Hyster D177 (H2.00-3.20XM) Service Manual

Description

• Model List:
  • D177 (H2.00-3.20XM)

• 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. INTRODUCTION
• 99. GENERAL
• 100. DESCRIPTION
• 101. FUEL SYSTEM
• 102. Description
• 103. Operation, Fuel Injection Pump, Model VE
• 104. Operation, Fuel Injection Pump, Model PE4A
• 105. Pneumatic Governor For Fuel Injection Pump, Model PE4A
• 106. Inlet Manifold For Fuel Injection Pump, Model PE4A
• 107. REPAIRS
• 108. FUEL INJECTION PUMP (ALL MODELS)
• 109. Removal
• 110. Installation
• 111. REMOVAL AND INSTALLATION OF THE ENGINE
• 112. CYLINDER HEAD AND VALVE MECHANISM
• 113. Cylinder Head, Removal
• 114. Valve Guides, Replacement
• 115. Cylinder Head, Inspection And Repair
• 116. Combustion Chamber Plugs, Inspection And Repair
• 117. Combustion Chamber Plugs, Installation
• 118. Valves, Inspection And Repair
• 119. Valve Seat, Inspection
• 120. Valve Seat, Removal
• 121. Valve Seat, Installation
• 122. Valve Spring, Inspection
• 123. Rocker Arms, Inspection And Assembly
• 124. Installation Of The Cylinder Head
• 125. TIMING GEAR CASE
• 126. Removal
• 127. Installation
• 128. CAMSHAFT
• 129. Removal
• 130. Inspection
• 131. Camshaft Bearings
• 132. Cam Followers
• 133. CAMSHAFT, INSTALLATION
• 134. CRANKSHAFT AND MAIN BEARINGS
• 135. Crankshaft, Removal
• 136. Crankshaft, Inspection And Repair
• 137. Main Bearings
• 138. Pilot Bearing
• 139. Crankshaft, Installation
• 140. FLYWHEEL AND RING GEAR, H2.003.20XM (H4065XM)
• 141. Flywheel, Removal
• 142. Ring Gear, Replacement
• 143. Flywheel, Installation
• 144. PISTONS AND CONNECTING RODS
• 145. Pistons And Connecting Rods, Removal
• 146. Disassembly
• 147. Pistons, Inspection And Repair
• 148. Piston Rings, Inspection And Repair
• 149. Piston Pins, Inspection And Repair
• 150. Connecting Rods, Inspection And Repair
• 151. Pistons And Connecting Rods, Assembly And Installation
• 152. CYLINDER BLOCK AND CYLINDER LINERS
• 153. Cylinder Liners, Inspection
• 154. Replacement Of A Cylinder Liner
• 155. LUBRICATION SYSTEM
• 156. Oil Pump, Removal And Disassembly
• 157. Oil Pump, Inspection
• 158. Oil Pump, Assembly And Installation
• 159. Oil Filter
• 160. COOLING SYSTEM
• 161. Coolant Pump, Removal
• 162. Coolant Pump, Disassembly
• 163. Coolant Pump, Assembly And Installation
• 164. Thermostat, Replacement
• 165. CHECKS AND ADJUSTMENTS
• 166. VALVE CLEARANCE ADJUSTMENT
• 167. CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL VE
• 168. CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL PE4A
• 169. FUEL INJECTORS
• 170. Fuel Injectors, Removal
• 171. Fuel Injectors, Inspection
• 172. Fuel Injectors, Installation
• 173. DIESEL FUEL FILTERS
• 174. Filter Replacement, Models With A Water Separator
• 175. Filter Replacement, Models Without A Water Separator
• 176. Filter For The Fuel Injection Pump, Model PE4A
• 177. REMOVE AIR FROM THE FUEL SYSTEM
• 178. Throttle Linkage, Adjustment
• 179. Idle Speed, Adjustment
• 180. Check The Elements For The Cold Start Aid System
• 181. ENGINE SPECIFICATIONS
• 182. TORQUE SPECIFICATIONS
• 183. INTRODUCTION
• 184. GENERAL
• 185. DESCRIPTION
• 186. REPAIRS
• 187. OPERATOR MODULE
• 188. Removal
• 189. Installation
• 190. HOOD AND SIDE COVERS
• 191. Removal
• 192. Installation
• 193. OVERHEAD GUARD
• 194. Removal and Installation
• 195. COUNTERWEIGHT
• 196. Removal
• 197. Installation
• 198. EXHAUST SYSTEM
• 199. Muffler Repacement
• 200. RADIATOR AND COOLING SYSTEM
• 201. Removal
• 202. Installation
• 203. OPERATOR RESTRAINT SYSTEM
• 204. Removal
• 205. Installation
• 206. FUEL AND HYDRAULIC TANKS
• 207. Inspection
• 208. Repairs, Small Leaks
• 209. Repairs, Large Leaks
• 210. Cleaning
• 211. Steam Method Of Cleaning
• 212. Chemical Solution Method of Cleaning
• 213. Additional Preparations For Repair
• 214. INTRODUCTION
• 215. GENERAL
• 216. DESCRIPTION
• 217. FUEL SYSTEM
• 218. Description
• 219. Operation, Fuel Injection Pump, Model VE
• 220. REPAIRS
• 221. FUEL INJECTION PUMP
• 222. Removal
• 223. Installation
• 224. REMOVAL AND INSTALLATION OF THE ENGINE
• 225. CYLINDER HEAD AND VALVE MECHANISM
• 226. Cylinder Head, Removal
• 227. Valves, Removal
• 228. Cylinder Head, Inspection And Repair
• 229. Valves, Inspection And Repair
• 230. Valve Guides, Replacement
• 231. Valve Seats, Inspection
• 232. Valve Seats, Removal
• 233. Valve Seats, Installation
• 234. Valve Springs, Inspection
• 235. Valves, Installation
• 236. Push Rods, Inspection
• 237. Rocker Arms, Disassembly And Inspection
• 238. Rocker Arm Shaft, Assembly
• 239. Cylinder Head, Installation
• 240. TIMING GEAR CASE
• 241. Removal
• 242. Inspection, Idler Gear A And Idler Gear Shaft
• 243. Inspection, Idler Gear B Bearings
• 244. Installation
• 245. CAMSHAFT
• 246. Camshaft, Removal
• 247. Camshaft, Disassembly And Inspection
• 248. Camshaft Bearing Replacement
• 249. Cam Followers (Tappets)
• 250. Camshaft, Assembly
• 251. Camshaft, Installation
• 252. LUBRICATION SYSTEM
• 253. Oil Pump, Removal And Disassembly
• 254. Oil Pump, Inspection
• 255. Oil Pump, Assembly And Installation
• 256. Oil Sump, Installation
• 257. Oil Filter Assembly
• 258. PISTONS AND CONNECTING RODS
• 259. Pistons And Connecting Rods, Removal
• 260. Disassembly
• 261. Pistons, Inspection And Repair
• 262. Piston Rings, Inspection
• 263. Piston Pins, Inspection And Repair
• 264. Connecting Rods, Inspection And Repair
• 265. New Pistons, Selection
• 266. Pistons And Connecting Rods, Assembly And Installation
• 267. CRANKSHAFT AND MAIN BEARINGS
• 268. Crankshaft, Removal
• 269. Crankshaft, Inspection And Repair
• 270. Crankshaft Timing Gear, Replacement
• 271. Crankshaft, Installation
• 272. FLYWHEEL AND RING GEAR, H2.003.00XL (H4060XL)
• 273. Flywheel, Removal
• 274. Ring Gear, Replacement
• 275. Flywheel, Installation
• 276. FLYWHEEL AND RING GEAR, H2.003.20XM (H4065XM)
• 277. Flywheel, Removal
• 278. Ring Gear, Replacement
• 279. Flywheel, Installation
• 280. ENGINE BLOCK AND CYLINDER LINERS
• 281. Cylinder Liners, Inspection
• 282. Replacement Of A Cylinder Liner
• 283. COOLING SYSTEM
• 284. Coolant Pump, Removal
• 285. Coolant Pump, Disassembly
• 286. Coolant Pump, Assembly And Installation
• 287. Thermostat, Replacement
• 288. CHECKS AND ADJUSTMENTS
• 289. VALVE CLEARANCE ADJUSTMENT
• 290. CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL VE
• 291. FUEL INJECTORS
• 292. DIESEL FUEL FILTER
• 293. THROTTLE LINKAGE, ADJUSTMENT
• 294. IDLE SPEED, ADJUSTMENT
• 295. CHECK THE ELEMENTS FOR THE COLD START AID SYSTEM
• 296. SPECIFICATIONS
• 297. TORQUE SPECIFICATIONS
• 298. INTRODUCTION
• 299. GENERAL
• 300. DESCRIPTION
• 301. REPAIRS
• 302. REMOVAL AND INSTALLATION OF THE ENGINE
• 303. CYLINDER HEAD, CAMSHAFT AND VALVE MECHANISM
• 304. Removal
• 305. Cleaning
• 306. Inspection And Repairs
• 307. Cylinder Head, Installation
• 308. CRANKSHAFT AND MAIN BEARINGS
• 309. Removal
• 310. Inspection And Repair
• 311. Installation
• 312. PISTONS AND CONNECTING RODS
• 313. Removal And Disassembly
• 314. Cleaning
• 315. Inspection And Repair
• 316. Assembly And Installation
• 317. CYLINDER BLOCK
• 318. Repairs
• 319. OIL PUMP
• 320. Removal
• 321. Disassembly
• 322. Cleaning
• 323. Inspection
• 324. Assembly
• 325. Installation
• 326. COOLING SYSTEM
• 327. Thermostat
• 328. Fan Assembly
• 329. Water Pump
• 330. DISTRIBUTOR
• 331. Removal
• 332. Installation
• 333. FLYWHEEL AND RING GEAR, S/H2.003.20XM (S/H4065XM)
• 334. Flywheel, Removal
• 335. Ring Gear, Replacement
• 336. Flywheel, Installation
• 337. FLYWHEEL, S/H1.501.75XM, S/H2.00XMS (S/H2535XM, S/H40XMS)
• 338. Removal
• 339. Installation
• 340. CHECKS AND ADJUSTMENTS
• 341. ADJUST THE VALVES
• 342. CHECK THE COMPRESSION PRESSURE
• 343. ENGINE SPECIFICATIONS
• 344. TORQUE SPECIFICATIONS
• 345. INTRODUCTION
• 346. GENERAL
• 347. DESCRIPTION
• 348. REPAIRS
• 349. REMOVAL AND INSTALLATION OF THE ENGINE
• 350. DRIVE BELT AND TENSIONER
• 351. Removal
• 352. Inspection
• 353. Installation
• 354. CYLINDER HEAD AND VALVE MECHANISM
• 355. Cylinder Head, Removal
• 356. Cylinder Head, Disassembly
• 357. Cleaning And Inspection
• 358. Valves And Valve Seats
• 359. Hydraulic Valve Lifters, Replacement
• 360. Hydraulic Valve Lifters, Cleaning And Inspection
• 361. Cylinder Head, Assembly
• 362. Cylinder Head, Installation
• 363. TIMING COVER
• 364. Removal
• 365. Installation
• 366. TIMING CHAIN AND SPROCKETS
• 367. Removal
• 368. Installation
• 369. CAMSHAFT
• 370. Removal
• 371. Inspection
• 372. Installation
• 373. CAMSHAFT BEARINGS
• 374. Removal
• 375. Installation
• 376. OIL PAN
• 377. Removal
• 378. Installation
• 379. OIL PUMP
• 380. Removal
• 381. Disassembly and Repair
• 382. Inspection
• 383. Assembly
• 384. Installation
• 385. PISTON AND CONNECTING ROD ASSEMBLIES
• 386. Connecting Rod Bearings, Replacement
• 387. Piston And Connecting Rod Assemblies, Removal and Disassembly
• 388. Piston, Cleaning
• 389. Pistons and Cylinder Bores, Inspection
• 390. Piston Rings
• 391. Piston And Connecting Rod Assemblies, Assembly and installation
• 392. CRANKSHAFT
• 393. Rear Oil Seal, Replacement
• 394. Crankshaft, Removal
• 395. Crankshaft, Inspection and Repair
• 396. Crankshaft, Installation
• 397. FLYWHEEL AND RING GEAR
• 398. Flywheel, Removal
• 399. Ring Gear, Replacement
• 400. Flywheel, Installation
• 401. COOLING SYSTEM
• 402. Water Pump
• 403. ENGINE SPECIFICATIONS
• 404. General
• 405. Valves
• 406. Camshaft
• 407. Pistons
• 408. Piston Rings
• 409. Piston Pin
• 410. Cylinder Bore