1993–1995 Hyster D001/C010 H25–35XM, H40XMS & S25–35XM, S40XMS Forklift Repair Manual Set (P/N 1459331, 897590, 897934)

This Hyster factory publication set covers the D001 H-series and C010 S-series trucks identified in the model-specific maintenance and specification sections: H25XM, H30XM, H35XM, H40XMS, S25XM, S30XM, S35XM, and S40XMS. The maintenance publication, P/N 1459331, is supplied with truck-specific repair material and the related Hyster component sections.

The set contains 30 PDFs totaling 578 pages, including the covers and supplementary pages detailed below. Text search varies by file; twelve sections have character-encoding problems that limit ordinary keyword searches.

• Mazda engine repair: M4-1.5G, M4-2.0G, and M4-2.5D engine disassembly, internal inspection, timing-system work, lubrication-system repair, reassembly, adjustments, and final checks.

• Powershift and drive axle work: Transmission teardown, clutch-pack service, converter and pump inspection, differential repair, ring-and-pinion setup, stall testing, and pressure diagnosis.

• Hydraulic, mast, and cylinder service: Gear-pump and pump-drive repair, flow-divider and relief-valve checks, main control valve service, LFL/FFL mast repair, and cylinder overhaul.

• Brake and steering repair: Service-brake overhaul, parking-brake and inching adjustments, bleeding, steering-axle service, steering-housing repair, and Ross HGF control-unit repair.

• Gasoline and LPG systems: Carburetor and governor repair, standard LPG fuel-valve and vaporizer service, throttle-linkage adjustments, fuel-system checks, and troubleshooting.

• Cooling and electrical diagnosis: Radiator and thermostat checks, water-pump inspection, starting and charging tests, distributor service, diesel cold-start diagnosis, and instrument-cluster repair.

• Factory reference data: Torque tables, pressure-test specifications, fluid capacities, wear and clearance limits, electrical test values, wiring diagrams, hydraulic schematics, and exploded views.

The repair sections are suited to trained, authorized lift-truck service personnel; the maintenance publication expressly requires both training and authorization for repairs and adjustments.

Mazda Engine Repair and Configuration Differences

The engine chapters distinguish the M4-1.5G timing chain, M4-2.0G timing belt, and M4-2.5D gears driving the camshaft and fuel-injection pump. These differences help identify the applicable parts and procedures before teardown.

Internal repair covers cylinder heads, camshafts and valves, crankshafts and main bearings, pistons and connecting rods, oil pumps, flywheels, and ring gears. Engine and transmission removal is handled in the included Frame section.

Diesel fuel-system scope: The diesel chapter includes fuel-filter service, injection-pump removal and installation, injection timing, fuel-system bleeding, and injector checks. Internal fuel-injection-pump repair is excluded; pump repair and injector inspection require specialist equipment and training.

The specifications identify the M4-1.5G configuration as Far East-only. The M4-2.5D diesel is used in the covered H-series trucks, not the covered S-series trucks.

Powershift Transmission and Drive Axle

The powershift material follows the converter circuit, transmission pump, forward and reverse clutches, direction and inching controls, control valve, output gearing, and differential. Axle procedures cover shafts, hubs, bearings, removal, inspection, and installation.

Repair limits and assembly details: The torque converter is a non-repairable assembly; the pump and transmission internals have repair procedures. Clutch assembly instructions identify the concave separator plate and the orientation of the chamfered thrust washers.

Hydraulics, Masts, and Cylinders

Hydraulic coverage traces the circuit from the tank and gear pump through the steering flow divider, relief valves, main control valve, lift and tilt cylinders, and steering cylinder. Pump-flow checks and relief-pressure tests accompany the component repair procedures.

Mast repair covers two-stage limited-free-lift, two-stage full-free-lift, and three-stage full-free-lift assemblies. Standard and side-shift carriage work includes forks, load rollers, wear pads, shims, chains, sheaves, hoses, and adjustment procedures.

Brakes and Steering

Brake coverage follows the reservoir and master cylinder through the wheel cylinders, shoes, drums, automatic adjusters, parking-brake linkage, and inching/brake pedal. The manual warns that interchanging the left- and right-side adjusters causes shoe clearance to increase during braking.

Steering work includes axle removal, wheel hubs and tapered-roller bearings, kingpins, tie rods, steering-cylinder repair, and the adjustable steering housing. The Ross HGF Hydraguide instructions address component-groove alignment and warn that direct vise clamping can distort and damage the machined housing.

Fuel Systems and Cooling

Gasoline sections cover carburetor disassembly, inspection, adjustment, and governor checks. Standard LPG sections address the fuel filter and valve unit, vaporizer, carburetor, solenoid valve, governor, and throttle linkage.

Separate application coverage: The included Aisan closed-loop LPG chapter applies to D010/E001 and D187/H177 trucks. Its oxygen-sensor, regulator, makeup-fuel-injector, and feedback checks should be matched to those applications rather than assumed to apply to D001/C010 trucks.

Cooling coverage includes radiator cleaning, thermostat and pressure-cap operation, water-pump inspection, fan and shroud condition, exhaust-leak checks, and overheating diagnosis.

Electrical Diagnosis and Wiring Diagrams

Engine-specific electrical sections cover starter and alternator repair, gasoline/LPG ignition and distributor service, and diesel glow-plug and cold-start circuits. Instrument-cluster procedures address the gauges, indicator lights, removal, and installation.

Engine and lighting drawings: Named examples include the Wiring Schematic for the Mazda M4-2.0G Gasoline or LPG Engine, Wiring Schematic for the Mazda M4-2.5D Diesel Engine, and Lights Wiring Schematic, US.

Truck controls and hydraulics: Other examples are the Instrument Cluster Wiring Schematic, Electrical Schematic for MONOTROL, and Hydraulic Schematic for the Transmission (Neutral). Hydraulic-system arrangement drawings support steering, lift, tilt, and auxiliary-circuit diagnosis.

Maintenance and Technical Reference

Engine tables provide identification, compression and valve data, fuel-injection settings, and inspection limits. Truck specifications add hydraulic pump output, transmission stall data, mast performance, tire specifications, capacities, fastener torque, and truck weights.

The maintenance section combines daily checks with scheduled brake, steering, lift-chain, filter, and fluid service. It also covers valve clearance, injection timing, hydraulic oil and filter changes, wheel and tire work, and engine break-in.

Mast, brake, hydraulic, wheel and tire, LPG, and powertrain work involves stored energy, heavy assemblies, flammable fuel, and changes in truck stability. The manual’s blocking, restraint, pressure-release, and fuel and electrical isolation precautions apply to these repairs.

PDF Section Breakdown and Readability

The individual page counts below include 11 section covers, nine revision-history pages, five contents pages, one Hyster parts promotional page, one notes page, and two blank pages. These 29 supplementary pages are already included in the total.

Text search: Sections marked † have unreliable English keyword search because of character encoding. The other eighteen PDFs have searchable body text, although image-based labels and some cover lettering are not searchable.

Navigation: All thirty PDFs contain embedded bookmarks for their sections, procedures, or drawings.

Wiring readability: Small wire and connector labels in the scanned engine and lighting schematics require magnification; some dense areas retain rough lettering when enlarged. The separate instrument-cluster and MONOTROL drawings have clearer labels.