Hyster M4-2.0G, M4-2.2G Mazda Engine Maintenance And Repair

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Hyster M4-2.0G, M4-2.2G Mazda Engine Maintenance And Repair

$30.00

Type Of Manual: Maintenance And Repair
Number of Pages: 1593
Size: 39.0MB
Format: PDF

Category: Hyster Service Manual PDF

Model List:
- M4-2.0G, M4-2.2G Mazda Engine

1. RM0496-(01-2011)-US-EN
1.1. Mazda Engine
1.2. Safety Precautions Maintenance and Repair
1.3. General
1.4. Description
1.5. Engine Removal and Installation
1.6. Cylinder Head, Camshaft, and Valve Mechanism Repair
1.7. Inspect and Repair
1.8. Cylinder Head
1.9. Rocker Shaft Assembly
1.10. Camshaft
1.11. Valve Guides
1.12. Valve Seats
1.13. Valve Springs
1.14. Install
1.15. Crankshaft and Main Bearings Repair
1.16. Inspect and Repair
1.17. Crankshaft
1.18. Main Bearings
1.19. Install
1.20. Pistons and Connecting Rods Repair
1.21. Remove and Disassemble
1.22. Inspect and Repair
1.23. Pistons
1.24. Piston Rings
1.25. Connecting Rods and Bearings
1.26. Assemble and Install
1.27. Cylinder Block Repair
1.28. Oil Pump Repair
1.29. Disassemble
1.30. Inspect
1.31. Assemble
1.32. Install
1.33. Cooling System Repair
1.34. Thermostat
1.35. Replace
1.36. Fan Assembly
1.37. Remove and Disassemble
1.38. Assemble and Install
1.39. Water Pump
1.40. Remove and Disassemble
1.41. Assemble and Install
1.42. Distributor Repair
1.43. Install
1.44. Flywheel and Ring Gear Repair S/H2.00-3.20XM (S/H40-65XM)
1.45. Ring Gear, Replace
1.46. Install
1.47. Flywheel Repair H1.50-175XM, H2.00XMS (S/H25-35XM, S/H40XMS)
1.48. Install
1.49. Valve Adjustment
1.50. Compression Pressure Check
1.51. Engine Timing Adjustment
1.52. Throttle Linkage Adjustment
1.53. Gasoline Engines
1.54. LPG Engines (IMPCO)
1.55. LPG Engines (AISAN)
1.56. Engine Specifications
1.57. Engine Data
1.58. Thermostat
1.59. Cylinder Head
1.60. Valve Mechanism
1.61. Camshaft
1.62. Crankshaft
1.63. Connecting Rods
1.64. Cylinder Block
1.65. Pistons
1.66. Oil Pump
1.67. Torque Specifications
1.68. Troubleshooting
2. RM0499-(10-2004)-US-EN
2.1. Drive Axle
2.2. Safety Precautions Maintenance and Repair
2.3. General
2.4. Description
2.5. Drive Axle Repair
2.6. Remove and Disassemble
2.7. Clean and Inspect
2.8. Assemble and Install
2.9. Torque Specifications
2.10. H2.00-3.20XM (H40-65XM)
2.11. S2.00-3.20XM (S40-65XM)
2.12. Troubleshooting
3. RM0500-(08-2003)-US-EN
3.1. Single-Speed Powershift Transmission
3.2. Safety Precautions Maintenance and Repair
3.3. General
3.4. Description and Operation
3.5. General
3.6. Torque Converter
3.7. Description
3.8. Operation
3.9. Clutch Assemblies
3.10. Description
3.11. Operation
3.12. Hydraulic System
3.13. General
3.14. Control Valve
3.15. General
3.16. Clutch Pressure Regulator
3.17. Inching Spool Assembly
3.18. Direction Spool
3.19. Modulator Circuit
3.20. Torque Converter Regulator
3.21. MONOTROL Pedal
3.22. MONOTROL Pedal Start Circuit
3.23. Direction Control Lever
3.24. Differential
3.25. Oil Flow Diagrams
3.26. Neutral
3.27. Modulator Operation
3.28. Forward
3.29. Forward-Inching
4. RM0501-(03-2004)-US-EN
4.1. Single-Speed Powershift Transmission
4.2. Safety Precautions Maintenance and Repair
4.3. General
4.4. Transmission Removal
4.5. Torque Converter and Housing Repair
4.6. Install
4.7. Transmission Pump Repair
4.8. Install
4.9. Front Cover and Pump Drive Repair
4.10. Remove and Disassemble
4.11. Assemble and Install
4.12. Clutch Assemblies Repair
4.13. Remove and Disassemble
4.14. Inspect
4.15. Assemble
4.16. Install
4.17. Differential Repair
4.18. Remove and Disassemble
4.19. Inspect
4.20. Assemble and Install
4.21. Control Valve Repair
4.22. Remove and Disassemble
4.23. Inspect
4.24. Assemble and Install
4.25. MONOTROL Pedal Repair
4.26. Remove and Disassemble
4.27. Assemble and Install
4.28. Direction Control Lever Repair
4.29. Remove and Disassemble
4.30. Assemble and Install
4.31. Stall Test
4.32. Inching/Brake Pedal Adjustment
4.33. Neutral Start Switch, MONOTROL Pedal Adjustment H2.00-3.20XM (H4
4.34. Neutral Start Switch, MONOTROL Pedal Adjustment S2.00-3.20XM (S4
4.35. Neutral Start Switch Test, MONOTROL Pedal
4.36. Oil Pressure Checks
4.37. Relief Valve for Transmission Pump Check, TEST PORT 1
4.38. Clutch Pressure Check, TEST PORTS 2 and 3
4.39. Torque Converter Regulator Check, TEST PORT 4
4.40. Lubrication Circuit Oil Pressure Check, TEST PORT 5
4.41. Modulator Pressure Check, TEST PORT 6
4.42. Troubleshooting
4.43. Troubleshooting – Pressure Tests
4.44. Table 1. Adjustment of Shims for Pinion Assembly
4.45. Table 2. Ring and Pinion Tooth Contact Adjustment
4.46. Table 3. Stall Speeds
4.47. Table 4. Transmission Oil Pressures Test Ports
5. RM0505-(06-2004)-US-EN
5.1. Safety Precautions Maintenance and Repair
5.2. General
5.3. Description
5.4. Operator Module Repair
5.5. Install
5.6. Hood and Side Covers Repair
5.7. Install
5.8. Overhead Guard Repair
5.9. Remove and Install
5.10. LED Backup and Brake Lights, Replace
5.11. Install
5.12. Counterweight Repair
5.13. Install
5.14. Exhaust System Repair
5.15. Muffler, Replace
5.16. Radiator and Cooling System Repair
5.17. Install
5.18. Operator Restraint System Repair
5.19. Engine Repair
5.20. Remove Engine Only
5.21. Remove Engine and Transmission
5.22. Install Engine Only
5.23. Install Engine and Transmission
5.24. Fuel and Hydraulic Tanks Repair
5.25. Inspect
5.26. Small Leaks, Repair
5.27. Large Leaks, Repair
5.28. Steam Method of Cleaning
5.29. Chemical Solution Method of Cleaning
5.30. Additional Preparations for Repair
5.31. Safety Labels
5.32. Table 1. Weight of Counterweights
6. RM0506-(05-2005)-US-EN
6.1. Brake System
6.2. Safety Precautions Maintenance and Repair
6.3. General
6.4. Description and Operation
6.5. Service Brakes
6.6. Master Cylinder
6.7. Parking Brake
6.8. Service Brakes Repair
6.9. Remove and Disassemble
6.10. Inspect
6.11. Assemble and Install
6.12. Parking Brake Repair
6.13. Remove and Disassemble
6.14. Assemble and Install
6.15. Master Cylinder Repair
6.16. Clean and Inspect
6.17. Install
6.18. Service Brakes Adjustment
6.19. Brake System Air Removal
6.20. Parking Brake Not Applied Switch Test
6.21. Parking Brake Switch Test (MONOTROL Pedal Only)
6.22. Inching/Brake Pedal Adjustment
6.23. Neutral Start Switch Adjustment, MONOTROL Pedal H2.00-3.20XM (H4
6.24. Neutral Start Switch Adjustment, MONOTROL Pedal S2.00-3.20XM (S4
6.25. Neutral Start Switch Test (MONOTROL Pedal)
6.26. Torque Specifications
6.27. H2.00-3.20XM (H40-65XM)
6.28. S2.00-3.20XM (S40-65XM)
6.29. Troubleshooting
7. RM0512-(08-2003)-US-EN
7.1. Steering Housing and Control Unit
7.2. Safety Precautions Maintenance and Repair
7.3. General
7.4. Description
7.5. Operation
7.6. Steering Wheel and Column Assembly Repair
7.7. Steering Column Assembly, Remove
7.8. Steering Control Unit
7.9. Steering Column Assembly, Install
7.10. System Air Removal
7.11. Troubleshooting
8. RM0513-(06-2004)-US-EN
8.1. Hydraulic System
8.2. Safety Precautions Maintenance and Repair
8.3. General
8.4. Description
8.5. Hydraulic System
8.6. Gear Pump Assembly
8.7. Flow Control Valve
8.8. Relief Valve
8.9. Operation
8.10. Hydraulic System
8.11. Gear Pump
8.12. Flow Control Valve
8.13. Relief Valve
8.14. Gear Pump Assembly Repair
8.15. Remove and Disassemble
8.16. Assemble and Install
8.17. Steering Relief Pressure Check and Adjustment
8.18. Gear Pump Flow Check
8.19. Troubleshooting
9. RM0514-(01-2004)-US-EN
9.1. Instrument Cluster
9.2. Safety Precautions Maintenance and Repair
9.3. General
9.4. Description
9.5. Display Panels on Steering Column, Internal Combustion
9.6. Display Panels on Steering Column, Electric Lift Trucks
9.7. Standard Display Panel
9.8. Enhanced Display Panel
9.9. Curtis 1215 Display Panel
9.10. Description and Features
9.11. Operation
9.12. Cluster-Type Display Panel (Internal Combustion) Replacement
9.13. Remove and Disassemble
9.14. Assemble and Install
9.15. Cluster Display Panel (Electric Lift Truck) Replacement
9.16. Display Panel Assembly, Replace
9.17. LED Indicators
9.18. Battery Indicators
9.19. Digital Display (Enhanced Display Panel Only)
9.20. Status Code or Performance Level Switches and LED indicators (En
9.21. Standard Display Panel Parts, Replace
9.22. Enhanced Display Panel Parts, Replace
9.23. Curtis 1215 Display Panel Replacement
9.24. Install
9.25. Table 1. Instrument Cluster, Internal Combustion
10. RM0521-(03-2006)-US-EN
10.1. Safety Precautions Maintenance and Repair
10.2. General
10.3. Description and Operation
10.4. Carriages
10.5. Mast Mounts
10.6. Two-Stage Mast, Limited Free-Lift (LFL)
10.7. Description and Operation
10.8. Two-Stage Mast, Full Free-Lift (FFL)
10.9. Description and Operation
10.10. Three-Stage Mast, Full Free-Lift (FFL)
10.11. Description and Operation
10.12. Four-Stage Mast
10.13. Description and Operation
10.14. Cylinder Cushion During Lifting Sequence
10.15. Cylinder Cushion During Lowering Sequence
11. RM0522-(07-2010)-US-EN
11.1. Mast Repairs
11.2. Safety Precautions Maintenance and Repair
11.3. General
11.4. Safety Procedures When Working Near Mast
11.5. Fork Repair
11.6. Install
11.7. Carriages Repair
11.8. Standard Carriage, Remove
11.9. Hang-On Sideshift Carriage, Remove
11.10. Standard Carriage and Hang-On Sideshift Carriage, Repair
11.11. Standard Carriage, Install
11.12. Hang-On Sideshift Carriage, Install
11.13. Integral Sideshift Carriage
11.14. Clean and Inspect
11.15. Install
11.16. Mast Repair
11.17. Two-Stage LFL and Two-Stage FFL Masts, Disassemble
11.18. Three-Stage FFL Mast
11.19. Disassemble
11.20. Mast and Chains, Clean and Inspect
11.21. Two-Stage LFL and Two-Stage FFL Mast, Assemble
11.22. Three-Stage FFL Mast, Assemble
11.23. Install
11.24. Lift Cylinders Repair
11.25. Main Lift Cylinders, Remove
11.26. Free-Lift Cylinder, Remove
11.27. Cylinders, Disassemble
11.28. Two-Stage Full Free-Lift Mast, Right-Hand Main Lift Cylinder
11.29. Two-Stage Full Free-Lift Mast, Left-Hand Main Lift Cylinder
11.30. Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift
11.31. Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift
11.32. Two-Stage Full Free-Lift Mast and Three-Stage Full Free-Lift Mas
11.33. Clean and Inspect
11.34. Cylinders, Assemble
11.35. Two-Stage Full Free-Lift Mast, Right-Hand Main Lift Cylinder
11.36. Two-Stage Full Free-Lift Mast, Left-Hand Main Lift Cylinder
11.37. Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift
11.38. Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift
11.39. Two-Stage Full Free-Lift Mast and Three-Stage Full Free-Lift Mas
11.40. Main Lift Cylinders, Install
11.41. Free-Lift Cylinder, Install
11.42. Header Hose Arrangements
11.43. Two-Stage LFL Mast, New Hose Install
11.44. Two-Stage LFL Mast, Adjust Hoses After Installation
11.45. Two-Stage FFL Mast, New Hose Install
11.46. Two-Stage FFL Mast, Adjust Hoses After Installation
11.47. Three-Stage FFL Mast, New Hose Install
11.48. Three-Stage FFL Mast, Adjust Hoses After Installation
11.49. Header Hose Arrangement
11.50. Two-Stage LFL Mast, New Hose Install
11.51. Two-Stage LFL Mast, Adjust Hoses After Installation
11.52. Two-Stage FFL Mast, New Hose Install
11.53. Two-Stage FFL Mast, Adjust Hoses After Installation
11.54. Three-Stage FFL Mast, New Hose Install
11.55. Three-Stage FFL Mast, Adjust Hoses After Install
11.56. Lift and Tilt System Leak Check
11.57. Lift Cylinders Leak Check
11.58. Tilt Cylinders Leak Check
11.59. Tilt Cylinders Adjustment
11.60. Lift Chains Adjustment
11.61. Mast Adjustment
11.62. Carriage Adjustment
11.63. Troubleshooting
11.64. Table 1. Hook-Type Carriage Chain Adjustment
11.65. Table 2. Pin-Type Carriage Chain Adjustment
12. RM0524-(02-2001)-US-EN
12.1. Electrical System
12.2. Safety Precautions Maintenance and Repair
12.3. General
12.4. Description
12.5. Starting System
12.6. Ignition System
12.7. Charging System
12.8. Starter Repair
12.9. Remove and Disassemble
12.10. Assemble and Install
12.11. Coil Replacement
12.12. Distributor Repair H1.50-1.75XM, H2.00XMS (S/H25-35XM, S/H40XMS)

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