Hyster C177 (H3.00XL Europe) Forklift Service Manual

1 INTRODUCTION GENERAL This section has the description and the repair instruc- tions for the engine. Disassembly, cleaning, assembly, specifications and troubleshooting are included. WARNING Some gaskets used in this engine can contain dangerous fibers. Breathing dust from these fibers is a cancer or lung disease hazard. Do not create dust! Use vacuum equipment for asbestos or follow the cleaning procedure described below. • Make sure the gasket material is wet with water or oil to prevent particles in the air. • Use a hand scraper to remove old gasket material. Do not use a power tool or compressed air. • Discard all asbestos material in a closed container while it is still wet. Put a “DANGEROUS FIBERS” warning label on the container. Discard dangerous fiber material safely. CAUTION Disconnect the battery cables before doing any disassembly and repair to the engine or parts of the electrical system. The diodes and resistors in the electrical system can be damaged if the following cautions are not followed: • Do not disconnect the battery when the engine is running. The voltage surge can damage the diodes and resistors. • Do not disconnect an electric wire before the engine is stopped and the switches are “OFF”. • Do not cause a short circuit by connection of the electric wires to the wrong terminals. Make sure a correct identification is made of the wire before it is connected. • Make sure a battery is the correct voltage and polarity before it is connected. • Do not check for current flow by making a spark because the electronic components can be damaged. FIGURE 1. GM ENGINES 10569 5. OIL SUMP 6. ENGINE BLOCK 7. CYLINDER HEAD ASSEMBLY 4–153, 4–181 AND 3.0L ENGINES 6–250 ENGINE 1. ROCKER ARM COVER 2. FILL CAP FOR ENGINE OIL 1 2 3 4 5 6 7 3. WATER PUMP 4. VIBRATION DAMPENER 4 5 2 1 7 6 3

2 DESCRIPTION The GM engines described in this section are the four cylinder and six cylinder models that have the arrange- ment of the cylinders in a straight line. These engines have a similar design. The number one cylinder for these engines is toward the cooling fan. These engines can have either a gasoline or a LPG fuel system. The GM 4–153 engine is used in some models of 2.00 to 3.00 ton (4000 to 6000 lb) capacity lift trucks from June 1975 until June 1990. During 1990, production of the GM 4–153 engine was stopped and it was replaced with variations of the GM 4–181 engine. The GM 4–181 engine is also used in some models of 2.00 to 3.00 ton (4000 to 6000 lb) capacity lift trucks beginning in 1978. The two engines are the same design except for different displacements. The GM 4–181 engines installed in the lift trucks with serial code B187 [S2.00–3.00XL (S40–60XL)] beginning in 1990 have a different camshaft than the GM 4–181 engines used in the lift trucks with other serial codes. The GM 4–181 engines installed in the lift trucks with serial codes C187 [S2.00–3.00XL (S40–60XL)] and serial codes B177 and C177 [H2.00–3.00XL (H40–60XL)] are the same engine. The GM 3.0L engine is a later model of the 4–181 engine. It is used in the S/H2.00–3.20XM (S/H40–65XM) lift trucks. The GM 6–250 engine is used in some models of 3.00 to 7.50 ton (6000 to 15 000 lb) capacity lift trucks from 1975 until 1988. A camshaft in the engine block operates the overhead valves with push rods. A cast iron crankshaft gear drives a camshaft gear. The cam lobes are hardened and have a taper with the high side toward the rear of the engine. The valve lifters have a rounded surface where they con- tact the cam lobes. This combination of surfaces causes the valve lifters to rotate during engine operation. All of the engines have hydraulic valve lifters. Each rocker arm rotates on a pivot ball stud fastened to the cylinder head. The valve guides and valve seats are part of the cylinder head. The exhaust valve seats are in- duction hardened. The crankshaft in the four cylinder engines has five main bearings. The crankshaft in the six cylinder engine has seven main bearings. The rear main bearing in all engines is the thrust bearing. The pistons are aluminum alloy and have three piston rings. The two compression rings each have a different design. Some oil control rings have three parts that must be assembled when the oil control ring is installed on the piston. The specifications for engine repair are shown in EN- GINE SPECIFICATIONS at the end of this section. REMOVAL AND INSTALLATION OF THE ENGINE NOTE: The removal and installation procedures for the engine and transmission are not included in this section. See the section, THE FRAME for the model of lift truck for these procedures. CYLINDER HEAD AND VALVE MECHANISM Cylinder Head, Removal 1. Disconnect the battery cables at the battery. 2. Drain the cooling system. 3. Disconnect and remove the coolant hose from the housing for the thermostat. 4. Remove or disconnect the air filter. 5. Disconnect the PCV valve. 6. Disconnect the wires and hoses fastened to brackets on the rocker arm cover. 7. Disconnect the spark plug wires. 8. Disconnect the linkages, fuel lines, and hoses for the fuel system. 9. Disconnect the exhaust pipe at the exhaust manifold and remove the intake and exhaust manifolds. 10. If necessary, remove the alternator and bracket. 11. Remove the dipstick tube for engine oil. 12. Remove the rocker arm cover. NOTE: Keep the rocker arm assemblies and the push rods in order so that they will be installed in the same po- sition.

3 13. Remove the rocker arms and the push rods. 14. Loosen the cylinder head bolts in two or three steps. Do not completely loosen the cylinder head bolts during the first sequence. Remove the cylinder head bolts. Re- move the cylinder head and the gasket. Cylinder Head, Disassembly 1. Use a compressor tool to compress the valve springs and remove the retainers. See FIGURE 2. and FIGURE 3. Release the compressor tool and remove the spring cap, (rotators, when used), oil shield, and valve springs. Remove the oil seal and any shims from the springs. 2. Remove the valves from the cylinder head and put them in a rack so that the valves can be installed again in their same positions in the cylinder head. FIGURE 2. CYLINDER HEAD 8908 1. PCV VALVE 2. ROCKER ARM COVER 3. INTAKE MANIFOLD 4. OUTLET 5. THERMOSTAT 6. CYLINDER HEAD 7. INTAKE VALVE 8. PUSH ROD 9. EXHAUST VALVE 10. VALVE SPRING 11. EXHAUST MANIFOLD 12. SHIELD 13. SPRING CAP 14. ROCKER ARM 15. BALL 16. NUT 17. RETAINER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 GM 6–250 SHOWN

4 FIGURE 3. COMPRESS THE VALVE SPRINGS Cleaning And Inspection 1. Clean the carbon from the combustion chambers and the valve ports. 2. Clean the valve guides. Use a tool as shown in the ex- ample in FIGURE 4. FIGURE 4. TOOL FOR CLEANING THE VALVE GUIDES 3. Clean the push rods and rocker arms. 4. Clean the surfaces of the cylinder head where the gaskets fit. 6. Inspect the cylinder head for cracks in the exhaust ports, combustion chambers, and external surfaces. 7. Inspect the valves for burned or damaged areas in the seat surfaces. Inspect for cracks and damaged or worn valve stems. 8. Check the clearance of each valve stem in its valve guide. Use the following procedure: a. Use a micrometer to measure the diameter of the valve stem in three places: top, center, and bot- tom. The stems of exhaust valves have a small taper. The end of the valve stem near the spring is approximately 0.0025 mm (0.001 in) larger than the diameter near the valve head. Use a hole gauge to measure the bore in the valve guide. b. Another method of measuring the clearance of the valve stem in its valve guide is to use a dial indicator as shown in FIGURE 5. Put the dial indicator so that it can measure the side–to–side movement of the valve stem. Lower the valve away from its valve seat approximately 3 mm (0.1 in). Move the valve stem from side–to–side and check the measurement on the dial indicator. FIGURE 5. CHECK THE CLEARANCE BETWEEN VALVE GUIDE AND VALVE 12686 c. The maximum clearance between the valve stems and their valve guides is shown in the EN- GINE SPECIFICATIONS. d. If the clearance between the valve stem and its valve guide is greater than the specification, a valve with an oversize stem must be installed. Use a reamer to make the bore the correct diameter for the next oversize valve. See the Parts Manual for oversize valves. 9. Use a valve spring tester to check the valve springs. A typical tester is shown in FIGURE 48. The specifica-

5 tions for the valve springs are shown in the ENGINE SPECIFICATIONS. 10. Inspect the rocker arm bolts for wear and damage. Valves And Valve Seats The condition and alignment of the valves to their valve seats is important so that the engine will operate correctly. Before any work is done on the valve seats, make sure the clearance of the valve stems in their valve guides is within specifications. A correction for minimum wear and damage to the valve and seat can be done by a process called “lapping”. When the valve seats are “lapped”, keep the valve seats within the specifications. Make sure all of the lapping compound is removed from the valve and valve seat when the process is completed. NOTE: Some engines have valve seats that can be replaced. If the valve seats cannot be repaired or replaced, install a new cylinder head. Damaged valve seats can be repaired with a cutter tool. If the valve seat can not be repaired so that the valve depth is within specifications, the cylinder head must be replaced. The specifications for the valve seats are shown in FIGURE 6. FIGURE 6. VALVE SEAT SPECIFICATIONS FOR INTAKE AND EXHAUST VALVES 1. VALVE SEAT 2. MINIMUM THICKNESS OF VALVE HEAD IS 0.80 mm (0.031 in) 46° 45° 2 1 Studs For The Rocker Arms Replace a stud that has damaged threads or is loose in the cylinder head. See the Parts Manual for oversize studs. 1. Remove the old stud. Install a spacer, flat washer, and nut to the damaged stud. Use a wrench to remove the damaged stud. See FIGURE 7. FIGURE 7. REMOVE A STUD FOR A ROCKER ARM CAUTION Do not try to install an oversize stud without reaming the stud hole to the new size. Installation of an oversize stud without reaming the stud hole can cause cracks in the cylinder head. 2. Use a reamer of the correct size for the new oversize stud. Apply SAE 90 lubricant to the new stud during installation. Install the new stud as shown in FIGURE 8. FIGURE 8. INSTALLATION OF A STUD FOR A ROCKER ARM Hydraulic Valve Lifters, Replacement The hydraulic valve lifters normally do not need service unless they are dirty or damaged. The hydraulic valve lifters must be clean to operate correctly. If the lifters make noise or do not operate correctly, replace them. The lifters can be removed with a flexible magnet after the push rods are removed.

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Hyster C177 (H3.00XL Europe) Forklift Service Manual

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