Hyster D177 Safety Precautions Maintenance And Repair
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Hyster D177 Safety Precautions Maintenance And Repair

Hyster D177 Safety Precautions Maintenance And Repair

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0$='$ (1*,1(
M4-2.0G AND M4-2.2G
H1.50-1.75XM (S/H25-35XM)
[C010, D001, D010, E001];
H2.00XMS (S/H40XMS)
[C010, D001, D010, E001]; S/H2.00-3.20XM
(S/H40-65XM)
[D177, D187, H177]
PART NO. 897477
600 SRM 496

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  • Page 1 0$='$ (1*,1( M4-2.0G AND M4-2.2G H1.50-1.75XM (S/H25-35XM) [C010, D001, D010, E001]; H2.00XMS (S/H40XMS) [C010, D001, D010, E001]; S/H2.00-3.20XM (S/H40-65XM) [D177, D187, H177] PART NO. 897477 600 SRM 496...
  • Page 2 • Use the correct tools for the job. • Keep the tools clean and in good condition. • Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer. • Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

  • Page 3: Table Of Contents

    Cooling System Repair ............................Thermostat..............................Replace ............................... Fan Assembly..............................Remove and Disassemble.......................... Assemble and Install..........................Water Pump ..............................Remove and Disassemble.......................... Assemble and Install..........................Distributor Repair.............................. Remove ................................Install ................................Flywheel and Ring Gear Repair S/H2.00-3.20XM (S/H40-65XM)..............Remove ................................©2002 HYSTER COMPANY...
  • Page 4 Table of Contents Mazda Engine TABLE OF CONTENTS (Continued) Ring Gear, Replace ............................Install ................................Flywheel Repair H1.50-175XM, H2.00XMS (S/H25-35XM, S/H40XMS)............Remove ................................Install ................................Valve Adjustment............................... Compression Pressure Check ..........................Engine Timing Adjustment ..........................Throttle Linkage Adjustment..........................Gasoline Engines ............................LPG Engines (IMPCO) ..........................

  • Page 5: General

    600 SRM 496 Engine Removal and Installation General This section has the instructions for removal, disas- Additional information on engine components can be sembly, repair, assembly, installation, checks, adjust- found in the sections for Gasoline Fuel System, ments, and troubleshooting for the Mazda M4-2.0G LPG Fuel System, and Electrical System.

  • Page 6: Cylinder Head, Camshaft, And Valve Mechanism Repair

    Cylinder Head, Camshaft, and Valve Mechanism Repair 600 SRM 496 Cylinder Head, Camshaft, and Valve Mechanism Repair REMOVE 8. Use chalk to mark direction of timing belt rota- tion. See Figure 2. Remove timing belt. 1. Disconnect connections at battery. 2.

  • Page 7: Clean

    600 SRM 496 Cylinder Head, Camshaft, and Valve Mechanism Repair 1. FRONT HOUSING 3. OIL SEAL Figure 6. Cylinder Head Removal Sequence 2. GASKET 16. Use valve spring compressor to remove valve re- Figure 4. Front Housing tainers, springs, and valves from head. See Fig- ure 7.

  • Page 8: Inspect And Repair

    Cylinder Head, Camshaft, and Valve Mechanism Repair 600 SRM 496 INSPECT AND REPAIR 0.6293 in.). If components do not meet specifica- tions, replace rocker arm(s) or rocker shaft(s) as Cylinder Head necessary. Use straight edge and thickness gauge to check bot- Camshaft tom surface of cylinder head for distortion.

  • Page 9: Valve Guides

    600 SRM 496 Cylinder Head, Camshaft, and Valve Mechanism Repair 6. Measure clearance between camshaft and bore in cylinder head as follows: a. Install camshaft in cylinder head. b. Put plastic gauge material between each camshaft journal and cap. Do not allow camshaft to rotate.

  • Page 10: Valve Seats

    Cylinder Head, Camshaft, and Valve Mechanism Repair 600 SRM 496 Valves 1. Inspect stem of each valve for wear. Use microm- eter to measure outside diameter of stem. See Figure 15. Minimum dimension intake valve 7.980 mm (0.3142 in.). Minimum dimension for exhaust valve is 7.975 mm (0.3140 in.).

  • Page 11: Valve Springs

    600 SRM 496 Cylinder Head, Camshaft, and Valve Mechanism Repair Valve Springs 1. Check valve springs for damage. 2. Measure free length of outer valve springs. See Figure 16. Minimum length of intake spring is 44.3 mm (1.74 in.). Minimum length of exhaust spring is 50.8 mm (2.00 in.).
  • Page 12 Cylinder Head, Camshaft, and Valve Mechanism Repair 600 SRM 496 9. Install capscrew and washer for camshaft pulley. See Figure 22. Keep pulley from turning and tighten capscrew to 48 to 66 N•m (35 to 49 lbf ft). A. NO. 1 AND NO. 3 ARE THE SAME B.
  • Page 13 600 SRM 496 Cylinder Head, Camshaft, and Valve Mechanism Repair 10. Align timing marks for crankshaft pulley. See Figure 23. Install crankshaft pulley, tapered ring, and capscrew. Tighten capscrew to 160 to 170 N•m (118 to 125 lbf ft). 1. TENSIONER 3.

  • Page 14: Crankshaft And Main Bearings Repair

    Crankshaft and Main Bearings Repair 600 SRM 496 Crankshaft and Main Bearings Repair REMOVE 8. Put identification marks on bearing caps. Loosen capscrews for main bearing caps in steps. Then 1. Remove bracket for cooling fan. remove capscrews, caps, and crankshaft. 2.

  • Page 15: Install

    600 SRM 496 Crankshaft and Main Bearings Repair 1. PLASTIC GAUGE 2. SCALE MATERIAL Figure 28. Main Bearings Clearance Check INSTALL 1. Clean areas of cylinder block around main bear- ings. Carefully install bottom half of new main bearings if necessary. Lubricate bearings with clean engine oil.

  • Page 16: Pistons And Connecting Rods Repair

    Pistons and Connecting Rods Repair 600 SRM 496 8. Install oil strainer. Tighten M6 capscrews to 8 to 12 N•m (6 to 9 lbf ft). Tighten M8 capscrews to 16 to 23 N•m (12 to 17 lbf ft). 9. Install gasket and oil pan. Tighten capscrews to 7 to 12 N•m (5 to 9 lbf ft).

  • Page 17: Connecting Rods And Bearings

    600 SRM 496 Pistons and Connecting Rods Repair of end clearance of each piston ring. See Fig- 2. Clean rod bearings and crankshaft journals. To ure 31. Correct dimensions are as follows: check bearings for wear, measure clearance be- Top Piston Ring - 0.20 to 0.35 mm (0.008 to tween rod bearings and journals.
  • Page 18 Pistons and Connecting Rods Repair 600 SRM 496 1. F MARK 2. OIL PORT Figure 33. Connecting Rod and Piston 3. Install piston rings on pistons. During instal- lation, writing on each piston ring must be to- ward top of piston. Check that rings rotate freely. Then put ends of rings in positions shown in Fig- ure 34.

  • Page 19: Cylinder Block Repair

    600 SRM 496 Oil Pump Repair Cylinder Block Repair 1. After cylinder block is cleaned, check its surface for distortion. See Figure 36. If amount of distortion is greater than 0.15 mm (0.0059 in.), grind surface of cylinder block. Max- imum amount of correction permitted is 0.20 mm (0.008 in.).

  • Page 20: Disassemble

    Oil Pump Repair 600 SRM 496 DISASSEMBLE 2. Remove outer gear and inner gear from pump body. 1. Remove screws and pump cover. See Figure 39. 3. Remove snap ring and plunger assembly from housing. CLEAN WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation.

  • Page 21: Inspect

    600 SRM 496 Oil Pump Repair INSPECT d. Measure clearance between body and outer gear. Correct clearance is 0.090 to 0.184 mm 1. Check front cover (pump housing) and pump (0.0035 to 0.0072 in.). If clearance is more cover for wear or damage. Check plunger spring than 0.20 mm (0.008 in.), repair as necessary.

  • Page 22: Install

    Cooling System Repair 600 SRM 496 INSTALL 1. Install O-ring on oil pump housing. Use grease to hold O-ring in position. Lubricate oil seal with engine oil. See Figure 41. 2. Use adhesive sealant to install oil pump hous- ing on cylinder block. Make sure there is no sealant in oil port.

  • Page 23: Assemble And Install

    600 SRM 496 Cooling System Repair WATER PUMP Remove and Disassemble NOTE: If either the shaft or impeller is damaged, the complete water pump must be replaced. 1. Drain cooling system. 2. Loosen alternator and remove fan belt. 3. Remove capscrews for the fan. Remove fan and pulley from the hub.

  • Page 24: Assemble And Install

    Cooling System Repair 600 SRM 496 6. Loosen capscrews for timing belt tensioner and remove spring. Remove capscrews and timing belt tensioner. CAUTION Do not rotate the camshaft gear or the crank- shaft gear while the timing belt is removed. If either of the gears is moved, it will be neces- sary to align the timing marks.

  • Page 25: Distributor Repair

    600 SRM 496 Distributor Repair WARNING DO NOT remove the radiator cap from the ra- diator when the engine is hot. When the radi- ator cap is removed, the pressure is released from the system. If the system is hot, the steam and boiling coolant can cause burns.

  • Page 26: Flywheel And Ring Gear Repair S/H2.00-3.20Xm (S/H40-65Xm)

    Flywheel and Ring Gear Repair S/H2.00-3.20XM (S/H40-65XM) 600 SRM 496 Flywheel and Ring Gear Repair S/H2.00-3.20XM (S/H40-65XM) REMOVE 1. Use hammer and chisel to break ring gear. See Figure 50. Be careful to not damage flywheel. 1. Remove capscrews for flywheel. Then remove fly- wheel and drive plate.

  • Page 27: Flywheel Repair H1.50-175Xm, H2.00Xms (S/H25-35Xm, S/H40Xms)

    600 SRM 496 Flywheel Repair H1.50-175XM, H2.00XMS (S/H25-35XM, S/H40XMS) Flywheel Repair H1.50-175XM, H2.00XMS (S/H25-35XM, S/H40XMS) REMOVE 2. Install flange and flywheel on crankshaft. 1. Remove capscrews for flywheel. Then remove fly- 3. Apply thread-locking adhesive on threads of cap- wheel and flange. See Figure 51. screws.

  • Page 28: Valve Adjustment

    Valve Adjustment 600 SRM 496 Valve Adjustment 1. Rotate crankshaft until No. 1 piston is at TDC on compression stroke (intake and exhaust valves closed). 2. Adjust clearance of intake valves for No. 1 and No. 2 cylinders and exhaust valves for the No. 1 and No.

  • Page 29: Compression Pressure Check

    600 SRM 496 Engine Timing Adjustment Compression Pressure Check 1. Remove spark plugs from cylinder head. Discon- • If pressure reading increases to normal nect high tension wire at ignition coil. See Fig- reading, low pressure was caused by worn ure 53.

  • Page 30: Throttle Linkage Adjustment

    Engine Specifications 600 SRM 496 Throttle Linkage Adjustment LPG ENGINES (IMPCO) Whenever the throttle linkage is disassembled, the throttle cable must be adjusted after installation. For earlier units, see LPG Fuel System 900 SRM 523 for the correct adjustment procedure. GASOLINE ENGINES LPG ENGINES (AISAN) For the H1.50-1.75XM, 2.00XMS (S/H25-35XM,...

  • Page 31: Valve Mechanism

    600 SRM 496 Engine Specifications VALVE MECHANISM Rocker Arm Shaft Diameter......15.966 to 15.984 mm Inside Diameter of Valve (0.6286 to 0.6293 in.) Guide........8.07 to 8.09 mm Rocker Arm Bore (0.3177 to 0.3185 in.) Diameter......16.000 to 16.027 mm Clearance in Guide (0.6299 to 0.6311 in.) (Exhaust) ......

  • Page 32: Connecting Rods

    Engine Specifications 600 SRM 496 – Grinding Limit .... 0.75 mm (0.030 in.) – Service Limit....0.15 mm (0.0059 in.) Piston Pin Diameter ..21.974 to 21.980 mm Clearance Between (0.8651 to 0.8654 in.) Journals and Main Bearings......0.031 to 0.049 mm Groove Width for Piston (0.0012 to 0.0019 in.) Rings Nos.

  • Page 33: Torque Specifications

    600 SRM 496 Torque Specifications Torque Specifications Camshaft Pulley Lock Bolt Oil Pan 48 to 66 N•m (35 to 49 lbf ft) 7 to 12 N•m (62 to 106 lbf in) Cooling Fan Oil Pump 8 to 11 N•m (71 to 97 lbf in) M8 Capscrews 19 to 26 N•m (14 to 19 lbf ft) M10 Capscrews 38 to 53 N•m (28 to 39 lbf ft) Connecting Rod Cap...

  • Page 34: Troubleshooting

    Troubleshooting 600 SRM 496 Troubleshooting PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION The engine will not start. The fuel tank is empty. Fill fuel tank. The battery is not fully charged. Charge battery. The connections at the battery are Check and tighten battery connec- loose or they have corrosion.
  • Page 35 600 SRM 496 Troubleshooting PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION The engine does not have The fuel is the wrong type. Fill tank with correct fuel. enough power. The air filter is dirty. Install new air filter. The ignition timing is not correct. Adjust timing.
  • Page 36 Troubleshooting 600 SRM 496 PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION The engine gets too hot. There is not enough coolant in the Fill cooling system. cooling system. The air filter has a restriction. Install new air filter. The water pump has damage. Install new water pump.
  • Page 38 TECHNICAL PUBLICATIONS 600 SRM 496 2/01 (4/96)(1/96)(1/95)(9/93)(4/93) Printed in U.S.A.

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