Hyster a177 (h2.50 xl europe) forklift service repair manual

SERVICE REPAIR
H2.00XL H2.50XL H3.00XL Europe [A177]

1
LIFT TRUCK WEIGHTS*
Unit Kilograms Pounds
H2.00XL (H40XL) 3515 7750
H2.50XL (H50XL) 3855 8500
H3.00 (H60XL) 4315 9510
*Lift trucks equipped with overhead guard, mast, carriage, load backrest extension, forks, gasoline engine and
operator.
H2,00–2.50XL (H40–50XL) with 3760 mm (148 in) two–stage mast.
H3.00XL (H60XL) with 3600 mm (142 in) two–stage mast.
ENGINE SPECIFICATIONS
Engine Mazda M4–121G
(A177, B177, C177)*
GM 4–181
(C177)*
Isuzu C240
(A177, B177, C177)*
Isuzu 4JB1
(C177)*
No. of Cylinders
Firing Order
Bore and Stroke
Displacement
Compression
Ratio
Compression
Pressure
4
1–3–4–2
82 mm x 94 mm
(3.23 in x3.70 in)
1985 cm3 (121.1 in3)
8.0:1 (A177)
8.6:1 (B177, C177)
1075 kPa (156 psi)
@ 200 rom
4
1–3–4–2
102 mm x 91 mm
(4.00 in x 3.60 in)
2966 cm3 (181 in3)
8.0:1
758 kPa (110 psi)
@ 200 rpm
4
1–3–4–2
86 mm x 102 mm
(3.39 in x 4.02 in)
2369 cm3 (144.5 in3)
20.0:1
3040 kPa (441 psi)
@ 200 rpm
4
1–3–4–2
93 mm x 102 mm
(3.67 in x 4.02 in)
2771 cm3 (169 in3)
18.2:1
3040 kPa (441 psi)
@ 200 rpm
Oil Pressure
Ignition Timing
Valve Clearance
(Inlet and
Exhaust)
Idle Speed
Governor Speed
@ No Load
Stall Speed**
Gasoline
LPG
450 kPa (65 psi)
minimum @3000 rpm
13° BTDC @625 rpm
0.3 mm (0.012 in)
Hot
600 to 650 rpm
3000 to 3100 rpm
2000 to 2100 rpm
1950 to 2050 rpm
138 kPa (20 psi)
minimum @1200 rpm
0° BTDC @500 rpm
One turn down from
zero clearance
560 to 600 rpm
2700 to 2800 rpm
2150 to 2250 rpm
2100 to 2200 rpm
390 kPa (57 psi)
minimum @1000 rpm
Not Applicable
0.45 mm (0.018 in)
Cold
600 to 650 rpm
3000 to 3100 rpm
2050 to 2150 rpm
(Diesel)
294 kPa (43 psi)
minimum @2000 rpm
Not Applicable
0.40 mm (0.016 in)
Cold
750 to 800 rpm
2250 to 2350 rpm
1955–2055 rpm
(Diesel)
Thermostat
Range
Cooling System
Pressure
Fuel Injector
Pressure
Fuel Injection
Timing
75 to 78°C
(167 to 172°F)
103 kPa (15 psi)
Not Applicable
Not Applicable
82°C (180°F)
88 kPa (13 psi)
Not Applicable
Not Applicable
75 to 78°C
(167 to 172°F)
103 kPa (15 psi)
1195 MPa (1706 psi)
14° BTDC Static
75 to 78°C
(167 to 172°F)
103 kPa (15 psi)
1814 MPa (2630 psi)
16° BTDC Static
*Lift truck serial number code
**Engines with 50 hours or more of operation
♦With initial timing connector disconnected

2
ENGINE ELECTRICAL SPECIFICATIONS
Item Mazda M4–121G
(A177, B177, C177)*
GM 4–181
(C177)*
Isuzu C240
(A177, B177, C177)*
Isuzu 4JB1
(C177)*
All Models
Alternator Output
(hot)
Distributor Points
A177 Only
Spark Plug Type
Gap
12 volt
Negative Ground
35 amps (A177) or
56 amps (B/C177)
@3000 rpm
0.4 to 0.5 mm (0.016
to 0.020 in)
NGK BP–2E or
ND W9EPR
0.7 to 0.8 mm
(0.028 to 0.032 in)
12 volt
Negative Ground
56 amps @2750 rpm
Electronic ignition
system
AC R46TS or
Champion RBL 17Y
1.1 mm (0.045 in)
12 volt
Negative Ground
56 amps @3000 rpm
Not Applicable
Not Applicable
Not Applicable
12 volt
Negative Ground
56 amps @2350 rpm
Not Applicable
Not Applicable
Not Applicable
HYDRAULIC SPECIFICATIONS
Item Specification
Pump Type
Main Flow (to Lift, Tilt, and Attachments)
A177** @ 2000 rpm with no load
B177** @ 2000 rpm with no load
C177** @ 2000 rpm with no load,
Mazda or Isuzu Engines
GM 4–181 Engine
**Lift truck serial number code
Controlled Flow (to Steering, all units)
Gear Pump with Flow Control Valve
32.9 litres per minute (8.7 gallons per minute)
6.4 litres/minute (1.7 gallons per minute)
Relief Pressure, Lift System
Control valve with three spools and one relief
valve
Control valves with four spools and two relief
valves:
Primary relief valve
Secondary relief valve
19.3 to 20.0 MPa (2800 to 2900 psi) at full flow
(Check at inlet line to control valve port.)
(Check at inlet line to control valve port with lift spool in full
Lift position.)
(Check at inlet line to control valve port with tilt spool in full
Tilt position.)
Relief Pressure, Steering System, all units 10.3 to 11.0 MPa (1435 to 1552 psi) @ 1000 rpm
Capacity, Hydraulic System 35.0 litre (9.2 gallons)
Capacity, Hydraulic Tank 31.8 litre (8.4 gallons)
Hydraulic System Hydraulic oil temperature at 55 to 65°C (130 to 150°F).
Hydraulic oil with different viscosity will change “flow” values.

3
CAPACITIES
Item Quantity
Engine Oil, Mazda M4–121G
Engine Oil, GM 4–181
Engine Oil, Isuzu C240
Engine Oil, Isuzu 4JB1
5.2 litre (5.5 qt)
4.3 litre (4.5 qt)
5.2 litre (5.5 qt)
6.5 litre (6.9 qt)
Cooling System, Mazda M4–121G
Cooling System, GM 4–181
Cooling System, Isuzu C240
Cooling System, Isuzu 4JB1
11.1 litre (11.7 qt)
11.0 litre (11.6 qt)
11.4 litre (12.0 qt)
11.0 litre (11.6 qt)
Transmission 9.0 litre (9.5 qt)
Differential 7.6 litre (8.0 qt)
Fuel Tank 43.5 litre (11.5 gallons)
Brake Fluid 0.2 litre (0.5 pint)
LIFT TRUCK TRAVEL SPEEDS
Unit Forward Reverse
H2.00XL (H40XL) 19.5 km/hr (12.1 mph) 19.5 km/hr (12.1 mph)
H2.50XL (H50XL) 19.5 km/hr (12.1 mph) 19.5 km/hr (12.1 mph)
H3.00 (H60XL) 21.4 km/hr (13.3 mph) 21.4 km/hr (13.3 mph)
TIRE SPECIFICATIONS
Steering Tires 6.00 x 9, 10 ply All Tire Pressures are 860 kPa (125 psi)
Steering Tires 7.00 x 12, 12 ply
Drive Tires 29 x 8 – 15, 12 ply
Drive Tires 28 x 9 – 15, 12 ply

4
MAST SPEEDS (Early A177* Units)
STANDARD MAST
Unit Lifting Lowering
NO LOAD RATED LOAD NO LOAD RATED LOAD
m/sec ft/min m/sec ft/min m/sec ft/min m/sec ft/min
H2.00–2.50XL (H40–50XL) 0.50 98 0.46 90 0.55 109 0.55 109
H3.00XL (H60XL) 0.42 82 0.38 74 0.47 92 0.47 92
VISTA TWO–STAGE MAST
H2.00–2.50XL (H40–50XL) 0.47 93 0.43 85 0.55 109 0.58 115
H3.00XL (H60XL) 0.37 82 0.34 74 0.47 92 0.47 92
VISTA THREE–STAGE MAST
H2.00–2.50XL (H40–50XL) 0.47 92 0.43 84 0.52 102 0.52 102
H3.00XL (H60XL) 0.40 78 0.35 69 0.44 86 0.44 86
MAST SPEEDS (Later A177* Units)
VISTA FREE–LIFT MAST
H2.00–2.50XL (H40–50XL) 0.40 79 0.37 74 0.41 81 0.49 96
H3.00XL (H60XL) 0.40 79 0.35 69 0.41 81 0.48 94
H2.00–2.50XL (H40–50XL) 0.42 83 0.37 74 0.45 89 0.46 91
H3.00XL (H60XL) 0.42 83 0.35 69 0.45 89 0.49 96
H2.00–2.50XL (H40–50XL) 0.40 79 0.37 74 0.43 85 0.45 89
H3.00XL (H60XL) 0.40 79 0.35 69 0.43 85 0.46 91

5
MAST SPEEDS
(B177* and C177* with Mazda M4–121G or Isuzu 240 Engines)
H2.00–2.50XL (H40–50XL) 0.45 98 0.41 81 0.39 77 0.49 96
H3.00XL (H60XL) 0.42 82 0.38 74 0.47 92 0.47 92
H2.00–2.50XL (H40–50XL) 0.47 93 0.43 85 0.42 83 0.47 92
H3.00XL (H60XL) 0.47 93 0.40 79 0.42 83 0.52 102
H2.00–2.50XL (H40–50XL) 0.45 89 0.41 81 0.41 81 0.46 91
H3.00XL (H60XL) 0.45 89 0.38 75 0.41 81 0.49 96
MAST SPEEDS (C177* with GM 4–181 or Isuzu 4JB1 Engines)
H2.00–2.50XL (H40–50XL) 0.51 100 0.48 94 0.41 81 0.49 96
H3.00XL (H60XL) 0.51 100 0.48 94 0.41 81 0.48 94
H2.00–2.50XL (H40–50XL) 0.53 104 0.50 98 0.45 89 0.46 91
H3.00XL (H60XL) 0.53 104 0.50 98 0.45 89 0.49 96
H2.00–2.50XL (H40–50XL) 0.51 100 0.48 94 0.43 85 0.45 89
H3.00XL (H60XL) 0.51 100 0.48 94 0.43 85 0.46 91

6
NOTES:
For HYSTER transmissions only.
All pressures are measured at 2000 rpm with oil temperature
at 50°C (130°F).
The difference in the Forward and Reverse clutch pressures
must not be more than 70 kPa (10 psi).
TEST PORT 1 – PRESSURE FROM TRANSMISSION PUMP
TEST PORT 2 – PRESSURE TO FORWARD CLUTCH
TEST PORT 3 – PRESSURE TO REVERSE CLUTCH
TEST PORT 4 – OIL PRESSURE TO TORQUE CONVERTER
TEST PORT 5 – OIL PRESSURE FROM OIL COOLER
TEST PORT 6 – MODULATOR PRESSURE
*On some T43 transmissions and on T42 transmissions before
serial number T42M 3040 (and one unit T42M 3068) test
ports 3 and 5 are reversed.
11166
kPa
(psi)
965 to 1170
(140 to 170)
724 to 860
(105 to 125)
724 to 860
(105 to 125)
724 to 860
(105 to 125)
105 to 175
(15 to 25)
PORT 6
Modulator
Pressure
PORT 5
Lubrication
Pressure
PORT 4
Torque
Converter
PORT 3
Reverse
Clutch
PORT 2
Forward
Clutch
PORT 1
Transmission
Pump
Pressure
Variation
Pressure
4
1
6 3*
5*
2
TRANSMISSION PRESSURES
NOTES:
For early (horizontal oil filter) transmissions only.
All pressures are measured at 2000 rpm with oil temperature
at 50°C (130°F).
TEST PORT 1 – MAIN REGULATOR
TEST PORT 2 – TORQUE CONVERTER REGULATOR
TEST PORT 3 – OIL COOLER
TEST PORT 4 – FORWARD CLUTCH PRESSURE
TEST PORT 5 – REVERSE CLUTCH PRESSURE
6. TORQUE CONVERTER REGULATOR
kPa
(psi)
985 to 1103
(140 to 160)
758 to 896
(110 to 130)
345 to 383
(50 to 70)
655 to 793
(95 to 115)
655 to 793
(95 to 115)
PORT 5
Reverse
Clutch
PORT 4
Forward
Clutch
PORT 3
Oil
Cooler In
PORT 2
Torque
Converter
PORT 1
Main
Regulator
Pressure
4
6
2
3
1 5
TRANSMISSION PRESSURES

7
TORQUE SPECIFICATIONS
Item Specification
ENGINE (MAZDA M4–121G)
Motor mount to engine
(upper capscrews are Grade 5)
(lower capscrews are Grade 8)
Motor mount bolts
See the torque specifications in the
Service Manual section for this engine.
56 N.m (41 lbf ft)
81 N.m (60 lbf ft)
53 N.m (39 lbf ft)
ENGINE (GM 4–181)
Motor mount bolts
Service Manual section for this engine .
53 N.m (39 lbf ft)
ENGINE (ISUZU C240)
Motor mount to engine (short capscrews)
Motor mount to engine (long capscrews)
Motor mount bolts
55 N.m (40 lbf ft)
40 N.m (30 lbf ft)
53 N.m (39 lbf ft)
ENGINE (ISUZU 4JB1)
Motor mount bolts
55 N.m (40 lbf ft)
178 N.m (130 lbf ft)
TRANSMISSION
Drive plate to torque converter
Torque converter housing to engine
Torque converter housing to transmission
3/8 inch capscrews
7/16 inch capscrews
Differential housing to transmission
See the torque specifications in the Ser-
vice Manual section for the transmission.
45 N.m (33 lbf ft)
38 N.m (28 lbf ft)
37 to 43 N.m (27 to 32 lbf ft)
57 to 68 N.m (42 to 50 lbf ft)
38 N.m (28 lbf ft)
HYDRAULIC PUMP
Acorn nut for adjustment screw
Plug for relief valve
Plug for regulator valve
Capscrews for pump body
28 to 31 N.m (20 to 23 lbf ft)
34 to 39 N.m (25 to 29 lbf ft)
59 to 69 N.m (43 to 51 lbf ft)
46 to 49 N.m (34 to 36 lbf ft)
HYDRAULIC CONTROL VALVE
Through bolts, 5/16 inch
Through bolts, 3/8 inch
19 N.m (14 lbf ft)
45 N.m (33 lbf ft)

8
TORQUE SPECIFICATIONS
Item Specification
BRAKES See the torque specifications in the
Service Manual section for the brakes.
DRIVE AXLE See the torque specifications in the
Service Manual section for the drive axle.
STEERING AXLE See the torque specifications in the
Service Manual section for the steering
axle.
Rod end capscrews, Tilt cylinders 77 N.m (57 lbf ft)
Mast, bolts for hanger caps 165 N.m (122 lbf ft)
Counterweight capscrews 320 N.m (235 lbf ft)

1
INTRODUCTION
GENERAL
This section has a description and the service proce-
dures for the brake system. The parts of the brake sys-
tem include the master cylinder, the brake shoes, wheel
cylinders, pedals and linkage, and the parking brake
system. Troubleshooting is included at the end of this
section.
DESCRIPTION AND OPERATION
The master cylinder has a housing, a piston with two
ring cups, a return spring and a check valve assembly.
The reservoir for the fluid is separate from the master
cylinder. When the brake pedal or inching pedal is
pushed, the push rod moves the piston assembly. The
primary cup forces the brake fluid through the check
valve to the wheel cylinders. The secondary cup keeps
the fluid that is above the primary cup in the master
cylinder.
When the brake pedal is released, the return spring
pushes the piston assembly back against the retainer
washer. The return springs for the brake shoes force the
fluid that is in the wheel cylinders back through the
lines to the check valve. The pressure in the lines
moves the check valve from its seat. The fluid flows
around the check valve to the master cylinder bore.
When the brake pedal is released quickly, the return
spring moves the piston faster than the brake fluid can
flow around the check valve. To prevent cavitation,
holes are drilled in the piston. Fluid from the inlet port
flows through the holes. The fluid bends the lip of the
primary cup and permits fluid to enter the pressure
chamber.
The check valve assembly permits fluid from the pres-
sure chamber to flow to the lines when the brake pedal
is pushed. When the pressure in the pressure chamber
is greater than pressure in the lines, the check valve
will open. When the brake pedal is released, the pres-
sure in the lines is greater than the pressure in the pres-
sure chamber. The check valve assembly then moves
against the spring pressure to permit fluid to return to
the pressure chamber. The check valve assembly re-
turns to its seat when the pressure in the lines decreases
to less than the spring pressure. This action keeps a low
pressure in the wheel cylinders to hold the lips of the
seals against the bores. This low pressure prevents
leaks, but cannot apply the brake shoes.
A very small hole is drilled between the inlet port and
the pressure chamber. The hole is just below the prima-
ry cup when the piston is against the stop washer. The
hole is a compensator port to permit fluid to flow be-
tween the reservoir and the pressure chamber. The
fluid expands because of the heat from using the
brakes. The additional volume of the expanded fluid
flows through the compensator port when the pedal is
fully released. If the push rod is adjusted so that there is
no clearance, the compensator port can be closed by
the primary cup. This condition can cause the brakes to
be applied without pushing the pedal.
A service brake assembly is installed at each end of the
drive axle. The parts of the brake assembly are shown
in FIGURE 2. When the brake pedal is pushed, fluid
pressure from the master cylinder causes the pistons in
the wheel cylinder to move out. The pistons cause the
brake shoes to expand against the drum.
The parking brake system uses the service brake shoes.
Additional linkage activates the parking brake system
when the lever for the parking brake is pulled. When
the lever for the parking brake is pulled, the cables
cause the cranks to rotate. This rotation causes the
cable guide to pull on the cable that is connected to the
levers for the brake shoes. The levers push the brake
shoes against the brake drum. The design of the system

2
permits the tension of each cable to be the same when
the lever is pulled.
FIGURE 1. MASTER CYLINDER
9671
1. PUSH ROD
2. RETAINER
WASHER/SNAP RING
3. SECONDARY CUP
4. BODY
5. PISTON
6. PRIMARY CUP
7. RETAINER
8. SPRING
9. PRESSURE CHAMBER
10. CHECK VALVE ASSEMBLY
11. COMPENSATOR PORT
12. FITTING
13. INLET PORT
FIGURE 2. PARTS OF THE
BRAKE ASSEMBLY
9524
1. WHEEL CYLINDER
2. RETURN SPRING
3. PIVOT PLATE
4. LINK
5. PIN
6. ACTUATOR FOR ADJUSTER WHEEL
7. ADJUSTER WHEEL
8. ADJUSTER NUT
9. CABLE
10. RETAINER
11. LEVERS FOR PARKING BRAKE
12. LINING FOR BRAKE SHOE
13. BRAKE SHOE
14. ANCHOR (SPECIAL CAPSCREW)
The clearance between the brake shoes and the brake
drum is adjusted automatically. The adjuster linkage
turns the adjuster wheel to adjust the clearance. The
primary (front) shoe and the adjuster links move with
the drum during a stop when the lift truck is moving in
the reverse direction. The linkage permits the adjuster
lever to rotate the adjuster wheel. The adjuster wheel
can turn only when there is clearance between the lin-
ing and the brake drum. The adjuster wheel can also be
turned manually. A hole in the drum is used to get ac-
cess to the adjuster wheel.

3
REPAIRS
REMOVAL AND DISASSEMBLY
Service and Parking Brakes
(See FIGURE 3. and FIGURE 4.)
WARNING
Brake linings contain dangerous fibers. Breathing
the dust from these brake linings can be a cancer or
lung disease hazard. Do not create dust! Do not clean
brake parts with compressed air or by brushing. Use
vacuum equipment approved for dangerous fibers
or follow the cleaning procedure in this section.
When the brake drums are removed, do not create
dust.
Do not sand, grind, chisel, hammer or change linings
in any way that will create dust. Any changes to
brake linings must be done in a restricted area with
special ventilation.Protectiveclothingandarespira-
tor must be used.
1. Remove the capscrews that hold the axle shaft to the
hub. Remove the axle shaft.
2. Start the engine and tilt the masts fully back. Put
blocks under the masts. Tilt the masts forward until the
wheels just touch the floor. Stop the engine. Put blocks
under the lift truck frame.
3. Bend the lock plate and remove the nut that holds the
axle bearing. Remove the washer and the bearing cone.
4. Put grease on the floor so that the wheel assembly
will slide easily from the axle tube. Pull the wheel as-
sembly from the lift truck.
5. If the wheel assembly cannot be removed easily, re-
move the wheel from the hub. Align the hole in the
brake drum with the adjuster wheel. Pull the adjuster
plate away from the adjuster wheel. Use a screwdriver
to turn the adjuster wheel to loosen the brake shoes.
Turn the adjuster wheel upward. Remove the hub and
drum assembly. Do not damage the seal when remov-
ing the hub.
CAUTION
The return springs are not the same. Make sure that
the return springs are installed in the same positions
from which they were removed. See FIGURE 3.
6. Remove the return springs with spring pliers.
FIGURE 3. BRAKE ASSEMBLY
9520
1
1
1. RETURN SPRING
CAUTION
The adjuster screw assemblies are not the same.
Make sure that each assembly has identification for
installation on the correct side of the axle.
7. Remove the spring assemblies that hold the brake
shoes to the back plate. Remove the brake shoes and
adjuster assembly.
8. Remove the brake line from the wheel cylinder. Re-
move the capscrews that hold the back plate to the axle
housing.
9. Remove the boots, pistons, cups and springs from
the wheel cylinder.
10. Remove the snap rings from the parking brake le-
vers. Remove the parking brake levers from the back
plate.

4
Master Cylinder
1. Remove the pin from the clevis for the push rod.
CAUTION
Brake fluid damages paint. Immediately removeany
brake fluid that is on a painted surface.
2. Disconnect the special capscrews from the fitting at
the bottom of the master cylinder.
3. Remove the hose from the nipple. Put a plug in the
hose to prevent the reservoir from draining.
4. Remove the capscrews and nuts that hold the master
cylinder to the bracket. Remove the master cylinder
from the lift truck.
5. Remove the rubber dust shield and push rod. Put the
bottom of the master cylinder in a container. Push on
the piston with a screwdriver to remove the brake fluid.
FIGURE 4. BRAKE SYSTEM PARTS
1. SNAP RING
2. PIN
3. BACK PLATE
4. CABLE
5. CABLE GUIDE
6. SPECIAL CAPSCREW
7. CAPSCREWS
8. PARKING BRAKE LEVER
9. WHEEL CYLINDER
10. PIVOT PIN
11. BRAKE SHOE
12. PIVOT PLATE
13. RETURN SPRING
14. RETURN SPRING
15. SPECIAL CAPSCREW
16. LINK
17. LINK
18. RETAINER SPRING ASSEMBLY
19. BRAKE SHOE
20. SPRING
21. ADJUSTER NUT
22. ADJUSTER WHEEL
23. ACTUATOR

5
WARNING
The piston has a compressed spring behind it. Care-
fully remove the piston so that you can control the
spring and prevent an injury.
6. Put the master cylinder in a vise with soft jaws. Push
on the piston with a screwdriver to release the tension
on the snap ring. Remove the snap ring, washer and
piston.
7. Remove the spring and the check valve.
CLEANING AND INSPECTION
CAUTION
Do not use an oil solvent to clean the wheel cylinder.
Use a solvent approved for cleaning of brake parts.
Do not permit oil or grease in the brake fluid or on
the brake linings.
WARNING
Cleaning solvents can be flammable and toxic, and
can cause skin irritation. When using cleaning sol-
vents, always follow the safety instructions of the sol-
vent manufacturer.
1. Do not release brake lining dust from the brake lin-
ings into the air when the brake drum is removed.
2. Use a solvent approved for cleaning of brake parts to
wet the brake lining dust. Follow the instructions and
cautions of the manufacturer for the use of the solvent.
If a solvent spray is used, spray at a distance so that the
dust is not released into the air.
3. When the brake lining dust is wet, clean the parts.
Put any rags or towels in a plastic bag or an airtight
container while they are still wet. Put a “DANGER-
OUS FIBERS” warning label on the plastic bag or air-
tight container.
4. Any cleaning rags that will be washed must be
cleaned so that fibers are not released into the air.
CAUTION
Donotpermitoilorgreaseonthebrakelinings.Usea
brakecleaningfluidasnecessarytocleanliningsthat
will not be replaced.
Inspection procedures:
WARNING
Cleaning solvents can be flammable and toxic, and
can cause skin irritation. When using cleaning
solvents, always follow the recommendations of the
manufacturer.
a. Clean all metal parts except the linings and the
wheel cylinder with solvent.
b. Check the bore of the wheel cylinder for holes or
scratches. Replace the wheel cylinder if there is
any damage.
c. Check the bore of the master cylinder and the
matching surfaces of the piston. Replace a master
cylinder that has been damaged.
d. Check the return springs for damage. Inspect the
back plate for wear where the brake shoes touch
the back plate.
e. Inspect the brake shoes for cracks or damage. If
the linings or shoes are worn or damaged, replace
the brake shoes. It is recommended that brake
shoes be replaced in complete sets.
f. Check the adjuster screw wheel for wear. Make
sure the adjuster screw turns. Check for bent or
broken adjuster links.
g. Inspect the brake drums for cracks or damage.
Use sandpaper on the surface for the brake shoes.
h. Make sure that the levers and cranks for the park-
ing brake move freely.
NOTE: If the brake drums require grinding, do not
grind more than 1.5 mm (0.060 in) from the diameter.
The maximum inside diameter of the brake drum, in-
cluding wear, is 262.7 mm (10.35 in). If the brake drum
is larger than this, replace the brake drum.
ASSEMBLY AND INSTALLATION
Service and Parking Brakes
1. Assemble the wheel cylinder according to
FIGURE 5. Use only HYSTER Approved Parts.

6
FIGURE 5. WHEEL CYLINDER
1025
1. PORT FOR SPECIAL FITTING
2. INLET PORT
3. BRAKE SHOE
4. BOOT
5. WHEEL CYLINDER
6. SPRING
7. CUP
8. PISTON ASSEMBLY
2. Install the wheel cylinder on the back plate. Make
sure that the special fitting for removing the air is in the
top hole. Apply adhesive–sealant (Hyster Part Number
264134) to the threads of the capscrews. Tighten the
two capscrews that are near the top of the wheel cylin-
der to 80 to 85 Nm (59 to 63 lbf ft). Tighten the two
larger capscrews to 80 to 102 Nm (59 to 75 lbf ft).
3. Put the pins that hold the brake shoes through the back
plate. See FIGURE 6. Install the shield and back plate
on the axle housing. Apply adhesive–sealant (Hyster
Part Number 264134) to the threads of the three special
capscrews (FIGURE 4., Items 6 and 15). Install the two
special capscrews (6) for the parking brake levers. See
SPECIFICATIONS for the correct torque. Install all the
othercapscrewsthatholdthebackplatetotheaxlehous-
ing. The special capscrew that is the anchor pin
(FIGURE 7.) has a different torque value. See SPECI-
FICATIONS for the correct torque.
4. Install the parking brake levers and cable. Install the
snap rings. Install the cable guide and snap ring on the
crank for the parking brake.
CAUTION
The upper link for the left brake assembly is not the
same as the upper link for the right brake assembly.
Install the pivot plate so that the letter “L” is seen on
the left brake assembly. Install the pivot plate on the
right brake assembly so that the letter “R” is seen.
FIGURE 6. INSTALL THE PINS
9517
5. Install the pivot pin through the brake shoe that is
toward the rear of the lift truck. Install the links in the
pivot plate. Install the pivot plate, links and cotter pin.
6. Lubricate the back plate with a small amount of
white grease where the shoes touch. Install the brake
shoes. Put a spring seat, spring and retainer on the pin.
See FIGURE 8. Push on the retainer and rotate the re-

7
tainer 90 degrees. Make sure that the retainer is in the
correct position. Install the other spring assembly.
FIGURE 7. INSTALL THE ANCHOR PIN
9516
FIGURE 8. INSTALL THE
RETAINER SPRING ASSEMBLY
9521
7. Put an anti–seize compound on the threads of the ad-
juster wheel. Install the adjuster wheel assembly be-
tween the two brake shoes. Make sure that the adjuster
wheel is toward the rear of the lift truck.
NOTE: The adjuster screw wheels have left–hand and
right–hand threads. Make sure that the movement of the
automaticadjusterlevercausestheadjusterscrewwheel
to expand the brake shoes.
Turn the adjuster wheel into the adjuster nut so that the
adjuster assembly is in its shortest position. This action
permits the brake drum to be easily installed over the
brake shoes.
8. Install the link in the adjuster wheel actuator. Put the
adjuster wheel actuator in the hole in the brake shoe.
Install the spring to the adjuster wheel actuator and the
brake shoe. The spring must be installed in the position
shown in FIGURE 9. Install the return springs for the
brake shoes. Make sure the return springs are installed
in the correct positions. See FIGURE 9. A grey spring
is installed on the front shoe on the right side of the lift
truck. A gray spring is installed on the rear shoe on the
left–hand brake assembly.
9. Make sure that the bottom edge of the adjuster wheel
actuator (6) is just above the horizontal centerline of
the adjuster wheel and nut (7). See FIGURE 9. Bend
the lower link (4) to align the adjuster wheel actuator if
necessary.
10. Clean the bearings and lubricate them with grease
for wheel bearings. Install the bearings and seals in the
hub. Install the assembly on the axle housing. See
FIGURE 10. and FIGURE 11.
NOTE: To prevent damage to the inner oil seal when in-
stalling the hub, the hub and drum assembly can be tem-
porarily fastened to the wheel. Align the height of the
axle housing with the bearings in the hub. Put grease un-
der the wheel and slide the wheel toward the axle hous-
ing. Install the outer bearing and nut. Remove the wheel
from the hub so that the clearance of the brake shoes can
be adjusted.
11. Adjust the wheel bearings by tightening the nut to
205 Nm (150 lbf ft) while rotating the hub. Loosen the
nut until the hub turns freely. The torque must be less
than 27 Nm (20 lbf ft). Tighten the nut to 34 Nm (25 lbf
ft) or until the first alignment position after 34 Nm (25
lbf ft). Bend the lock plate over the nut.
12. Adjust the clearance of the brake shoes. Put a
screwdriver through the hole in the drum. Move the
screwdriver so that the teeth of the adjuster wheel
move downward. Turn the adjuster wheel until the
brake drum will not rotate. Move the actuator away
from the adjuster wheel. Turn the adjuster wheel up-
ward 15 teeth to loosen the brake shoes. The brakes
will adjust to the correct clearance when they are
applied as the lift truck travels in the reverse direction.

8
WARNING
The brakes and the automatic adjusters cannot op-
erate if the clearance between the shoes and drum is
too large. A clearance that is too small can cause rap-
idwearoftheadjusterwheel.Thisconditioncanpre-
vent automatic adjustment of the brakes.
FIGURE 9. INSTALLATION OF THE SPRINGS
9524
1. SPRING FOR SECONDARY SHOE
2. SPRING FOR PRIMARY (FRONT) SHOE
3. UPPER LINK
4. LOWER LINK
5. GRAY
6. ADJUSTER WHEEL ACTUATOR
7. ADJUSTER WHEEL AND NUT
RIGHT SIDE FRONT
LEFT SIDE
FRONT
6
7

9
FIGURE 10. LOCATION OF
THE GREASE SEALS
9519
NOTE: Units from later production
have a one–piece hub and brake drum.
1. OUTER SEAL
2. INNER SEAL
3. BRAKE DRUM
FIGURE 11. INSTALL THE INNER
GREASE SEAL
9518
13. Put sealant on the flange of the axle shaft. Install
the axle shaft and capscrews. Tighten the capscrews to
98 Nm (72 lbf ft).
14. Install the cranks that actuate the brakes for park-
ing. The correct position of the crank (1) when the
parking brake lever is released is shown in
FIGURE 12. Connect the cables to the cranks.
15. Remove the air from the brake hydraulic system.
See REMOVE THE AIR FROM THE BRAKE SYS-
TEM in this section.
FIGURE 12. ADJUST THE CRANKS
FOR THE PARKING BRAKE
40° to 60° in
released position
0° to 20° in
released position
1. CRANK
2. PIN
3. CLEVIS
12607
4. CABLE
5. VERTICAL REFERENCE
H2.00–3.00XL (H40–60XL)
S2.00–3.00XL (S40–60XL)
16. Install the wheel on the hub. Tighten the nuts:
S2.00–3.00XL (S40–60XL), 270 Nm (200 lbf ft)
H2.00–3.00XL (H40–60XL), 610 to 680 Nm
(450 to 500 lbf ft)

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17. Start the engine and tilt the masts back to remove
the blocks. Push on the brake pedal. The pedal must
not touch the floor plate. Move the lift truck in the re-
verse direction and push on the brake pedal to operate
the adjusting mechanism.
Master Cylinder
1. Lubricate the parts with clean brake fluid. Use only
HYSTER Approved Parts.
2. Install the secondary cup in the piston with the lip
away from the push rod. See FIGURE 13.
3. Install the primary cup and retainer on the piston.
The lip must be toward the spring.
4. Install the new check valve assembly in the bore. Put
the spring and the piston assembly in the bore. Push on
the piston with a screwdriver to allow installation of
the retainer washer and snap ring. Install the retainer
washer and snap ring.
5. Install the push rod and dust boot.
6. Install the master cylinder in the lift truck. Connect
the hose to the reservoir. Adjust the push rod so that the
clearance between the piston and the push rod is 1 mm
(0.04 in). See “Adjust the Brake Pedal and Inching
Pedal”, step 2.
7. To remove the air from the master cylinder, fill the
reservoir with clean brake fluid. Put a container under
the master cylinder and slowly push the brake pedal.
Slowly release the pedal. Repeat this procedure until
brake fluid without bubbles flows from the outlet port.
8. Connect the fitting to the master cylinder. Remove
any air in the system as described in CHECKS AND
ADJUSTMENTS.
FIGURE 13. MASTER CYLINDER PARTS
1. SHIELD
2. SNAP RING
3. RETAINER WASHER
4. SECONDARY CUP
5. PISTON
6. PRIMARY CUP
7. RETAINER
8. SPRING
9. CHECK VALVE ASSEMBLY
CHECKS AND ADJUSTMENTS
ADJUST THE SERVICE BRAKES
Put the lift truck on blocks so that the drive wheels can
be removed. See the section 8000 SRM 259, PERI-
ODIC MAINTENANCE, for the correct procedure.
Remove the drive wheels. Use a screwdriver to adjust
the clearance of the brake shoes. Put the screwdriver
through the hole in the brake drum. Move the screw-
driver so that the teeth of the adjuster wheel move
downward. Turn the adjuster wheel until the brake
drum will not rotate. Move the actuator away from the
teeth of the adjuster wheel. Turn the adjuster wheel up-
ward 15 teeth to loosen the brake shoes.
Install the drive wheels. Remove the lift truck from the
blocks. Operate the lift truck in the forward and reverse

11
directions. Apply the brake pedal to stop the lift truck
10 times in each direction.
ADJUST THE PARKING BRAKE
Make sure that the service brakes are adjusted and that
the operation of the automatic adjuster mechanism is
correct. Test the operation of the parking brake. The
brake must hold the lift truck and a capacity load on a
15% grade [a slope that increases 1.5 metres in 10
metres (1.5 ft increase in 10 ft)]. Turn the knob on the
parking brake lever if a small adjustment is necessary.
Adjust the cranks that actuate the brakes for parking if
more adjustment is necessary. See FIGURE 12. Make
sure that the hand lever is in the released position.
Loosen the knob on the end of the hand lever. Loosen
the bolt and nut for the crank. Move the crank toward
the front of the truck to tighten the cable. Make sure
that the shaft does not rotate when the crank moves.
Tighten the bolt for the crank. Make sure that the posi-
tion of the crank is as shown in FIGURE 12. when the
parking brake is released.
Units with Monotrol Pedal
(See FIGURE 14.)
Lift trucks with a Monotrol pedal have a switch (4) in
the assembly for the parking brake lever. A link (3, ear-
ly production) or cam (5, later production) operates the
switch. The switch closes the circuit for starting the en-
gine and opens the circuit for the Monotrol control
when the parking brake is applied. Check or adjust the
operation of the switch according to one of the follow-
ing procedures.
Early Production:
a. Put the lift truck on blocks so that the drive tires
do not touch the ground. See the section 8000
SRM 259, PERIODIC MAINTENANCE, for
the correct procedure.
b. Release the parking brake. The link (3) must not
actuate the switch (4). Turn the ignition key to the
START position. The engine must not start. Turn
the ignition key to the OFF position.
FIGURE 14. PARKING BRAKE LEVER FOR UNITS WITH MONOTROL PEDAL
1. LEVER, PARKING BRAKE
2. RELEASE LATCH
3. LINK (SWITCH ACTUATOR)
4. NEUTRAL START SWITCH
5. CAM (SWITCH ACTUATOR)
EARLY PRODUCTION LATER PRODUCTION
12663

12
c. Apply the parking brake. The link(3) must move
upward far enough to actuate the switch (4). Turn
the ignition key to the START position. The en-
gine must start. Release the parking brake. The
circuit for the transmission must be energized
(the drive wheels rotate). Turn the ignition key to
the OFF position.
d. Adjust the link by bending the link if the switch
does not operate according to step b. and step c.
The link must actuate the switch when the park-
ing brake is applied. Make sure that the circuit for
the transmission is energized when the parking
brake is released.
Later Production:
a. Put the lift truck on blocks so that the drive tires
do not touch the ground. See the section 8000
SRM 259, PERIODIC MAINTENANCE, for
the correct procedure.
b. Release the parking brake. The cam (5) must ac-
tuate the switch (4). Turn the ignition key to the
START position. The engine must not start. Turn
the ignition key to the OFF position.
c. Apply the parking brake. The cam must fully re-
lease the lever on the switch. Turn the ignition
key to the START position. The engine must
start, but the circuit for the transmission must be
open (drive wheels do not rotate). Release the
parking brake while the engine runs. The circuit
for the transmission must be energized (the drive
wheels rotate).
d. Apply the parking brake while the engine runs.
Push the parking brake lever toward the released
position without using the release latch (2). The
parkingbrakemustremainintheappliedposition
and the transmission must remain in neutral.
e. Inspect the switch for incorrect wiring if the
switch does not operate according to steps b. and
c. Replace the assembly that has the parking
brake lever if it fails the check in step d.
REMOVE THE AIR FROM THE BRAKE
SYSTEM
Before removing the air from the brake system, make
sure the service brakes are adjusted. Fill the master cyl-
inder reservoir with brake fluid. Put one end of a rub-
ber hose on the special fitting of the wheel cylinder. Put
the other end of the hose into a clear container of brake
fluid. Loosen the special fitting one turn. Slowly push
the brake pedal and hold it at the end of its stroke.
Close the special fitting. Repeat the procedure until
there are no bubbles in the container. Check the level of
the brake fluid in the reservoir for the master cylinder
during the procedure. Keep the brake fluid at the cor-
rect level. Repeat the procedure for the other wheel
cylinder. If there is still air in the system, the air must
be removed from the master cylinder. Slowly push on
the brake pedal. Release the pedal slowly. Repeat this
procedure until there are no air bubbles entering the
reservoir.
ADJUST THE BRAKE PEDAL AND
INCHING PEDAL (See FIGURE 15.)
Always check and adjust the brake pedal and the inch-
ing pedal if the control valve was removed for repairs.
NOTE: If the lift truck has been operated for more than
25 hours since the brake shoes were installed, and the
operation of the brakes is normal, continue at Step 1. If
the lift truck has new brake shoes, adjust the brake shoes
before you adjust the pedals. See ADJUST THE SER-
VICE BRAKES in this section.
1. Adjust the pedal stops (5) so that the bottom of each
pedal pad is at Dimension A from the floor plate.
Tighten the jam nuts. Loosen the pedal synchronizer
screw (7) as required to adjust the inching pedal (2).
2. Loosen the jam nut (11) on the push rod (12) for the
master cylinder (13). Turn the push rod (12) clockwise
so that it touches the piston of the master cylinder. Turn
the push rod one–half turn counterclockwise to set the
correct clearance between the push rod and the piston.
Tighten the jam nut.
3. Early Production Only (Note appearance of Item
6, FIGURE 15.). Disconnect the ball joint (3) at the
inching pedal. Loosen the jam nut on the inching spool
(6). Turn the inching spool to adjust the length of the
inching spring to dimension B. Do not tighten the jam
nut on the inching spool.

Hyster a177 (h2.50 xl europe) forklift service repair manual

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Hyster a177 (h2.50 xl europe) forklift service repair manual