Re-Manufactured Forklift Engine Installation Guidelines
Please Read BEFORE Installing Your New EngineYour new engine has been carefully re-manufactured and tested to meet OEM standards and specifications. It will perform properly if certain steps are taken during installation and use. In order to help assure proper engine operation and desired performance, please use these recommended installation procedures and instructions as a guide.
If Possible, determine the root cause of failure for the engine being replaced. This may help to avoid similar repeat engine failures.
Visually inspect the engine and verify that it is the correct replacement engine prior to installing into the forklift.
Remove all protective plugs and tape from the engine. (DO NOT REMOVE OR TAMPER WITH THE HEAT TABS).
Installation Checklist:Gasoline and Propane Engines: Install and set fuel system as accurately as possible before starting the engine. Check to be sure the fuel systems are working properly and not running too lean or too rich.
Diesel Engines: The injection pump has been re-manufactured and timed by an OEM certified injection pump technician. Any unauthorized opening of the pump or breaking of the seals will void the engine warranty. The only adjustments that may be necessary can be completed by loosening the injection pump mounting bolts and slightly rotating the pump either clockwise or counter-clockwise, to advance or retard the timing. Check the lift pump for proper operation and the lines for kinks or leaks to make certain there is proper fuel supply.
Completely clean all auxiliary parts and components that will be re-installed from the old engine. Do not re-use parts or components that are broken or do not meet OEM specifications. It is recommended that you install a NEW thermostat, NEW water pump, NEW belts, NEW hoses, NEW filters and PVC system. It is also recommended that the radiator be replaced or re-cored.
Thoroughly inspect the complete air intake system and verify that there are no leaks. Make sure the intake manifold, aluminum to cast mounting areas, and all other sealing surfaces are true, not warped, and be sure to thoroughly clean these areas before installation.
Install new ignition components.
Initial Start-Up ChecklistFill the engine with the proper fluids and levels as shown in the OEM service manual. Ask us if you're not sure.
Build up the oil pressure by starting the engine and bring the engine up to normal operating temperature.
Verify that the engine coolant is flowing properly and monitor the engine temperature to ensure it does not exceed normal operating temperature.
Before returning the truck to service, be sure to verify that there are no leaks and that the engine is operating properly.
Do not let the engine idle for prolonged periods of time. The idle time should never exceed 5 minutes during the first 3 hours of operation.
Re-torque the cylinder head bolts per OEM service manual specs after two hours of run time.
Operate the engine in the normal RPM range at approximately 75% load for the first three hours.
Limit periods of full load or full speed operation during the break-in period to short intervals of no more than 2 to 3 minutes at a time.
Before engine shut down, be sure to allow the engine operating temperature to cool down and stabilize by operating at no load for 3 to 4 minutes.
Vary the operating speed for the first 20 to 25 hours of operation, avoid running the new engine at a constant RPM.
Refer to and follow all OEM service manual requirements for all servicing intervals. Including: Head torque, valve adjustments, fluid changes, and belt checks.
Tips:Check the exhaust system to see if the previous engine burned oil. Verify that the muffler isn't starting to plug up. Also, when running the new engine, make sure it burns out any and all excess oil left by the previous engine.
When installing all accessories, be sure to check for proper bolt lengths. Sometimes bolt holes intersect with moving internal components.
This engine is equipped with two heat indicators; the engine warranty will be void if any of these indicators are melted, removed, or tampered with.
Following these procedures may help to reduce unnecessary problems, repeat engine failures and denied warranty claims.
These are general guidelines for installation and break-in. Additional procedures may be required for your particular application. Please refer to your OEM service manual or contact us directly if you are unsure of anything.