Hyster C177 (H2.00-3.00XL) Service Manual

Description

• Model List:
  • C177 (H2.00-3.00XL)

• 1. INTRODUCTION
• 2. GENERAL
• 3. DESCRIPTION
• 4. REMOVAL AND INSTALLATION OF THE ENGINE
• 5. CYLINDER HEAD AND MECHANISM
• 6. Cylinder Head, Removal
• 7. Cylinder Head, Disassembly
• 8. Cleaning And Inspection
• 9. Valve And Valve Seats
• 10. Studs For The Rocker Arms
• 11. Hydraulic Valve Lifters, Replacement
• 12. Hydraulic Valve Lifters, Cleaning And Inspection
• 13. Cylinder Head, Assembly
• 14. Cylinder Head, Installation
• 15. Rocker Arm Cover, Installation
• 16. TIMING GEAR COVER
• 17. Removal
• 18. Installation
• 19. CAMSHAFT
• 20. Removal
• 21. Inspection
• 22. Camshaft Bearings, Removal
• 23. Camshaft Bearings, Installation
• 24. DISTRIBUTOR
• 25. Removal
• 26. Installation
• 27. LUBRICATION SYSTEM
• 28. Oil Sump, Removal
• 29. Oil Sump, Installation
• 30. Oil Pump, Removal
• 31. Oil Pump, Disassembly and Repair
• 32. Oil Pump, Assembly
• 33. Oil Pump, Installation
• 34. PISTON AND CONNECTING ROD ASSEMBLIES
• 35. Connecting Rod Bearings, Replacement
• 36. Piston And Connecting Rod Assemblies, Removal
• 37. Disassembly
• 38. Piston, Cleaning And Inspection
• 39. Cylinder Bores, Inspection And Repair
• 40. Piston Rings
• 41. Assembly
• 42. Piston And Connecting Rod Assemblies, Installation
• 43. CRANKSHAFT
• 44. Main Bearings, Replacement
• 45. Oil Seal For The Rear Main Bearing, Replacement (GM 4-181 and 3.0L Only)
• 46. Oil Seal For The Rear Main Bearing, Replacement (Engines That Have A Two-Piece Oil Seal)
• 47. Crankshaft, Removal
• 48. Inspection and Repair
• 49. How To Check The Clearance Between The Main Bearings And Their Journals
• 50. Installation
• 51. FLYWHEEL AND FLYWHEEL HOUSING
• 52. Flywheel, Removal
• 53. Ring Gear, Replacement
• 54. Flywheel, Installation
• 55. COOLING SYSTEM
• 56. Coolant Pump
• 57. Fan Drive
• 58. Viscous Fan Drive
• 59. ENGINE SPECIFICATIONS
• 60. ENGINE DATA
• 61. CYLINDER HEAD
• 62. HYDRAULIC VALVE LIFTER
• 63. CAMSHAFT
• 64. PISTONS
• 65. CYLINDER BORE
• 66. CRANKSHAFT
• 67. CONNECTING RODS
• 68. COOLING SYSTEM
• 69. LUBRICATION SYSTEM
• 70. TORQUE SPECIFICATIONS
• 71. INTRODUCTION
• 72. GENERAL
• 73. DESCRIPTION
• 74. REPAIRS
• 75. GENERAL
• 76. REMOVAL AND DISASSEMBLY (Type A)
• 77. CLEANING
• 78. ASSEMBLY (Type A)
• 79. REMOVAL AND DISAASSEMBLY (Type B)
• 80. CLEANING
• 81. ASSEMBLY (Type B)
• 82. INSTALLATION (Type A and Type B)
• 83. CHECKS AND ADJUSTMENTS
• 84. GENERAL
• 85. CHECK THE ALTERNATOR FOR LOW OUTPUT (Type A or Type B)
• 86. CHECK THE ALTERNATOR FOR HIGH OUTPUT (Type A or Type B)
• 87. CHECK THE CIRCUIT FOR THE BRUSHES
• 88. Delco Alternators
• 89. Motorola Alternators
• 90. CHECK THE DIODES
• 91. CHECK THE DIODE BRIDGE
• 92. Delco and LeeceNeville Alternators
• 93. Motorola Alternators
• 94. CHECK THE FIELD WINDING FOR THE ROTOR
• 95. CHECK THE WINDINGS IN THE STATOR
• 96. CHECK THE VOLTAGE REGULATOR
• 97. TROUBLESHOOTING
• 98. MAZDA M4-121G ENGINE
• 99. GENERAL
• 100. DESCRIPTION
• 101. REMOVAL AND INSTALLATION OF THE ENGINE
• 102. CYLINDER HEAD AND VALVE MECHANISM
• 103. Cylinder Head, Removal
• 104. Cylinder Head, Inspection and Repairs
• 105. Rocker Arm Assembly
• 106. Valve Guides
• 107. Valve Seats
• 108. Valve Springs
• 109. Cylinder Head, Installation
• 110. TIMING GEAR CASE, REMOVAL
• 111. TIMING GEAR CASE, INSTALLATION
• 112. CAMSHAFT
• 113. Removal
• 114. Inspection
• 115. Cam Followers, Inspection
• 116. Installation
• 117. CRANKSHAFT AND MAIN BEARINGS
• 118. Crankshaft, Removal
• 119. Crankshaft, Inspection And Repair
• 120. Main Bearings
• 121. Crankshaft, Installation
• 122. PISTONS AND CONNECTING RODS
• 123. Removal
• 124. Disassembly
• 125. Pistons, Inspection And Repair
• 126. Piston Rings
• 127. Piston Pin and Bushing
• 128. Connecting Rods and Bearings, Inspection
• 129. Pistons and Connecting Rods, Assembly
• 130. Pistons and Connecting Rods, Installation
• 131. CYLINDER BLOCK AND CYLINDER LINERS
• 132. Cylinder Block, Repairs
• 133. Cylinder Liners
• 134. DISTRIBUTOR
• 135. Removal
• 136. Installation
• 137. OIL PUMP
• 138. Removal
• 139. Repairs
• 140. Installation
• 141. GOVERNOR
• 142. Description
• 143. Removal
• 144. Disassembly
• 145. Assembly
• 146. Installation
• 147. COOLANT PUMP
• 148. Removal
• 149. Disassembly and Repair
• 150. Assembly
• 151. Installation
• 152. FLYWHEEL
• 153. Repairs
• 154. Installation
• 155. CHECKS AND ADJUSTMENTS
• 156. ADJUST THE VALVES
• 157. ADJUST THE THROTTLE LINKAGE
• 158. ENGINE SPECIFICATIONS
• 159. ENGINE SPECIFICATIONS
• 160. Engine Data
• 161. Cooling System
• 162. Cylinder Head and Valve Mechanism
• 163. Camshaft
• 164. Timing Gear
• 165. Camshaft
• 166. Connecting Rods
• 167. Cylinder Liners
• 168. Pistons
• 169. Lubrication System
• 170. Fuel Pump
• 171. TORQUE SPECIFICATIONS
• 172. TROUBLESHOOTING
• 173. INTRODUCTION
• 174. GENERAL
• 175. DESCRIPTION
• 176. FUEL SYSTEM
• 177. Description
• 178. Operation, Fuel Injection Pump, Model VE
• 179. Operation, Fuel Injection Pump, Model PE4A
• 180. Pneumatic Governor For Fuel Injection Pump, Model PE4A
• 181. Inlet Manifold For Fuel Injection Pump, Model PE4A
• 182. REPAIRS
• 183. FUEL INJECTION PUMP (ALL MODELS)
• 184. Removal
• 185. Installation
• 186. REMOVAL AND INSTALLATION OF THE ENGINE
• 187. CYLINDER HEAD AND VALVE MECHANISM
• 188. Cylinder Head, Removal
• 189. Valve Guides, Replacement
• 190. Cylinder Head, Inspection And Repair
• 191. Combustion Chamber Plugs, Inspection And Repair
• 192. Combustion Chamber Plugs, Installation
• 193. Valves, Inspection And Repair
• 194. Valve Seat, Inspection
• 195. Valve Seat, Removal
• 196. Valve Seat, Installation
• 197. Valve Spring, Inspection
• 198. Rocker Arms, Inspection And Assembly
• 199. Installation Of The Cylinder Head
• 200. TIMING GEAR CASE
• 201. Removal
• 202. Installation
• 203. CAMSHAFT
• 204. Removal
• 205. Inspection
• 206. Camshaft Bearings
• 207. Cam Followers
• 208. CAMSHAFT, INSTALLATION
• 209. CRANKSHAFT AND MAIN BEARINGS
• 210. Crankshaft, Removal
• 211. Crankshaft, Inspection And Repair
• 212. Main Bearings
• 213. Pilot Bearing
• 214. Crankshaft, Installation
• 215. FLYWHEEL AND RING GEAR, H2.003.20XM (H4065XM)
• 216. Flywheel, Removal
• 217. Ring Gear, Replacement
• 218. Flywheel, Installation
• 219. PISTONS AND CONNECTING RODS
• 220. Pistons And Connecting Rods, Removal
• 221. Disassembly
• 222. Pistons, Inspection And Repair
• 223. Piston Rings, Inspection And Repair
• 224. Piston Pins, Inspection And Repair
• 225. Connecting Rods, Inspection And Repair
• 226. Pistons And Connecting Rods, Assembly And Installation
• 227. CYLINDER BLOCK AND CYLINDER LINERS
• 228. Cylinder Liners, Inspection
• 229. Replacement Of A Cylinder Liner
• 230. LUBRICATION SYSTEM
• 231. Oil Pump, Removal And Disassembly
• 232. Oil Pump, Inspection
• 233. Oil Pump, Assembly And Installation
• 234. Oil Filter
• 235. COOLING SYSTEM
• 236. Coolant Pump, Removal
• 237. Coolant Pump, Disassembly
• 238. Coolant Pump, Assembly And Installation
• 239. Thermostat, Replacement
• 240. CHECKS AND ADJUSTMENTS
• 241. VALVE CLEARANCE ADJUSTMENT
• 242. CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL VE
• 243. CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL PE4A
• 244. FUEL INJECTORS
• 245. Fuel Injectors, Removal
• 246. Fuel Injectors, Inspection
• 247. Fuel Injectors, Installation
• 248. DIESEL FUEL FILTERS
• 249. Filter Replacement, Models With A Water Separator
• 250. Filter Replacement, Models Without A Water Separator
• 251. Filter For The Fuel Injection Pump, Model PE4A
• 252. REMOVE AIR FROM THE FUEL SYSTEM
• 253. Throttle Linkage, Adjustment
• 254. Idle Speed, Adjustment
• 255. Check The Elements For The Cold Start Aid System
• 256. ENGINE SPECIFICATIONS
• 257. TORQUE SPECIFICATIONS
• 258. INTRODUCTION
• 259. GENERAL
• 260. DESCRIPTION
• 261. OPERATION
• 262. The Float System
• 263. The Idle System
• 264. The Main Metering System (GM 6-250)
• 265. The Power System (GM 6-250)
• 266. The Accelerator Pump System
• 267. Choke System
• 268. REPAIRS
• 269. REMOVAL
• 270. DISASSEMBLY
• 271. Cleaning
• 272. ASSEMBLY
• 273. INSTALLATION
• 274. GOVERNOR (ELECTONIC) (IMPCO Type) (Later Units)
• 275. GOVERNOR (PNEUMATIC) (Early Units)
• 276. CHECKS AND ADJUSTMENTS
• 277. GENERAL
• 278. ADJUST THE CHOKE CONTROL
• 279. ADJUST THE IDLE SPEED
• 280. ADJSUT THE IDLE MIXTURE
• 281. ADJUST THE FAST IDLE
• 282. ADJUST THE THROTTLE LINKAGE,(Later Models)
• 283. ADJUST THE THROTTLE LINKAGE,(Early Models)
• 284. GOVERNOR (IMPCO Type) (Later GM 4-153 and 4-181 Engines Only)
• 285. Check the Governor
• 286. GOVERNOR (AISAN Type) (Early GM Engines Only)
• 287. Adjustments
• 288. GOVERNOR (HOOF Type) (Early GM Engines Only)
• 289. Adjust the Governor
• 290. TROUBLESHOOTING
• 291. THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100)
• 292. GENERAL
• 293. DESCRIPTION
• 294. Fuel Tank
• 295. Fuel Filter And Fuel Valve Unit
• 296. Vaporizer
• 297. The IMPCO CA 100 Carbureto
• 298. IMPCO CA 50 Carburetor
• 299. The Governor (GM Engines Only)
• 300. Governor With Electronic Controller
• 301. REPAIRS
• 302. LPG TANK
• 303. Removal
• 304. Installation
• 305. REPLACE THE HOSES
• 306. HYDROSTATIC RELIEF VALVE
• 307. Removal and Installation
• 308. FILTER UNIT
• 309. Replacement Of the Fuel Filter Element
• 310. Replacement of the Diaphragm and Fuel Valve
• 311. VAPORIZER
• 312. Removal
• 313. Disassembly
• 314. Cleaning
• 315. Inspection
• 316. Assembly
• 317. Installation
• 318. CARBURETOR (IMPCO CA 100)
• 319. Removal
• 320. Disassembly
• 321. Cleaning
• 322. Assembly
• 323. Installation
• 324. CARBURETER (IMPCO CA 50)
• 325. Removal
• 326. Disassembly
• 327. Cleaning
• 328. Inspection
• 329. Assembly (See FIGURE 26.)
• 330. Installation
• 331. CHECKS AND ADJUSTMENTS
• 332. CHECK THE FILTER UNIT
• 333. CHECK THE VAPORIZER
• 334. Pressure Reducer Valve
• 335. Vapor Valve
• 336. ADJUST THE CARBURETOR
• 337. Idle Mixture
• 338. Idle Speed
• 339. Power Mixture
• 340. ADJUST THE GOVERNOR (GM Engines Only)
• 341. Main Adjusting Screw
• 342. Secondary Adjusting Screw
• 343. AISAN Governor
• 344. Adjustment, AISAN Governor
• 345. TROUBLESHOOTING
• 346. INTRODUCTION
• 347. GENERAL
• 348. DESCRIPTION
• 349. REPAIRS
• 350. COUNTERWEIGHT
• 351. Removal
• 352. Installation
• 353. MUFFLER
• 354. Removal
• 355. Installation
• 356. RADIATOR AND COOLANT SYSTEM
• 357. Removal
• 358. Installation
• 359. OVERHEAD GUARD
• 360. Removal And Installation
• 361. OPERATOR RESTRAINT SYSTEM
• 362. ENGINE REMOVAL AND INSTALLATION
• 363. Removal of the Engine and Transmission
• 364. Installation of the Engine and Transmission
• 365. FUEL AND HYDRAULIC TANKS
• 366. Inspection
• 367. Repairs, Small Leaks
• 368. Repairs, Large Leaks
• 369. Cleaning
• 370. Steam Method Of Cleaning
• 371. Chemical Solution Method of Cleaning
• 372. Additional Preparations For Repair
• 373. SAFETY LABELS
• 374. Cab Replacement
• 375. Window Replacement
• 376. Windshield Wipers and Heater
• 377. INTRODUCTION
• 378. GENERAL
• 379. DESCRIPTION
• 380. REPAIRS
• 381. REMOVAL
• 382. CLEANING
• 383. INSPECTION
• 384. ASSEMBLY
• 385. TROUBLESHOOTING
• 386. SPECIFICATIONS
• 387. INTRODUCTION
• 388. DESCRIPTION
• 389. GENERAL
• 390. REPAIRS
• 391. STEERING AXLE
• 392. Removal
• 393. Installation
• 394. STEERING CYLINDER
• 395. Removal
• 396. Service
• 397. Installation
• 398. Removal
• 399. Installation
• 400. SPINDLES
• 401. Removal
• 402. Installation
• 403. CHECKS AND ADJUSTMENTS
• 404. REMOVE THE AIR FROM THE STEERING SYSTEM
• 405. SET THE PRESSURE RELIEF VALVE
• 406. S/H1.25-1.75XL (S/H25-35XL) and H2.00-3.00XL (H40-60XL)
• 407. H2.00-3.00J (H40-60J) WITH OIL CLUTCH TRANSMISSION
• 408. H2.00-3.00J (H40-60J) With Powershift Transmission
• 409. TROUBLESHOOTING
• 410. INTRODUCTION
• 411. GENERAL
• 412. DESCRIPTION
• 413. OPERATION
• 414. Lift Section
• 415. Tilt Section
• 416. Relief Valve
• 417. SOLENOID VALVE FOR AUXILIARY FUNCTION
• 418. Operation
• 419. REPAIRS
• 420. MAIN CONTROL VALVE
• 421. Removal and Disassembly
• 422. Cleaning and Inspection
• 423. Assembly
• 424. Installation
• 425. SOLENOID VALVE FOR AUXILIARY FUNCTION
• 426. Removal and Disassembly
• 427. Assembly and Installation