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

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

This official Hyster service manual provides detailed diagnostic, maintenance, and repair instructions for the E25XM, E30XM, E35XM, and E40XMS electric forklift trucks. From electric motor service and steering components to advanced EV-100ZX motor controller adjustments, this manual offers extensive support for technicians looking to ensure reliable performance and precise troubleshooting for industrial operations.

Model Covers:

Hyster E25XM, E30XM, E35XM, E40XMS Forklift Trucks
Model Series: E25-35XM, E40XMS

File Format: PDF

Size: 15.66 MB

No. of pages: 549

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

📑 Included Sections:

Frame and Major Components

• Overhead guard removal and installation
• Battery restraint, seat assembly, and traction motor servicing
• Hydraulic tank leak repairs and chemical cleaning procedures

DC Motor Maintenance

• Brush wear inspection, commutator tests, and brush replacement
• Traction, hydraulic pump, and steering pump motor disassembly and reassembly
• Open and short-circuit field coil diagnostics

Drive Axle and Differential

• Speed reducer teardown, differential inspection, and axle shaft repair
• Pinion shimming, gear installation, and torque specifications

Steering System

• Steering column and wheel removal and alignment
• Hydraulic steering pump and motor repairs
• Chain tensioning and steering circuit troubleshooting

Brake System

• Service brake pad installation, cleaning, and adjustment
• Master cylinder rebuild and brake warning switch settings
• Parking brake inspection and seat brake control calibration

Hydraulics and Cylinders

• Hydraulic pump removal, cleaning, and reinstallation
• Main control valve diagnostics and pressure adjustments
• Steering cylinder and actuator valve servicing

Main Control Valve and Tilt Cylinders

• Valve disassembly, reassembly, linkage checks, and pressure settings
• Removal, leak testing, and adjustment of tilt cylinder stroke and mast angle

Electrical and Display Systems

• Display panel functions: LCD/LED indicators, battery state, and hourmeter
• Switches, potentiometers, horn, lighting, and fuse diagnostics
• Seat brake sensors and brush wear indicators

EV-100ZX Motor Controller

• Parameter registers, fault code clearing, and SCR control theory
• Contactor inspection, diode testing, and brush wear monitoring
• Traction and pump circuit diagnostics with performance display interaction

Industrial Battery Systems

• Lead-acid battery servicing, hydrometer use, water levels, and temperature considerations
• Charging types, methods, safety zones, and connector care

Global Mast & Lift System

• Two-stage and three-stage mast disassembly and lift cylinder installation
• Side-shift carriage repair, lift chain adjustments, and header hose routing

Periodic Maintenance & Capacities

• Daily, 350-hour, and 2000-hour inspection procedures
• Lubrication intervals, filter changes, torque specs, and fluid charts
• PMT circuit checks, battery safety, and wheel/tire installation methods

This Hyster E25XM, E30XM, E35XM, E40XMS Forklift Service Manual is an essential technical guide for electric lift truck service professionals, supporting every stage of diagnostics, calibration, and long-term equipment reliability.