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Complete service repair manual for Hyster H135-155XL, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Hyster H135XL-H155XL 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.
897137 – Hyster Service Manual H135-155XL (F006).pdf
Total Pages: 1,453 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
| Section |
Part No. |
SRM Number |
Rev Date |
| FRAME |
897104 |
0100 SRM 0322 |
11/03 |
| GM V6-4.3L ENGINE (CARBURETED) |
599805 |
0600 SRM 0104 |
09/93 |
| PERKINS ENGINES 4.236, 4.2482 |
910150 |
0600 SRM 0105 |
06/97 |
| PERKINS DIESEL ENGINE-1000 SERIES |
897341 |
0600 SRM 0412 |
08/97 |
| GM V6-4.3L ENGINE WITH FUEL INJECTION |
897800 |
0600 SRM 0590 |
11/03 |
| PERKINS DIESEL ENGINE-1000 SERIES (AR, YG, YH) |
1455747 |
0600 SRM 0705 |
09/03 |
| COOLING SYSTEM |
897934 |
0700 SRM 0626 |
11/01 |
| WEBER CARBURETOR WITH GOVERNOR |
897128 |
0900 SRM 0347 |
12/92 |
| LPG FUEL SYSTEM |
897129 |
0900 SRM 0348 |
09/01 |
| MANUAL TRANSMISSION AND OIL CLUTCH |
910233 |
1300 SRM 0061 |
02/97 |
| TWO-SPEED PS TRANS-DESCR / OPER |
897106 |
1300 SRM 0324 |
10/03 |
| TWO-SPEED PS TRANSMISSION-REPAIR |
897107 |
1300 SRM 0325 |
10/03 |
| SPEED REDUCER |
897125 |
1300 SRM 0344 |
03/97 |
| 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 VANE PUMPS |
910092 |
1900 SRM 0098 |
07/03 |
| 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 |
| HIGH ENERGY IGNITION SYSTEM |
899788 |
2200 SRM 0107 |
03/02 |
| INSTRUMENT PANEL INDICATORS / SENDERS |
910110 |
2200 SRM 0143 |
12/03 |
| MSTS-GM V6-4.3L (EARLY CONTROL MODULES) |
897412 |
2200 SRM 0463 |
04/93 |
| MSTS-GM V6-4.3L (LATER CONTROL MODULES) |
1473385 |
2200 SRM 0765 |
11/01 |
| GM V6 ENG CONTROL-DESC/OPER (EARLY MODULES) |
897435 |
2200 SRM 0473 |
03/94 |
| GM V6 ENGINE CONTROL-REPAIR (EARLY MODULES) |
897420 |
2200 SRM 0468 |
05/96 |
| GM V6 ENG CONTROL-DESC/OPER (LATER MODULES) |
1474823 |
2200 SRM 0781 |
01/00 |
| GM V6 ENGINE CONTROL-REPAIR (LATER MODULES) |
1474824 |
2200 SRM 0782 |
03/00 |
| 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 |
| DIAGRAMS |
897114 |
8000 SRM 0332 |
03/03 |
| PERIODIC MAINTENANCE |
897123 |
8000 SRM 0341 |
12/03 |
| DIAGRAMS-GM ELECTRONIC ENGINE CONTROL |
897501 |
8000 SRM 0519 |
12/03 |
| |
| PART NO. 897137 Rev. 12/03 |
Perkins Diesel Engines..3
Safety Precautions Maintenance and Repair..4
General..11
General Safety Rules..11
Description..12
Engine Serial Number Codes..15
Engine Data..15
Engine Removal and Installation..17
Lift Engine..17
Cylinder Head Assembly Repair..17
Valve Cover..17
Remove..17
Install..18
Rocker Arm Assembly..18
Remove..18
Install..18
Disassemble..18
Inspect..18
Assemble..19
Valve Clearance Adjustments..19
Four-Cylinder Engines..20
Six-Cylinder Engines..20
Valve Springs..20
Cylinder Head Assembly..22
Remove..22
Install..24
Valves and Valve Springs..28
Remove..28
Inspect..28
Install..29
Valve Guides..29
Inspect..29
Remove..30
Install..30
Cylinder Head and Valve Seats..30
Inspect..30
Repair..30
New Valve Seats, Install..30
Piston and Connecting Rod Assemblies Repair..32
Rod Bearings..32
Remove..33
Install..33
Piston and Connecting Rod Assembly..34
Service Note..34
Remove..34
Install..35
Piston Rings..36
Remove..36
Inspect..36
Install..36
Piston and Connecting Rod..37
Disassemble..37
Inspect..38
How to Select Correct Replacements..38
Install..39
Piston Cooling Jets..39
Remove..39
Install..40
Crankshaft Assembly Repair..40
General..40
Crankshaft Pulley..41
Engine AR, Remove..41
Engines YG and YH, Remove..41
Inspect..42
Engine AR, Install..42
Engines YG and YH, Install..42
Rear Oil Seal..43
Replace..43
Main Bearings..44
Remove..44
Inspect..45
Install..45
Thrust Washers..45
Crankshaft Axial Movement, Check..45
Remove..46
Install..46
Crankshaft..47
Remove..47
Inspect..47
Install..47
Flywheel..49
Remove..49
Ring Gear, Replace..49
Install..49
Flywheel Housing..50
Remove..50
Install..50
Timing Case and Timing Gears Repair..51
General..51
Timing Case Cover..51
Remove..51
Install..52
Front Oil Seal..52
Remove..52
Install..52
Crankshaft Pulley Wear Sleeve..53
Install..53
Idler Gear and Hub..53
Remove..53
Install..54
Air Compressor Drive, Bendix..55
Disassemble..55
Assemble..56
Fuel Injection Pump Gear..56
Remove..57
Install..57
Camshaft Gear..58
Remove..58
Install..58
Crankshaft Gear..59
Remove..59
Install..59
Timing Case..59
Remove..59
Install..60
Camshaft and Tappets..61
Remove..61
Install..61
Cylinder Block Assembly Repair..62
Description..62
Cylinder Block..62
Disassemble..62
Inspect..63
Assemble..63
Cylinder Bore (Four-Cylinder Engines)..64
Cylinder Liner (Six-Cylinder Engines)..64
Inspect..64
Cylinder Liner Condition, Check..64
Remove..65
Service Liner, Install..66
Partially Finished Liner, Install..67
Engine Timing..68
Description..68
How to Set Number One Piston to TDC on Compression Stroke..69
How to Set Number One Piston to TDC on Compression Stroke (Alter..70
Valve Timing, Check..70
Fuel Injection Pump Timing, Check..71
Turbocharger – Engine YH Repair..72
General..72
Remove..72
Install..72
Impeller and Compressor Housing, Clean..73
Lubrication System Repair..74
General..74
Oil Filter, Replace..74
Filter Head..75
Remove and Install..75
Oil Sump..75
Remove..75
Install..76
Oil Pump..76
Remove..76
Inspect..76
Install..77
Relief Valve..77
Remove..77
Disassemble..78
Inspect..78
Assemble..78
Install..78
Idler Gear Shaft, Replace..79
Remove..79
Remove (Alternative)..79
Install..80
Install (Alternative)..80
Install (Alternative for Four-Cylinder Engines Only)..81
Fuel System Repair..81
Description..81
Fuel Injection Pump..82
Remove..82
Install..83
Check and Adjust..84
Fuel System, Remove Air..84
Fuel Filter, Replace..85
Canister Type..86
Quick Release Canister Type..86
Fuel Injectors..87
Remove..87
Inspect..88
Install..88
Fuel Pump..89
Remove..89
Disassemble..89
Assemble..89
Install..90
Test..90
Cooling System Repair..91
General..91
Thermostat..91
Remove..91
Install..91
Test..92
Coolant Pump..92
Remove..92
Disassemble..92
Assemble..94
Install..96
Fan and Fan Drive..97
Remove..97
Install..97
Oil Cooler (Six-Cylinder Engines)..98
Remove..98
Disassemble and Assemble..98
Install..98
Oil Cooler By-Pass Valve..98
Electrical Equipment Repair..99
Drive Belts..99
Alternator..100
Remove..100
Install..100
Starter Motor..100
Remove..100
Install..100
Cold Start Aid..100
Air Compressor – Engines YG and YH..100
General..100
Repair..101
Remove..101
Install..101
Rotary Exhauster Replacement..102
Remove..102
Clean..102
Install..102
Engine Specifications..103
Cylinder Head Assembly..103
Piston and Connecting Rods..106
Crankshaft Assembly..109
Crankshaft Overhaul..110
Timing Case and Drive Assembly..112
Engine Block Assembly..113
Turbocharger..116
Lubrication System..116
Fuel System..118
Cooling System..120
Flywheel and Housing..120
Electrical Equipment..121
Torque Specifications..122
Cylinder Head Assembly..122
Piston and Connecting Rod Assemblies..122
Crankshaft Assembly..122
Timing Case and Drive Assembly..122
Turbocharger..122
Lubrication System..122
Fuel System..122
Cooling System..123
Flywheel..123
Auxiliary Equipment..123
Special Torque Specifications..124
Flywheel and Housing..124
Turbocharger..124
Electrical Equipment..124
Auxiliary Equipment..124
Special Tools..125
Troubleshooting..129
tables..3
Table 1. Cylinder Head..103
Table 2. Valve Guides..103
Table 3. Inlet Valves..104
Table 4. Exhaust Valves..105
Table 5. Valve Springs..106
Table 6. Tappets..106
Table 7. Rocker Arm Shaft..106
Table 8. Rocker Arms and Bushings..106
Table 9. Pistons (Engine AR)..106
Table 10. Pistons (Engines YG and YH)..107
Table 11. Piston Rings (Engine AR)..107
Table 12. Piston Rings (Engines YG and YH)..108
Table 13. Piston Pins..108
Table 14. Connecting Rods..108
Table 15. Small End Bushings..108
Table 16. Connecting Rod Bearings (Engines AR and YG)..109
Table 17. Connecting Rod Bearings (Engine YH)..109
Table 18. Piston Cooling Jets..109
Table 19. Crankshaft..109
Table 20. Main Bearings..110
Table 21. Crankshaft Thrust Washers..110
Table 22. Crankshaft Heat Treatment..110
Table 23. Crankshaft Overhaul Specifications..111
Table 24. Maximum Variation (Run-out)..112
Table 25. Camshaft..112
Table 26. Camshaft Thrust Washer..112
Table 27. Camshaft Gear..113
Table 28. Gear for Fuel Injection Pump..113
Table 29. Crankshaft Gear..113
Table 30. Idler Gear and Hub..113
Table 31. Cylinder Block (Engine AR)..114
Table 32. Cylinder Bore Specifications..114
Table 33. Cylinder Block (Engines YG and YH)..115
Table 34. Cylinder Liners (Engines YG and YH)..115
Table 35. Cylinder Liner Specifications (Partially Finished)..116
Table 36. Oil Pump (Engine AR)..116
Table 37. Oil Pump (Engines YG and YH)..117
Table 38. Idler Gear for Oil Pump..117
Table 39. Relief Valve..117
Table 40. Oil Filter..117
Table 41. Lucas Fuel Injection Pump..118
Table 42. Fuel Pump (Engine AR)..118
Table 43. Fuel Pump (Engines YG and YH)..118
Table 44. Fuel Filter..118
Table 45. Fuel Injector Codes..119
Table 46. Coolant Pump..120
Table 47. Thermostat..120
Table 48. Fan Drive Housing..120
Table 49. Limits for Flywheel Run Out and Alignment (Total Indic..120
Table 50. Alternator..121
Table 51. Starter Motor..121
Table 52. Cold Start Aid..121
Table 53. List of Possible Causes..130
hyster-1473385-11-01-srm0765..135
hyster-1474823-01-00-srm0781..183
hyster-897104-11-03-srm0322..335
toc..335
Frame..335
Safety Precautions Maintenance and Repair..336
General..339
Description..339
Counterweight Repair..340
Remove..340
Install..340
Hood Repair..341
Remove..341
Install..341
Overhead Guard Repair..341
Remove..341
Install..341
Operator Restraint System Repair..342
Hydraulic Tank Repair..343
Remove..343
Inspect..343
Small Leaks Repair..343
Large Leaks Repair..343
Clean..343
Steam Method..344
Chemical Solution Method..344
Other Methods of Preparation for Repair..344
Install..344
Fuel Tank Repair..345
Remove..345
Repair..345
Install..345
Radiator Repair..345
Remove..345
Install..345
Engine Repair..346
Remove..346
Install..346
Safety Labels..348
Cab Repair..350
Cab, Replace..350
Window, Replace..350
Windshield Wipers and Heater..350
tables..335
Table 1. Material Specifications for Cab Windows..352
hyster-897106-10-03-srm0324..355
toc..355
Two-Speed Powershift Transmission..355
Safety Precautions Maintenance and Repair..356
General..359
Mechanical Description..359
Torque Converter..359
Transmission Pump..360
Shaft Assemblies..360
Input Shaft..361
Forward Clutch Shaft..361
Clutch Assemblies..361
Countershaft..368
Output Shaft..368
Hydraulic Operation..369
Torque Converter..369
Seal Rings..370
Control Valve..370
System Pressure Regulator..373
Clutch Pressure Regulator..373
Torque Converter Regulator..374
Inching Spool..374
Direction Spool, Direction Control Lever..374
Direction Spool, MONOTROL Pedal..375
Range Spool..375
Drain Spool..376
Accumulator..376
Modulator Spool..376
Operation..376
Lubrication Circuit..377
MONOTROL Pedal..377
Oil Flow Diagrams..379
Neutral..379
Forward-Low..380
Forward-Low-Inching..381
Reverse-Low..382
hyster-897107-10-03-srm0325..385
toc..385
Two-Speed Powershift Transmission..385
Safety Precautions Maintenance and Repair..386
General..389
Transmission Repair..389
Transmission and Torque Converter, Remove..389
Transmission, Disassemble..391
Reverse-Low Clutch, Disassemble..394
Reverse-High Clutch, Disassemble..397
Forward-Low Clutch, Disassemble..400
Forward-High Clutch, Disassemble..403
Clean and Inspect..405
Forward Low and High Clutches Assembly..406
Forward Clutches, Assemble..408
Reverse-Low Clutch, Assemble..414
Reverse Clutches, Assemble..416
Transmission, Assemble..423
Torque Converter, Install..430
Control Valve Repair..431
Remove..431
Disassemble..432
Assemble..433
Install..435
MONOTROL Pedal..435
Remove and Disassemble..435
Assemble and Install..435
Stall Test..438
Linkage Adjustments..439
Linkage for Inching Pedal H6.00-7.00XL (H135-155XL, H135-155XL 2..439
Linkage for Inching Pedal S6.00-7.00XL (S135-155XL, S135-155XL 2..442
Linkage for Range Lever – Early Model H6.00-7.00XL (H135-155XL) ..445
Linkage for Direction Control Lever – Early Model H6.00-7.00XL (..445
Linkage for Range Lever – Later Model H6.00-7.00XL (H135-155XL, ..447
Linkage for Direction Control Lever – Later Model H6.00-7.00XL (..449
Linkage for Range Lever S6.00-7.00XL (S135-155XL, S135-155XL 2 )..451
Linkage for Direction Control Lever S6.00-7.00XL (S135-155XL, S1..451
Oil Pressure Check..453
System Pressure Check Port..453
Torque Converter Check Port..453
Clutch Pressure Check Port..453
Inching Pressure..454
Solenoid Check Ports (MONOTROL Control Only)..454
Lubrication Pressure Check Ports..454
Specifications..455
Troubleshooting..455
Correct System Pressure: 1300 ±124 kPa ( 189 ±18 psi)..458
Correct Clutch Pressure: 924 ±69 kPa ( 134 ±10 psi)..459
Correct Solenoid Pressure (MONOTROL Only): 965 ±138 kPa ( 140 ±2..460
Torque Converter Pressure: 834 ±69 kPa ( 121 ±10 psi)..460
Lubrication Pressure: 83 ±21 kPa ( 12 ±3 psi)..460
tables..385
Table 1. Stall Speed Specifications..438
hyster-897108-10-03-srm0326..463
toc..463
Steering Axle..463
Safety Precautions Maintenance and Repair..464
General..467
Description..467
Steering Axle Assembly Repair..471
Steering Axle H3.50-5.00XL (H70-110XL) (G005), S3.50-5.50XL (S70..471
Remove..471
Install..472
Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL 2 ) (F006, G0..472
Remove..472
Install..473
Wheels and Hubs Repair (All Units)..473
Remove and Disassemble..473
Clean..473
Inspect..473
Assemble and Install..474
Spindles and Bearings Repair (All Units)..475
Remove..475
Clean..475
Assemble and Install..475
Tie Rods Repair (All Units)..476
Remove..476
Clean..476
Install..476
Steering Cylinder Repair..479
Remove and Disassemble..479
Clean and Inspect..479
Assemble and Install..479
Troubleshooting..480
hyster-897109-09-03-srm0327..485
toc..485
Brake System..485
Safety Precautions Maintenance and Repair..486
General..489
Description..489
Operation..490
Brake Booster and Master Cylinder..490
Brake Booster..490
Master Cylinder..491
Service Brake Assembly..492
Parking Brake..493
Brake Shoe Assemblies Repair..494
Remove and Disassemble..494
Clean and Inspect..495
Cleaning Procedures..495
Inspect..495
Assemble and Install..496
Master Cylinder Repair..497
Remove..497
Disassemble..497
Assemble..499
Install..499
Brake Booster Repair..499
Remove..499
Disassemble..499
Clean and Inspect..501
Assemble..501
Install..501
Brake System Air Removal..501
Brake Pedal Adjustment..502
Brake Shoes Adjustment..503
Parking Brake Adjustment..503
Parking Brake Switch Adjustment..503
Brake Booster Relief Valve Check..503
Troubleshooting..504
hyster-897110-09-03-srm0328..509
toc..509
Hydraulic System..509
Safety Precautions Maintenance and Repair..510
General..513
Description and Operation..513
Hydraulic Pumps..515
Main Control Valve..515
Control Valve Lever..516
Steering Control Unit..516
Brake Valve..516
Oil Clutch, H6.00-7.00XL (H135-155XL) (F006)..517
Troubleshooting..517
Lift, Lower, and Tilt Circuit..518
Steering, Brake, and Oil Clutch System..519
hyster-897111-10-03-srm0329..523
toc..523
Masts..523
Safety Precautions Maintenance and Repair..524
General..527
Description and Operation..527
General..527
Safety Procedures When Working Near Mast..528
Two-Stage Mast..528
Three-Stage Mast..530
Carriage Repair..532
Remove..532
Sideshift Carriage, Disassemble..532
Sideshift Carriage, Assemble..533
Install..533
Two-Stage Mast Repair..535
Remove..535
Disassemble..536
Clean and Inspect..537
Assemble..538
Install..538
Three-Stage Mast Repair..540
Remove..540
Disassemble..540
Clean and Inspect..540
Assemble..540
Install..542
Mast Operation Check..542
Lift and Tilt System Leaks Check..543
Lift System..543
Tilt System..543
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment..544
Lift Chain Adjustments..544
Mast Adjustments..547
Carriage Adjustment..547
Troubleshooting..549
tables..523
Table 1. Mast Parts Weight..536
Table 2. Hook-Type Carriage Chain Adjustment..545
Table 3. Pin-Type Carriage Chain Adjustment..545
hyster-897113-09-03-srm0331..553
toc..553
Capacities and Specifications..553
Safety Precautions Maintenance and Repair..554
Lift Truck Weights..557
Capacities..557
Tire Sizes..558
Tire Pressure..558
Electrical System..558
Wheel Nut Torque..558
Engine Specifications..559
Hydraulic System..559
Mast Speeds..560
Transmission Oil Pressures..560
Torque Specifications..561
Engine – GM 4.3L V-6..561
Engine – Perkins 4.2482..561
Engine – Perkins 1004.4..561
Clutch..561
Manual Transmission..562
Powershift Transmission..562
Speed Reducer..562
Drive Axle..562
Steering System..562
Brake System..562
Hydraulic System..563
Tilt Cylinder..563
Mast..563
hyster-897114-03-03-srm0332..567
toc..567
Diagrams..567
Safety Precautions Maintenance and Repair..568
hyster-897123-12-03-srm0341..591
toc..591
Periodic Maintenance..591
Safety Precautions Maintenance and Repair..592
General..597
Serial Number Data..597
How to Move Disabled Truck..597
How to Tow Lift Truck..597
How to Put Lift Truck on Blocks..598
How to Raise Drive Tires..598
How to Raise Steering Tires..598
Maintenance Schedule..599
Maintenance Procedures Every 8 Hours or Daily..615
How to Make Checks With Engine Stopped..615
Hydraulic System Oil..616
Engine Oil..616
Drive Belts..617
Intake Manifold Rubber Cap..617
Cooling System..617
Air Filter..618
Fuel System..618
Primary Fuel Filter, Diesel Engine..619
Battery..619
Tires and Wheels..619
Forks..620
Adjust..620
Remove and Install..620
Forks, Mast, and Lift Chains, Inspect..623
Operator Restraint System..624
Safety Labels..625
How to Make Checks With Engine Running..625
Gauges, Lights, Horn, and Fuses..625
Oil Level, Powershift Transmission..627
Oil Level, Oil Clutch System, H3.50-5.00XL (H70-110XL)..627
Control Levers and Pedals..627
Lift System Operation..627
Inching/Brake Pedal..628
Service Brakes..628
Parking Brake..628
Steering System..628
Maintenance Procedures Every 250 Hours or 6 Weeks..629
Engine Oil and Filter, GM V-6 Engine..629
Lift Chains, Lubrication..629
Drive Shafts..629
Mast Lubrication..630
Crankcase Breather, GM V-6..630
Air Filter, GM V-6 EPA Compliant Engine ..630
Maintenance Procedures Every 350 Hours or 2 Months..631
Engine Oil and Filter, Perkins 4.2482 Diesel Engine..631
Drive Belts..631
Perkins Diesel Engine..631
GM V-6 Engine (Early Models)..632
GM V-6 Engine (Late Models)..632
Brake Fluid..634
Lift Chains Wear Check..634
Forks Wear and Damage Check..635
Steering Axle Lubrication..635
Fuel System, Checks and Adjustments..635
Diesel Fuel System..635
LPG Carburetor (Early Models)..635
Gasoline Carburetor (Early Models)..636
Fuel Injection (Late Models)..636
Crankcase Breather, Perkins 4.2482 Diesel Engine..636
Hydraulic Tank Breather..636
Cooling System, Clean Debris from Radiator Core..636
Maintenance Procedures Every 500 Hours or 3 Months..637
Engine Oil and Filter, Perkins Diesel Engine..637
Crankcase Breather, Perkins Diesel Engine..637
PCV Valve, GM V-6..637
Maintenance Procedures Every 1000 Hours or 6 Months..638
Manifold Heat Valve, GM V-6 (Early Models)..638
Ignition System, GM V-6..638
Valve Clearance Adjustment..638
Fuel Filter, Replace (Diesel Engine)..638
Fuel System Air Removal (Perkins 1004-4 Diesel Engine)..638
Fuel Injection Pump With Vent Tube..639
Fuel Injection Pump With Vent Screw..639
Fuel System Air Removal (Perkins 4.2482 Diesel Engine)..641
Oil Level Check in Transmission..641
Manual Transmission, H3.50-5.00XL (H70-110XL)..641
Speed Reducer for Powershift Transmission, H3.50-5.00XL (H70-110..641
Manual Transmission, H6.00-7.00XL (H135-155XL)..641
Differential and Drive Axle for Powershift Transmission, H6.00-7..641
Differential, Speed Reducer, and Drive Axle for Manual Transmiss..642
Control Levers and Pedals, Lubricate..642
Crankcase Breather, Replace..642
Cooling System, GM V-6 EPA Compliant Engine..642
Spark Plug Replacement..642
Remove..642
Install..643
LPG Fuel Filter GM V-6 EPA Compliant Engine, Replace..643
Inspect Engine Electrical System, Connectors, and FCVS Connectio..644
Maintenance Procedures Every 2000 Hours or Yearly..644
Hydraulic System..644
Hydraulic Oil and Filter, H3.50-5.00XL (H70-110XL), Replace..644
Hydraulic Oil and Filter, H6.00-7.00XL (H135-155XL, H135-155XL 2..645
Oil Change and Oil Filter Replacement, Powershift Transmission, ..645
Oil Change, Manual Transmission, H3.50-5.00XL (H70-110XL)..645
Oil Change, Manual Transmission, H6.00-7.00XL (H135-155XL)..645
Oil Change, Speed Reducer, Powershift Transmission, H3.50-5.00XL..645
Oil and Filter Change, Oil Clutch System, H3.50-5.00XL (H70-110X..646
Oil Change, Differential and Drive Axle, Powershift Transmission..646
Oil Change, Differential, Speed Reducer, and Drive Axle, Manual ..646
Cooling System..646
PCV Valve, GM V-6..646
Service Brakes..647
LPG Filter, Replace..647
Gasoline Fuel Filter, Replace..648
Hood Latch Check, H3.50-5.00XL (H70-110XL)..648
Air Filter Element, GM V-6 EPA Compliant Engine..648
Oxygen Sensor GM V-6 EPA Compliant Engine..648
Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks..649
Check Throttle Shaft for Sticking..650
Inspect Exhaust Manifold and Piping for Leaks..650
Test LPG/GAS Regulator Pressure..650
Safety Procedures When Working Near Mast..650
Lift Chain Adjustments..652
Fuel Injectors Repair..654
Lift and Tilt System Leak Check..654
Lift Cylinders, Leak Check..654
Tilt Cylinders, Leak Check..655
Welding Repairs..655
Overhead Guard Changes..656
Wheel and Tire Replacement..657
Remove Wheels From Lift Truck..657
Remove Wheels From Tire..657
Remove Tire From Two-Piece Wheel..658
Remove Tire From Three- and Four-Piece Wheels..660
Install Wheel in Tire..661
Install Three- or Four-Piece Wheel in Tire..662
Install Two-Piece Wheel in Tire..663
Add Air to Pneumatic Tires..664
Wheels, Install..664
Solid Rubber Tires Repair..665
Wheel, Tire Remove..665
Wheel, Tire Install..667
SIT Tire, Change for H3.50-5.00XL (G005), and H6.00-7.00XL (F006..668
Remove SIT Solid Tire From Wheel..669
Install SIT Solid Tire on Wheel..670
Adhesives and Sealants..671
Hydraulic Oil, Lubricant, and Coolant Specifications..672
tables..591
Table 1. Maintenance Schedule..601
Table 2. Hook-Type Carriage Chain Adjustment..653
Table 3. Pin-Type Carriage Chain Adjustment..653
hyster-897129-09-01-srm0348..699
toc..699
LPG Fuel System..699
Safety Precautions Maintenance and Repair..700
General..703
Description and Operation..705
Fuel Tank..705
Fuel Filter and Fuel Valve Unit..706
Vaporizer..707
Carburetor..708
Governor..710
LPG Tank Repair..711
Remove..711
LPG Tanks with Fixed Mounting Bracket..711
LPG Tanks with EZ Lift Mounting Bracket..711
Install..712
LPG Tanks with Fixed Mounting Bracket..712
LPG Tanks with EZ Lift Mounting Bracket..713
Hydrostatic Relief Valve Repair..714
Remove and Install..714
Filter Unit Repair..714
Fuel Filter Element, Replace..714
Diaphragm and Fuel Valve, Replace..714
Hoses Replacement..716
Vaporizer Repair..716
Remove..716
Disassemble..716
Clean..716
Inspect..716
Assemble..718
Install..722
Carburetor Repair..722
Remove..722
Disassemble..722
Clean..722
Assemble..722
Install..722
Governor Repair..724
Filter Unit Check..726
Vaporizer Check..726
Pressure Reducer Valve..726
Vapor Valve..726
Carburetor Adjustment..726
Idle Mixture..726
Idle Speed..726
Power Mixture..727
Throttle Linkage Adjustment..727
Troubleshooting..729
Diagrams..949
Safety Precautions Maintenance and Repair..950
hyster-897800-11-03-srm0590..1013
toc..1013
GM Engines..1013
Safety Precautions Maintenance and Repair..1014
General..1017
Description..1017
Engine Removal and Installation..1018
Cylinder Head Repair..1018
Remove and Disassemble..1018
Clean and Inspect..1018
Valve Guides and Seats, Repairs..1019
Valves, Repair..1019
Valve Seats, Repair..1020
Valve Springs..1021
Rocker Arm Studs (Early Models)..1021
Rocker Arm Studs (Late Models)..1022
Assemble and Install..1022
Cylinder Block Cleaning and Inspection..1026
Piston Bore Preparation..1026
Engine Mounts Installation..1026
Lubrication System Repair..1027
Oil Pump, Remove and Disassemble..1027
Clean and Inspect..1027
Oil Pump, Assemble and Install..1027
Oil Sump, Install..1028
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters..1029
Timing Cover..1029
Remove..1029
Install..1031
Timing Sprockets..1031
Remove..1031
Install..1031
Camshaft..1032
Remove..1032
Inspect..1032
Install..1032
Balance Shaft..1033
Remove..1033
Install..1034
Hydraulic Valve Lifters..1034
Remove..1034
Disassemble..1035
Clean and Inspect..1035
Assemble..1035
Install..1036
Crankshaft Repair..1037
Remove..1037
Inspect and Repair..1037
How to Check Clearance Between Main Bearings and Their Journals..1038
Install..1039
Piston and Connecting Rod Assemblies Repair..1040
Connecting Rod Bearings, Replace..1040
Piston and Connecting Rod Assemblies, Remove..1041
Disassemble..1041
Piston, Clean and Inspect..1042
Cylinder Bores, Inspect and Repair..1042
Piston Rings..1043
Assemble..1044
Piston and Connecting Rod Assemblies, Install..1044
Flywheel and Flywheel Housing Repair..1045
Flywheel, Repair..1045
Flywheel, Install..1045
H3.50-5.00XL (H70-110XL), S3.50-5.50XL (S70-120XL), S6.00-7.00XL..1045
H6.00-7.00XL (H135-155XL)..1045
Flywheel Housing H3.50-5.00XL (H70-110XL), H3.50-5.50XM (H70-120..1045
Engine Adapter H6.00-7.00XL (H135-155XL)..1045
Coolant Pump Repair..1046
Thermostat Replacement..1046
Fan Mount Repair (Early Models)..1046
Fan Mount Assembly Repair (Late Models)..1046
Drive Belt Installation..1048
Valve Clearance Adjustment (Early Models)..1049
Valve Clearance Adjustment (New Models)..1050
Compression Check..1050
Engine Specifications..1050
Engine Data..1050
Cylinder Head..1051
Hydraulic Valve Lifter..1051
Camshaft..1051
Pistons..1051
Crankshaft..1052
Connecting Rods..1053
Balance Shaft..1053
Cooling System..1053
Lubrication System..1053
Torque Specifications..1054
Troubleshooting..1055
tables..1013
Table 1. Piston Rings Arrangement on Piston..1044
hyster-897934-11-01-srm0626..1061
toc..1061
Cooling System..1061
Safety Precautions Maintenance and Repair..1062
General..1065
Description..1066
Radiator..1066
Radiator Cap..1066
Thermostat..1066
Water Pump..1067
Fan and Fan Shroud..1067
Cooling System Checks..1067
Radiator..1067
Thermostat..1067
Water Pump..1068
Exhaust Leaks..1068
Fan and Fan Shroud..1068
Radiator Cleaning..1068
Drain..1068
Clean..1068
Fill..1069
Troubleshooting..1070
hyster-899783-10-03-srm0090..1073
toc..1073
Main Control Valve..1073
Safety Precautions Maintenance and Repair..1074
General..1077
Description..1077
Operation..1080
Lift Spool..1080
Tilt Spool..1081
Tilt Backward..1081
Tilt Forward..1082
Single-Stage Relief Valve..1084
Two-Stage Relief Valve..1085
Main Control Valve Repair..1086
Remove and Disassemble..1086
Clean and Inspect..1086
Assemble..1086
Install..1087
Single-Stage Relief Valve Adjustment..1087
Two-Stage Relief Valve..1088
Auxiliary Control Valve Relief Valve Adjustment (H60-110E Only)..1088
Troubleshooting..1089
tables..1073
Table 1. Relief Pressures (Oil temperature at 55 to 66 C ( 131 t..1087
hyster-899784-10-03-srm0002..1093
toc..1093
Alternator with Regulator..1093
Safety Precautions Maintenance and Repair..1094
General..1097
Description..1097
Alternator Repair..1099
Alternator Type A..1099
Remove and Disassemble..1099
Clean..1100
Assemble..1101
Install..1101
Alternator Type B..1104
Remove and Disassemble..1104
Clean..1104
Assemble..1105
Install..1106
General Check and Adjustment..1107
Low Output Check (Type A or Type B)..1107
High Output Check (Type A or Type B)..1109
Brushes Circuit Check..1110
Delco Alternators..1110
Motorola Alternators..1111
Diodes Check..1112
Diode Bridge Check..1112
Delco and Leece-Neville Alternators..1112
Motorola Alternators..1112
Rotor Field Winding Check..1113
Stator Windings Check..1114
Voltage Regulator Check..1114
Troubleshooting..1114
hyster-899788-03-02-srm0107..1119
toc..1119
High Energy Ignition (HEI) System..1119
Safety Precautions Maintenance and Repair..1120
Description..1123
Distributor Repair..1125
Remove..1125
Disassemble..1125
Assemble..1130
Install, If Crankshaft WAS NOT Rotated when Distributor was Remo..1131
Install, If Crankshaft WAS Rotated when Distributor was Removed..1131
Ignition Coil Replacement..1132
Some Four- and Six-Cylinder Models..1132
Remove..1132
Install..1133
V8, Some Four- and Six-Cylinder Models..1133
Remove..1133
Install..1134
Electronic Module Replacement..1135
Remove..1135
Install..1135
Sensing Coil Replacement..1136
Remove..1136
Install..1136
Spark Plugs Replacement..1136
Remove..1136
Install..1137
Visual Check..1137
High Voltage Wires Check..1137
Ignition Coil Check..1138
Coil in Distributor Cap Design..1138
Separate Coil Design..1138
Sensing Coil, Check..1139
Electronic Module Check..1139
Ignition Timing Adjustment..1139
GM V8-366 (6-liter) Ignition System Check..1141
GM V6-LPG (4.3 liter) GM V6-LPG (4.3 liter) Ignition Timing and ..1141
Specifications..1141
Troubleshooting..1142
hyster-910072-11-03-srm0046..1147
toc..1147
Differential..1147
Safety Precautions Maintenance and Repair..1148
General..1151
Description..1151
Differential Repair..1151
Remove..1151
Differential Carrier From Axle Housing, Remove..1151
Differential and Ring Gear From Differential Carrier, Remove..1155
Drive Pinion and Pinion Carrier From Differential Carrier, Remov..1157
Disassemble..1158
Differential and Ring Gear Assembly, Disassemble..1158
Drive Pinion and Pinion Carrier, Disassemble..1160
Clean and Inspect..1162
Assemble..1163
Pinion, Bearings, and Pinion Carrier, Assemble..1163
Pinion Bearings, Adjust Preload..1164
Press Method..1164
Yoke or Flange Method..1164
Triple-Lip Seal, Install..1165
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)..1166
Differential and Ring Gear, Assemble..1168
Differential Gears Rotating Torque, Check..1171
Differential and Ring Gear Assembly, Install..1172
Differential Bearings, Preload Adjust..1173
Ring Gear, Runout Check..1174
Ring Gear Backlash, Adjust..1174
Gear Set, Tooth Contact Pattern Check..1176
Thrust Screw, Install and Adjust..1178
Install..1179
Differential Assembly Into Axle Housing, Install..1179
Specifications..1181
Troubleshooting..1185
tables..1147
Table 1. Ring Gear Backlash Adjustment Specifications..1175
Table 2. Ring and Pinion Tooth Contact Adjustment..1177
Table 3. General Specifications..1181
Table 4. Rivet Installation Pressure..1181
Table 5. Pinion Adjustment..1181
Table 6. Pinion Preload Pressure..1182
Table 7. Torque Specifications..1183
Table 8. Torque Specifications for Metric Hardware..1184
Table 9. Torque Specifications for Metric (Fine) Hardware..1184
hyster-910073-09-03-srm0049..1189
toc..1189
Drive Axle..1189
Safety Precautions Maintenance and Repair..1190
General..1193
Description..1193
Drive Axle Repair..1194
Disassemble (Type 1 Shown)..1194
Clean..1197
Inspect..1197
Assemble (Type 1 Shown)..1198
Torque Specifications..1201
Troubleshooting..1202
hyster-910076-10-03-srm0054..1205
toc..1205
Steering Control Unit..1205
Safety Precautions Maintenance and Repair..1206
General..1209
Description..1209
Operation..1209
Steering Wheel and Column Assembly Repair..1211
Steering Column Assembly Repair..1211
Type A Steering Column Assembly..1211
Remove and Disassemble..1211
Assemble and Install..1213
Type B Steering Column Assembly..1215
Remove and Disassemble..1215
Assemble and Install..1215
Steering Control Unit..1218
Disassemble..1218
Clean..1221
Assemble..1222
System Air Removal..1227
Troubleshooting..1227
hyster-910091-10-03-srm0097..1231
toc..1231
Hydraulic Gear Pumps..1231
Safety Precautions Maintenance and Repair..1232
Description..1235
Operation..1236
Flow Control Valve..1236
Relief Valve..1237
Hydraulic Gear Pump Repair..1237
Remove..1237
Disassemble..1238
Clean..1238
Inspect..1239
Assemble..1242
Install..1244
Pump Output Check..1244
Method No. 1..1244
Method No. 2..1245
Hydraulic System Air Check..1246
Troubleshooting..1247
hyster-910092-07-03-srm0098..1253
toc..1253
Hydraulic Vane Pumps..1253
Safety Precautions Maintenance and Repair..1254
General..1257
Description..1257
Operation..1258
Pump..1258
Relief Valve..1258
Hydraulic Vane Pumps Repair..1259
Remove..1259
Disassemble..1259
Assemble..1260
Install..1263
Relief Valve Relief Pressure Check..1263
Lift Trucks With Internal Combustion Engines..1263
Electric Lift Trucks..1263
Electric Lift Trucks With Adjustable Relief Valve..1264
Specifications..1265
Pressure Relief Valve..1265
Troubleshooting..1265
hyster-910102-10-03-srm0103..1269
toc..1269
Tilt Cylinders..1269
Safety Precautions Maintenance and Repair..1270
General..1273
Description..1273
Tilt Cylinder Repair..1273
Remove..1273
Disassemble..1273
Clean..1273
Assemble..1274
Tilt Cylinders With O-Ring or Single-Lip Seals..1274
Tilt Cylinders for XM and XMS Models..1275
Tilt Cylinders for H700-800A and Early Model H700-920B..1276
Install..1277
Tilt Cylinders Using Chevron Packing..1278
Install..1279
Tilt Cylinder Leak Check..1281
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment..1282
Torque Specifications..1283
Piston Rod Nut..1283
Retainer..1284
Troubleshooting..1286
tables..1269
Table 1. Movement Rates (Maximum) for Tilt Cylinders..1282
hyster-910107-02-01-srm0106..1289
toc..1289
Starter..1289
Safety Precautions Maintenance and Repair..1290
General..1293
Description and Operation..1293
Starter Repair..1295
Remove..1295
Disassemble..1295
Clean..1296
Assemble..1296
Install..1297
General Checks and Adjustments..1297
Troubleshooting..1300
hyster-910110-12-03-srm0143..1305
toc..1305
Instrument Panel Indicators and Senders..1305
Safety Precautions Maintenance and Repair..1306
General..1309
Description..1310
Steering Column Gauges, Meters, and Indicators..1310
LED Display Panel..1310
Battery Discharge Indicators..1310
Brush Wear Indicators..1317
Motor Temperature Indicators..1317
LX Series Display Panel..1319
Hourmeter Functions..1319
Battery Indicator Function..1320
Status Code Function..1321
ZX Series Display Panels..1321
Display Panel..1321
Basic Display Panels..1321
Performance Display..1324
Brush Wear Indicators..1327
Adjustments – General..1328
Replacement – General Information..1328
Meter Replacement..1329
Sender Replacement..1330
Fuel Level Sender..1330
Pressure and Temperature Sender..1330
ITW Display Panel Replacement..1331
Remove..1331
Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl..1332
Remove..1332
Display Panel Assembly, Replace..1332
Indicator LEDs..1333
Battery Indicators..1333
Digital Display (Performance Display Panel Only)..1333
Status Code or Performance Level Switches and Indicator LEDs (Pe..1333
Basic Display Panel, Replace Parts..1333
Performance Display Panel, Replace Parts..1335
Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace..1336
Remove and Replace..1336
Specifications..1336
Meter Specifications..1336
Sender Specifications..1337
Troubleshooting..1337
Meter..1337
hyster-910119-10-03-srm0135..1341
toc..1341
Lift Cylinders..1341
Safety Precautions Maintenance and Repair..1342
Safety Procedures When Working Near Mast..1345
General..1349
Description..1349
Lowering Control Valve..1349
Cylinders (General)..1352
Cylinders (H520-620B, H700-800A)..1352
Retainer, Install..1352
Cylinders (H360-460B)..1354
Cylinders (Two-Speed)..1356
Lift Cylinder Repair..1358
Lift Cylinder Removal Without Removing Mast..1358
Standard Masts With Main Lift Cylinder Fastened to Crossmember o..1358
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to..1358
Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift ..1358
Disassemble..1360
Assemble..1360
Lift Cylinder Installation in Mast..1362
Standard Masts With Main Lift Cylinder Fastened to Crossmember o..1362
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to..1362
Chevron-Style Packing..1362
Chevron-Style Packing Installation on Piston..1363
Chevron-Style Packing Installation in Packing Gland..1365
Lift Cylinders for VISTA® Masts..1366
Description..1366
Lowering Control Valve..1366
Remove..1368
Disassemble..1369
Assemble..1370
Install..1371
Main Lift Cylinders..1371
Free-Lift Cylinder..1371
Lift System Leak Check..1372
Specifications..1373
Troubleshooting..1374
tables..1341
Table 1. Lift Trucks with Two-Speed Lift Cylinders..1357
Table 2. Cylinder Retainer Torque Specifications and Weight Guid..1373
toc..1441
Metric and Inch (SAE) Fasteners..1441
Safety Precautions Maintenance and Repair..1442
General..1445
Threaded Fasteners..1445
Nomenclature, Threads..1445
Strength Identification..1446
Cotter (Split) Pins..1446
Fastener Torque Tables..1451
Conversion Table..1453
Table 1. Bolts and Screws..1447
Table 2. Studs and Nuts..1448
Table 3. Torque Nuts..1449
Table 4. Torque Nuts With Nylon Insert..1450
Table 5. Torque Values for Metric Fasteners*..1451
Table 6. Torque Values for Inch Fasteners*..1452
Table 7. Conversion Table for Metric and English units..1453
Table 8. Cotter Pin Dimensional Data..1454
Hyster H135-155XL (F006) Repair Service Manual
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