Hyster E25XM-2, E30XM-2, E35XM-2, E40XMS-2 Forklift Trucks Service Manual

Hyster E25XM-2, E30XM-2, E35XM-2, E40XMS-2 Forklift Trucks Service Manual

This comprehensive service manual provides detailed diagnostic, repair, and maintenance procedures for the Hyster E25XM-2, E30XM-2, E35XM-2, and E40XMS-2 electric forklift trucks. With full coverage of motor control systems, hydraulic repairs, electrical diagnostics, brake servicing, steering mechanisms, masts, and display technologies, this guide is essential for technicians maintaining high-efficiency lift trucks across demanding industrial environments.

Model Covers:

Hyster E25XM-2, E30XM-2, E35XM-2, E40XMS-2 Forklift Trucks
Model Series: E25-35XM2, E40XMS2

File Format: PDF

Size: 19.48 MB

No. of pages: 592

Delivery Method: Instant Download – Access your file immediately after purchase.

📑 Included Sections:

Frame and Structural Repairs

• Overhead guard and counterweight removal and installation
• Traction motor and hydraulic tank servicing and cleaning procedures
• Battery restraint systems and hood frame components

Electric Motor Maintenance

• DC brush and commutator inspection and replacement
• Hydraulic pump, traction motor, and steering motor disassembly
• Short circuit and open field coil testing

Drive Axle and Differential

• Disassembly and reassembly of speed reducer and axle housing
• Pinion shimming, hypoid gear setup, and bearing inspections
• Traction motor mounting and torque specifications

Steering and Steering Components

• Steering wheel column, chain tensioning, and power steering motor service
• Hydraulic steering motor cleaning and installation
• Checks for air removal, steering pressure, and encoder circuits

Brake System

• Service brake disassembly and installation
• Master cylinder, pedal, parking brake switch, and warning systems
• Brake fluid bleeding and service/parking brake adjustments

Hydraulic System and Cylinders

• Hydraulic tank repairs, filter servicing, and control valve diagnostics
• Pump and steering pump disassembly and pressure relief valve tuning
• Tilt cylinder rebuild and stroke/angle adjustments

Electrical System and Instrumentation

• Display panel types (LX, ZX, SEM), functions, and error code decoding
• Switches, fuses, indicators, seat/brake sensors, and motor wiring
• Battery monitoring, status codes, and performance adjustment screens

Motor Controllers (SR/SP)

• EV-100ZX, EV-T100, and SEM motor controller diagnostics
• Parameter tables, hand set/PC adjustments, and system protections
• Regenerative braking, field weakening, ramp control, and PMT overrides

Industrial Battery and Charging

• Battery care, hydrometer use, water addition, and charging practices
• Charging locations, connector types, and troubleshooting methods

Global Mast and Lift Components

• Two-stage and three-stage mast assemblies, lift chain and carriage checks
• Fork, tilt cylinder, lift cylinder repairs, and hose routing/adjustments
• Header hose arrangements and mast alignment checks

Periodic Maintenance

• 8-hour, 350-hour, and 2000-hour service intervals
• Lift chain lubrication, electrical contact checks, brake inspection
• Battery replacement, tire/wheel service, PMT checks, safety labels

This Hyster E25XM-2, E30XM-2, E35XM-2, E40XMS-2 Service Manual is a trusted resource for diagnostic precision, long-term durability, and efficient servicing of your electric lift trucks across all applications.