connecting rods and crankshaft: rod to keep parts together.
a. Use a hammer to lightly hit connecting rod DISASSEMBLE

parallel to crankshaft journal to make sure
there is clearance.
CAUTION
b. Measure side clearance between caps for con- The pistons are aluminum alloy and can be
necting rods and crankshaft. See Figure 48 damaged if they are hit with a hard object. The
and Engine Specifications. 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 piston rings from pistons.
2. Use a press to remove piston pins from piston.

See Figure 49.
Figure 48. Measuring Connecting Rods Side

Clearance
PISTON AND CONNECTING ROD

ASSEMBLIES, REMOVE
1. Remove oil sump and oil pump.
2. Remove cylinder head as described in Cylinder

Head Repair, Remove and Disassemble.
3. If 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 crankshaft to lower piston to bottom
of stroke in its cylinder. Put cloth on top of pis-
ton for a collector of metal particles. Use a ridge
reamer to remove ridge at top of cylinder.
4. Clean carbon from top of each cylinder.
5. Put an identification mark on top of each piston.
6. Remove caps and bearings from each connecting

Figure 49. Piston Pin Removal
rod. Keep caps and bearings with their original
piston assemblies. Mark caps so they will be in-
stalled again in their original positions. Do not
mix parts.
25
PISTON, CLEAN AND INSPECT
WARNING
Commercial cleaning solvents can be
flammable and toxic and can cause severe
skin irritation. When using commercial
cleaning solvents, always comply with the
solvent manufacturer’s recommended safety
precautions.
Compressed air can move particles so they

cause injury to the user or to other personnel.
Figure 50. Cylinder Bore Measurement
gles or a face shield to prevent injury to the Measure cylinder bore in positions from top to bottom
eyes. to find any taper from wear. A normal wear pattern
for a cylinder bore is shown in Figure 51. A cylinder
1. Use solvent to clean pistons and connecting rods.
that has a taper (measurement A that is 0.127 mm
Use compressed air to dry parts.
(0.005 in.) greater than measurement B) must have a
2. Clean piston ring grooves with a ring groove new bore. A tool called a hone can be used to remove
cleaning tool. a small amount of taper from a cylinder bore. Use a
boring machine to repair a badly worn cylinder. The
3. Clean piston oil lubrication holes and slots. boring machine will make a more accurate cylinder
bore. The hone is then used to finish the surface of
4. Inspect pistons for wear, cracks, and damage. the cylinder bore.
Replace a piston that is worn or damaged.
NOTE: If the cylinder bore must be repaired, the pis-

ton must be changed to the correct oversize. Check
clearance of piston in its cylinder after surface of
cylinder bore has been finished with a hone.
5. Check clearance of piston pin in piston. The nor-

mal clearance is shown in the Engine Specifica-
tions. The piston pin will normally fall from the
hole in the 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 re-
placed as a unit if the clearances are greater than
the specifications. Figure 51. Pattern for Normal Cylinder Wear
CYLINDER BORES, INSPECT AND REPAIR A cylinder bore that has been repaired with a hone
or a boring machine must be fitted with a piston that
Inspect cylinder bores for wear and damage. Mea- is the correct size. Measure outer diameter of piston
sure cylinder bores in several positions as shown in and inner diameter of cylinder bore as shown in Fig-
Figure 50. Measure cylinder bore at right angles ure 52. Using different oversize pistons in the engine
to centerline to find any distortion from wear. A does not affect the dynamic balance of the engine.
cylinder that is out-of-round greater than 0.05 mm Replacement pistons from standard size to 0.508 mm
(0.002 in.) must be repaired. (0.020 in.) oversize normally have the same weight.
The clearance specifications between a piston and its
cylinder bore is shown in Engine Specifications.
26
600 SRM 590 Piston and Connecting Rod Assemblies Repair
PISTON RINGS clearances are shown in the Engine Specifica-

tions. Replace piston if clearances are greater
NOTE: Check clearance of piston rings in cylinder af- than specifications.
ter surface of cylinder has been finished with a hone.
New piston rings are available for the following pis- 2. Measure end clearance of each piston ring as
ton sizes: standard size, and 0.127 mm (0.005 in.), shown in Figure 54. The end clearances are
0.254 mm (0.010 in.), 0.508 mm (0.020 in.), and shown in the Engine Specifications. Install
0.762 mm (0.030 in.) oversize. The piston rings piston ring into cylinder where it will be used.
must match the size of the piston on which they are Use a thickness gauge to measure the amount of
installed. Check side clearance and end clearance end clearance. Replace piston if clearances are
of piston rings as described in the following para- greater than the specifications.
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 com-
pression ring normally has a chrome or molybdenum
surface.
Figure 53. Piston Ring and Groove Clearance

Check
A. PISTON GAUGE B. BORE GAUGE

POINT POINT
Figure 52. Piston and Cylinder Bore Gauge

Points
The oil control ring has three pieces. There are two
thin steel rings separated by a spacer.
1. Measure clearance between piston ring and

groove in piston as shown in Figure 53. The Figure 54. Piston Rings End Clearance Check
27
ASSEMBLE Table 1. Piston Rings Arrangement on Piston
NOTE: There are notches cast in the top of all pis- A Position of Gap for Fan End of Engine
tons to indicate the correct assembly and installa- Spacer of Oil Ring
tion. The pistons must always be installed with this
notch toward the fan end of the engine. See Table 1. B Position of Gap for Oil
Ring
The connecting rods have a notch cast in the bearing
C Position of Gap for
journal as shown in Figure 55. This notch must be
Second Compression
opposite the notch on the top of the piston when the
Ring
piston and connecting rod are assembled. On later
engines the flanges on the connecting rods and caps D Position of Gap for
should face to the front of the engine on the left bank First Compression
and to the rear of the engine on the right bank. Ring
PISTON AND CONNECTING ROD

ASSEMBLIES, INSTALL
1. Lubricate assembly with engine oil during instal-
lation. Arrange piston rings on piston as shown
in Table 1. Install ring compressor on piston.
2. Make sure notch in piston is toward fan end of

engine. Install piston and connecting rod assem-
blies in cylinder bores.
3. Install bearings and caps for connecting rods.

Tighten nuts. See the procedure in Connecting
1. NOTCHES ON ROD OPPOSITE NOTCH IN Rod Bearings, Replace.
PISTON
4. Check side clearance of each connecting rod after
Figure 55. Connecting Rod Identification bearing cap is installed. See the procedure in
Connecting Rod Bearings, Replace.
1. Assemble connecting rod to piston. Make sure
the orientation of connecting rod and piston are 5. Install cylinder head as described in Cylinder
correct as described in the NOTE above. Use a Head Repair, Assemble and Install.
press to install piston pin into piston and con-
necting rod. Lubricate piston pin with engine oil 6. Install oil pump and oil sump.
during installation.
2. Check clearances of piston rings as described in

Piston Rings. Install piston rings on piston as
shown in Table 1.
28
600 SRM 590 Flywheel and Flywheel Housing Repair
Flywheel and Flywheel Housing Repair

FLYWHEEL, REPAIR ENGINE ADAPTER H6.00-7.00XL
(H135-155XL)
1. Replace ring gear (if applicable) on flywheel.
During removal or installation, do not heat gear The engine adapter is used on engines with a man-
to more than 230 C (450 F). ual transmission. When the seal in the adapter is
replaced, use a sealant (Hyster Part No. 246108)
2. During installation, push ring gear fully against
between seal and adapter. When installing adapter
flywheel.
on engine, make sure O-rings are installed under
3. The bearing in the flywheel can be replaced. washers. Tighten capscrews for adapter to 48 N•m
Push old bearing from flywheel and push in new (35 lbf ft). See Figure 56.
bearing.
FLYWHEEL, INSTALL
H3.50-5.00XL (H70-110XL), S3.50-5.50XL
(S70-120XL), S6.00-7.00XL (S135-155XL)
NOTE: For model H3.50-5.50XM (H70-120XM), refer
to the section Cooling System 700 SRM 740 for hy-
draulic pump drive.
When installing the flywheel on these units, refer to

the section Hydraulic Pump Drive Assembly.
H6.00-7.00XL (H135-155XL)
Make sure dowel pin is installed in crankshaft. In-
stall flywheel.
Units with a manual transmission: Make sure

O-ring is installed between flywheel and crankshaft.
Use a sealant (Hyster Part No. 246108) on heads
of capscrews. Tighten capscrews for flywheel to
79 N•m (58 lbf ft).
Units with a powershift transmission: Tighten

capscrews to 79 N•m (58 lbf ft).
FLYWHEEL HOUSING H3.50-5.00XL

(H70-110XL), H3.50-5.50XM (H70-120XM), 1. ENGINE ADAPTER 5. SEAL
2. ENGINE 6. CAPSCREW
S3.50-5.50XL (S70-120XL), S6.00-7.00XL 3. FLYWHEEL 7. WASHER
(S135-155XL) 4. PILOT BEARING 8. O-RING
The flywheel housing on these units has the parts for Figure 56. Engine Adapter H6.00-7.00XL
the hydraulic pump drive assembly. When doing any (H135-155XL)
service to the housing, refer to section Hydraulic
Pump Drive Assembly.
29
Fan Mount Assembly Repair (Late Models) 600 SRM 590
Coolant Pump Repair

If any parts of the coolant pump are worn or dam- Tighten capscrews for coolant pump to 41 N•m
aged, replace coolant pump. Parts for the coolant (30 lbf ft). Adjust tension of belt as described in the
pump are not available separately. During instal- Periodic Maintenance section for your lift truck.
lation, apply a sealant to gasket for coolant pump.
Thermostat Replacement
When installing the thermostat, make sure flange is
CAUTION completely in its seat. Install gasket and housing.
DO NOT operate the engine without a ther- Tighten capscrews to 25 N•m (221 lbf in).
mostat. The engine and cooling system can be
damaged.
Fan Mount Repair (Early Models)

The fan mount has the shaft and bearings for the fan.
On some early units the mount has an idler pulley for
adjustment of the fan belt. When the fan is installed,
tighten capscrews to 20 N•m (177 lbf in). See Fig-
ure 57.
1. INNER SNAP RING 3. BEARING

2. OUTER SNAP 4. FAN MOUNT
RING 5. SHAFT
Figure 57. Fan Mount (Early Models)
Fan Mount Assembly Repair (Late Models)

NOTE: For model H3.50-5.50XM (H70-120XM), refer The fan mount assembly includes brackets and
to the section Cooling System 700 SRM 740. mounts that hold fan, belt tensioner, alternator,
and hydraulic pump (where used) to engine. When
the fan is installed, tighten capscrews to 20 N•m
WARNING
(177 lbf in). See Figure 58.
Do not try to disassemble the belt tensioner.
There is a strong spring inside the tensioner
that, if removed, can cause an injury.
30
600 SRM 590 Fan Mount Assembly Repair (Late Models)
NOTE: S/H6.00-7.00XL (S/H135-155XL) SHOWN, OTHERS SIMILAR.

A. EARLY MODELS B. LATE MODELS
1. MOUNT 8. FAN
2. BEARING 9. DRIVE BELT
3. SNAP RING 10. BELT TENSIONER
4. SHAFT 11. CRANKSHAFT PULLEY
5. HUB 12. BRACKET
6. SPACER 13. ALTERNATOR BRACKET
7. FAN PULLEY 14. TENSIONER BRACKET
Figure 58. Fan Mount Assembly
31
Drive Belt Installation 600 SRM 590
Drive Belt Installation

NOTE: For model H3.50-5.50XM (H70-120XM), refer
to the section Cooling System 700 SRM 740.
1. Check alignment of fan, alternator, and crank-

shaft pulleys. The pulleys must be aligned cor-
rectly to prevent damage to drive belt. See Fig-
ure 59.
1. BRACKET 4. TENSIONER
2. UPPER HOLE 5. ALIGNMENT LUG
3. PULLEY 6. LOWER HOLE
Figure 60. Drive Belt Tensioner Installation
CAUTION
Do not use a pry bar to install the drive belt on
the pulleys. The pry bar can damage the drive
belt and pulleys.
3. Loosen top capscrew at alternator mount and

move alternator toward engine. Install drive
belt over fan and onto pulleys.
NOTE: S/H3.50-5.50XL (S/H70-120XL) SHOWN, OTH-
ERS SIMILAR. 4. Use a socket with a long handle on capscrew for
the pulley (Figure 60) on belt tensioner. (The cap-
1. ALTERNATOR 4. CRANKSHAFT screw has left-hand threads and will not loosen.)
PULLEY PULLEY Use the handle to pull the pulley away from drive
2. FAN PULLEY 5. DRIVE BELT
3. WATER PUMP 6. TENSIONER belt. While holding pulley away from belt, pull
PULLEY PULLEY alternator away from engine (as far as it will
move) and tighten capscrew at mount. Release
Figure 59. Drive Belt Arrangement pulley for belt tensioner.
2. Install drive belt tensioner on bracket and 5. After installation is complete, check position of
tighten bolts. See Figure 60. Make sure lug on indicator on tensioner. When tension is correct,
back of tensioner fits into lower hole in bracket indicator will be in the area (3) as shown in Fig-
for new drive belts. Do not use the upper hole ure 61. If indicator is in the area as shown by (4),
when installing a NEW drive belt. Putting the change position of tensioner to upper hole (Fig-
lug in the upper hole is only necessary to extend ure 60). Use the procedure described in Step 4.
the life of a used drive belt. If tension on drive belt is still not correct, install
new drive belt. Also check that brackets and pul-
leys are installed correctly.
32
600 SRM 590 Valve Clearance Adjustment (Early Models)
1. TENSIONER 3. TENSION IS CORRECT

2. INDICATOR 4. ADJUST TENSION OR REPLACE DRIVE BELT
Figure 61. Drive Belt Tension Check
Valve Clearance Adjustment (Early Models)

NOTE: The early models use rocker arm studs that 4. Adjust valve clearance by loosening nut for
are pressed into the head. rocker arm until push rod is loose. Tighten nut
for rocker arm until there is no clearance at push
1. Disconnect negative cable at battery. Remove rod. Check clearance by rotating push rod while
rocker covers. tightening nut. When there is no clearance at
push rod, tighten nut for rocker arm one full
2. Rotate engine until mark on vibration damper or
turn. The additional turn of the nut will put the
crankshaft pulley is aligned with 0 timing mark
push rod in the seat of the valve lifter.
on timing tab. Make sure valves for No. 1 cylin-
der are closed. If valves are moving as 0 timing 5. After the valves are adjusted in Step 3, rotate
mark is reached, engine is in firing position for engine one full turn. Make sure timing marks
No. 4 cylinder; rotate crankshaft one more turn are aligned. The valves on the No. 4 cylinder
to reach firing position for No. 1 cylinder. See will be closed. When engine is in this position,
Figure 62. adjust valves for the following cylinders:
3. When engine is in No. 1 firing position, adjust Inlet Valves for Numbers. 4, 5, and 6 and Ex-
valves for the following cylinders: haust Valves for Numbers. 2, 3, and 4.
Inlet Valves for Numbers: 1, 2, and 3 and Ex- 6. Install valve covers. Connect battery cable. Start
haust Valves for Numbers: 1, 5, and 6. engine and check for correct operation.
33
Compression Check 600 SRM 590
NOTE: Early models shown.
Figure 62. Valve Clearance Adjustment
Valve Clearance Adjustment (New Models)

NOTE: The new models use rocker arm studs screwed tighten nuts for rocker arms to 25 N•m (221 lbf in).
into the head. The hydraulic valve lifter acts as an automatic ad-
juster and maintains zero lash in the valve train.
The new models have a valve system that is not ad-
justable. After the valve system has been assembled,
Compression Check
Check the compression as follows: b. Crank engine approximately ten revolutions
to distribute oil.
1. Remove all spark plugs.
c. Install compression gauge and do the same
2. Make sure battery is fully charged. tests as described in Step 3.
3. Install a compression gauge. Hold throttle open d. If compression pressure increases to a nor-
and crank engine with starter. The minimum mal reading, the low pressure was caused by
pressure is 690 kPa (100 psi). The lowest pres- worn or damaged piston rings. The cylinder
sure in a cylinder must not be less than 70% of bore can also be damaged.
the highest pressure.
e. If compression pressure does not increase,
4. If the readings are lower than the minimum the low pressure was caused by worn valves,
readings, there is a problem with the valves, valve seats, or valve guides.
piston rings, or cylinder head gasket. Do the
following tests to find the problem: f. If low pressure readings are in two cylinders
next to each other, the cylinder head gasket
a. Add approximately 30 ml (1 oz) of engine oil can be leaking.
to each cylinder at spark plug hole.
34
600 SRM 590 Engine Specifications
Engine Specifications
ENGINE DATA
Number of cylinders 6
Firing order 1 6 5 4 3 2
Bore 101.62 to 101.64 mm (4.0008 to 4.0016 in.)
Stroke 88.39 mm (3.480 in.)
Compression Ratio 9.2:1
Displacement 4.3 liter (262.4 in. 3 )
Governor speed See Periodic Maintenance section for each model
of lift truck.
CYLINDER HEAD
Valve seat specifications See Figure 4 and Figure 6.
Valve seat width (inlet valves)
Early Models 1.02 to 1.65 mm (0.040 to 0.065 in.)
Late Models 0.89 to 1.52 mm (0.035 to 0.060 in.)
Valve seat width (exhaust valves)
Clearance between inlet valve and guide
Late Models 0.0254 mm (0.001 in.) max
Clearance between exhaust valve and guide
Late Models 0.0508 mm (0.002 in.) max
Valve spring, free length See Figure 7.
35
Engine Specifications 600 SRM 590
HYDRAULIC VALVE LIFTER

Leak rate 12 to 90 seconds with 50-lb load
Body diameter 21.3868 to 21.4046 mm (0.8420 to 0.8427 in.)
Plunger travel 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.)
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 to 47.48 mm (1.8681 to 1.8693 in.)
Bearing journals, clearance 0.01778 to 0.9685 mm (0.0007 to 0.0381 in.)
Variation of a bearing journal in either diameter or
axial direction 0.03 mm (0.001 in.)
Axial clearance 0.10 to 0.30 mm (0.004 to 0.012 in.)
PISTONS
Piston diameter (see gauge points in Figure 52)
Cylinder Bore Out-of-round (see Figure 50) 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 53)
Compression rings 0.107 mm (0.0042 in.)
Oil ring to groove clearance
Early Models 0.203 mm (0.008 in.) max
Piston ring end clearance (see Figure 54)
Compression rings
Early Models 0.89 mm (0.035 in.)
Oil ring
Early Models 1.65 mm (0.065 in.)
Piston pin to piston clearance 0.025 mm (0.001 in.)
Piston pin to connecting rod clearance 0.020 to 0.040 mm (0.0008 to 0.0016 in.)
36
600 SRM 590 Engine Specifications
CRANKSHAFT
Diameter of main bearing journal
Number 1 62.20 to 62.22 mm (2.4488 to 2.4496 in.)
Number 2, 3 62.20 to 62.21 mm (2.4488 to 2.4492 in.)
Number 4 62.18 to 62.20 mm (2.4480 to 2.4488 in.)
Out-of-round of main bearing journal (maximum) 0.0254 mm (0.001 in.)
Taper of main bearing journal (maximum) 0.0254 mm (0.001 in.)
Clearance between journals and main bearings
Early Models
Number 1 0.025 to 0.038 mm (0.0010 to 0.0015 in.)
Number 2, 3 0.025 to 0.064 mm (0.0010 to 0.0025 in.)
Number 4 0.064 to 0.090 mm (0.0025 to 0.0035 in.)
Late Models
Number 1 0.0254 to 0.05 mm (0.0010 to 0.0020 in.)
Number 2, 3, 4 0.025 to 0.006 mm (0.0010 to 0.0002 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.)
Axial Clearance (crankshaft to thrust surface main bearing)
CONNECTING RODS
Diameter of connecting rod journals 57.12 to 57.14 mm (2.2488 to 2.2496 in.)
Out-of-round of bearing journal (maximum) 0.0254 mm (0.001 in.)
Taper of bearing journal (maximum) 0.0254 mm (0.001 in.)
Clearance between crankshaft journals and 0.076 mm (0.0030 in.)
connecting rod bearings
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
37
Torque Specifications 600 SRM 590

BALANCE SHAFT
Front bearing journal diameter 54.99 to 55.00 mm (2.1650 to 2.1654 in.)
Rear Bearing Journal Diameter 38.08 to 38.10 mm (1.4992 to 1.500 in.)
Rear Bearing Journal Clearance 0.025 to 0.091 mm (0.001 to 0.0036 in.)
COOLING SYSTEM
Thermostat 82 C (180 F)
LUBRICATION SYSTEM
Oil pressure @ 2500 rpm 170 to 241 kPa (25 to 35 psi)
Minimum oil pressure
Early Model @ idle rpm 48 kPa (7 psi)
Late Model @ 1000 rpm 41.4 kPa (6 psi)
Oil pressure switch ON 20 to 39 kPa (2.9 to 5.7 psi)
Torque Specifications
Alternator Pulley Cooling Fan to Pulley
61 N•m (45 lbf ft) 24 N•m (212 lbf in)
Balance Shaft Gear Capscrew Cylinder Head See Text

20 N•m (177 lbf in) Plus 35 Degrees
Distributor Mount Capscrew
Balance Shaft Retainer Capscrews 34 N•m (25 lbf ft)
14 N•m (124 lbf in)
Exhaust Manifold
Camshaft Retainer Screws 15 N•m (133 lbf in) - first step
14 N•m (124 lbf in) 30 N•m (22 lbf ft) - second step
Camshaft Sprocket Capscrews Flywheel

28 N•m (21 lbf ft) 80 N•m (60 lbf ft)
Camshaft Sprocket Nut Flywheel Housing

28 N•m (21 lbf ft) 48 N•m (35 lbf ft)
Chain Control Block for Hydraulic Pump Drive Inlet Manifold to Cylinder Head (Early Models)
19 N•m (168 lbf in) with Adhesive Sealant 48 N•m (35 lbf ft)
Connecting Rod Cap See Text Inlet Manifold to Cylinder Head (Late Models)
15 N•m (133 lbf in) - in three steps
Coolant Pump to Engine Block
41 N•m (30 lbf ft) Main Bearing Cap
106 N•m (78 lbf ft)
38
600 SRM 590 Troubleshooting
Motor Mount to Engine Rocker Arm Cover

S/H3.50-5.00XL (S/H70-110XL) 31 N•m (23 lbf ft) 10 N•m (89 lbf in)
S/H6.00-7.00XL (S/H135-155XL) 50 N•m
(37 lbf ft) Rocker Arm Nuts (Late Models)
25 N•m (18 lbf ft)
Oil Pump Cover
14 N•m (124 lbf in) Rocker Arm Studs
47 N•m (35 lbf ft)
Oil Pump to Crankcase
90 N•m (66 lbf ft) Rocker Arm Bolts (Model Year 2002
or Later Engines)
Oil Pressure Switch 30 N•m (22 lbf ft)
27 N•m (20 lbf ft)
Thermostat Housing
Oil Screen Support to Crankcase 25 N•m (18 lbf ft)
50 N•m (37 lbf ft)
Timing Cover
Oil Sump to Crankcase (Early Models) 14 N•m (124 lbf in)
(1/4-20) 10 N•m (89 lbf in)
(5/16-18) 19 N•m (168 lbf in) Valve Lifter Retainer Capscrews
16 N•m (142 lbf in)
Oil Sump to Crankcase (Late Models)
Capscrews 25 N•m (18 lbf ft) Vibration Damper
Nuts 25 N•m (18 lbf ft) 95 N•m (70 lbf ft)
Rear Oil Seal Retainer Screws and Nut

15 N•m (133 lbf in)
Troubleshooting
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION
When the key switch is in Battery is damaged. Install new battery.

the START position, engine
does not crank.
Battery is not fully charged. Charge battery.
Connections at the battery are loose Clean and tighten battery connec-
or they have corrosion. tions.
Key switch does not operate cor- Check operation of the key switch.
rectly. Check electrical wiring. Install new
key switch.
Starter or starter circuit is damaged. Check starter, starter relay, and

wiring. Install new parts as re-
quired.
There is a seizure of parts in the en- Rotate crankshaft manually. If

gine or ring gear is damaged. crankshaft will rotate, check ring
gear, if not overhaul engine.
39
Troubleshooting 600 SRM 590
The engine will not start. No fuel in fuel tank or fuel not enter- Fill tank with correct fuel. If LPG,
ing engine. open shutoff valve. Check fuel de-
livery system (fuel pump, lines, etc.).
Install new parts as required.
Cranking speed is too slow. Battery Charge battery or install new bat-
is not fully charged. tery.
Valves are worn or damaged. Grind valves. Install new valves.
Low compression. The piston rings Install new piston rings. Overhaul
are worn or damaged. engine.
Ignition system does not operate cor- Check spark delivery system. Repair
rectly. or install new parts as required.
Ignition timing is not correct. Adjust timing. Check timing chain

and sprockets.
The engine does not run Valves are not adjusted correctly. Adjust valves.
smoothly.
Head gasket is damaged. Install new head gasket.
Cylinder head has cracks. Install new cylinder head.
There is a leak in the intake system. Repair leak.
Ignition timing is not correct. Adjust timing.
Spark plugs are worn or damaged. Install new spark plugs.
Ignition system does not operate cor- See sections for Electrical Systems
rectly. for more information.
The engine does not have Restriction in air inlet. The air filter Check air restriction indicator. Clean
enough power. is dirty. or install new filter element.
Fuel is the wrong type or grade. Drain fuel. Fill with correct fuel.
Ignition timing is not correct. Check and adjust timing.
Valve mechanism is damaged. Repair or install new parts.
Piston assemblies are damaged. Repair or install new parts. Over-

haul engine.
Valve timing is not correct. Adjust valve timing.
Exhaust system has restrictions. Remove restrictions. Install new

parts as necessary.
40
600 SRM 590 Troubleshooting
There is noise inside the en- Main bearings are worn or damaged. Install new main bearings or over-
gine. haul engine.
Bearings for the connecting rods are Install new rod bearings or overhaul
worn or damaged. engine.
Pistons or rings are worn or dam- Install new rings and piston or over-
aged. haul engine.
Engine is too hot. Check thermostat. Check cooling

system (radiator, fan, drive belt,
etc.). Clean and repair as required.
Low oil pressure. Not enough oil in Check oil level. Add oil to full mark
the engine. on dipstick. Check oil pressure. Re-
pair oil pump. Overhaul engine.
Flywheel is loose. Tighten flywheel mounting bolts.
There is a leak in the exhaust sys- Repair leak.

tem.
Valve mechanism is damaged. Repair or install new parts as re-

quired.
Valves are not adjusted correctly. Check and adjust valve clearance.
The engine makes noise dur- Spark plugs are dirty. Clean spark plugs and reinstall.
ing acceleration.
Spark plugs are the wrong type or Install new spark plugs of correct
heat range. type and heat range.
Ignition timing is not correct. Check and adjust ignition timing.
Fuel is the wrong type or grade. Drain fuel. Fill with correct fuel.
There is too much carbon in the com- Put truck in hard work cycle. Add
bustion chamber (preignition). engine cleaner to fuel. Do top engine
overhaul.
Engine is too hot. Check thermostat. Check cooling

system (radiator, fan, drive belt,
etc.). Clean or repair as required.
Fuel system is not adjusted correctly. Adjust fuel system.
41
Troubleshooting 600 SRM 590
The engine is too hot during There is not enough coolant in the Check coolant level in radiator and
operation. cooling system. coolant recovery bottle. Add coolant
to correct level.
Radiator is dirty. Drain and flush radiator. Clean ra-

diator fins with high pressure air or
water in reverse direction of normal
airflow. Refill with clean coolant.
Drive belt for water pump is not ad- Check water pump drive belt. Adjust
justed correctly, worn, or broken. or install new belt as required.
Thermostat is wrong heat range or Check heat range. Install new ther-
does not operate correctly. mostat.
Cooling system has restrictions. Drain and back-flush engine and ra-
diator. Refill with clean coolant.
Water pump worn or damaged. Install new water pump.
Exhaust system has restrictions. Check the exhaust system. Remove

restrictions.
The bearings in the engine There is not enough oil in the engine. Add oil to full mark on dipstick.
are damaged.
Oil in the engine is dirty. Make sure dirt is not entering engine
through air inlet system. Drain and
fill with clean oil. Reduce time inter-
val for oil and filter change.
Oil in the engine is the wrong type. Drain and fill with correct oil.
Oil pump is worn or damaged. Install new oil pump.
Connecting rod(s) and bearings have Check and repair crankshaft. Install
damage. new connecting rods and bearings.
Camshaft and bearings have dam- Install new camshaft and bearings.
age.
Passages for oil have restrictions. Remove restrictions or overhaul en-

gine.
Bearings are not installed correctly. Install new bearings or overhaul en-
gine.
42
TECHNICAL PUBLICATIONS
600 SRM 590 8/05 (11/03)(11/02)(3/02)(11/01)(7/99)(6/97)(5/96)(5/95) Printed in U.S.A.

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GM ENGINES

4.3 LITER V-6

PART NO. 897800 600 SRM 590

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

©2005 HYSTER COMPANY i

TABLE OF CONTENTS (Continued)

This section is for the following models:

H3.50-5.00XL (H70-110XL) [G005];

Engine Removal and Installation

Cylinder Head Repair

1. Drain cooling system.

2. Disconnect and remove coolant hose from hous-

3. Remove air cleaner, distributor, throttle body, in-

4. Remove spark plugs.

5. Remove rocker arm cover. See Figure 1.

NOTE: For year 2002 or later model engines, go to

6. Remove nuts and balls for rocker arms. Remove

valve faces and seats within the specifications. Make

Valves with minor pits in the valve faces can be ma-

1. VALVE ROCKER ARM

Figure 2. Remove Valve Rocker Arm and Push

7. Inspect valves for burned or damaged areas in

VALVE GUIDES AND SEATS, REPAIRS

The correct dimensions for the valve seat widths and

Figure 5. Valve Head Measurements VALVE SPRINGS

A. EXHAUST VALVE B. INLET VALVE

Figure 6. Valve Seat Widths and Valve/Valve Seat Overlap

Figure 7. Valve Spring Specifications

ROCKER ARM STUDS (EARLY MODELS)

2. Use a reamer of the correct size for new oversized

NOTE: EARLY MODELS ONLY.

Figure 8. Rocker Arm Stud Removal

ROCKER ARM STUDS (LATE MODELS)

Legend for Figure 11

2. Clean surface of cylinder head and top of cylinder

Figure 12. Cylinder Head Tightening Sequence

b. On 1996 model and later engines, tighten all

1. EXTEND BEAD 13 mm (0.5 in.) UP HEADS

NOTE: For year 2002 or later model engines, perform

NOTE: Install parts as marked during removal.

7. Install push rods, making sure they are in the

Legend for Figure 17

Figure 16. Install Valve Rocker Arm Supports

10. Apply a molybdenum grease or equivalent to the

Figure 18. Install Valve Rocker Arm Assemblies

12. Rotate the crankshaft balancer to position the

NOTE: Once the valve rocker arm assemblies are in-

13. Tighten the valve rocker arm bolts to 30 N•m

14. Use new gasket and install valve covers. Tighten

15. Install spark plugs.

16. Install throttle body, air cleaner, and distributor.

17. Install exhaust manifolds. Tighten capscrews in

18. Install coolant hose to housing for thermostat.

1. CRANKSHAFT BALANCER ALIGNMENT MARK

Figure 19. Rotate Crankshaft Balancer

Cylinder Block Cleaning and Inspection

Piston Bore Preparation

Engine Mounts Installation