Hyster D001 H1.50XM H1.75XM H2.00XMS Forklift Repair Manual (P/N 100 SRM 545)

• Covers the D1/D001 H1.50–1.75XM and H2.00XMS trucks (H25–35XM, H40XMS) and the C10 S1.25–1.75XM and S2.00XMS additions (S25–35XM, S40XMS), with H- and S-series differences identified in the chassis and diagram sections.
• Includes repair procedures for the Mazda M4-1.5G, M4-2.0G, and M4-2.5D engines: cylinder head and valve train, timing chain/belt/gear systems, pistons, crankshaft and bearings, lubrication and cooling components, flywheel, compression testing, timing adjustment, and troubleshooting.
• Covers the single-speed powershift transmission and torque converter, Forward/Reverse clutch assemblies, transmission pump, control and modulator valves, differential setup, stall testing, pressure checks, removal, disassembly, inspection, reassembly, and fault isolation.
• Details service-brake, parking-brake, drive-axle, steering-axle, and Ross HGF Hydraguide repair, including wheel and master cylinders, automatic adjusters, hub seals and bearings, kingpins, steering cylinder work, bleeding, preload checks, and steering-system troubleshooting.
• Provides hydraulic pump and pump-drive repair, relief and flow testing, main control valve overhaul, lift/tilt/auxiliary spool diagnosis, mast and carriage work, side-shift service, lift- and tilt-cylinder repair, chain and roller adjustment, leakage checks, and troubleshooting.
• Includes Mazda-specific starting, charging, ignition, and glow-plug tests, instrument-cluster repair, connector functions, electrical schematics, hydraulic diagrams, transmission circuits, torque tables, capacities, wear limits, clearances, and adjustment data.

Publication and Model Coverage

This is a 28-file PDF set totaling 507 file pages, not a single 100 SRM 545 booklet. That number identifies the frame section. The package combines related Hyster SRM publications for the frame, transmission, drive axle, brake system, hydraulic system, main control valve, steering axle and housing, steering control unit, mast, lift and tilt cylinders, engines, fuel systems, electrical systems, instrument cluster, periodic maintenance, capacities, fasteners, and diagrams.

Publication dates span several revisions rather than one November 1994 update. Many D1 chassis sections were issued in 1993 and received S-series additions in November 1994; the drive-axle section was expanded in December 1994. Diagrams 8000 SRM 544, P/N 897558, is dated January 1995 and expressly identifies D1 (Beta) H25–40XMS and C10 (Beta) S25–40XMS coverage. The specification section also marks the M4-1.5G as a Far East configuration, while the frame chapter states that the diesel installation is not used on S25–35XM or S40XMS trucks.

Engine, Fuel-System, and Drivetrain Repair

The engine material is configuration-specific. The M4-1.5G chapter covers a chain-driven camshaft, the M4-2.0G chapter includes timing-belt service, and the M4-2.5D section covers timing gears and fuel-injection-pump timing. Factory repair content includes cylinder-head and valve-mechanism work, camshaft and crankshaft inspection, piston and bearing service, oil-pump and water-pump repair, flywheel and ring-gear work, compression and timing checks, component-specific torque sequences, inspection limits, and engine troubleshooting.

Fuel-system coverage includes gasoline carburetor removal, disassembly, cleaning, inspection, assembly, float setting, governor adjustment, and troubleshooting. Two LPG sections cover the tank and valve, fuel filter and valve unit, vaporizer, carburetor, pressure switch, governor, hose and diaphragm replacement, leak inspection, pressure checks, and final adjustments. The diesel chapter covers injection-pump removal and installation, timing, water-separator service, fuel-filter replacement, injector checks, and removal of air from the system. Internal injection-pump repair is outside this section and is assigned to a specialist repair service.

The transmission chapter goes well beyond fluid specifications. It documents complete single-speed powershift teardown and assembly, clutch-pack inspection and clearance checks, transmission-pump service, control-valve and modulator repair, differential and ring-and-pinion adjustment, directional-control components, torque-converter and clutch pressure testing, stall-speed checks, and symptom-based troubleshooting.

Hydraulic, Mast, Brake, Steering, and Electrical Coverage

Hydraulic material follows the gear pump, pump drive, flow divider, steering and main relief circuits, test ports, and main control valve. The valve chapter separates inlet, lift/lower, tilt, and auxiliary sections and includes disassembly, seal replacement, reassembly, linkage checks, relief-valve adjustment, and fault diagnosis. Mast material covers forks and carriages, side-shift components, mast removal and installation, two-stage limited-free-lift and three-stage full-free-lift assemblies, lift cylinders, tilt cylinders, chains, rollers, wear strips, header hoses, leakage testing, and adjustment procedures.

Electrical support includes the M4-2.0G gasoline/LPG wiring schematic, M4-2.5D diesel schematic, US and European lighting diagrams, the instrument-cluster schematic with connector functions, hydraulic-system schematic and arrangement, hand-lever and Monotrol direction-control schematics, and the transmission hydraulic circuit in neutral. Separate electrical repair chapters cover starters, alternators, distributors, ignition timing, glow plugs, charging-output diagnosis, and component testing.

An LPG tank installed outside its alignment-pin position can damage the hose or fittings and release fuel. The right- and left-hand brake adjusters have opposite thread directions; swapping them makes shoe clearance increase when the brakes are applied. During Ross HGF Hydraguide assembly, the drive link, valve plate, alignment grooves, pins, and spring slots must remain indexed, or a centering spring can be damaged and steering response can remain active or operate incorrectly.

The set includes a Hydraguide service-fixture drawing and references lift-cylinder seal tools in Parts-Service Gram L-A-2, along with Hyster packing lubricant P/N 186061; the external Parts-Service Gram is not part of this package. One file-scope limitation also matters: the 4000 SRM 521 and 4000 SRM 522 mast PDFs have different cover identification but the same 35-page body in this set, so they do not provide two separate mast chapters.

Follow the manual’s blocking, mast-restraint, fuel-isolation, hydraulic-pressure-release, and battery-disconnection precautions before repair work.