Magnetism, electromagnets and basic DC motor principles open this 574-page Hyster J25A service manual PDF, OEM reference 620 SRM 145, which covers four electric lift truck variants, including the J30AS. Brush seating, commutator turning, and checks for opens, grounds and shorts lead into the EV-100 motor controllers, transaxle, tilt cylinders and Vista mast repair. Wiring diagrams cover the controller circuits. Hold a fully charged battery at a specific gravity of 1.265 to 1.310 at 25°C (77°F), and keep electrolyte below 49°C (120°F) while charging. If your job is the power steering pump and relief valve, the hydraulic schematics show how that circuit connects. Bookmarks and a text layer take you straight to the exploded views, so you can confirm the correct component before ordering.
What's Inside This Hyster J25A, J30A, J35A, J30AS Manual
| System | Pages | Key Topics |
|---|---|---|
| Frame and Connected Parts | 1-6 | Counterweight Assembly, Overhead Guard, Hydraulic Tank, Access Panels, Decal Positions |
| DC Motor Maintenance | 7-36 | Introduction to Magnetism, Basic Motors, Motor Repair, Commutator Inspection |
| DC Motor Maintenance (All Electric Lift Trucks) | 37-66 | Brush and Commutator Inspection, Brush Replacement, Motors Repair, Tests for Damaged Field and Armature |
| Transaxle Assembly | 67-75 | Gear Reduction System, Drive Axle Housing, Disc Brakes, Traction Motors, Axle Gear |
| Steering Control Unit | 76-116 | Spool, Sleeve, Rotor, Metering Section, Manifold Block, Check Valve |
| Power Steering Motor and Pump | 117-170 | Power Steering Motor, Power Steering Pump, Relief Valve, Hydraulic Hoses, Coupling |
| Tilt Cylinders | 171-187 | Piston Rod, Retainer, Seals, Lowering Control Valve, Internal Check Valve |
| Ev-100 Motor Controller | 188-248 | Control Card, SCR, Contactors, Electronic Drivers, Current Sensor, Suppressors |
| Ev-100 Dual Motor Controller | 249-267 | Balance Contactor, Traction Motors, Control Card, Contactors, Fuses |
| EV-100LXT/LX/LXP/LXD EV-200LXT/LX Motor Controller | 268-355 | Diagnostic Control Card, Hand Set, Instrument Panel Display, Function Codes, Traction Control Cards, Pump Control Card |
| Electrical Checks and Adjustments | 356-391 | Control and Power Fuses, Control Card Adjustments, Accelerator Potentiometer, Start Switch, Direction Switches, Steering Potentiometer |
| Battery Maintenance | 392-405 | Lead-Acid Batteries, Battery Inspection, Battery Cleaning, Battery Charging, Battery Connectors, Battery Care |
| Battery Indicators | 406-467 | Battery Indicator Function, Hourmeter Functions, Battery Discharge Display, Battery Indicator Controller, Curtis 933-1 Meter, Sevcon Powergauge |
| Vista Masts | 468-477 | Mast Weldments, Carriage, Two-Stage Mast, Free-Lift Mast, Three-Stage Mast, Four-Stage Mast |
| Vista Mast Repair | 478-574 | Safety Procedures, Fork Removal, Carriage Removal, Mast Removal, Lift Chain Adjustments, Mast Adjustments, Side-Shift Carriage |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Overhead guard to cowl capscrews torque | 85 N.m (63 lbf ft) | p. 2 |
| Overhead guard to counterweight capscrews torque | 300 N.m (220 lbf ft) | p. 2 |
| Specific gravity of a fully charged battery | 1.265 to 1.310 at 25°C (77°F) | p. 401 |
| Maximum electrolyte temperature during charging | 49°C (120°F) | p. 401 |
| Overhead guard to cowl torque | 85 N.m (63 lbf ft) | p. 2 |
| Overhead guard to counterweight torque | 300 N.m (220 lbf ft) | p. 2 |
| Counterweight to frame bolts torque | 75-80 N.m (55-60 lbf ft) | p. 3 |
| Hydraulic system relief valve pressure | 15.5 MPa (2250 psi) | p. 170 |
| Steering system relief valve pressure | 8.6 MPa (1250 psi) | p. 170 |
| Hydraulic system capacity | 15.6 litre (16.5 qt) | p. 170 |
| J25A, J30A, J35A | ||
| Counterweight weight | 340 kg (750 lb) | p. 2 |
| J30AS | ||
| Counterweight weight (J30AS) | 580 kg (1275 lb) | p. 2 |
Hyster J25A, J30A, J35A, J30AS Common Problems This Manual Covers
Hyster J25A/J30A/J35A/J30AS electric lift truck battery runs hot on charge with low specific gravity readings
Measure specific gravity on a charged battery; page 401 calls for 1.265 to 1.310 at 25°C (77°F). Check that electrolyte stays under 49°C (120°F) while charging, and that the rise over an eight hour charge stays within 14°C (25°F) per page 403. Never discharge below 1.130 (page 393). Use only an approved charger, never plug it into the truck plug, and keep sparks away from charging fumes (page 400).
Manual Section: Battery Maintenance p. 401DC motor commutator showing heavy streaks and fine grooves with brushes wearing fast
Inspect the brushes for wear and check brush pressure. Page 25 lists worn brushes, low brush pressure, dirty abrasive conditions and continuous light-load running as causes. Grooves the width of the brushes point to brush pressure that is too high or the wrong brush type for the motor (page 26). Remove the armature from the motor so the grooved commutator can be repaired.
Manual Section: DC Motor Maintenance Troubleshooting p. 25DC motor commutator shows small copper flakes dragged over the trailing edges of the bars
Clean the commutator with a light brush seater stone as page 27 describes. If the drag has progressed too far, rake and clean the slots. When stoning, wear eye protection, raise the drive wheels, run the motor at low speed and keep your fingers clear of moving parts. Use a stone no shorter than 60 mm (2.4 in) per page 50. Check for wrong brush grade, contaminated air and excessive vibration.
Manual Section: DC Motor Maintenance Troubleshooting p. 27Hydraulic tank showing a small oil leak on the tank
Clean the area around the leak with steam and strip all paint and dirt. Then apply Loctite 290 following the manufacturer's instructions, per page 3. Do not use tools that make sparks, heat or static electricity, because tank vapors can explode. Large leaks that need welding or cutting require special procedures, authorized personnel only, and enough ventilation if the tank is cleaned indoors (page 4).
Manual Section: Hydraulic Tank Repairs p. 3Tilt cylinder leaking internally from seal failure with a capacity load on the forks
Test for internal leaks with a capacity load on the forks per page 181. Never allow anyone under a raised carriage, and never feel for leaks with your hand on pressurized components, because oil can inject into the body. Before removing a cylinder, tilt the mast forward and chain it to the frame (page 173). On reassembly, torque the retainer to 407 to 475 N.m (300 to 350 lbf ft) per page 184.
Manual Section: Tilt Cylinder Leak Check p. 181Hydraulic pump low pressure with relief valve opening and output below specification
Fill the hydraulic tank to the FULL mark, which takes 15.6 litre (16.5 qt). Then gauge the hydraulic system relief valve against 15.5 MPa (2250 psi), listed on page 170. Test the steering system relief valve separately against 8.6 MPa (1250 psi) so you do not confuse the two circuits when chasing low pressure or pump noise.
Manual Section: Hydraulic Pump Troubleshooting p. 170Frequently Asked Questions
What causes a Hyster J-series forklift to lose power or stop lifting?
A lift truck may lose power or stop lifting due to a shorted 1A coil, which can cause the traction contactor contacts to open during high-speed operation. Additionally, if the coil of the field weakening (FW) contactor has a short-circuit, the lift truck will operate normally until the FW contactor is energized, at which point it will lose power and the traction contactor contacts will open. p. 318
What are replacement specs for the Hyster J25A, J30A, J35A, J30AS traction battery and battery cables/connectors?
The battery must fit the battery compartment correctly, and spacers must be used to prevent the battery from moving more than 13 mm (0.5 in) in any horizontal direction. The replacement battery must have the correct voltage for the lift truck, and the weight must be within the maximum and minimum weights shown on the nameplate. p. 529
What is the torque specification for the counterweight capscrews on the Hyster J25A, J30A, J35A, J30AS?
The four 1/2 UNC x 3-1/2 in bolts that hold the counterweight to the frame should be tightened to 75-80 N.m (55-60 lbf ft). p. 3
What is the correct torque for the wheel nuts on a Hyster J25A, J30A, J35A, J30AS lift truck?
The drive tire wheel nuts on J25-35A/B lift trucks should be tightened to 170 N.m (125 lbf ft), and the pneumatic steering tire wheel nuts to 155 N.m (115 lbf ft). p. 552
What is the maximum lowering speed for the carriage if there is an internal leak in the lift system?
The maximum lowering speed for the carriage due to internal leakage in the lift system is 33 mm (1.3 in) per 10 minutes when the hydraulic oil is at 30°C (90°F). If the oil temperature is 60°C (140°F), the maximum lowering speed is 146 mm (5.8 in) per 10 minutes. p. 464
Is this Hyster J25A manual a PDF I download?
You download the Service Manual yourself: 574 pages, searchable PDF, available immediately. Keep a copy on every device you use.
Can I print just the pages I need from this Hyster J25A manual?
Yes. Print the pages or sections you need for your own shop use. Any standard printer works.
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