Hyster H177 (H2.00-H3.20XM Europe) Forklift Service Repair Manual

PERKINS DIESEL ENGINES 704-26 (UB) H2.00-3.20XM (H40-65XM) [D177, H177] PART NO. 1456975 600 SRM 706 HM090521

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load. • Do not lift heavy parts by hand, use a lifting mechanism. • Wear safety glasses. • DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. • Disconnect the battery ground cable on internal combustion lift trucks. • Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte- nance section. • Keep the unit clean and the working area clean and orderly. • 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. • Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs. • Be sure to follow the WARNING and CAUTION notes in the instructions. • Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems. • Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated. NOTE: The following symbols and words indicate safety information in this manual: WARNING Indicates a condition that can cause immediate death or injury! CAUTION Indicates a condition that can cause property damage!

Perkins Diesel Engines Table of Contents TABLE OF CONTENTS Description ......................................................................................................................................................... 1 General Safety Rules ......................................................................................................................................... 1 Engine Removal and Installation ..................................................................................................................... 2 General ........................................................................................................................................................... 2 Lifting Engine ................................................................................................................................................ 2 Engine Identification ......................................................................................................................................... 3 General ........................................................................................................................................................... 3 Engine Data ................................................................................................................................................... 3 Cylinder Head Assembly Repair ....................................................................................................................... 4 Description ..................................................................................................................................................... 4 Valve Cover .................................................................................................................................................... 4 Remove ....................................................................................................................................................... 4 Breather System, Clean and Replace....................................................................................................... 4 Install ......................................................................................................................................................... 5 Rocker Assembly............................................................................................................................................ 5 Remove ....................................................................................................................................................... 5 Disassemble ............................................................................................................................................... 6 Assemble .................................................................................................................................................... 6 Install ......................................................................................................................................................... 6 Valve Clearance, Adjust ............................................................................................................................ 6 Valve Spring, Replace................................................................................................................................ 7 Piston TDC ................................................................................................................................................ 8 Cylinder Head ................................................................................................................................................ 8 Remove ....................................................................................................................................................... 8 Clean and Inspect ...................................................................................................................................... 10 Valve, Check .............................................................................................................................................. 10 Install ......................................................................................................................................................... 10 Valves and Valve Springs .............................................................................................................................. 12 Remove ....................................................................................................................................................... 12 Install ......................................................................................................................................................... 12 Valve Guides .................................................................................................................................................. 13 Inspect ........................................................................................................................................................ 13 Remove ....................................................................................................................................................... 13 Install ......................................................................................................................................................... 13 Valve Seats, Repair ................................................................................................................................... 14 Valve Seat Insert, Install .......................................................................................................................... 14 Piston and Connecting Rod Assembly Repair .................................................................................................. 15 Description ..................................................................................................................................................... 15 Connecting Rod Bearings, Replace ............................................................................................................... 16 Piston and Connecting Rods ......................................................................................................................... 17 Remove ....................................................................................................................................................... 17 Disassemble ............................................................................................................................................... 17 Inspect ........................................................................................................................................................ 18 Replace ....................................................................................................................................................... 18 Assemble .................................................................................................................................................... 18 Install ......................................................................................................................................................... 19 Piston Rings ................................................................................................................................................... 20 Remove ....................................................................................................................................................... 20 Inspect ........................................................................................................................................................ 20 Install ......................................................................................................................................................... 21 Crankshaft Assembly Repair ............................................................................................................................ 22 ©2003 HYSTER COMPANY i

Table of Contents Perkins Diesel Engines TABLE OF CONTENTS (Continued) Description ..................................................................................................................................................... 22 Crankshaft Pulley.......................................................................................................................................... 22 Remove ....................................................................................................................................................... 22 Install ......................................................................................................................................................... 22 Rear Oil Seal .................................................................................................................................................. 22 Remove ....................................................................................................................................................... 22 Install ......................................................................................................................................................... 23 Wear Sleeve, Install .................................................................................................................................. 23 Thrust Washers.............................................................................................................................................. 24 Crankshaft Axial Movement, Check ........................................................................................................ 24 Remove ....................................................................................................................................................... 24 Install ......................................................................................................................................................... 25 Main Bearings................................................................................................................................................ 25 Remove ....................................................................................................................................................... 25 Install ......................................................................................................................................................... 26 Crankshaft ..................................................................................................................................................... 26 Remove ....................................................................................................................................................... 26 Inspect ........................................................................................................................................................ 27 Wear Sleeve, Install .................................................................................................................................. 27 Install ......................................................................................................................................................... 28 Front and Rear Bearing Cap Seals, Install .................................................................................................. 29 Timing Case and Timing Gears Repair ............................................................................................................ 30 Description ..................................................................................................................................................... 30 Timing Case ................................................................................................................................................... 31 Remove ....................................................................................................................................................... 31 Replace ....................................................................................................................................................... 31 Install ......................................................................................................................................................... 32 Front Oil Seal................................................................................................................................................. 33 Remove ....................................................................................................................................................... 33 Install ......................................................................................................................................................... 33 Idler Gear ....................................................................................................................................................... 34 Remove ....................................................................................................................................................... 34 Install ......................................................................................................................................................... 34 Idler Gear Bushings, Replace ....................................................................................................................... 35 Idler Gear Hub ............................................................................................................................................... 35 Remove ....................................................................................................................................................... 35 Install ......................................................................................................................................................... 35 Camshaft Assembly, Fuel Injection Pump ................................................................................................... 36 Remove ....................................................................................................................................................... 36 Install ......................................................................................................................................................... 37 Camshaft Assembly, Valves........................................................................................................................... 37 Remove ....................................................................................................................................................... 37 Install ......................................................................................................................................................... 38 Crankshaft Gear ............................................................................................................................................ 38 Remove ....................................................................................................................................................... 38 Install ......................................................................................................................................................... 38 Timing Case Backplate ................................................................................................................................. 39 Remove ....................................................................................................................................................... 39 Install ......................................................................................................................................................... 39 Cylinder Block Assembly Repair....................................................................................................................... 39 Description ..................................................................................................................................................... 39 ii

Perkins Diesel Engines Table of Contents TABLE OF CONTENTS (Continued) Cylinder Block ............................................................................................................................................... 39 Disassemble ............................................................................................................................................... 39 Inspect ........................................................................................................................................................ 40 Cylinder Bore, Check ................................................................................................................................ 40 Assemble .................................................................................................................................................... 41 Engine Timing .................................................................................................................................................... 41 Description ..................................................................................................................................................... 41 Set Timing of Number One Piston to Top Dead Center (TDC) ................................................................... 42 Valve Timing, Check ...................................................................................................................................... 43 Fuel Pump Timing Check.............................................................................................................................. 44 Lubrication System Repair................................................................................................................................ 46 Description ..................................................................................................................................................... 46 Oil Filter, Replace .......................................................................................................................................... 46 Oil Sump ........................................................................................................................................................ 46 Remove ....................................................................................................................................................... 46 Install ......................................................................................................................................................... 47 Oil Pump ........................................................................................................................................................ 47 Remove ....................................................................................................................................................... 47 Inspect ........................................................................................................................................................ 47 Install ......................................................................................................................................................... 48 Relief Valve .................................................................................................................................................... 48 Remove ....................................................................................................................................................... 48 Disassemble ............................................................................................................................................... 48 Inspect ........................................................................................................................................................ 49 Assemble .................................................................................................................................................... 49 Install ......................................................................................................................................................... 49 Fuel System Repair............................................................................................................................................ 49 Description ..................................................................................................................................................... 49 Fuel Filter, Replace ....................................................................................................................................... 50 Fuel Injectors ................................................................................................................................................. 50 Remove ....................................................................................................................................................... 50 Inspect ........................................................................................................................................................ 51 Install ......................................................................................................................................................... 51 Fuel Pump ...................................................................................................................................................... 52 Remove ....................................................................................................................................................... 52 Disassemble ............................................................................................................................................... 52 Assemble .................................................................................................................................................... 52 Install ......................................................................................................................................................... 53 Test ............................................................................................................................................................. 53 Water Separator............................................................................................................................................. 53 Remove ....................................................................................................................................................... 53 Disassemble ............................................................................................................................................... 53 Assemble .................................................................................................................................................... 54 Install ......................................................................................................................................................... 54 Fuel Injection Pump ...................................................................................................................................... 54 Remove ....................................................................................................................................................... 54 Install ......................................................................................................................................................... 55 Fuel System Air Removal .............................................................................................................................. 56 Governor Weight Assembly ........................................................................................................................... 57 Remove ....................................................................................................................................................... 57 Install ......................................................................................................................................................... 57 iii

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Hyster H177 (H2.00-H3.20XM Europe) Forklift Service Repair Manual

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