background image

Inspecting

Only  the inspections to be performed by using special tools or measuring instruments are covered. General service procedures
not covered in this manual, such as visual inspections and cleaning of parts should always be performed during actual service
operations.

Scope of Explanation

This book describes the service procedures for the engine removed from a vehicle.
For procedures concerning the removal of the engine from the vehicle and on-vehicle inspection and servicing,
refer to the appropriate service manuals separately prepared for the individual models.

Classification of Major Maintenance/Service Points

When there are major points relative to maintenance and
servicing procedures (such as essential maintenance and
service points, maintenance and service standard values,
information regarding the use of special tools, etc.), these are
arranged together as major maintenance and service points
and explained in detail.

Indicates there are essential points for removal or
disassembly.

Indicates there are essential points for installation or
reassembly.

A

B

Grease
(multi-purpose grease unless there is a
brand or type specified)

Sealant or adhesive

Brake fluid, automatic transmission fluid
or air conditioner compressor oil

Engine oil or gear oil

Symbols for Lubrication, Sealants and
Adhesives

Information concerning the locations for lubrication
and application of sealants and adhesives is
provided, by using symbols, in the diagram of
component parts, or on the page following the
component parts page, and explained.

Maintenance and Servicing Procedures

(1)   A diagram of the component parts is provided near
        the  front of each section in order to give the reader
        a better understanding of the installed condition of
        component parts.

(2)   The numbers provided within the diagram indicate
        the sequence for maintenance and servicing
         procedures; the symbol      indicates a non- reusable
        part; the tightening torque is provided wher e
        applicable.

• 

Removal Steps:

  The part designation number corresponds to the number
   in the illustration to indicate removal steps.

• Installation Steps:
  Specified in case installation is impossible in reverse order
  of removal steps. Omitted if installation is possible in reverse
  order of removal steps.

• Disassembly Steps:
  The part designation number corresponds to the number
  in the illustration to indicate disassembly steps.

• Reassembly Steps:
  Specified in case reassembly is impossible in reverse order
  of disassembly steps. Omitted if reassembly is possible
  in reverse order of disassembly steps.

N

How to Read This Manual

-II-

Summary of Contents for FG35-FG50

Page 1: ...Service Manual 99789 74120 For use with the FGC35K FGC70K FG35 FG50 FG40K FG50K Chassis Service Manuals GM 4 3L G6 Gasoline Engine 003103 up...

Page 2: ...reserves the right to change specifications or design without notice and without incurring obligation Whenever a question arises regarding this engine or this manual consult your Cat lift truck deale...

Page 3: ...automatic transmission fluid or air conditioner compressor oil Engine oil or gear oil Symbols for Lubrication Sealants and Adhesives Information concerning the locations for lubrication and applicatio...

Page 4: ...15 Plug 16 Valve 17 Spring 18 Filter 19 Fitting 20 Valve 21 Bolt 22 Adapter Oil Filter 23 Gasket 24 Connector 25 Gasket 22 20 19 18 25 24 21 10 9 8 14 13 12 11 7 6 17 16 15 23 Lubricate all inter nal...

Page 5: ...ck unless you have read and understand the instructions in the OPERATOR S MANUAL Improper truck operation is dangerous and could result in injury or death 5 Use steps and grab handles if applicable wh...

Page 6: ...ard or paper to locate pin hole leaks 19 Tighten connections to the correct torque Make sure all heat shields clamps and guards are installed correctly to avoid excessive heat vibration or rubbing aga...

Page 7: ...necting rod cap Crankshaft bearings and connecting rod bearings Engine camshaft and valve lifters Valve lifters valve rocker arms and valve rocker arm supports Valve to valve guide Valve spring to cyl...

Page 8: ...emoved for service they should be retained in order At the time of installation they should be installed in the same locations and with the same mating surface as when removed 1 Wash all parts except...

Page 9: ...parts in order 2 Make a distinction between the parts to be replaced and the parts to be reused 3 When replacing bolts and nuts use only ones of the specified size Special Tools When specified be sur...

Page 10: ...disconnecting a connector do not pull the harness Hold the halves of the connector to separate them from each other When disconnecting a lock type connector push the lock lever s in the direction s s...

Page 11: ...bber hoses or tubes otherwise the rubber is likely to deteriorate Greasing During assembly or installation coat the designated surfaces with the specified grease or oil Cooperation When two or more pe...

Page 12: ...epairing the Leak 23 Engine Lubrication 25 Intake Manifold 29 Intake Manifold Removal 30 Intake Manifold Installation 31 Exhaust Manifold 33 Oil Level Indicator and Tube Removal 34 Exhaust Manifold an...

Page 13: ...on 86 Crankshaft Flywheel Rear Seal and Bearings 89 Engine Flywheel Removal 90 Crankshaft Rear Oil Seal and Housing Removal 90 Crankshaft and Bearings Removal 91 Crankshaft and Bearings Clean and Insp...

Page 14: ...165 Alternator 167 Accessory Drive Belt Replacement 168 Starter Motor 169 Starter Motor Testing 170 Troubleshooting 170 Fuel System Gasoline Units built before 01 01 2004 173 Fuel Pump and Fuel Hose U...

Page 15: ...er troubles Engine Set Up and Testing After overhaul the engine must be tested before it is installed in the truck If a suitable test stand is not available the following procedures can be used after...

Page 16: ...BUY NOW Then Instant Download the Complete Manual Thank you very much...

Reviews:

Related manuals for FG35-FG50