&$3$&,7,(6 $1'

63(&,),&$7,216

H1.50-1.75XM (S/H25-35XM)

[C010, D001, D010, E001];

H2.00XMS (S/H40XMS)

[C010, D001, D010, E001]

PART NO. 897590

8000 SRM 546

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!

8000 SRM 546

Electrical System

Engine Specifications

Item

Mazda M4-1.5G*

Mazda M4-2.0G

Mazda M4-2.5D

No. of Cylinders

4

4

4

Firing Order

1-3-4-2

1-3-4-2

1-3-4-2

Bore and Stroke

77 mm × 80 mm

(3.03 in. × 3.15 in.)

86 mm × 86 mm

(3.39 in. × 3.39 in.)

88.9 mm × 101.6 mm

(3.50 in. × 4.00 in.)

Displacement

1489 cm

3

(90.8 in.

3

)

1998 cm

3

(121.9 in.

3

)

2522 cm

3

(153.9 in.

3

)

Compression Ratio

9.0:1

8.6:1

21:1

Compression Pressure

1180 kPa (171 psi)

@ 300 rpm

1131 kPa (164 psi)

@ 270 rpm

2944 kPa (427 psi)

@ 200 rpm

Oil Pressure

226 to 362 kPa

(33 to 53 psi) @ 2400 rpm

226 to 362 kPa

(33 to 53 psi) @ 2400 rpm

390 kPa (57 psi)

minimum @ 1000 rpm

Valve Clearance
(Intake/Exhaust)

0.25 mm (0.010 in.)

Intake

0.3 mm (0.12 in.)

Exhaust

0.3 mm (0.012 in.) Intake

and Exhaust (Cold)

0.45 mm (0.018 in.)

Intake and Exhaust

(Cold)

Idle Speed

725 ±25 rpm

725 ±25 rpm

775 ±25 rpm

Governed Speed @ No
Load

2500 to 2900 rpm

2600 to 2700 rpm

2100 to 2200 rpm

Thermostat Range

82 to 95 C (180 to 203 F)

82 C (180 F)

75 to 78 C (167 to 172 F)

Cooling System Pressure

103 kPa (15 psi)

103 kPa (15 psi)

103 kPa (15 psi)

Fuel Injector Pressure

--

--

13.4 to 13.9 MPa

(1944 to 2016 psi)

Fuel Injection Timing

--

--

0 /TDC Static

*Available in the Far East only.

Electrical System

Item

Mazda M4-1.5G*

Mazda M4-2.0G

Mazda M4-2.5D

All Models

12 volts, negative ground

12 volts, negative ground

12 volts, negative ground

Alternator Output

35 amps

35 amps

40 amps

Ignition Timing

Gasoline
LPG

0 /TDC

10 BTDC

0 /TDC

8 BTDC

--

Spark Plugs

ND W14 EXR-U

ND War EXR-U

--

Spark Plug Clearance

0.8 mm (0.031 in.)

0.8 mm (0.031 in.)

--

*Available in the Far East only.

1

Torque Converter Stall Speeds

8000 SRM 546

Hydraulic System

Item

Specification

Hydraulic Pump

Type
Priority Flow

Gasoline/LPG
Diesel

Gear

45.8 liter/min (12.1 gal/min)
66.6 liter/min (17.6 gal/min)

Relief Pressures

Steering (At Control Valve)
Primary (At Control Valve)
Secondary (At Control Valve)

5.4 to 5.9 MPa (783 to 856 psi)

17.7 to 18.2 MPa (2567 to 2640 psi)
15.7 to 16.2 MPa (2277 to 2350 psi)

All pressures with oil at 55 to 65 C (130 to 150 F) and engine at 2000 rpm.

Lift Truck Weights

Model

kg

lb

H25XM

1870

4125

H1.50XM (H30XM)

2030

4475

H1.75XM (H35XM)

2205

4860

H2.00XMS (H40XMS)

2385

5260

S25XM

1885

4155

S30XM

2060

4545

S35XM

2245

4590

S40XMS

2440

5380

NOTE:

Weight is for complete truck without mast.

Torque Converter Stall Speeds

Engine

Speed

Mazda M4-1.5G*

Gasoline
LPG

1456 to 1656 rpm
1404 to 1604 rpm

Mazda M4-2.0G

Gasoline
LPG

1482 to 1682 rpm
1435 to 1635 rpm

Mazda M4-2.5D

1679 to 1879 rpm

*Available in the Far East only.

2

8000 SRM 546

Capacities

Tire Pressure

Bias Ply Tires

Tire Size

kPa

psi

5.00 × 8, 8 ply

700

100

5.00 × 8, 10 ply

900

130

6.50 × 10, 10 ply

790

115

6.50 × 10, 12 ply

900

130

Capacities

Item

Quantity

Engine Oil (with filter)

Mazda M4-1.5G*
Mazda M4-2.0G
Mazda M4-2.5D

3.7 liter (3.9 qt)
4.3 liter (4.5 qt)
7.9 liter (8.3 qt)

Cooling System

Mazda M4-1.5G*
Mazda M4-2.0G

H25-40XM
S25-40XM

Mazda M4-2.5D

9.1 liter (2.4 gal)

12.0 liter (3.2 gal)
10.8 liter (2.9 gal)
13.8 liter (3.6 gal)

Hydraulic System

H25-40XM
S25-40XM

30 liter (7.9 gal)

19.7 liter (5.20 gal)

Transmission

H25-40XM
S25-40XM

9.2 liter (9.7 qt)
7.5 liter (7.9 qt)

Differential

2.5 liter (2.6 qt)

Fuel Tank

H25-40XM
S25-40XM

30 liter (7.9 gal)
26 liter (6.9 gal)

Brake Fluid

0.3 liter (0.6 pt)

*Available in the Far East only.

3

Mast Speeds

8000 SRM 546

Mast Speeds

MAZDA M4-1.5G ENGINE MAST SPEEDS

Lifting

Lowering

No Load

Rated Load

No Load

Rated Load

Unit

m/sec

ft/min

m/sec

ft/min

m/sec

ft/min

m/sec

ft/min

Two-Stage Limited Free-Lift

H1.50-1.75XM

.54

106

0.51

100

0.45

89

0.54

106

Two-Stage Full Free-Lift

H1.50-1.75XM

.49

96

0.47

93

0.38

75

0.50

98

Three-Stage Full Free-Lift

H1.50-1.75XM

0.51

100

0.49

96

0.39

77

0.51

100

NOTE:

Available in the Far East only.

MAZDA M4-2.0G ENGINE MAST SPEEDS

Lifting

Lowering

No Load

Rated Load

No Load

Rated Load

Unit

m/sec

ft/min

m/sec

ft/min

m/sec

ft/min

m/sec

ft/min

Two-Stage Limited Free-Lift

H1.50-1.75XM,
H2.00XMS
(H25-35XM,
H40XMS)

0.55

108

0.52

102

0.45

89

0.54

106

S25-35XM,
S40XMS

0.55

108

0.53

104

0.47

93

0.51

100

Two-Stage Full Free-Lift

H1.50-1.75XM,
H2.00XMS
(H25-35XM,
H40XMS)

0.50

98

0.48

94

0.38

75

0.50

98

S25-35XM,
S40XMS

0.50

98

0.475

94

0.37

73

0.46

91

Three-Stage Full Free-Lift

H1.50-1.75XM,
H2.00XMS
(H25-35XM,
H40XMS)

0.52

103

0.49

96

0.39

77

0.51

100

S25-35XM,
S40XMS

0.51

100

0.49

96

0.41

81

0.48

94

4

8000 SRM 546

Transmission Oil Pressures

MAZDA M4-2.5D ENGINE MAST SPEEDS

Lifting

Lowering

No Load

Rated Load

No Load

Rated Load

Unit

m/sec

ft/min

m/sec

ft/min

m/sec

ft/min

m/sec

ft/min

Two-Stage Limited Free-Lift

H1.50-1.75XM,
H2.00XMS
(H25-35XM,
H40XMS)

0.65

128

0.64

126

0.45

89

0.54

106

Two-Stage Full Free-Lift

H1.50-1.75XM,
H2.00XMS
(H25-35XM,
H40XMS)

0.60

118

0.58

114

0.38

75

0.50

98

Three-Stage Full Free-Lift

H1.50-1.75XM,
H2.00XMS
(H25-35XM,
H40XMS)

0.62

122

0.60

118

0.39

77

0.51

100

Transmission Oil Pressures

Item

Specification

Test Port No. 1 (Pump Pressure)

1170 to 1470 kPa (170 to 213 psi)

Test Port No. 2 (Torque Converter Inlet)

296 to 685 kPa (43 to 99 psi)

Test Port No. 3 (Clutch Pressure)

1075 to 1370 kPa (156 to 199 psi)

LATER MODEL CONTROL VALVE

5

Torque Specifications

8000 SRM 546

Torque Specifications

BRAKE SYSTEM

Axle Shaft Capscrews

66 N•m (49 lbf ft)

Back Plate to Axle Mount Capscrews

102 N•m (75 lbf ft)

Wheel Nuts (Pneumatic)

204 to 225 N•m (150 to 166 lbf ft)

Wheel Nuts (Cushion)

128.5 N•m (94.8 lbf ft)

Wheel Stud Assembly Nuts

127 N•m (94 lbf ft)

DRIVE AXLE

Axle Mounts to Frame Capscrews

72 N•m (53 lbf ft)

Axle Shaft Capscrews

66 N•m (49 lbf ft)

Back Plate to Axle Mount Capscrews

102 N•m (75 lbf ft)

Wheel Nuts (Pneumatic)

204 to 225 N•m (150 to 166 lbf ft)

Wheel Nuts (Cushion)

128.5 N•m (94.8 lbf ft)

ENGINE - MAZDA M4-1.5G

Camshaft Nut

69 to 79 N•m (51 to 58 lbf ft)

Connecting Rod Cap Nuts

30 to 34 N•m (22 to 25 lbf in)

Crankshaft Pulley

156 to 165 N•m (115 to 122 lbf ft)

Cylinder Head

85 to 91 N•m (63 to 67 lbf ft)

Engine Mount to Engine

41 to 49 N•m (30 to 36 lbf ft)

Exhaust Manifold

19 to 26 N•m (14 to 19 lbf ft)

Flywheel

71 N•m (52 lbf ft)

Flywheel Housing

41 N•m (30 lbf ft)

Front Cover

19 to 26 N•m (14 to 19 lbf in)

Intake Manifold

19 to 26 N•m (14 to 19 lbf ft)

Main Bearing Cap

65 to 69 N•m (48 to 51 lbf ft)

Oil Pan

7 to 9 N•m (5 to 7 lbf ft)

Oil Pump Shaft

30 to 34 N•m (22 to 25 lbf ft)

Spark Plugs

15 to 23 N•m (11 to 17 lbf ft)

Starter

41 N•m (30 lbf ft)

Thermostat Cover

12 to 18 N•m (9 to 13 lbf ft)

Valve Cover

19 to 30 N•m (14 to 22 lbf ft)

Water Pump

19 to 26 N•m (14 to 19 lbf ft)

ENGINE - MAZDA M4-2.0G

Camshaft Pulley Lock Bolt

48 to 66 N•m (35 to 49 lbf ft)

Cooling Fan

8 to 11 N•m (6 to 8 lbf ft)

Connecting Rod Cap

51 to 56 N•m (38 to 41 lbf ft)

Crankshaft Pulley

30 to 33 N•m (22 to 24 lbf ft)

Cylinder Head (Cold)

81 to 88 N•m (60 to 65 lbf ft)

Engine Mount to Engine

41 to 49 N•m (30 to 36 lbf ft)

Engine Mount Capscrew

66 N•m (49 lbf ft)

6

8000 SRM 546

Torque Specifications

Exhaust Manifold

22 to 29 N•m (16 to 21 lbf ft)

Flywheel

96 to 103 N•m (71 to 76 lbf ft)

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 (5 to 9 lbf ft)

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

30 to 40 N•m (22 to 30 lbf ft)

Rocker Shaft Assembly

18 to 27 N•m (13 to 20 lbf ft)

Spark Plugs

15 to 23 N•m (11 to 17 lbf ft)

Starter

66 to 79 N•m (49 to 58 lbf ft)

Thermostat Cover

12 to 18 N•m (9 to 13 lbf ft)

Timing Belt Cover

Upper Capscrews 8 to 12 N•m (6 to 9 lbf ft)
Lower Capscrews 7 to 8 N•m (5 to 6 lbf ft)

Timing Belt Tension Lock Bolt

20 to 35 N•m (15 to 26 lbf ft)

Torque Converter Housing Adapter

M8 Capscrews 21 to 25 N•m (15 to 18 lbf ft)
M14 Capscrews 118 to 142 N•m (87 to 105 lbf ft)

Torque Converter Housing

M10 Capscrews 41 N•m (30 lbf ft)
M12 Capscrews 71 N•m (52 lbf ft)

Water Pump

19 to 26 N•m (14 to 19 lbf ft)

ENGINE - MAZDA M4-2.5D

Camshaft Gear

64 to 95 N•m (47 to 70 lbf ft)

Camshaft Thrust Plate

16 to 24 N•m (12 to 18 lbf ft)

Cooling Fan

16 to 24 N•m (12 to 18 lbf ft)

Connecting Rod Cap

82 to 90 N•m (60 to 66 lbf ft)

Crankshaft Pulley

343 to 392 N•m (253 to 289 lbf ft)

Cylinder Head

118 to 125 N•m (87 to 92 lbf ft)

Engine Mount to Engine

41 to 49 N•m (30 to 36 lbf ft)

Exhaust Manifold

18 to 22 N•m (13 to 16 lbf ft)

Flywheel

206 to 225 N•m (152 to 166 lbf ft)

Glow Plug

10 to 15 N•m (7 to 11 lbf ft)

Injection Pump Drive Gear

40 to 70 N•m (30 to 52 lbf ft)

Intake Manifold

16 to 24 N•m (12 to 18 lbf ft)

Main Bearing Cap

110 to 117 N•m (81 to 86 lbf ft)

Oil Pan

16 to 24 N•m (12 to 18 lbf ft)

Rear Oil Seal

15 to 20 N•m (11 to 15 lbf ft)

Rocker Cover

2.7 to 4.1 N•m (24 to 36 lbf in)

Rocker Shaft Assembly

118 to 125 N•m (87 to 92 lbf ft)

Starter

66 to 79 N•m (49 to 58 lbf ft)

Timing Gear Cover

16 to 24 N•m (12 to 18 lbf ft)

Torque Converter Housing Adapter

43 to 51 N•m (32 to 38 lbf ft)

7

Torque Specifications

8000 SRM 546

Torque Converter Housing

41 N•m (30 lbf ft)

Water Pump

16 to 24 N•m (12 to 18 lbf ft)

FRAME

Counterweight Capscrews

621 to 746 N•m (458 to 550 lbf ft)

MAST

Lift Cylinder Mount Bolts

53 N•m (40 lbf ft)

Mast Pivot Capscrews

90 N•m (66 lbf ft)

STEERING SYSTEM

Axle Mount Capscrews

41 to 49 N•m (30 to 36 lbf ft)

Steering Cylinder Capscrews

294 to 353 N•m (217 to 260 lbf ft)

Wheel Bearings (While rotating the wheel)

Pneumatic 200 N•m (148 lbf ft) Initial
Pneumatic 34 N•m (25 lbf ft) Final
Cushion 200 N•m (148 lbf ft) Initial
Cushion 3 to 5 N•m (2 to 4 lbf ft) Final

Wheel Nuts (Pneumatic Only)

114 to 136 N•m (84 to 100 lbf ft)

TRANSMISSION AND DIFFERENTIAL

Control Valve Capscrews

Pneumatic 31 N•m (23 lbf ft)
Cushion 61 N•m (45 lbf ft)

Torque Converter Drive Plate Capscrews

41 N•m (30 lbf ft)

Torque Converter Housing Adapter to Engine

M4-1.5G Engine (Pneumatic Only) 43 to
51 N•m (32 to 38 lbf ft)

M4-2.0G Engine

M8 Capscrews (Pneumatic Only) 21 to
25 N•m (16 to 18 lbf ft)
M14 Capscrews (Pneumatic Only) 118 to
142 N•m (87 to 105 lbf ft)
Cushion Only 96 to 103 N•m (71 to 76 lbf ft)
M4-2.5D Engine (Pneumatic Only) 43 to
51 N•m (32 to 38 lbf ft)

Torque Converter Housing to Adapter Plate

M10 Capscrews 41 N•m (30 lbf ft)
M12 Capscrews 71 N•m (52 lbf ft)

Transmission Housing to Torque Converter
Housing Capscrews

41 N•m (30 lbf ft)

Transmission Pump

Pneumatic 20 N•m (15 lbf ft)
Cushion 21 N•m (15 lbf ft)

Differential Bearing Caps

263 to 314 N•m (194 to 232 lbf ft)

Ring Gear Capscrews

152 to 167 N•m (112 to 123 lbf ft)

8