Hyster A177, H40XL, H50XL, H60XL Repair Manual (P/N 4000 SRM 135)

This 564-page PDF set combines 28 OEM Hyster service sections for the H2.00XL, H2.50XL, and H3.00XL lift trucks, sold as the H40XL, H50XL, and H60XL. The model-specific material covers A177, B177, and C177 serial codes; the maintenance section identifies B177 production after April 1990 and C177 production after June 1990. Mazda M4-121G and Isuzu C240 data cover A177, B177, and C177 trucks, while GM 4-181 and Isuzu 4JB1 specifications apply to C177 configurations.

Publication 4000 SRM 135 / Part No. 910119 is the 32-page Lift Cylinders section within this set, not the publication number for the complete 28-file collection.

• Engine and fuel-system repair: Covers Mazda M4-121G and Isuzu C240 disassembly, inspection, reassembly, timing, valve-train, piston, crankshaft, bearing, lubrication, cooling, adjustment, and troubleshooting work. Separate sections address the Mazda carburetor and IMPCO CA50/CA100 LPG equipment.
• Transmission, differential, and brakes: Provides T43 single-speed powershift repair procedures for the torque converter, oil pump, clutch packs, control valve, differential, Monotrol controls, neutral-start switches, stall and pressure tests, brake/inching linkage, wheel brakes, master cylinder, and parking brake.
• Hydraulic and steering systems: Details the gear pump, flow-control and relief valves, main control valve, lift and tilt circuits, cylinder repair, steering axle, steering cylinder, steering-control-unit service, bleeding, and pressure and flow testing.
• Frame and mast procedures: Includes counterweight and radiator work, engine/transmission removal, standard upright and Vista mast repair, carriage and fork inspection, lift-chain and sheave service, load-roller and shim adjustment, sequence valves, and two-stage and three-stage mast assembly.
• Electrical diagnosis: Covers Mazda starting, charging, contact-point and HEI ignition systems, plus Isuzu C240 starting, glow-plug/cold-start, alternator, starter, sender, meter, and instrument-panel checks.
• Diagrams and factory data: Supplies hydraulic and transmission schematics, gasoline/LPG and diesel wiring and cable diagrams, wire-color and gauge identification, torque tables, fluid capacities, pressure-test data, clearances, wear limits, adjustment specifications, and troubleshooting charts.

Engine and Fuel-System Scope

The Mazda M4-121G and Isuzu C240 files are full engine repair sections, reaching into the cylinder head and valve mechanism, timing drive, camshaft, pistons and connecting rods, crankshaft and main bearings, flywheel, oiling system, and cooling components. Engine removal and installation are handled in the Frame section, where connections and mounting arrangements are separated by truck configuration.

Production changes matter. Mazda engines built before April 1990 use contact-point distributors, while some later units use HEI ignition. The C240 material identifies PE4A inline injection pumps on pre-April 1990 trucks and distinguishes later PE4A and VE rotary-pump applications; PE4A uses a pneumatic governor and VE uses a mechanical governor. Injection timing, bleeding, testing, and external service are covered, but internal injection-pump and injector overhaul is left to a properly equipped diesel service facility.

For deeper C240 repair, the manual identifies a cylinder-liner remover (P/N 320901), special shaft (P/N 320902), installation tool (P/N 320903), and camshaft-bearing tool (P/N 320905). The GM 4-181 and Isuzu 4JB1 appear in model-specific specification and maintenance data, but this set does not contain dedicated internal engine-overhaul chapters for those engines.

Drivetrain, Brake, and Hydraulic Depth

The transmission chapters cover the Hyster T43 used on late A177 trucks and all B177/C177 trucks. They include converter, pump, clutch-pack, control-valve, and differential repair, followed by linkage adjustment, neutral-start-switch checks, stall testing, pressure testing, and troubleshooting. Warner-transmission schematics are included, but the supplied internal overhaul chapter is for the T43.

Brake coverage includes the master cylinder, shoes, wheel cylinders, pedal linkage, booster arrangements, parking brake, bleeding, adjustment, and brake/inching synchronization. The repair notes flag two costly errors: damaging a forward or reverse clutch-piston lip seal can require complete transmission disassembly, while incorrect master-cylinder pushrod free play can block the compensator port and keep the brakes applied.

The gear-pump and main-control-valve sections cover removal, disassembly, cleaning, inspection, reassembly, pressure and flow checks, and fault isolation. Separate lift-cylinder, tilt-cylinder, steering-axle, steering-cylinder, and steering-control-unit sections support resealing, bearing adjustment, bleeding, synchronization, and operational checks.

Mast, Frame, and Diagram Coverage

Standard upright and Vista mast files cover carriage and mast removal, two-stage and three-stage disassembly and reassembly, chain and sheave inspection, load-roller and shim setup, header-hose rollers, side-shift carriage equipment, sequence valves, leak checks, tilt-cylinder checks, and final mast adjustments.

The 20-page Diagrams section contains 12 numbered figures: five hydraulic/transmission references and seven electrical, cable, or instrument-panel diagrams. Examples include the Hydraulic System Schematic—Warner Transmission, Hydraulic System Schematic—Hyster T41/T42/T43, Transmission Hydraulic Schematic—Hyster T41/T42/T43, Gasoline/LPG (Safety) Engine Wiring Diagram, Diesel (Safety) Engine Wiring Diagram, and Electrical Diagram, Instrument Panel.

Several shared SRM sections also cover other Hyster product families. Match the truck serial code, engine, transmission, mast, and production arrangement before choosing a procedure or ordering parts. Before mast, cylinder, brake, or engine-removal work, lower and mechanically secure raised components, relieve hydraulic pressure, isolate electrical power, use correctly rated lifting equipment, and wear appropriate personal protective equipment.