Hyster D010 Safety Precautions Maintenance And Repair Download Page 35

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600 SRM 496

Troubleshooting

PROBLEM

POSSIBLE CAUSE

PROCEDURE OR ACTION

The engine does not have
enough power.

The fuel is the wrong type.

Fill tank with correct fuel.

The air filter is dirty.

Install new air filter.

The ignition timing is not correct.

Adjust timing.

The valve mechanism does not work
correctly.

Check and repair valve mechanism.

The piston assemblies are worn or
damaged.

Install new pistons.

The exhaust system has restrictions.

Clean parts or install new muffler or
pipes.

Fuel lines or fuel filter has a restric-
tion.

Clean or use new fuel lines and filter.

Engine is too hot or too cold.

Check cooling system.

Cylinder head gasket leaks.

Install new gasket.

There is noise inside the en-
gine.

The main bearings are worn or dam-
aged.

Install new main bearings.

Engine is too hot.

Check and repair cooling system.

Valves are not adjusted correctly.

Adjust valves.

The bearings for the connecting rods
are worn or damaged.

Install new bearings.

The pistons are worn or damaged.

Install new pistons.

Valve spring is broken.

Install new valve springs.

There is not enough oil in the engine.

Fill engine with correct oil.

The flywheel is loose.

Tighten capscrews for flywheel.

A connecting rod is bent.

Repair engine.

There is a leak in the exhaust sys-
tem.

Repair exhaust system.

The valve mechanism does not oper-
ate correctly.

Check and repair valve mechanism.

Spark plugs are dirty.

Install new spark plugs.

Summary of Contents for D010

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: ...d 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 follo...

Page 3: ... Install 11 Pistons and Connecting Rods Repair 12 Remove and Disassemble 12 Clean 12 Inspect and Repair 12 Pistons 12 Piston Rings 12 Connecting Rods and Bearings 13 Assemble and Install 13 Cylinder Block Repair 15 Oil Pump Repair 15 Remove 15 Disassemble 16 Clean 16 Inspect 17 Assemble 17 Install 18 Cooling System Repair 18 Thermostat 18 Replace 18 Fan Assembly 18 Remove and Disassemble 18 Assemb...

Page 4: ...ge Adjustment 26 Gasoline Engines 26 LPG Engines IMPCO 26 LPG Engines AISAN 26 Engine Specifications 26 Engine Data 26 Thermostat 26 Cylinder Head 26 Valve Mechanism 27 Camshaft 27 Crankshaft 27 Connecting Rods 28 Cylinder Block 28 Pistons 28 Oil Pump 28 Torque Specifications 29 Troubleshooting 30 This section is for the following models H1 50 1 75XM S H25 35XM C010 D001 D010 E001 H2 00XMS S H40XM...

Page 5: ...voltage surge can dam age the diodes and resistors Do not disconnect an electric wire before the engine is stopped and the key switch is OFF Do not cause a short circuit by connection of the electric wires to the wrong terminals Make sure a correct identification of the wire is made wire before it is connected Make sure a battery is the correct voltage and polarity before it is connected Do not ch...

Page 6: ...Timing Belt Covers 7 Loosen capscrews for timing belt tensioner and remove spring Remove capscrews and timing belt tensioner 8 Use chalk to mark direction of timing belt rota tion See Figure 2 Remove timing belt Figure 2 Timing Belt 9 Put labels on wires to aid in correct installation Disconnect wires at distributor Remove cap screw for distributor mount and pull distributor from front housing 10 ...

Page 7: ...der head in proper se quence See Figure 6 15 Lift cylinder head from the block Figure 6 Cylinder Head Removal Sequence 16 Use valve spring compressor to remove valve re tainers springs and valves from head See Fig ure 7 Figure 7 Valve Removal CLEAN WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation When using cleaning solvents always follow the solvent manufacturer ...

Page 8: ...cker shaft is 15 966 to 15 984 mm 0 6286 to 0 6293 in If components do not meet specifica tions replace rocker arm s or rocker shaft s as necessary Camshaft 1 Check camshaft for cracks or damage 2 Use dial indicator on end of camshaft to check movement of camshaft in cylinder head See Figure 9 Maximum movement is 0 20 mm 0 008 in Figure 9 Camshaft Check 3 Measure height of camshaft lobes See Figur...

Page 9: ...s any damage or if it does not meet specifications 1 FRONT OIL SEAL SURFACE 2 FRONT JOURNAL NO 1 3 CENTER JOURNALS NOS 2 3 AND 4 4 REAR JOURNAL NO 5 5 FUEL PUMP LOBE Figure 10 Camshaft Inspection Figure 11 Camshaft Check 1 PLASTIC GAUGE 2 SCALE Figure 12 Camshaft Clearance Measurement Valve Guides 1 Measure clearance between valve stems and valve guides Normal clearance is 0 025 to 0 060 mm 0 001 ...

Page 10: ...T WIDTH 2 EXHAUST VALVE SEAT 3 INTAKE VALVE SEAT Figure 14 Valve Seat Specifications Valves 1 Inspect stem of each valve for wear Use microm eter to measure outside diameter of stem See Figure 15 Minimum dimension for intake valve is 7 980 mm 0 3142 in Minimum dimension for exhaust valve is 7 975 mm 0 3140 in 2 Inspect valves for cracks burned faces and dis tortion Inspect seat face of valves for ...

Page 11: ...of cylinder head and surface of en gine block 2 Install new gasket and cylinder head on engine block 3 Install capscrews and washers for cylinder head Tighten capscrews to 82 to 88 N m 60 to 65 lbf ft in proper sequence See Figure 17 4 Apply gasket sealer to areas shown by arrows Lubricate camshaft with clean engine oil Then install camshaft Make sure dowel pin is at top of camshaft See Figure 18 ...

Page 12: ... Figure 21 Use new gasket and install front hous ing on cylinder head Tighten capscrews for front housing to 19 to 26 N m 14 to 19 lbf ft 8 With dowel pin at top of camshaft install camshaft pulley Check that letter A on pulley is aligned with timing mark on front housing See Figure 22 9 Install capscrew and washer for camshaft pulley See Figure 22 Keep pulley from turning and tighten capscrew to ...

Page 13: ...pply spring tension on belt Rotate crankshaft pulley clockwise two complete turns and check timing marks If timing marks are correct tighten lock bolt for tensioner to 20 to 35 N m 15 to 26 lbf ft Check movement on tension side of timing belt If ten sion is correct belt will move 12 to 14 mm 0 47 to 0 55 in with 10 kg 20 lb of force See Fig ure 24 14 Install lower timing belt cover and gasket Tigh...

Page 14: ... in steps Then remove capscrews caps and crankshaft INSPECT AND REPAIR Crankshaft 1 Inspect crankshaft for wear cracks or other damage Replace crankshaft if it has cracks 2 Use micrometer to measure diameter of journals for crankshaft See Figure 27 Make measure ment at several locations for each journal Cor rect dimensions for journals are as follows Main Journal Diameter 59 937 to 59 995 mm 2 359...

Page 15: ...bearings if necessary Lubricate bearings with clean engine oil 2 Install crankshaft 3 Install top half of main bearings in caps and lubricate with oil Use identification marks to install main bearing caps in correct locations Tighten capscrews for main bearing caps to 84 to 90 N m 62 to 66 lbf ft 4 Install pistons and connecting rods as described in Pistons and Connecting Rods Repair 5 Make sure O...

Page 16: ...ies 6 Push connecting rod and piston from cylinder block 7 Carefully remove piston rings from pistons Use tool to push piston pin from connecting rod CLEAN WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation When using cleaning solvents always follow solvent man ufacturer s recommended safety procedures Clean all parts in solvent Make sure all oil passages and groove...

Page 17: ...ings and crankshaft journals To check bearings for wear measure clearance be tween rod bearings and journals See Figure 32 a Put plastic gauge material on crankshaft journals and install rod caps Tighten cap screws for rod caps to 51 to 56 N m 38 to 41 lbf ft Do not rotate connecting rod b Remove rod caps Plastic gauge material will adhere to journals or rod caps c Use graduations on scale to meas...

Page 18: ... pin Lubricate rings with engine oil 4 Apply clean engine oil to piston assembly Install bearings for connecting rods Install piston into correct cylinder making sure F is toward front timing belt end of engine See Figure 35 5 Apply clean engine oil to bearing Then install each cap to correct connecting rod During in stallation of caps make sure to align identifi cation marks that were made during...

Page 19: ...bearings need repair REMOVE 1 Remove bracket for cooling fan 2 Remove upper and lower timing belt covers See Figure 37 3 Loosen capscrews for timing belt tensioner and remove spring Remove capscrews and timing belt tensioner 4 Use chalk to mark direction of rotation of timing belt See Figure 38 Remove timing belt 5 Remove six capscrews and plate from crankshaft pulley Remove six capscrews that hol...

Page 20: ...Figure 39 Oil Pump 2 Remove outer gear and inner gear from pump body 3 Remove snap ring and plunger assembly from housing CLEAN WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation When using cleaning solvents always follow the solvent manufacturer s recommended safety proce dures Clean all parts in solvent Make sure all machined surfaces are smooth 16 ...

Page 21: ... is 0 03 to 0 63 mm 0 0012 to 0 0248 in If clearance is more than 0 10 mm 0 004 in repair as necessary d Measure clearance between body and outer gear Correct clearance is 0 090 to 0 184 mm 0 0035 to 0 0072 in If clearance is more than 0 20 mm 0 008 in repair as necessary ASSEMBLE 1 Install oil seal in oil pump housing Make sure front edge of oil seal is even with outer edge of housing See Figure ...

Page 22: ...rmostat See Figure 42 1 CYLINDER BLOCK 2 GASKET 3 THERMOSTAT 4 HOUSING Figure 42 Thermostat 3 Test operation of thermostat See Cooling Sys tem 700 SRM 626 Thermostat must begin to open at 82 1 5 C 180 3 F Thermostat must be completely open at 95 C 203 F 4 Install thermostat and new gasket Make sure print side of gasket is toward thermostat 5 Install thermostat housing and tighten cap screws to 12 ...

Page 23: ...belt Adjust tension of the fan belt Check movement of fan belt between fan and al ternator Tension for NEW belt is correct when it moves 8 to 10 mm 0 32 to 0 39 in with 10 kg 22 lb of force Tension for USED belt is correct when it moves 10 to 12 mm 0 39 to 0 47 in with 10 kg 22 lb of force Tighten alternator when tension is correct WATER PUMP Remove and Disassemble NOTE If either the shaft or impe...

Page 24: ...ft and bearing in the pump body Make sure the shaft turns smoothly 1 PULLEY 2 SHAFT AND BEARING ASSEMBLY 3 WASHER 4 HOUSING 5 SEAL 6 IMPELLER Figure 46 Water Pump 4 Install water pump with a new gasket Tighten capscrews to 19 to 26 N m 14 to 19 lbf ft 5 Clean any oil or grease from pulleys Install tim ing belt so that it goes in same direction as mark made during removal 6 Loosen lock bolt and app...

Page 25: ... section only has the removal and instal lation procedures for the distributor Service proce dures for the ignition system are found in the Elec trical System section REMOVE 1 Rotate crankshaft until No 1 piston is at TDC on compression stroke Make note of position of distributor rotor See Figure 48 2 Disconnect wires at spark plugs 3 Remove capscrew from flange of distributor shaft housing Lift d...

Page 26: ...eeth 1 Use hammer and chisel to break ring gear See Figure 50 Be careful to not damage flywheel Figure 50 Ring Gear Removal WARNING Parts are hot Wear protective clothing and gloves to prevent burns 2 Heat ring gear before installation on flywheel Make sure ring gear is not heated to more than 200 C 392 F 3 Install ring gear on flywheel Make sure chamfer on teeth is in correct direction toward sta...

Page 27: ...ing was removed install it on engine See Fig ure 51 Tighten capscrews to 43 to 51 N m 32 to 38 lbf ft 2 Install flange and flywheel on crankshaft 3 Apply thread locking adhesive on threads of cap screws Then install capscrews and lockwash ers Tighten capscrews to 96 to 103 N m 71 to 76 lbf ft NOTE EARLIER MODEL TORQUE CONVERTER HOUSING IS SHOWN LATER MODEL IS SIMILAR 1 FLANGE 2 FLYWHEEL 3 DRIVE PL...

Page 28: ...0 3 mm 0 012 in To adjust clearance loosen lock nut and turn ad justment screw Tighten lock nut to 16 to 21 N m 12 to 15 lbf ft NOTE During adjustment of valves check position of balls in ends of rocker arms Flat surface of ball must be in contact with stem of valve 3 Rotate crankshaft clockwise one complete turn Adjust remaining valves 4 If valves are adjusted when engine is cold check adjustment...

Page 29: ...ately 10 revolutions to distribute oil c Install compression gauge and do same tests as described in Step 3 If pressure reading increases to normal reading low pressure was caused by worn or damaged piston rings Cylinder bore may also be damaged If pressure reading does not increase low pressure was caused by worn valves valve seats or valve guides If low pressure readings are in two cylin ders ne...

Page 30: ...39 in 94 mm 3 70 in Displacement M4 2 0G 1998 cm3 121 9 in 3 Displacement M4 2 2G 2184 cm3 133 2 in 3 Firing Order 1 3 4 2 Compression Ratio 8 6 1 Compression Pressure 1131 kPa 164 psi 270 rpm Engine Timing No 1 Cylinder Gasoline LPG H1 50 1 75XM 2 00 XMS S H25 35XM 40XMS LPG S H2 00 3 20XM S H40 65XM 0 TDC 8 BTDC 9 BTDC Engine Speed M4 2 0G IMPCO Idle Speed Governed Speed 725 25 rpm 2650 50 rpm E...

Page 31: ...2 0G 44 3 mm 1 744 in Spring Free Length Inner M4 2 2G 47 7 mm 1 878 in Service Limit M4 2 2G 46 3 mm 1 823 in Rocker Arm Shaft Diameter 15 966 to 15 984 mm 0 6286 to 0 6293 in Rocker Arm Bore Diameter 16 000 to 16 027 mm 0 6299 to 0 6311 in Clearance Between Rocker Arm and Shaft 0 016 to 0 061 mm 0 0006 to 0 0024 in CAMSHAFT Cam Lobes to Production Limit 37 102 mm 1 4607 in Cam Lobes to Service L...

Page 32: ...Clearance Between Piston and Bore 0 036 to 0 075 mm 0 0014 to 0 0030 in Service Limit 0 15 mm 0 0059 in Piston Pin Diameter 21 974 to 21 980 mm 0 8651 to 0 8654 in Groove Width for Piston Rings Nos 1 and 2 1 520 to 1 540 mm 0 0598 to 0 0606 in Groove Width for Oil Ring 4 020 to 4 040 mm 0 1583 to 0 1591 in Piston Ring Clearance in Groove Nos 1 and 2 0 03 to 0 07 mm 0 0012 to 0 0028 in Service Limi...

Page 33: ...Intake Manifold 19 to 31 N m 14 to 23 lbf ft Main Bearing Cap 84 to 90 N m 62 to 66 lbf ft Oil Pan 7 to 12 N m 62 to 106 lbf in Oil Pump M8 Capscrews 19 to 26 N m 14 to 19 lbf ft M10 Capscrews 38 to 53 N m 28 to 39 lbf ft Rocker Cover M4 2 0G 30 to 40 N m 22 to 30 lbf ft M4 2 2G 40 to 60 N m 30 to 44 lbf ft Rocker Shaft Assembly 18 to 27 N m 13 to 20 lbf ft Spark Plugs 15 to 23 N m 133 to 204 lbf ...

Page 34: ... The fuel system has a problem Check and repair fuel system Ignition timing is not correct Adjust timing Fuel line has a restriction Clean or use new fuel lines Fuel filter has a restriction Install new fuel filter Ignition system does not operate cor rectly Check and repair ignition system The engine does not run smoothly The valve mechanism does not oper ate correctly Check and repair valve mech...

Page 35: ... Check cooling system Cylinder head gasket leaks Install new gasket There is noise inside the en gine The main bearings are worn or dam aged Install new main bearings Engine is too hot Check and repair cooling system Valves are not adjusted correctly Adjust valves The bearings for the connecting rods are worn or damaged Install new bearings The pistons are worn or damaged Install new pistons Valve...

Page 36: ...he radiator is dirty Clean or repair the radiator The cooling system has restrictions Check radiator and hoses The belt for the water pump is worn or not adjusted correctly Check and adjust the belt The thermostat has damage Install new thermostat The exhaust system has restrictions Check and repair exhaust system Ignition timing is not correct Adjust timing Cylinder head gasket leaks Install new ...

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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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