Hyster C177 (H40-60XL) Service Manual

Description

• Model List:
  • C177 (H40-60XL)

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