Complete service repair manual for Hyster Lift Trucks H135XL2, H155XL2 (G006), with all the technical information to maintain, diagnose, repair, and service like professional mechanics.
Hyster Service Manual H135-155XL2 (G006) workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
Total Pages: 1,149 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
1559725 – Hyster Service Manual H135-155XL2 (G006).pdf
| Section | Part No. | SRM Number | Rev Date |
| FRAME | 897104 | 0100 SRM 0322 | 11/03 |
| GM V6-4.3L ENGINE WITH FUEL INJECTION | 897800 | 0600 SRM 0590 | 11/03 |
| PERKINS DIESEL ENGINE 1104 (RE) | 155202 | 0600 SRM 1070 | 12/03 |
| COOLING SYSTEM | 897934 | 0700 SRM 0626 | 11/01 |
| ELECTRONIC CONTROLLED LPG/GASOLINE FUEL SYSTEM GM 3.0L & 4.3L EPA COMPLIANT ENGINES |
1559540 | 0900 SRM 1088 | 03/04 |
| TWO-SPEED PS TRANS-DESCR / OPER | 897106 | 1300 SRM 0324 | 10/03 |
| TWO-SPEED PS TRANSMISSION-REPAIR | 897107 | 1300 SRM 0325 | 10/03 |
| DIFFERENTIAL | 910072 | 1400 SRM 0046 | 11/03 |
| DRIVE AXLE | 910073 | 1400 SRM 0049 | 09/03 |
| STEERING CONTROL UNIT | 910076 | 1600 SRM 0054 | 10/03 |
| STEERING AXLE | 897108 | 1600 SRM 0326 | 10/03 |
| BRAKE SYSTEM | 897109 | 1800 SRM 0327 | 09/03 |
| HYDRAULIC GEAR PUMPS | 910091 | 1900 SRM 0097 | 10/03 |
| HYDRAULIC SYSTEM | 897110 | 1900 SRM 0328 | 09/03 |
| MAIN CONTROL VALVE | 899783 | 2000 SRM 0090 | 10/03 |
| TILT CYLINDERS | 910102 | 2100 SRM 0103 | 10/03 |
| ALTERNATOR | 899784 | 2200 SRM 0002 | 10/03 |
| STARTER | 910107 | 2200 SRM 0106 | 02/01 |
| INSTRUMENT PANEL INDICATORS / SENDERS | 910110 | 2200 SRM 0143 | 12/03 |
| ELECTRONIC CONTROL MODULE (ECM) DIAGNOSTIC TROUBLESHOOTING GM 3.0L AND 4.3L EPA COMPLIANT ENGINES |
1559545 | 2200 SRM 1090 | 01/04 |
| HIGH VOLTAGE SWITCH (HVS) IGNITION GM 4.3L EPA COMPLIANT ENGINES | 1559550 | 2200 SRM 1097 | 12/03 |
| LIFT CYLINDERS | 910119 | 4000 SRM 0135 | 10/03 |
| MASTS | 897111 | 4000 SRM 0329 | 10/03 |
| METRIC AND INCH (SAE) FASTENERS | 910442 | 8000 SRM 0231 | 03/03 |
| CAPACITIES and SPECIFICATIONS | 897113 | 8000 SRM 0331 | 09/03 |
| PERIODIC MAINTENANCE | 897123 | 8000 SRM 0341 | 12/03 |
| DIAGRAMS-GM ELECTRONIC ENGINE CONTROL | 897501 | 8000 SRM 0519 | 12/03 |
| PART NO. 1559725 | |||
| Rev. 03/04 | |||
Perkins Diesel Engines…2
Safety Precautions Maintenance and Repair…3
General…10
General Safety Rules…10
Description…11
Engine Serial Number Codes…11
Engine Data…13
Engine Removal and Installation…14
Cylinder Head Assembly Repair…14
Engine Breather…14
Remove…14
Install…14
Valve Cover…15
Remove…15
Install…15
Rocker Arm Assembly…17
Remove…17
Disassemble…17
Inspect…17
Assemble…17
Install…18
Valve Clearance Adjustments…18
Valve Springs…19
Cylinder Head Assembly…20
Remove…20
Inspect…21
Install…22
Valves and Valve Springs…23
Remove…23
Inspect…24
Install…24
Valve Guides…25
Inspect…25
Remove…25
Install…25
Valve Seats…27
Inspect…27
Repair…27
New Valve Seats, Install…28
Piston and Connecting Rod Assemblies Repair…28
General…28
Rod Bearings…29
Remove…29
Install…29
Piston and Connecting Rod Assembly…30
Service Note…30
Remove…30
Disassemble…31
Inspect…31
How to Select Correct Replacements…32
Assemble…33
Install…34
Piston Cooling Jets…35
Remove…35
Install…36
Crankshaft Assembly Repair…36
General…36
Crankshaft Pulley…36
Remove…36
Inspect…36
Install…37
Rear Oil Seal…37
Remove…37
Install…37
Crankshaft Flange Wear Sleeve…39
Remove…39
Install…39
Main Bearings…40
Remove…40
Inspect…40
Install…41
Thrust Washers…42
Crankshaft Axle Movement, Check…42
Remove…42
Install…43
Crankshaft…43
Remove…43
Inspect…44
Install…44
Crankshaft Timing Ring…46
Remove…46
Install…46
Flywheel…46
Remove…46
Ring Gear, Replace…47
Install…47
Flywheel Housing…47
Remove…47
Install…48
Timing Case and Timing Gears Repair…48
General…48
Timing Case Cover…48
Remove…48
Install…49
Front Oil Seal…50
Remove, With Timing Case Installed…50
Install, With Timing Case Installed…50
Remove, With Timing Case Removed…51
Install, With Timing Case Removed…51
Crankshaft Pulley Wear Sleeve, Install…52
Fuel Pump Gear…52
Remove…52
Install…54
Idler Gear and Hub…55
Remove…55
Disassemble…56
Standard Idler Gear and Hub Assembly…56
Heavy Duty Idler Gear and Hub Assembly…56
Assemble…56
Standard Idler Gear and Hub Assembly…56
Heavy Duty Idler Gear and Hub Assembly…57
Install…57
Camshaft Gear…58
Remove…58
Install…58
Crankshaft Gear…59
Remove…59
Install…59
Timing Case…59
Remove…59
Install…60
Power Take-Off (PTO) Adaptor…61
Remove…61
Disassemble…62
Assemble…62
Install…62
Camshaft and Tappets…62
Remove…62
Install…63
Cylinder Block Assembly Repair…63
General…63
Cylinder Block…64
Disassemble…64
Inspect…64
Assemble…64
Cylinder Bore…65
Inspect…65
Cylinder Liner Condition Check…65
Engine Timing…65
General…65
How to Set Number One Piston to TDC on Compression Stroke…65
Fuel Injection Pump Timing, Check…67
Fuel Injection Pump Timing, Adjust…68
Lubrication System Repair…69
General…69
Oil Filter, Replace…69
Oil Filter Head…70
Remove…70
Install…70
Oil Sump…71
Remove…71
Install…71
Oil Pump…72
Remove…72
Inspect…72
Install…73
Oil Strainer and Suction Pipe…74
Remove…74
Install…74
Relief Valve…74
Remove…74
Install…74
Dipstick Tube…75
Remove and Install…75
Fuel System Repair…75
General…75
Cold Start Advance Unit (KSB)…76
Typical Fuel System…77
Fuel Filter…78
Remove…78
Install…78
Fuel Injectors…79
Remove…79
Install…80
Fuel System Air Removal…81
Bosch EVPE Fuel Injection Pump…81
General…81
Remove…82
Install…83
Cooling System Repair…83
General…83
Thermostat…85
Remove…85
Install…85
Test…86
Coolant Pump…86
Remove…86
Disassemble…87
Assemble…88
Install…89
Fan…89
Remove and Install…89
Fan Drive…90
Remove…90
Install…90
Oil Cooler…90
Remove…90
Disassemble and Assemble…90
Install…91
Coolant By-Pass Hose…91
Removal…91
Install…91
Electrical Equipment Repair…91
Drive Belt…91
Check…91
Adjust…92
Remove…92
Install…92
Alternator…92
Remove…92
Install…92
Fault Diagnosis…93
Normal Operation:…93
If the warning lamp is not illuminated when the ignition switch …93
If the Warning Light Continues to be Illuminated When the Altern…94
Starter Motor…94
Remove…94
Install…95
Test…95
Starting Aid…95
Remove…95
Install…95
Check…96
Power Supply Continuity…96
Operation…96
Pressure Sensor…97
Remove…97
Install…98
Temperature Sensor…98
Remove…98
Install…98
Engine Specifications…99
Cylinder Head Assembly…99
Piston and Connecting Rods…102
Crankshaft Assembly…103
Crankshaft Overhaul…103
Timing Case and Drive Assembly…105
Engine Block Assembly…106
Lubrication System…107
Fuel System…107
Cooling System…108
Flywheel and Housing…109
Electrical Equipment…109
Torque Specifications…109
Special Torque Specifications…110
Cylinder Head Assembly…110
Piston and Connecting Rod Assemblies…110
Crankshaft Assembly…110
Timing Case and Drive Assembly…110
Cylinder block…110
Fuel System…110
Lubrication System…110
Cooling System…111
Flywheel and Housing…111
Electrical Equipment…111
Special Tools…112
Troubleshooting…115
tables…2
Table 1. Cylinder Head…99
Table 2. Valve Guides…99
Table 3. Inlet Valves…100
Table 4. Exhaust Valves…100
Table 5. Valve Springs…101
Table 6. Tappets…101
Table 7. Rocker Arm Shaft…101
Table 8. Rocker Arms and Bushings…102
Table 9. Pistons…102
Table 10. Piston Rings…102
Table 11. Piston Pins…102
Table 12. Connecting Rods…102
Table 13. Small End Bushings…103
Table 14. Connecting Rod Bearings…103
Table 15. Piston Cooling Jets…103
Table 16. Crankshaft Overhaul Specifications…104
Table 17. Maximum Variation (Run-out)…105
Table 18. Camshaft…105
Table 19. Camshaft Thrust Washer…105
Table 20. Camshaft Gear…105
Table 21. Gear for Fuel Pump…105
Table 22. Crankshaft Gear…105
Table 23. Idler Gear and Hub…106
Table 24. Timing Gear Backlash Values…106
Table 25. Cylinder Block…106
Table 26. Oil Pump…107
Table 27. Idler Gear for Oil Pump…107
Table 28. Relief Valve…107
Table 29. Oil Filter…107
Table 30. Bosch Fuel Injection Pump…107
Table 31. Fuel Injector Settings…108
Table 32. Fuel Pump…108
Table 33. Fuel Filter…108
Table 34. Coolant Pump…108
Table 35. Thermostat…108
Table 36. Fan Drive Housing…109
Table 37. Limits for Flywheel Run Out and Alignment (Total Indic…109
Table 38. Alternator…109
Table 39. Starter Motor…109
Table 40. Starting Aids…109
Table 41. List of Possible Causes…116
hyster-1559540-03-04-srm1088…120
toc…120
Electronic Controlled LPG/Gasoline Fuel System…120
Safety Precautions Maintenance and Repair…121
General…126
Fuel System Warnings and Cautions…126
Glossary…127
Description and Operation of LPG Fuel System…131
Propane Fuel System…131
LPG Fuel Tank…131
Service Line…131
Fuel Filter…131
Low Pressure Lock-Off (LPL)…131
Low Pressure Regulator (LPR)…133
Air Fuel Mixer…134
Throttle Control Device…135
Drive By Cable…135
Three-Way Catalytic (TWC) Muffler…136
Electronic Control Module (ECM)…136
Heated Exhaust Gas Oxygen (HEGO) Sensor…138
Description and Operation of Gasoline Fuel System…138
Gasoline Fuel System Throttle Body Injection (TBI), 3.0L Engine …138
Gasoline Multi-Point Fuel Injection (MPFI) System, 4.3L Only…138
Gasoline Fuel Storage Tank…140
Gasoline Fuel Pump…140
Fuel Filter…140
Fuel Pressure Regulator, 3.0L Only…140
Fuel Rail and Pressure Regulator, 4.3L Only…142
Fuel Injector…143
Throttle Control Device…143
Drive By Cable…143
Three-Way Catalytic Muffler…143
Electronic Control Module (ECM)…144
Heated Exhaust Gas Oxygen (HEGO) Sensor…146
LPG Fuel System Repair…146
Propane Fuel System Pressure Relief…146
Propane Fuel System Leak Test…146
Propane Fuel Filter Replacement…147
Remove…147
Install…147
Low Pressure Lock-Off (LPL) Replacement…147
Remove…147
Install…147
Pressure Trim Valve (PTV) Replacement…148
Remove…148
Install…149
Low Pressure Regulator…149
Remove…149
Install…149
Fuel Trim Valve (FTV) Solenoid Replacement…150
Remove…150
Install…151
Temperature Manifold Absolute Pressure (TMAP)…151
Remove…151
Install…151
Throttle Body Replacement…151
Remove…151
Install…152
Mixer Replacement…152
Remove…152
Install…152
Coolant Hose Replacement…152
Remove…152
Install…152
Vapor Hose Replacement…153
Remove…153
Install…153
Balance Line Hose Replacement…153
Remove…153
Install…153
PTV Hose Replacement…153
Remove…153
Install…153
FTV Hose Replacement…153
Remove…153
Install…154
Throttle Position Sensor (TPS) Replacement…154
Remove…154
Install…154
Foot Pedal Position (FPP) Sensor Replacement…154
Remove…154
Install…154
Electronic Control Module (ECM) Replacement…154
Remove…154
Install…155
Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement…155
Remove…155
Install…155
Three-Way Catalytic Muffler (TWC) Replacement…155
Remove…155
Install…155
Restricted Exhaust System Diagnosis…155
Exhaust System Description…155
Tools Required…156
Diagnostic Tool…156
Check at Heated Exhaust Gas Oxygen Sensor (HEGO)…156
Gasoline Fuel System Repair…157
Gasoline MPFI and TBI Fuel System Pressure Relief…157
Gasoline Fuel System Leak Test…157
Throttle Body Injector (TBI) Assembly Replacement, 3.0L Only…157
Remove…157
Install…158
Throttle Body Assembly Replacement, 3.0L Only…158
Remove…158
Install…158
Throttle Body Assembly Replacement, 4.3L Only…159
Remove…159
Install…159
Fuel Rail Replacement, Gasoline 4.3L Only…160
Remove…160
Install…160
Injector Replacement, Gasoline 4.3L Only…160
Remove…160
Install…160
Injector Replacement, Gasoline 3.0L Only…162
Remove…162
Install…162
Temperature Manifold Absolute Pressure (TMAP) Replacement…162
Remove…162
Install…162
Throttle Position Sensor (TPS) Replacement…162
Remove…162
Install…162
Foot Pedal Position (FPP) Sensor Replacement…163
Remove…163
Install…163
Electronic Control Module (ECM) Replacement…163
Remove…163
Install…163
Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement…163
Remove…163
Install…163
Three-Way Catalytic Muffler (TWC) Replacement…164
Remove…164
Install…164
Restricted Exhaust System Diagnosis…164
Exhaust System Description…164
Tools Required…164
Diagnostic Tool…164
Check at Heated Exhaust Gas Oxygen Sensor (HEGO)…164
LPG System Diagnosis…165
Fuel System Description…165
Diagnostic Aids…166
Tools Required…166
Duty Cycle Monitoring Tool…166
Diagnostic Tool…166
Pressure Gauges…166
Test Description…166
Gasoline System Diagnosis…173
Fuel System Description, 3.0L Only…173
Fuel System Description, 4.3L Only…174
Diagnostic Aids…174
Tools Required…175
Diagnostic Tool…175
Test Description…175
LPG Symptom Diagnosis…182
Gasoline Symptom Diagnosis…195
Wire Harness Repair…205
On Vehicle Service Wiring Harness Repair…205
Connectors and Terminals…206
Twisted/Shielded Cable Repair…206
Twisted Leads Repair…207
Micro-Pack…208
Metri-Pack…208
Remove…208
Weather-Pack…210
Weather-Pack Terminal Repair…211
tables…120
Table 1. LPG Fuel System Diagnosis…166
Table 2. Fuel Control Diagnosis…170
Table 3. Gasoline Fuel System Diagnosis, 3.0L Only…176
Table 4. Gasoline Fuel System Diagnosis, 4.3L Only…179
Table 5. Preliminary Checks…182
Table 6. Intermittent …183
Table 7. No Start…184
Table 8. Hard Start…185
Table 9. Cuts Out or Misses…187
Table 10. Hesitation, Sag, or Stumble…188
Table 11. Backfire…189
Table 12. Lack of Power, Sluggishness, or Sponginess…190
Table 13. Poor Fuel Economy…191
Table 14. Rough, Unstable, Incorrect Idle, or Stalling…192
Table 15. Surges or Chuggles…194
Table 16. Preliminary Checks…195
Table 17. Intermittent…196
Table 18. No Start…197
Table 19. Hard Start…198
Table 20. Cuts Out or Misses…199
Table 21. Hesitation, Sag, or Stumble…200
Table 22. Backfire…201
Table 23. Lack of Power, Sluggishness, or Sponginess…202
Table 24. Poor Fuel Economy…203
Table 25. Rough, Unstable, Incorrect Idle, or Stalling…204
Table 26. Surges or Chuggles…205
hyster-1559545-01-04-srm1090…216
toc…216
Electronic Control Module (ECM) Diagnostic Troubleshooting…216
Safety Precautions Maintenance and Repair…217
General…224
Description of ECM Based Diagnostics…224
Definition of Terms…224
Diagnostics Overview of the Spectrum Fuel System…224
Malfunction Indicator Lamp (MIL)…225
Spectrum Diagnostic Trouble Codes (DTC)…225
Using a Laptop Computer to Diagnose the Spectrum System…225
Installing the Spectrum Diagnostic Software…225
Connecting a Laptop Computer to the Spectrum System…226
Diagnostic Trouble Codes…226
Checking Diagnostic Trouble Codes…226
Clearing Diagnostic Trouble Codes…227
DATA Stream…227
Reading Sensor and Actuator Values…227
Graphing and Data Logging…228
Ignition System Test…229
Disabling Ignition Outputs…229
Injector Test…230
Disabling Injectors…230
Throttle Test…231
Using a Diagnostic Jumper to Diagnose the ECI System…231
On-Board Diagnostics System Check/Malfunction indicator lamp…232
Circuit Description…232
Preliminary and Intermittent Checks…235
DTC 111 – IAT High Voltage Bosch® TMAP…237
Circuit Description…237
Conditions for Setting the DTC…237
DTC 111 – IAT High Voltage Motorola® TMAP…240
Circuit Description…240
Conditions for Setting the DTC…240
DTC 112 – IAT Low Voltage Bosch® TMap…243
Circuit Description…243
Conditions for Setting the DTC…243
DTC 112 – IAT Low Voltage Motorola® TMAP…245
Circuit Description…245
Conditions for Setting the DTC…245
DTC 113 – IAT Higher Than Expected 1 Bosch® TMAP…248
Circuit Description…248
Conditions for Setting the DTC…248
Diagnostic Aids…248
DTC 113 – IAT Higher Than Expected 1 Motorola® TMAP…249
Circuit Description…249
Conditions for Setting the DTC…249
Diagnostic Aids…249
DTC 114 – IAT Higher Than Expected 2 Bosch® TMAP…250
Circuit Description…250
Conditions for Setting the DTC…250
Diagnostic Aids…250
DTC 114 – IAT Higher Than Expected 2 Motorola® TMAP…251
Circuit Description…251
Conditions for Setting the DTC…251
Diagnostic Aids…251
DTC 115 – Oil Pressure Low…252
Circuit Description…252
Conditions for Setting the DTC…252
DTC 121 – ECT Voltage High…255
Circuit Description…255
Conditions for Setting the DTC…256
DTC 122 – ECT Low Voltage…259
Circuit Description…259
Conditions for Setting the DTC…259
DTC 123 – ECT Higher Than Expected 1…261
Circuit Description…261
Conditions for Setting the DTC…261
DTC 124 – ECT Higher Than Expected 2…263
Circuit Description…263
Conditions for Setting the DTC…263
DTC 131 – MAP High Pressure Bosch® TMAP…264
Circuit Description…264
Conditions for Setting the DTC…264
Diagnostic Aids…265
DTC 131 – MAP High Pressure Motorola® TMAP…267
Circuit Description…267
Conditions for Setting the DTC…267
Diagnostic Aids…268
DTC 132 – MAP Low Voltage Bosch® TMAP…271
Circuit Description…271
Conditions for Setting the DTC…271
DTC 132 – MAP Low Voltage Motorola® TMAP…275
Circuit Description…275
Conditions for Setting the DTC…275
DTC 134 – BP High Pressure Bosch® TMAP…279
Circuit Description…279
Conditions for Setting the DTC…279
DTC 134 – BP High Pressure Motorola® TMAP…281
Circuit Description…281
Conditions for Setting the DTC…281
DTC 135 – BP Low Pressure Bosch® TMAP…283
Circuit Description…283
Conditions for Setting the DTC…283
DTC 135 – BP Low Pressure Motorola® TMAP…287
Circuit Description…287
Conditions for Setting the DTC…287
DTC 142 – Crank Sync Noise…291
Circuit Description…291
Conditions for setting the DTC…291
DTC 143 – Never Crank Synced At Start…294
Circuit Description…294
Conditions for Setting the DTC…294
DTC 144 – Camshaft Sensor Loss…297
Circuit Description…297
Conditions for Setting the DTC…297
DTC 145 – Camshaft Sensor Noise…300
Circuit Description…300
Conditions for Setting the DTC…300
DTC 211 – Closed Loop Multiplier High (LPG)…303
Circuit Description…303
Conditions for Setting the DTC…303
Diagnostic Aids…304
DTC 212 – HO 2 S Open/Inactive…305
Circuit Description…305
Conditions for Setting the DTC…305
DTC 213 – HO 2 S Open/Inactive (Post-Cat)…309
Circuit Description…309
Conditions for Setting the DTC…309
DTC 221 – Closed Loop Multiplier High (Gasoline)…311
Circuit Description…311
Conditions for Setting the DTC…311
Diagnostic Aids…311
DTC 222 – Closed Loop Multiplier Low (Gasoline)…314
Circuit Description…314
Conditions for Setting the DTC…314
Diagnostic Aids…315
DTC 224 – Closed Loop Multiplier Low (LPG)…316
Circuit Description…316
Conditions for Setting the DTC…316
Diagnostic Aids…317
DTC 241 – Adaptive Lean Fault (High Limit-Gasoline)…318
Circuit Description…318
Conditions for Setting the DTC…318
Diagnostic Aids…319
DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline)…321
Circuit Description…321
Conditions for Setting the DTC…321
Diagnostic Aids…321
DTC 243 – Adaptive Learn High (LPG)…323
Circuit Description…323
Conditions for Setting the DTC…323
Diagnostic Aids…324
DTC 244 – Adaptive Learn Low (LPG)…327
Circuit Description…327
Conditions for Setting the DTC…327
Diagnostic Aids…328
DTC 261 – System Voltage Low…330
Circuit Description…330
Conditions for Setting the DTC…330
DTC 262 – System Voltage High…333
Circuit Description…333
Conditions for Setting the DTC…333
DTC 411 – Injector Driver 1 Open (3.0L only)…335
Circuit Description…335
Conditions for Setting the DTC…335
DTC 412 – Injector Driver 1 Shorted (3.0L only)…338
Circuit Description…338
Conditions for Setting the DTC…338
DTC 511 – COP Failure…341
Circuit Description…341
Conditions for Setting the DTC…341
DTC 512 – Invalid Interrupt…343
Circuit Description…343
Conditions for Setting the DTC…343
DTC 513 – A/D Loss…345
Circuit Description…345
Conditions for Setting the DTC…345
DTC 514 – RTI 1 Loss…347
Circuit Description…347
Conditions for Setting the DTC…347
DTC 515 – Flash Checksum Invalid…349
Circuit Description…349
Conditions for Setting the DTC…349
DTC 516 – Ram Failure…351
Circuit Description…351
Conditions for Setting the DTC…351
DTC 531 – External 5V Ref Lower Than Expected…353
Circuit Description…353
Conditions for Setting the DTC…353
DTC 532 – External 5V Ref Higher Than Expected…355
Circuit Description…355
Conditions for Setting the DTC…355
DTC 555 – RTI 2 Loss…357
Circuit Description…357
Conditions for Setting the DTC…357
DTC 556 – RTI 3 Loss…359
Circuit Description…359
Conditions for Setting the DTC…359
DTC 611 – FPP High Voltage…361
Circuit Description…361
Conditions for Setting the DTC…361
DTC 612 – FPP Low Voltage…365
Circuit Description…365
Conditions for Setting the DTC…365
DTC 631 – TPS1 Signal Voltage High…369
Circuit Description…369
Conditions for Setting the DTC…369
DTC 632 – TPS1 Signal Voltage Low…372
Circuit Description…372
Conditions for Setting the DTC…372
DTC 637 – Throttle Unable To Open…375
Circuit Description…375
Conditions for Setting the DTC…375
DTC 638 – Throttle Unable To Close…377
Circuit Description…377
Conditions for Setting the DTC…377
DTC 651 – Maximum Govern Speed Override…381
Circuit Description…381
Conditions for Setting the DTC…381
DTC 652 – Fuel Rev Limit…383
Circuit Description…383
Conditions for Setting the DTC…383
DTC 653 – Spark Rev Limit…386
Circuit Description…386
Conditions for Setting the DTC…386
Wire Harness Repair…388
On Vehicle Service Wiring Harness Repair…388
Connectors and Terminals…389
Twisted/Shielded Cable Repair…389
Twisted Leads Repair…390
Micro-Pack…391
Metri-Pack…391
Remove…391
Weather-Pack…393
Weather-Pack Terminal Repair…393
tables…216
Table 1. OBD System Check…233
Table 2. Preliminary Checks…235
Table 3. Intermittent Checks…236
Table 4. DTC 111 – IAT Voltage High (Bosch® TMAP)…238
Table 5. DTC 111 – IAT Voltage High (Motorola® TMAP)…241
Table 6. DTC 112 – IAT Low Voltage (Bosch® TMAP)…244
Table 7. DTC 112 – IAT Low Voltage (Motorola® TMAP)…246
Table 8. DTC 115 – Oil Pressure Low…253
Table 9. Temperature Resistance…255
Table 10. DTC 121 – ECT VOLTAGE HIGH…256
Table 11. DTC 122 – ECT Low Voltage…260
Table 12. DTC 123 – ECT Higher Than Expected 1…262
Table 13. DTC 124 – ECT Higher Than Expected 2…264
Table 14. DTC 131 – MAP HIGH PRESSURE (Bosch® TMAP)…265
Table 15. DTC 131 – MAP HIGH PRESSURE (Motorola® TMAP)…268
Table 16. DTC 132 – MAP Low Voltage (Bosch® TMAP)…272
Table 17. DTC 132 – MAP Low Voltage (Motorola® TMAP)…276
Table 18. DTC 134 – BP High Pressure (Bosch® TMAP)…280
Table 19. DTC 134 – BP High Pressure (Motorola® TMAP)…282
Table 20. DTC 135 – BP Low Pressure (Bosch® TMAP)…284
Table 21. DTC 135 – BP Low Pressure (Motorola® TMAP)…288
Table 22. DTC 142 – Crank Sync Noise…292
Table 23. DTC 143 – Never Crank Synced At Start…294
Table 24. DTC 144 – Camshaft Sensor Loss…297
Table 25. DTC 145 – Camshaft Sensor Noise…301
Table 26. DTC 211 – Closed Loop Multiplier High (LPG)…304
Table 27. DTC 212 – HO 2 S Open/Inactive…306
Table 28. DTC 213 – HO 2 S Open/Inactive (Post-Cat)…310
Table 29. DTC 221 – Closed Loop Multiplier High (Gasoline)…312
Table 30. DTC 222 – Closed Loop Multiplier Low (Gasoline)…315
Table 31. DTC 224 – Closed Loop Multiplier Low (LPG)…317
Table 32. DTC 241 – Adaptive Lean Fault (High Limit-Gasoline)…319
Table 33. DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline)…322
Table 34. DTC 243 – Adaptive Learn High (LPG)…325
Table 35. DTC 244 – Adaptive Learn Low (LPG)…328
Table 36. DTC 261 – System Voltage Low…331
Table 37. DTC 262 – System Voltage High…334
Table 38. DTC 411 – Injector Driver 1 Open (3.0L Only)…336
Table 39. DTC 412 – Injector Driver 1 Shorted (3.0L only)…339
Table 40. DTC 511 – COP Failure…342
Table 41. DTC 512 – Invalid Interrupt…344
Table 42. DTC 513 – A/D Loss…346
Table 43. DTC 514 – RTI 1 Loss…348
Table 44. DTC 515 – Flash Checksum Invalid…350
Table 45. DTC 516 – Ram Failure…352
Table 46. DTC 531 – External 5V Ref Lower Than Expected…354
Table 47. DTC 532 – External 5 V Ref Higher Than Expected…356
Table 48. DTC 555 – RTI 2 Loss…358
Table 49. DTC 556 – RTI 3 Loss…360
Table 50. DTC 611 – FPP High Voltage…362
Table 51. DTC 612 – FPP Low Voltage…366
Table 52. DTC 631 – TPS1 Signal Voltage High…370
Table 53. DTC 632 – TPS1 Signal Voltage Low…373
Table 54. DTC 637 – Throttle Unable To Open…376
Table 55. DTC 638 – Throttle Unable To Close…378
Table 56. DTC 651 – Maximum Govern Speed Override…382
Table 57. DTC 652 – Fuel Rev Limit…384
Table 58. DTC 653 – Spark Rev Limit…387
hyster-1559550-12-03-srm1097…398
toc…398
High Voltage Switch (HVS) Ignition…398
Safety Precautions Maintenance and Repair…399
Description…402
Distributor Ignition (DI) System…402
Crankshaft Position (CKP) Sensor…402
Camshaft Position (CMP) Sensor…402
Ignition Coil and Ignition Control Module (ICM)…402
Secondary Ignition Components…402
Spark Plugs and Wires…402
Spark Plug Wire Inspection…402
Spark Plug Wire Replacement…402
Remove…402
Install…403
Spark Plug Inspection…403
Usage…403
Inspection…403
Visual Inspection…405
Spark Plug Replacement…405
Remove…405
Install…405
Distributor Repair…406
Inspect…406
Overhaul…406
Disassemble…406
Assemble…409
Replace…409
Remove…409
Install Procedure 1…411
Install Procedure 2…412
Ignition Coil Replacement…414
Remove…414
Install…414
Ignition Control Module Replacement…415
Remove…415
Install…415
Camshaft Position (CMP) Sensor Replacement…415
Remove…415
Install…417
Crankshaft Position (CKP) Sensor Replacement…417
Remove…417
Install…417
Wire Harness Repair…419
On Vehicle Service Wiring Harness Repair…419
Connectors and Terminals…419
Twisted/Shielded Cable Repair…420
Twisted Leads Repair…421
Micro-Pack…421
Metri-Pack…421
Remove…422
Weather-Pack…423
Weather-Pack Terminal Repair…424
Specifications and Special Tools…425
System Diagnosis…427
tables…398
Table 1. Ignition System Specifications…425
Table 2. Fastener Tightening Specifications…425
Table 3. Special Tools…426
Table 4. Distributor Ignition (DI)…427
hyster-897104-11-03-srm0322…434
toc…434
Frame…434
Safety Precautions Maintenance and Repair…435
General…438
Description…438
Counterweight Repair…439
Remove…439
Install…439
Hood Repair…440
Remove…440
Install…440
Overhead Guard Repair…440
Remove…440
Install…440
Operator Restraint System Repair…441
Hydraulic Tank Repair…442
Remove…442
Inspect…442
Small Leaks Repair…442
Large Leaks Repair…442
Clean…442
Steam Method…443
Chemical Solution Method…443
Other Methods of Preparation for Repair…443
Install…443
Fuel Tank Repair…444
Remove…444
Repair…444
Install…444
Radiator Repair…444
Remove…444
Install…444
Engine Repair…445
Remove…445
Install…445
Safety Labels…447
Cab Repair…449
Cab, Replace…449
Window, Replace…449
Windshield Wipers and Heater…449
tables…434
Table 1. Material Specifications for Cab Windows…451
hyster-897106-10-03-srm0324…454
toc…454
Two-Speed Powershift Transmission…454
Safety Precautions Maintenance and Repair…455
General…458
Mechanical Description…458
Torque Converter…458
Transmission Pump…459
Shaft Assemblies…459
Input Shaft…460
Forward Clutch Shaft…460
Clutch Assemblies…460
Countershaft…467
Output Shaft…467
Hydraulic Operation…468
Torque Converter…468
Seal Rings…469
Control Valve…469
System Pressure Regulator…472
Clutch Pressure Regulator…472
Torque Converter Regulator…473
Inching Spool…473
Direction Spool, Direction Control Lever…473
Direction Spool, MONOTROL Pedal…474
Range Spool…474
Drain Spool…475
Accumulator…475
Modulator Spool…475
Operation…475
Lubrication Circuit…476
MONOTROL Pedal…476
Oil Flow Diagrams…478
Neutral…478
Forward-Low…479
Forward-Low-Inching…480
Reverse-Low…481
hyster-897107-10-03-srm0325…484
toc…484
Two-Speed Powershift Transmission…484
Safety Precautions Maintenance and Repair…485
General…488
Transmission Repair…488
Transmission and Torque Converter, Remove…488
Transmission, Disassemble…490
Reverse-Low Clutch, Disassemble…493
Reverse-High Clutch, Disassemble…496
Forward-Low Clutch, Disassemble…499
Forward-High Clutch, Disassemble…502
Clean and Inspect…504
Forward Low and High Clutches Assembly…505
Forward Clutches, Assemble…507
Reverse-Low Clutch, Assemble…513
Reverse Clutches, Assemble…515
Transmission, Assemble…522
Torque Converter, Install…529
Control Valve Repair…530
Remove…530
Disassemble…531
Assemble…532
Install…534
MONOTROL Pedal…534
Remove and Disassemble…534
Assemble and Install…534
Stall Test…537
Linkage Adjustments…538
Linkage for Inching Pedal H6.00-7.00XL (H135-155XL, H135-155XL 2…538
Linkage for Inching Pedal S6.00-7.00XL (S135-155XL, S135-155XL 2…541
Linkage for Range Lever – Early Model H6.00-7.00XL (H135-155XL) …544
Linkage for Direction Control Lever – Early Model H6.00-7.00XL (…544
Linkage for Range Lever – Later Model H6.00-7.00XL (H135-155XL, …546
Linkage for Direction Control Lever – Later Model H6.00-7.00XL (…548
Linkage for Range Lever S6.00-7.00XL (S135-155XL, S135-155XL 2 )…550
Linkage for Direction Control Lever S6.00-7.00XL (S135-155XL, S1…550
Oil Pressure Check…552
System Pressure Check Port…552
Torque Converter Check Port…552
Clutch Pressure Check Port…552
Inching Pressure…553
Solenoid Check Ports (MONOTROL Control Only)…553
Lubrication Pressure Check Ports…553
Specifications…554
Troubleshooting…554
Correct System Pressure: 1300 ±124 kPa ( 189 ±18 psi)…557
Correct Clutch Pressure: 924 ±69 kPa ( 134 ±10 psi)…558
Correct Solenoid Pressure (MONOTROL Only): 965 ±138 kPa ( 140 ±2…559
Torque Converter Pressure: 834 ±69 kPa ( 121 ±10 psi)…559
Lubrication Pressure: 83 ±21 kPa ( 12 ±3 psi)…559
tables…484
Table 1. Stall Speed Specifications…537
hyster-897108-10-03-srm0326…562
toc…562
Steering Axle…562
Safety Precautions Maintenance and Repair…563
General…566
Description…566
Steering Axle Assembly Repair…570
Steering Axle H3.50-5.00XL (H70-110XL) (G005), S3.50-5.50XL (S70…570
Remove…570
Install…571
Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL 2 ) (F006, G0…571
Remove…571
Install…572
Wheels and Hubs Repair (All Units)…572
Remove and Disassemble…572
Clean…572
Inspect…572
Assemble and Install…573
Spindles and Bearings Repair (All Units)…574
Remove…574
Clean…574
Assemble and Install…574
Tie Rods Repair (All Units)…575
Remove…575
Clean…575
Install…575
Steering Cylinder Repair…578
Remove and Disassemble…578
Clean and Inspect…578
Assemble and Install…578
Troubleshooting…579
hyster-897109-09-03-srm0327…584
toc…584
Brake System…584
Safety Precautions Maintenance and Repair…585
General…588
Description…588
Operation…589
Brake Booster and Master Cylinder…589
Brake Booster…589
Master Cylinder…590
Service Brake Assembly…591
Parking Brake…592
Brake Shoe Assemblies Repair…593
Remove and Disassemble…593
Clean and Inspect…594
Cleaning Procedures…594
Inspect…594
Assemble and Install…595
Master Cylinder Repair…596
Remove…596
Disassemble…596
Assemble…598
Install…598
Brake Booster Repair…598
Remove…598
Disassemble…598
Clean and Inspect…600
Assemble…600
Install…600
Brake System Air Removal…600
Brake Pedal Adjustment…601
Brake Shoes Adjustment…602
Parking Brake Adjustment…602
Parking Brake Switch Adjustment…602
Brake Booster Relief Valve Check…602
Troubleshooting…603
hyster-897110-09-03-srm0328…608
toc…608
Hydraulic System…608
Safety Precautions Maintenance and Repair…609
General…612
Description and Operation…612
Hydraulic Pumps…614
Main Control Valve…614
Control Valve Lever…615
Steering Control Unit…615
Brake Valve…615
Oil Clutch, H6.00-7.00XL (H135-155XL) (F006)…616
Troubleshooting…616
Lift, Lower, and Tilt Circuit…617
Steering, Brake, and Oil Clutch System…618
hyster-897111-10-03-srm0329…622
toc…622
Masts…622
Safety Precautions Maintenance and Repair…623
General…626
Description and Operation…626
General…626
Safety Procedures When Working Near Mast…627
Two-Stage Mast…627
Three-Stage Mast…629
Carriage Repair…631
Remove…631
Sideshift Carriage, Disassemble…631
Sideshift Carriage, Assemble…632
Install…632
Two-Stage Mast Repair…634
Remove…634
Disassemble…635
Clean and Inspect…636
Assemble…637
Install…637
Three-Stage Mast Repair…639
Remove…639
Disassemble…639
Clean and Inspect…639
Assemble…639
Install…641
Mast Operation Check…641
Lift and Tilt System Leaks Check…642
Lift System…642
Tilt System…642
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment…643
Lift Chain Adjustments…643
Mast Adjustments…646
Carriage Adjustment…646
Troubleshooting…648
tables…622
Table 1. Mast Parts Weight…635
Table 2. Hook-Type Carriage Chain Adjustment…644
Table 3. Pin-Type Carriage Chain Adjustment…644
hyster-897113-09-03-srm0331…652
toc…652
Capacities and Specifications…652
Safety Precautions Maintenance and Repair…653
Lift Truck Weights…656
Capacities…656
Tire Sizes…657
Tire Pressure…657
Electrical System…657
Wheel Nut Torque…657
Engine Specifications…658
Hydraulic System…658
Mast Speeds…659
Transmission Oil Pressures…659
Torque Specifications…660
Engine – GM 4.3L V-6…660
Engine – Perkins 4.2482…660
Engine – Perkins 1004.4…660
Clutch…660
Manual Transmission…661
Powershift Transmission…661
Speed Reducer…661
Drive Axle…661
Steering System…661
Brake System…661
Hydraulic System…662
Tilt Cylinder…662
Mast…662
hyster-897123-12-03-srm0341…666
toc…666
Periodic Maintenance…666
Safety Precautions Maintenance and Repair…667
General…672
Serial Number Data…672
How to Move Disabled Truck…672
How to Tow Lift Truck…672
How to Put Lift Truck on Blocks…673
How to Raise Drive Tires…673
How to Raise Steering Tires…673
Maintenance Schedule…674
Maintenance Procedures Every 8 Hours or Daily…690
How to Make Checks With Engine Stopped…690
Hydraulic System Oil…691
Engine Oil…691
Drive Belts…692
Intake Manifold Rubber Cap…692
Cooling System…692
Air Filter…693
Fuel System…693
Primary Fuel Filter, Diesel Engine…694
Battery…694
Tires and Wheels…694
Forks…695
Adjust…695
Remove and Install…695
Forks, Mast, and Lift Chains, Inspect…698
Operator Restraint System…699
Safety Labels…700
How to Make Checks With Engine Running…700
Gauges, Lights, Horn, and Fuses…700
Oil Level, Powershift Transmission…702
Oil Level, Oil Clutch System, H3.50-5.00XL (H70-110XL)…702
Control Levers and Pedals…702
Lift System Operation…702
Inching/Brake Pedal…703
Service Brakes…703
Parking Brake…703
Steering System…703
Maintenance Procedures Every 250 Hours or 6 Weeks…704
Engine Oil and Filter, GM V-6 Engine…704
Lift Chains, Lubrication…704
Drive Shafts…704
Mast Lubrication…705
Crankcase Breather, GM V-6…705
Air Filter, GM V-6 EPA Compliant Engine …705
Maintenance Procedures Every 350 Hours or 2 Months…706
Engine Oil and Filter, Perkins 4.2482 Diesel Engine…706
Drive Belts…706
Perkins Diesel Engine…706
GM V-6 Engine (Early Models)…707
GM V-6 Engine (Late Models)…707
Brake Fluid…709
Lift Chains Wear Check…709
Forks Wear and Damage Check…710
Steering Axle Lubrication…710
Fuel System, Checks and Adjustments…710
Diesel Fuel System…710
LPG Carburetor (Early Models)…710
Gasoline Carburetor (Early Models)…711
Fuel Injection (Late Models)…711
Crankcase Breather, Perkins 4.2482 Diesel Engine…711
Hydraulic Tank Breather…711
Cooling System, Clean Debris from Radiator Core…711
Maintenance Procedures Every 500 Hours or 3 Months…712
Engine Oil and Filter, Perkins Diesel Engine…712
Crankcase Breather, Perkins Diesel Engine…712
PCV Valve, GM V-6…712
Maintenance Procedures Every 1000 Hours or 6 Months…713
Manifold Heat Valve, GM V-6 (Early Models)…713
Ignition System, GM V-6…713
Valve Clearance Adjustment…713
Fuel Filter, Replace (Diesel Engine)…713
Fuel System Air Removal (Perkins 1004-4 Diesel Engine)…713
Fuel Injection Pump With Vent Tube…714
Fuel Injection Pump With Vent Screw…714
Fuel System Air Removal (Perkins 4.2482 Diesel Engine)…716
Oil Level Check in Transmission…716
Manual Transmission, H3.50-5.00XL (H70-110XL)…716
Speed Reducer for Powershift Transmission, H3.50-5.00XL (H70-110…716
Manual Transmission, H6.00-7.00XL (H135-155XL)…716
Differential and Drive Axle for Powershift Transmission, H6.00-7…716
Differential, Speed Reducer, and Drive Axle for Manual Transmiss…717
Control Levers and Pedals, Lubricate…717
Crankcase Breather, Replace…717
Cooling System, GM V-6 EPA Compliant Engine…717
Spark Plug Replacement…717
Remove…717
Install…718
LPG Fuel Filter GM V-6 EPA Compliant Engine, Replace…718
Inspect Engine Electrical System, Connectors, and FCVS Connectio…719
Maintenance Procedures Every 2000 Hours or Yearly…719
Hydraulic System…719
Hydraulic Oil and Filter, H3.50-5.00XL (H70-110XL), Replace…719
Hydraulic Oil and Filter, H6.00-7.00XL (H135-155XL, H135-155XL 2…720
Oil Change and Oil Filter Replacement, Powershift Transmission, …720
Oil Change, Manual Transmission, H3.50-5.00XL (H70-110XL)…720
Oil Change, Manual Transmission, H6.00-7.00XL (H135-155XL)…720
Oil Change, Speed Reducer, Powershift Transmission, H3.50-5.00XL…720
Oil and Filter Change, Oil Clutch System, H3.50-5.00XL (H70-110X…721
Oil Change, Differential and Drive Axle, Powershift Transmission…721
Oil Change, Differential, Speed Reducer, and Drive Axle, Manual …721
Cooling System…721
PCV Valve, GM V-6…721
Service Brakes…722
LPG Filter, Replace…722
Gasoline Fuel Filter, Replace…723
Hood Latch Check, H3.50-5.00XL (H70-110XL)…723
Air Filter Element, GM V-6 EPA Compliant Engine…723
Oxygen Sensor GM V-6 EPA Compliant Engine…723
Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks…724
Check Throttle Shaft for Sticking…725
Inspect Exhaust Manifold and Piping for Leaks…725
Test LPG/GAS Regulator Pressure…725
Safety Procedures When Working Near Mast…725
Lift Chain Adjustments…727
Fuel Injectors Repair…729
Lift and Tilt System Leak Check…729
Lift Cylinders, Leak Check…729
Tilt Cylinders, Leak Check…730
Welding Repairs…730
Overhead Guard Changes…731
Wheel and Tire Replacement…732
Remove Wheels From Lift Truck…732
Remove Wheels From Tire…732
Remove Tire From Two-Piece Wheel…733
Remove Tire From Three- and Four-Piece Wheels…735
Install Wheel in Tire…736
Install Three- or Four-Piece Wheel in Tire…737
Install Two-Piece Wheel in Tire…738
Add Air to Pneumatic Tires…739
Wheels, Install…739
Solid Rubber Tires Repair…740
Wheel, Tire Remove…740
Wheel, Tire Install…742
SIT Tire, Change for H3.50-5.00XL (G005), and H6.00-7.00XL (F006…743
Remove SIT Solid Tire From Wheel…744
Install SIT Solid Tire on Wheel…745
Adhesives and Sealants…746
Hydraulic Oil, Lubricant, and Coolant Specifications…747
tables…666
Table 1. Maintenance Schedule…676
Table 2. Hook-Type Carriage Chain Adjustment…728
Table 3. Pin-Type Carriage Chain Adjustment…728
hyster-897501-12-03-srm0519…750
toc…750
Diagrams…750
Safety Precautions Maintenance and Repair…751
hyster-897800-11-03-srm0590…814
toc…814
GM Engines…814
Safety Precautions Maintenance and Repair…815
General…818
Description…818
Engine Removal and Installation…819
Cylinder Head Repair…819
Remove and Disassemble…819
Clean and Inspect…819
Valve Guides and Seats, Repairs…820
Valves, Repair…820
Valve Seats, Repair…821
Valve Springs…822
Rocker Arm Studs (Early Models)…822
Rocker Arm Studs (Late Models)…823
Assemble and Install…823
Cylinder Block Cleaning and Inspection…827
Piston Bore Preparation…827
Engine Mounts Installation…827
Lubrication System Repair…828
Oil Pump, Remove and Disassemble…828
Clean and Inspect…828
Oil Pump, Assemble and Install…828
Oil Sump, Install…829
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters…830
Timing Cover…830
Remove…830
Install…832
Timing Sprockets…832
Remove…832
Install…832
Camshaft…833
Remove…833
Inspect…833
Install…833
Balance Shaft…834
Remove…834
Install…835
Hydraulic Valve Lifters…835
Remove…835
Disassemble…836
Clean and Inspect…836
Assemble…836
Install…837
Crankshaft Repair…838
Remove…838
Inspect and Repair…838
How to Check Clearance Between Main Bearings and Their Journals…839
Install…840
Piston and Connecting Rod Assemblies Repair…841
Connecting Rod Bearings, Replace…841
Piston and Connecting Rod Assemblies, Remove…842
Disassemble…842
Piston, Clean and Inspect…843
Cylinder Bores, Inspect and Repair…843
Piston Rings…844
Assemble…845
Piston and Connecting Rod Assemblies, Install…845
Flywheel and Flywheel Housing Repair…846
Flywheel, Repair…846
Flywheel, Install…846
H3.50-5.00XL (H70-110XL), S3.50-5.50XL (S70-120XL), S6.00-7.00XL…846
H6.00-7.00XL (H135-155XL)…846
Flywheel Housing H3.50-5.00XL (H70-110XL), H3.50-5.50XM (H70-120…846
Engine Adapter H6.00-7.00XL (H135-155XL)…846
Coolant Pump Repair…847
Thermostat Replacement…847
Fan Mount Repair (Early Models)…847
Fan Mount Assembly Repair (Late Models)…847
Drive Belt Installation…849
Valve Clearance Adjustment (Early Models)…850
Valve Clearance Adjustment (New Models)…851
Compression Check…851
Engine Specifications…851
Engine Data…851
Cylinder Head…852
Hydraulic Valve Lifter…852
Camshaft…852
Pistons…852
Crankshaft…853
Connecting Rods…854
Balance Shaft…854
Cooling System…854
Lubrication System…854
Torque Specifications…855
Troubleshooting…856
tables…814
Table 1. Piston Rings Arrangement on Piston…845
hyster-897934-11-01-srm0626…862
toc…862
Cooling System…862
Safety Precautions Maintenance and Repair…863
General…866
Description…867
Radiator…867
Radiator Cap…867
Thermostat…867
Water Pump…868
Fan and Fan Shroud…868
Cooling System Checks…868
Radiator…868
Thermostat…868
Water Pump…869
Exhaust Leaks…869
Fan and Fan Shroud…869
Radiator Cleaning…869
Drain…869
Clean…869
Fill…870
Troubleshooting…871
hyster-899783-10-03-srm0090…874
toc…874
Main Control Valve…874
Safety Precautions Maintenance and Repair…875
General…878
Description…878
Operation…881
Lift Spool…881
Tilt Spool…882
Tilt Backward…882
Tilt Forward…883
Single-Stage Relief Valve…885
Two-Stage Relief Valve…886
Main Control Valve Repair…887
Remove and Disassemble…887
Clean and Inspect…887
Assemble…887
Install…888
Single-Stage Relief Valve Adjustment…888
Two-Stage Relief Valve…889
Auxiliary Control Valve Relief Valve Adjustment (H60-110E Only)…889
Troubleshooting…890
tables…874
Table 1. Relief Pressures (Oil temperature at 55 to 66 C ( 131 t…888
hyster-899784-10-03-srm0002…894
toc…894
Alternator with Regulator…894
Safety Precautions Maintenance and Repair…895
General…898
Description…898
Alternator Repair…900
Alternator Type A…900
Remove and Disassemble…900
Clean…901
Assemble…902
Install…902
Alternator Type B…905
Remove and Disassemble…905
Clean…905
Assemble…906
Install…907
General Check and Adjustment…908
Low Output Check (Type A or Type B)…908
High Output Check (Type A or Type B)…910
Brushes Circuit Check…911
Delco Alternators…911
Motorola Alternators…912
Diodes Check…913
Diode Bridge Check…913
Delco and Leece-Neville Alternators…913
Motorola Alternators…913
Rotor Field Winding Check…914
Stator Windings Check…915
Voltage Regulator Check…915
Troubleshooting…915
hyster-910072-11-03-srm0046…920
toc…920
Differential…920
Safety Precautions Maintenance and Repair…921
General…924
Description…924
Differential Repair…924
Remove…924
Differential Carrier From Axle Housing, Remove…924
Differential and Ring Gear From Differential Carrier, Remove…928
Drive Pinion and Pinion Carrier From Differential Carrier, Remov…930
Disassemble…931
Differential and Ring Gear Assembly, Disassemble…931
Drive Pinion and Pinion Carrier, Disassemble…933
Clean and Inspect…935
Assemble…936
Pinion, Bearings, and Pinion Carrier, Assemble…936
Pinion Bearings, Adjust Preload…937
Press Method…937
Yoke or Flange Method…937
Triple-Lip Seal, Install…938
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)…939
Differential and Ring Gear, Assemble…941
Differential Gears Rotating Torque, Check…944
Differential and Ring Gear Assembly, Install…945
Differential Bearings, Preload Adjust…946
Ring Gear, Runout Check…947
Ring Gear Backlash, Adjust…947
Gear Set, Tooth Contact Pattern Check…949
Thrust Screw, Install and Adjust…951
Install…952
Differential Assembly Into Axle Housing, Install…952
Specifications…954
Troubleshooting…958
tables…920
Table 1. Ring Gear Backlash Adjustment Specifications…948
Table 2. Ring and Pinion Tooth Contact Adjustment…950
Table 3. General Specifications…954
Table 4. Rivet Installation Pressure…954
Table 5. Pinion Adjustment…954
Table 6. Pinion Preload Pressure…955
Table 7. Torque Specifications…956
Table 8. Torque Specifications for Metric Hardware…957
Table 9. Torque Specifications for Metric (Fine) Hardware…957
hyster-910073-09-03-srm0049…962
toc…962
Drive Axle…962
Safety Precautions Maintenance and Repair…963
General…966
Description…966
Drive Axle Repair…967
Disassemble (Type 1 Shown)…967
Clean…970
Inspect…970
Assemble (Type 1 Shown)…971
Torque Specifications…974
Troubleshooting…975
hyster-910076-10-03-srm0054…978
toc…978
Steering Control Unit…978
Safety Precautions Maintenance and Repair…979
General…982
Description…982
Operation…982
Steering Wheel and Column Assembly Repair…984
Steering Column Assembly Repair…984
Type A Steering Column Assembly…984
Remove and Disassemble…984
Assemble and Install…986
Type B Steering Column Assembly…988
Remove and Disassemble…988
Assemble and Install…988
Steering Control Unit…991
Disassemble…991
Clean…994
Assemble…995
System Air Removal…1000
Troubleshooting…1000
hyster-910091-10-03-srm0097…1004
toc…1004
Hydraulic Gear Pumps…1004
Safety Precautions Maintenance and Repair…1005
Description…1008
Operation…1009
Flow Control Valve…1009
Relief Valve…1010
Hydraulic Gear Pump Repair…1010
Remove…1010
Disassemble…1011
Clean…1011
Inspect…1012
Assemble…1015
Install…1017
Pump Output Check…1017
Method No. 1…1017
Method No. 2…1018
Hydraulic System Air Check…1019
Troubleshooting…1020
hyster-910102-10-03-srm0103…1026
toc…1026
Tilt Cylinders…1026
Safety Precautions Maintenance and Repair…1027
General…1030
Description…1030
Tilt Cylinder Repair…1030
Remove…1030
Disassemble…1030
Clean…1030
Assemble…1031
Tilt Cylinders With O-Ring or Single-Lip Seals…1031
Tilt Cylinders for XM and XMS Models…1032
Tilt Cylinders for H700-800A and Early Model H700-920B…1033
Install…1034
Tilt Cylinders Using Chevron Packing…1035
Install…1036
Tilt Cylinder Leak Check…1038
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment…1039
Torque Specifications…1040
Piston Rod Nut…1040
Retainer…1041
Troubleshooting…1043
tables…1026
Table 1. Movement Rates (Maximum) for Tilt Cylinders…1039
hyster-910107-02-01-srm0106…1046
toc…1046
Starter…1046
Safety Precautions Maintenance and Repair…1047
General…1050
Description and Operation…1050
Starter Repair…1052
Remove…1052
Disassemble…1052
Clean…1053
Assemble…1053
Install…1054
General Checks and Adjustments…1054
Troubleshooting…1057
hyster-910110-12-03-srm0143…1062
toc…1062
Instrument Panel Indicators and Senders…1062
Safety Precautions Maintenance and Repair…1063
General…1066
Description…1067
Steering Column Gauges, Meters, and Indicators…1067
LED Display Panel…1067
Battery Discharge Indicators…1067
Brush Wear Indicators…1074
Motor Temperature Indicators…1074
LX Series Display Panel…1076
Hourmeter Functions…1076
Battery Indicator Function…1077
Status Code Function…1078
ZX Series Display Panels…1078
Display Panel…1078
Basic Display Panels…1078
Performance Display…1081
Brush Wear Indicators…1084
Adjustments – General…1085
Replacement – General Information…1085
Meter Replacement…1086
Sender Replacement…1087
Fuel Level Sender…1087
Pressure and Temperature Sender…1087
ITW Display Panel Replacement…1088
Remove…1088
Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl…1089
Remove…1089
Display Panel Assembly, Replace…1089
Indicator LEDs…1090
Battery Indicators…1090
Digital Display (Performance Display Panel Only)…1090
Status Code or Performance Level Switches and Indicator LEDs (Pe…1090
Basic Display Panel, Replace Parts…1090
Performance Display Panel, Replace Parts…1092
Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace…1093
Remove and Replace…1093
Specifications…1093
Meter Specifications…1093
Sender Specifications…1094
Troubleshooting…1094
Meter…1094
hyster-910119-10-03-srm0135…1098
toc…1098
Lift Cylinders…1098
Safety Precautions Maintenance and Repair…1099
Safety Procedures When Working Near Mast…1102
General…1106
Description…1106
Lowering Control Valve…1106
Cylinders (General)…1109
Cylinders (H520-620B, H700-800A)…1109
Retainer, Install…1109
Cylinders (H360-460B)…1111
Cylinders (Two-Speed)…1113
Lift Cylinder Repair…1115
Lift Cylinder Removal Without Removing Mast…1115
Standard Masts With Main Lift Cylinder Fastened to Crossmember o…1115
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to…1115
Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift …1115
Disassemble…1117
Assemble…1117
Lift Cylinder Installation in Mast…1119
Standard Masts With Main Lift Cylinder Fastened to Crossmember o…1119
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to…1119
Chevron-Style Packing…1119
Chevron-Style Packing Installation on Piston…1120
Chevron-Style Packing Installation in Packing Gland…1122
Lift Cylinders for VISTA® Masts…1123
Description…1123
Lowering Control Valve…1123
Remove…1125
Disassemble…1126
Assemble…1127
Install…1128
Main Lift Cylinders…1128
Free-Lift Cylinder…1128
Lift System Leak Check…1129
Specifications…1130
Troubleshooting…1131
tables…1098
Table 1. Lift Trucks with Two-Speed Lift Cylinders…1114
Table 2. Cylinder Retainer Torque Specifications and Weight Guid…1130
hyster-910442-03-03-srm0231…1134
toc…1134
Metric and Inch (SAE) Fasteners…1134
Safety Precautions Maintenance and Repair…1135
General…1138
Threaded Fasteners…1138
Nomenclature, Threads…1138
Strength Identification…1139
Cotter (Split) Pins…1139
Fastener Torque Tables…1144
Conversion Table…1146
tables…1134
Table 1. Bolts and Screws…1140
Table 2. Studs and Nuts…1141
Table 3. Torque Nuts…1142
Table 4. Torque Nuts With Nylon Insert…1143
Table 5. Torque Values for Metric Fasteners*…1144
Table 6. Torque Values for Inch Fasteners*…1145
Table 7. Conversion Table for Metric and English units…1146
Table 8. Cotter Pin Dimensional Data…1147
Hyster H135-155XL2 (G006) Repair Service Manual
