Complete service repair manual with Electrical Wiring Diagrams for Hyster S135-155XL (B024) Forklifts Trucks, with all the shop information to maintain, diagnostic, repair, refurbish/rebuild like professional mechanics.
Hyster S135XL-S155XL (B024) 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.
897335 – Hyster S135-155XL (B024) Service Manual.pdf
Total Pages: 1,424 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
| Section | Part No. | SRM Number | Rev Date |
| FRAME | 897390 | 0100 SRM 0449 | 12/03 |
| GM V6-4.3L ENGINE (CARBURETED) | 599805 | 0600 SRM 0104 | 09/93 |
| 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 |
| OIL CLUTCH SYSTEM | 897116 | 1200 SRM 0334 | 11/97 |
| TWO-SPEED PS TRANS-DESCR / OPER | 897106 | 1300 SRM 0324 | 10/03 |
| TWO-SPEED PS TRANSMISSION-REPAIR | 897107 | 1300 SRM 0325 | 10/03 |
| THREE-SPEED MANUAL TRANSMISSION | 897117 | 1300 SRM 0335 | 02/04 |
| DIFFERENTIAL | 910072 | 1400 SRM 0046 | 11/03 |
| DRIVE AXLE | 897391 | 1400 SRM 0450 | 09/03 |
| STEERING CONTROL UNIT | 910076 | 1600 SRM 0054 | 10/03 |
| STEERING AXLE | 897392 | 1600 SRM 0451 | 09/03 |
| BRAKE SYSTEM | 897393 | 1800 SRM 0452 | 02/04 |
| HYDRAULIC GEAR PUMPS | 910091 | 1900 SRM 0097 | 10/03 |
| HYDRAULIC PUMP DRIVE ASSEMBLY | 897121 | 1900 SRM 0339 | 10/03 |
| HYDRAULIC SYSTEM | 897394 | 1900 SRM 0453 | 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 |
| GM V6 ENGINE CONTROL-REPAIR (EARLY MODULES) | 897420 | 2200 SRM 0468 | 05/96 |
| GM V6 ENG CONTROL-DESC/OPER (EARLY MODULES) | 897435 | 2200 SRM 0473 | 03/94 |
| MSTS-GM V6-4.3L (LATER CONTROL MODULES) | 1473385 | 2200 SRM 0765 | 11/01 |
| 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 INCE (SAE) FASTENERS | 910442 | 8000 SRM 0231 | 03/03 |
| PERIODIC MAINTENANCE | 897304 | 8000 SRM 0393 | 12/03 |
| CAPACITIES and SPECIFICATIONS | 897395 | 8000 SRM 0454 | 10/03 |
| DIAGRAMS | 897396 | 8000 SRM 0455 | 03/97 |
| DIAGRAMS-GM ELECTRONIC ENGINE CONTROL | 897501 | 8000 SRM 0519 | 12/03 |
| PART NO. 897335 Rev 02/04 | |||
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
toc….135
Microprocessor Spark Timing System (MSTS)….135
Safety Precautions Maintenance and Repair….136
General….139
Description….140
What MSTS Does….140
How MSTS Begins Operation….140
Operation….141
Distributor….141
Ignition Coil….141
Ignition Module….141
When Engine Is Being Started….142
When Engine Is Running….143
Manifold Absolute Pressure (MAP) Sensor….144
Engine Coolant Temperature (ECT) Sensor….144
MSTS Module Corrections….145
Troubleshooting….146
General….146
Tools and Test Equipment….148
MSTS….149
Troubleshooting Procedure….149
Where to Start….149
Visual/Physical Inspection….149
Knowledge/Tools Required….149
Damage from Static Discharge (Static Electricity)….149
Troubleshooting Information….150
Malfunction Indicator Lamp (MIL)….150
Connecting CodeMate Tester….150
Reading Diagnostic Trouble Codes (DTC)….151
Clearing Diagnostic Trouble Codes (DTC's)….152
On-Board Diagnostic (OBD) System Check….152
Test Description….152
No Malfunction Indicator Lamp….154
Circuit Description….154
Test Description….154
No DTC-12, Malfunction Indicator Lamp ON….156
Circuit Description….156
Test Description….156
Starter Rotates Engine, Engine Does Not Run….157
Test Description….157
DTC-14 Engine Coolant Temperature (ECT) (Low Temperature Indicat….161
Circuit Description….161
Test Description….161
DTC-15 Engine Coolant Temperature Sensor (ECT) (High Temperature….163
Circuit Description….163
Test Description….163
DTC-34 Manifold Absolute Pressure (MAP) Sensor….165
Circuit Description….165
Test Description….165
DTC-41 Electronic Spark Timing (EST) Open Circuit….168
Circuit Description….168
Test Description….168
DTC-42 Electronic Spark Timing (EST) Grounded Circuit….170
Circuit Description….170
Test Description….170
DTC-51 MSTS Failure….172
Circuit Description….172
Distributor Repair….172
Remove….172
Disassemble….173
Inspect….173
Assemble….173
Install….174
Ignition Timing….174
Ignition Module Repair….175
Test For Fault….175
Replace….176
Sensing Coil Repair….176
Test For Fault….176
Replace….176
Ignition Coil Repair….177
Test For Fault….177
Remove….177
Install….177
MSTS Module Repair….178
Remove….178
Install….178
ECT Sensor Replacement….178
MAP Sensor Replacement….179
tables….135
Table 1. MSTS Module Connections….147
Table 2. Pressure Conversion Chart….148
Table 3. MSTS Diagnostic Codes….150
hyster-1474823-01-00-srm0781….183
Two-Speed Powershift Transmission….335
Safety Precautions Maintenance and Repair….336
General….339
Mechanical Description….339
Torque Converter….339
Transmission Pump….340
Shaft Assemblies….340
Input Shaft….341
Forward Clutch Shaft….341
Clutch Assemblies….341
Countershaft….348
Output Shaft….348
Hydraulic Operation….349
Torque Converter….349
Seal Rings….350
Control Valve….350
System Pressure Regulator….353
Clutch Pressure Regulator….353
Torque Converter Regulator….354
Inching Spool….354
Direction Spool, Direction Control Lever….354
Direction Spool, MONOTROL Pedal….355
Range Spool….355
Drain Spool….356
Accumulator….356
Modulator Spool….356
Operation….356
Lubrication Circuit….357
MONOTROL Pedal….357
Oil Flow Diagrams….359
Neutral….359
Forward-Low….360
Forward-Low-Inching….361
Reverse-Low….362
hyster-897107-10-03-srm0325….365
toc….365
Two-Speed Powershift Transmission….365
Safety Precautions Maintenance and Repair….366
General….369
Transmission Repair….369
Transmission and Torque Converter, Remove….369
Transmission, Disassemble….371
Reverse-Low Clutch, Disassemble….374
Reverse-High Clutch, Disassemble….377
Forward-Low Clutch, Disassemble….380
Forward-High Clutch, Disassemble….383
Clean and Inspect….385
Forward Low and High Clutches Assembly….386
Forward Clutches, Assemble….388
Reverse-Low Clutch, Assemble….394
Reverse Clutches, Assemble….396
Transmission, Assemble….403
Torque Converter, Install….410
Control Valve Repair….411
Remove….411
Disassemble….412
Assemble….413
Install….415
MONOTROL Pedal….415
Remove and Disassemble….415
Assemble and Install….415
Stall Test….418
Linkage Adjustments….419
Linkage for Inching Pedal H6.00-7.00XL (H135-155XL, H135-155XL 2….419
Linkage for Inching Pedal S6.00-7.00XL (S135-155XL, S135-155XL 2….422
Linkage for Range Lever – Early Model H6.00-7.00XL (H135-155XL) ….425
Linkage for Direction Control Lever – Early Model H6.00-7.00XL (….425
Linkage for Range Lever – Later Model H6.00-7.00XL (H135-155XL, ….427
Linkage for Direction Control Lever – Later Model H6.00-7.00XL (….429
Linkage for Range Lever S6.00-7.00XL (S135-155XL, S135-155XL 2 )….431
Linkage for Direction Control Lever S6.00-7.00XL (S135-155XL, S1….431
Oil Pressure Check….433
System Pressure Check Port….433
Torque Converter Check Port….433
Clutch Pressure Check Port….433
Inching Pressure….434
Solenoid Check Ports (MONOTROL Control Only)….434
Lubrication Pressure Check Ports….434
Specifications….435
Troubleshooting….435
Correct System Pressure: 1300 ±124 kPa ( 189 ±18 psi)….438
Correct Clutch Pressure: 924 ±69 kPa ( 134 ±10 psi)….439
Correct Solenoid Pressure (MONOTROL Only): 965 ±138 kPa ( 140 ±2….440
Torque Converter Pressure: 834 ±69 kPa ( 121 ±10 psi)….440
Lubrication Pressure: 83 ±21 kPa ( 12 ±3 psi)….440
tables….365
Table 1. Stall Speed Specifications….418
hyster-897111-10-03-srm0329….443
toc….443
Masts….443
Safety Precautions Maintenance and Repair….444
General….447
Description and Operation….447
General….447
Safety Procedures When Working Near Mast….448
Two-Stage Mast….448
Three-Stage Mast….450
Carriage Repair….452
Remove….452
Sideshift Carriage, Disassemble….452
Sideshift Carriage, Assemble….453
Install….453
Two-Stage Mast Repair….455
Remove….455
Disassemble….456
Clean and Inspect….457
Assemble….458
Install….458
Three-Stage Mast Repair….460
Remove….460
Disassemble….460
Clean and Inspect….460
Assemble….460
Install….462
Mast Operation Check….462
Lift and Tilt System Leaks Check….463
Lift System….463
Tilt System….463
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment….464
Lift Chain Adjustments….464
Mast Adjustments….467
Carriage Adjustment….467
Troubleshooting….469
tables….443
Table 1. Mast Parts Weight….456
Table 2. Hook-Type Carriage Chain Adjustment….465
Table 3. Pin-Type Carriage Chain Adjustment….465
hyster-897116-11-97-srm0334….473
toc….473
Oil Clutch Assembly….473
Safety Precautions Maintenance and Repair….474
General….477
Description….477
Oil Clutch Assembly Repair….481
Remove and Disassemble….481
Clean and Inspect….482
Assemble and Install….482
Clutch Pedal and Linkage Adjustment….485
Bypass Valve Adjustment for Cold Oil….485
Troubleshooting….486
hyster-897117-02-04-srm0335….491
toc….491
Three-Speed Manual Transmission….491
Safety Precautions Maintenance and Repair….492
General….495
Description….495
Operation….496
Transmission Repair….497
Remove….497
Selector Rails and Forks, Disassemble….498
Gear Assemblies, Disassemble….498
Output Gear and Differential, Disassemble….500
Clean….500
Inspect….501
Shaft Assemblies, Assemble….502
Output Gear and Differential, Assemble….506
Pinion and Ring Gear, Adjust….512
Input Yoke, Install….513
Transmission, Install Cover….513
Selector Rails and Forks, Install….514
Install….515
Shift Linkage Adjustment….516
H3.50-5.00XL (H70-110XL) Shift Linkage, Adjust….516
S6.00-7.00XL (S135-155XL) Shift Linkage, Adjust….518
Clutch Pedal and Linkage Adjustment….520
Troubleshooting….521
Differential Troubleshooting….523
Specifications….525
Torque Specifications….525
Lubrication….525
tables….491
Table 1. Pinion Assembly Shims Adjustment….508
Table 2. Ring and Pinion Tooth Contact Adjustment….510
hyster-897121-10-03-srm0339….529
toc….529
Hydraulic Pump Drive Assembly….529
Safety Precautions Maintenance and Repair….530
General….533
Description….533
Hydraulic Pump Drive Assembly Repair….535
Remove and Disassemble….535
Clean….536
Inspect….536
Assemble and Install….536
Troubleshooting….537
General….561
Description and Operation….563
Fuel Tank….563
Fuel Filter and Fuel Valve Unit….564
Vaporizer….565
Carburetor….566
Governor….568
LPG Tank Repair….569
Remove….569
LPG Tanks with Fixed Mounting Bracket….569
LPG Tanks with EZ Lift Mounting Bracket….569
Install….570
LPG Tanks with Fixed Mounting Bracket….570
LPG Tanks with EZ Lift Mounting Bracket….571
Hydrostatic Relief Valve Repair….572
Remove and Install….572
Filter Unit Repair….572
Fuel Filter Element, Replace….572
Diaphragm and Fuel Valve, Replace….572
Hoses Replacement….574
Vaporizer Repair….574
Remove….574
Disassemble….574
Clean….574
Inspect….574
Assemble….576
Install….580
Carburetor Repair….580
Remove….580
Disassemble….580
Clean….580
Assemble….580
Install….580
Governor Repair….582
Filter Unit Check….584
Vaporizer Check….584
Pressure Reducer Valve….584
Vapor Valve….584
Carburetor Adjustment….584
Idle Mixture….584
Idle Speed….584
Power Mixture….585
Throttle Linkage Adjustment….585
Troubleshooting….587
hyster-897304-12-03-srm0393….593
toc….593
Periodic Maintenance….593
Safety Precautions Maintenance and Repair….594
General….599
Serial Number Data….599
How to Move Disabled Lift Truck….599
How to Tow Lift Truck….599
How to Put Lift Truck on Blocks….600
How to Raise Drive Tires….600
How to Raise Steering Tires….600
Maintenance Schedule….601
Safety Procedures When Working Near Mast….612
Maintenance Procedures Every 8 Hours or Daily….614
How to Make Checks With Engine Stopped….614
Hydraulic System….614
Engine Oil….614
Drive Belts….614
Intake Manifold Rubber Cap….614
Cooling System….614
Air Filter….615
Fuel System….617
Primary Fuel Filter, Diesel Engine….617
Battery….617
Tires and Wheels….617
Forks….618
Adjust….618
Remove….618
Install….618
Forks, Mast, and Lift Chains, Inspect….620
Operator Restraint System….621
Safety Labels….622
How to Make Checks With Engine Running….623
Gauges, Lights, Horn, and Fuses….623
Oil Level, Powershift Transmission….624
Oil Level, Oil Clutch System, S6.00-7.00XL (S135-155XL)….624
Control Levers and Pedals….624
Lift System Operation….625
Inching/Brake Pedal….625
Service Brakes….625
Parking Brake….625
Steering System….626
Maintenance Procedures Every 250 Hours or 6 Weeks….626
Engine Oil and Filter, GM V-6….626
Mast, Lubrication….626
Lift Chains, Lubrication….627
Crankcase Breather, GM V-6 Engine….627
Drive Shafts, S6.00-7.00XL (S135-155XL)….627
Air Filter GM V-6 EPA Compliant Engine….627
Maintenance Procedures Every 350 Hours or 2 Months….628
Drive Belts….628
Perkins Diesel Engine….628
GM V-6 Engine, Early Models….628
GM V-6 Engine, Late Models….628
Forks, Wear and Damage Check….630
Lift Chains, Wear Check….631
Hydraulic Tank Breather, Clean and Check….631
Brake Fluid….631
Fuel System, Checks and Adjustments….631
Diesel Fuel System….631
LPG Carburetor….632
Gasoline Carburetor (Early Models)….632
Fuel Injection (Late Model GM V-6)….633
Steering Axle, Lubrication….633
Cooling System, Clean Debris from Radiator Core….633
Air Filter….633
Maintenance Procedures Every 500 Hours or 3 Months….634
Engine Oil and Filter, Perkins Diesel Engine….634
Crankcase Breather, Perkins Diesel Engine….634
PCV Valve, GM V-6….634
Maintenance Procedures Every 1000 Hours or 6 Months….634
Manifold Heat Valve, GM V-6….634
Crankcase Breather, GM V-6….634
Ignition System, GM V-6….634
Valve Clearance, Check and Adjust….635
Fuel Filter, Diesel Engine, Replace….635
Fuel System Air Removal, Perkins (1004.42 Diesel Engine)….635
Fuel Injection Pump With Vent Tube….635
Fuel Injection Pump With Vent Screw….636
Differential and Drive Axle, Oil Level Check….638
Differential S3.50-5.50XL (S70-120XL)….638
Differential and Drive Axle for Powershift Transmission S6.00-7….638
Differential, Speed Reducer, and Drive Axle for Manual Transmiss….638
Control Levers and Pedals, Lubrication….638
Cooling System GM V-6 EPA Compliant Engine….638
LPG Fuel Filter GM V-6 EPA Compliant Engine, Replace….639
Inspect Engine Electrical System, Connectors, and FCVS Connectio….639
Spark Plug Replacement….640
Remove….640
Install….640
Maintenance Procedures Every 2000 Hours or Yearly….641
Hydraulic System….641
Hydraulic Oil and Filter S3.50-5.50XL (S70-120XL), Replace….641
Hydraulic Oil and Filter S6.00-7.00XL (S135-155XL), Replace….641
Powershift Transmission (All Units), Oil Change and Oil Filter, ….641
Manual Transmission and Differential S6.00-7.00XL (S135-155XL), ….642
Oil Clutch System S6.00-7.00XL (S135-155XL), Oil and Filter Chan….642
Differential and Drive Axle for Powershift Transmission (All Uni….642
Cooling System….643
PCV Valve, GM V-6….643
Service Brakes….643
LPG Filter, Replace (Pre-2004)….643
Oxygen Sensor GM V-6 EPA Compliant Engine….644
Gasoline Fuel Filter, Replace….644
Air Filter Element, GM V-6 EPA Compliant Engine….644
Test LPG/GAS Regulator Pressure….644
Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks….644
Check Throttle Shaft for Sticking….645
Inspect Exhaust Manifold and Piping for Leaks….645
Hood Latch Check….646
Lift Chain Adjustments….646
Fuel Injectors Repair….648
Lift and Tilt System Leak Check….648
Lift Cylinders, Leak Check….648
Tilt Cylinders, Leak Check….648
Welding Repairs….649
Overhead Guard Changes….649
Wheel and Tire Replacement….650
Solid Rubber Tire, Change….650
Wheels, Install….651
SIT Tire, Change for S3.50-5.50XL (D004), and S6.00-7.00XL (B024….651
Remove SIT Solid Tire From Wheel….652
Install SIT Solid Tire on Wheel….653
Adhesives and Sealants….654
Hydraulic Oil, Lubricant, and Coolant Specifications….654
tables….593
Table 1. Maintenance Schedule….601
Table 2. Hook-Type Carriage Chain Adjustment….647
Table 3. Pin-Type Carriage Chain Adjustment….647
Remove….767
Install….767
Overhead Guard Repair….768
Remove….768
Install….768
Operator Restraint System Repair….769
Fuel and Hydraulic Tanks Repair….769
Inspect….769
Small Leaks, Repair….769
Large Leaks, Repair….769
Clean….770
Steam Method of Cleaning….770
Chemical Solution Method of Cleaning….770
Additional Preparations for Repair….770
Radiator Repair….771
Remove….771
Install….771
Exhaust System Repair….771
Muffler, Remove….771
Install….771
Engine Repair….775
Remove….775
Install….775
Safety Labels….777
hyster-897391-09-03-srm0450….781
toc….781
Drive Axle….781
Safety Precautions Maintenance and Repair….782
General….785
Description….785
Drive Axle Repair….786
Remove….786
Units With Manual Transmission….786
Units With Powershift Transmission….786
Disassemble….786
Clean….787
Inspect….787
Assemble….788
Install….788
Units With Manual Transmission….788
Units With Powershift Transmission….789
Torque Specifications….789
Troubleshooting….790
hyster-897392-09-03-srm0451….793
toc….793
Steering Axle….793
Safety Precautions Maintenance and Repair….794
General….797
Description….797
Steering Axle Assembly Repair….798
Remove….798
Install….798
Wheels and Hubs Repair….799
Remove and Disassemble….799
Clean….799
Assemble and Install….799
Spindles, Bearings, and Tie Rods Repair….800
Remove….800
Clean….800
Assemble and Install….800
Steering Cylinder Repair….801
Remove and Disassemble….801
Clean and Inspect….801
Assemble and Install….802
Troubleshooting….803
hyster-897393-02-04-srm0452….807
toc….807
Brake System….807
Safety Precautions Maintenance and Repair….808
General….811
Description and Operation….811
Brake Booster and Master Cylinder….811
Service Brake Assembly….813
Parking Brake….813
Brake Shoe Assemblies Repair….814
Remove and Disassemble….814
Clean….815
Inspect….815
Assemble and Install….815
Master Cylinder Repair….816
Remove….816
Disassemble….816
Clean and Inspect….817
Assemble….817
Install….818
Brake Booster Repair….818
Remove….818
Disassemble….818
Clean and Inspect….818
Assemble….819
Install….820
Brake System Air Removal….820
Brake Pedal Adjustment….820
Brake Shoes Adjustment….821
Parking Brake Adjustment….821
Brake Booster Relief Valve Check….821
Troubleshooting….822
Hydraulic System….827
Safety Precautions Maintenance and Repair….828
General….831
Description and Operation….831
Main Hydraulic Pump….831
Steering Pump….831
Main Control Valve….831
Control Valve Lever….835
Filter….835
Steering Control Unit….835
Brake Booster….835
Main Hydraulic Pump Repair….836
Remove….836
Disassemble….836
Clean and Inspect….836
Assemble….837
Install….837
Specifications….837
Hydraulic System….837
Hydraulic Tank….837
Hydraulic Oil….837
Relief Pressures*….837
Hydraulic Pump….837
Steering Pump….837
Troubleshooting….838
Lift, Lower, and Tilt Circuit….839
Steering and Brake System….840
hyster-897395-10-03-srm0454….845
toc….845
Capacities and Specifications….845
Safety Precautions Maintenance and Repair….846
Lift Truck Weights….849
Hydraulic System….849
Tire Sizes….849
Electrical System….850
Engine Specifications….850
Transmission Oil Pressures….851
Upright Speeds….851
Torque Specifications….852
Frame….852
Engine – GM V-6….852
Engine – Perkins….852
Powershift Transmission….852
Manual Transmission….852
Oil Clutch Assembly….853
Steering System….853
Brake System….853
Hydraulic System….853
Main Control Valve….853
Tilt Cylinders….853
Upright….853
GM Engines….1087
Safety Precautions Maintenance and Repair….1088
General….1091
Description….1091
Engine Removal and Installation….1092
Cylinder Head Repair….1092
Remove and Disassemble….1092
Clean and Inspect….1092
Valve Guides and Seats, Repairs….1093
Valves, Repair….1093
Valve Seats, Repair….1094
Valve Springs….1095
Rocker Arm Studs (Early Models)….1095
Rocker Arm Studs (Late Models)….1096
Assemble and Install….1096
Cylinder Block Cleaning and Inspection….1100
Piston Bore Preparation….1100
Engine Mounts Installation….1100
Lubrication System Repair….1101
Oil Pump, Remove and Disassemble….1101
Clean and Inspect….1101
Oil Pump, Assemble and Install….1101
Oil Sump, Install….1102
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters….1103
Timing Cover….1103
Remove….1103
Install….1105
Timing Sprockets….1105
Remove….1105
Install….1105
Camshaft….1106
Remove….1106
Inspect….1106
Install….1106
Balance Shaft….1107
Remove….1107
Install….1108
Hydraulic Valve Lifters….1108
Remove….1108
Disassemble….1109
Clean and Inspect….1109
Assemble….1109
Install….1110
Crankshaft Repair….1111
Remove….1111
Inspect and Repair….1111
How to Check Clearance Between Main Bearings and Their Journals….1112
Install….1113
Piston and Connecting Rod Assemblies Repair….1114
Connecting Rod Bearings, Replace….1114
Piston and Connecting Rod Assemblies, Remove….1115
Disassemble….1115
Piston, Clean and Inspect….1116
Cylinder Bores, Inspect and Repair….1116
Piston Rings….1117
Assemble….1118
Piston and Connecting Rod Assemblies, Install….1118
Flywheel and Flywheel Housing Repair….1119
Flywheel, Repair….1119
Flywheel, Install….1119
H3.50-5.00XL (H70-110XL), S3.50-5.50XL (S70-120XL), S6.00-7.00XL….1119
H6.00-7.00XL (H135-155XL)….1119
Flywheel Housing H3.50-5.00XL (H70-110XL), H3.50-5.50XM (H70-120….1119
Engine Adapter H6.00-7.00XL (H135-155XL)….1119
Coolant Pump Repair….1120
Thermostat Replacement….1120
Fan Mount Repair (Early Models)….1120
Fan Mount Assembly Repair (Late Models)….1120
Drive Belt Installation….1122
Valve Clearance Adjustment (Early Models)….1123
Valve Clearance Adjustment (New Models)….1124
Compression Check….1124
Engine Specifications….1124
Engine Data….1124
Cylinder Head….1125
Hydraulic Valve Lifter….1125
Camshaft….1125
Pistons….1125
Crankshaft….1126
Connecting Rods….1127
Balance Shaft….1127
Cooling System….1127
Lubrication System….1127
Torque Specifications….1128
Troubleshooting….1129
tables….1087
Table 1. Piston Rings Arrangement on Piston….1118
hyster-897934-11-01-srm0626….1135
toc….1135
Cooling System….1135
Safety Precautions Maintenance and Repair….1136
General….1139
Description….1140
Radiator….1140
Radiator Cap….1140
Thermostat….1140
Water Pump….1141
Fan and Fan Shroud….1141
Cooling System Checks….1141
Radiator….1141
Thermostat….1141
Water Pump….1142
Exhaust Leaks….1142
Fan and Fan Shroud….1142
Radiator Cleaning….1142
Drain….1142
Clean….1142
Fill….1143
Troubleshooting….1144
hyster-899783-10-03-srm0090….1147
toc….1147
Main Control Valve….1147
Safety Precautions Maintenance and Repair….1148
General….1151
Description….1151
Operation….1154
Lift Spool….1154
Tilt Spool….1155
Tilt Backward….1155
Tilt Forward….1156
Single-Stage Relief Valve….1158
Two-Stage Relief Valve….1159
Main Control Valve Repair….1160
Remove and Disassemble….1160
Clean and Inspect….1160
Assemble….1160
Install….1161
Single-Stage Relief Valve Adjustment….1161
Two-Stage Relief Valve….1162
Auxiliary Control Valve Relief Valve Adjustment (H60-110E Only)….1162
Troubleshooting….1163
tables….1147
Table 1. Relief Pressures (Oil temperature at 55 to 66 C ( 131 t….1161
hyster-899784-10-03-srm0002….1167
toc….1167
Alternator with Regulator….1167
Safety Precautions Maintenance and Repair….1168
General….1171
Description….1171
Alternator Repair….1173
Alternator Type A….1173
Remove and Disassemble….1173
Clean….1174
Assemble….1175
Install….1175
Alternator Type B….1178
Remove and Disassemble….1178
Clean….1178
Assemble….1179
Install….1180
General Check and Adjustment….1181
Low Output Check (Type A or Type B)….1181
High Output Check (Type A or Type B)….1183
Brushes Circuit Check….1184
Delco Alternators….1184
Motorola Alternators….1185
Diodes Check….1186
Diode Bridge Check….1186
Delco and Leece-Neville Alternators….1186
Motorola Alternators….1186
Rotor Field Winding Check….1187
Stator Windings Check….1188
Voltage Regulator Check….1188
Troubleshooting….1188
hyster-899788-03-02-srm0107….1193
toc….1193
High Energy Ignition (HEI) System….1193
Safety Precautions Maintenance and Repair….1194
Description….1197
Distributor Repair….1199
Remove….1199
Disassemble….1199
Assemble….1204
Install, If Crankshaft WAS NOT Rotated when Distributor was Remo….1205
Install, If Crankshaft WAS Rotated when Distributor was Removed….1205
Ignition Coil Replacement….1206
Some Four- and Six-Cylinder Models….1206
Remove….1206
Install….1207
V8, Some Four- and Six-Cylinder Models….1207
Remove….1207
Install….1208
Electronic Module Replacement….1209
Remove….1209
Install….1209
Sensing Coil Replacement….1210
Remove….1210
Install….1210
Spark Plugs Replacement….1210
Remove….1210
Install….1211
Visual Check….1211
High Voltage Wires Check….1211
Ignition Coil Check….1212
Coil in Distributor Cap Design….1212
Separate Coil Design….1212
Sensing Coil, Check….1213
Electronic Module Check….1213
Ignition Timing Adjustment….1213
GM V8-366 (6-liter) Ignition System Check….1215
GM V6-LPG (4.3 liter) GM V6-LPG (4.3 liter) Ignition Timing and ….1215
Specifications….1215
Troubleshooting….1216
Differential….1221
Safety Precautions Maintenance and Repair….1222
General….1225
Description….1225
Differential Repair….1225
Remove….1225
Differential Carrier From Axle Housing, Remove….1225
Differential and Ring Gear From Differential Carrier, Remove….1229
Drive Pinion and Pinion Carrier From Differential Carrier, Remov….1231
Disassemble….1232
Differential and Ring Gear Assembly, Disassemble….1232
Drive Pinion and Pinion Carrier, Disassemble….1234
Clean and Inspect….1236
Assemble….1237
Pinion, Bearings, and Pinion Carrier, Assemble….1237
Pinion Bearings, Adjust Preload….1238
Press Method….1238
Yoke or Flange Method….1238
Triple-Lip Seal, Install….1239
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)….1240
Differential and Ring Gear, Assemble….1242
Differential Gears Rotating Torque, Check….1245
Differential and Ring Gear Assembly, Install….1246
Differential Bearings, Preload Adjust….1247
Ring Gear, Runout Check….1248
Ring Gear Backlash, Adjust….1248
Gear Set, Tooth Contact Pattern Check….1250
Thrust Screw, Install and Adjust….1252
Install….1253
Differential Assembly Into Axle Housing, Install….1253
Specifications….1255
Troubleshooting….1259
tables….1221
Table 1. Ring Gear Backlash Adjustment Specifications….1249
Table 2. Ring and Pinion Tooth Contact Adjustment….1251
Table 3. General Specifications….1255
Table 4. Rivet Installation Pressure….1255
Table 5. Pinion Adjustment….1255
Table 6. Pinion Preload Pressure….1256
Table 7. Torque Specifications….1257
Table 8. Torque Specifications for Metric Hardware….1258
Table 9. Torque Specifications for Metric (Fine) Hardware….1258
hyster-910076-10-03-srm0054….1263
toc….1263
Steering Control Unit….1263
Safety Precautions Maintenance and Repair….1264
General….1267
Description….1267
Operation….1267
Steering Wheel and Column Assembly Repair….1269
Steering Column Assembly Repair….1269
Type A Steering Column Assembly….1269
Remove and Disassemble….1269
Assemble and Install….1271
Type B Steering Column Assembly….1273
Remove and Disassemble….1273
Assemble and Install….1273
Steering Control Unit….1276
Disassemble….1276
Clean….1279
Assemble….1280
System Air Removal….1285
Troubleshooting….1285
hyster-910091-10-03-srm0097….1289
toc….1289
Hydraulic Gear Pumps….1289
Safety Precautions Maintenance and Repair….1290
Description….1293
Operation….1294
Flow Control Valve….1294
Relief Valve….1295
Hydraulic Gear Pump Repair….1295
Remove….1295
Disassemble….1296
Clean….1296
Inspect….1297
Assemble….1300
Install….1302
Pump Output Check….1302
Method No. 1….1302
Method No. 2….1303
Hydraulic System Air Check….1304
Troubleshooting….1305
hyster-910102-10-03-srm0103….1311
toc….1311
Tilt Cylinders….1311
Safety Precautions Maintenance and Repair….1312
General….1315
Description….1315
Tilt Cylinder Repair….1315
Remove….1315
Disassemble….1315
Clean….1315
Assemble….1316
Tilt Cylinders With O-Ring or Single-Lip Seals….1316
Tilt Cylinders for XM and XMS Models….1317
Tilt Cylinders for H700-800A and Early Model H700-920B….1318
Install….1319
Tilt Cylinders Using Chevron Packing….1320
Install….1321
Tilt Cylinder Leak Check….1323
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment….1324
Torque Specifications….1325
Piston Rod Nut….1325
Retainer….1326
Troubleshooting….1328
tables….1311
Table 1. Movement Rates (Maximum) for Tilt Cylinders….1324
hyster-910107-02-01-srm0106….1331
toc….1331
Starter….1331
Safety Precautions Maintenance and Repair….1332
General….1335
Description and Operation….1335
Starter Repair….1337
Remove….1337
Disassemble….1337
Clean….1338
Assemble….1338
Install….1339
General Checks and Adjustments….1339
Troubleshooting….1342
hyster-910110-12-03-srm0143….1347
toc….1347
Instrument Panel Indicators and Senders….1347
Safety Precautions Maintenance and Repair….1348
General….1351
Description….1352
Steering Column Gauges, Meters, and Indicators….1352
LED Display Panel….1352
Battery Discharge Indicators….1352
Brush Wear Indicators….1359
Motor Temperature Indicators….1359
LX Series Display Panel….1361
Hourmeter Functions….1361
Battery Indicator Function….1362
Status Code Function….1363
ZX Series Display Panels….1363
Display Panel….1363
Basic Display Panels….1363
Performance Display….1366
Brush Wear Indicators….1369
Adjustments – General….1370
Replacement – General Information….1370
Meter Replacement….1371
Sender Replacement….1372
Fuel Level Sender….1372
Pressure and Temperature Sender….1372
ITW Display Panel Replacement….1373
Remove….1373
Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl….1374
Remove….1374
Display Panel Assembly, Replace….1374
Indicator LEDs….1375
Battery Indicators….1375
Digital Display (Performance Display Panel Only)….1375
Status Code or Performance Level Switches and Indicator LEDs (Pe….1375
Basic Display Panel, Replace Parts….1375
Performance Display Panel, Replace Parts….1377
Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace….1378
Remove and Replace….1378
Specifications….1378
Meter Specifications….1378
Sender Specifications….1379
Troubleshooting….1379
Meter….1379
hyster-910119-10-03-srm0135….1383
toc….1383
Lift Cylinders….1383
Safety Precautions Maintenance and Repair….1384
Safety Procedures When Working Near Mast….1387
General….1391
Description….1391
Lowering Control Valve….1391
Cylinders (General)….1394
Cylinders (H520-620B, H700-800A)….1394
Retainer, Install….1394
Cylinders (H360-460B)….1396
Cylinders (Two-Speed)….1398
Lift Cylinder Repair….1400
Lift Cylinder Removal Without Removing Mast….1400
Standard Masts With Main Lift Cylinder Fastened to Crossmember o….1400
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to….1400
Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift ….1400
Disassemble….1402
Assemble….1402
Lift Cylinder Installation in Mast….1404
Standard Masts With Main Lift Cylinder Fastened to Crossmember o….1404
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to….1404
Chevron-Style Packing….1404
Chevron-Style Packing Installation on Piston….1405
Chevron-Style Packing Installation in Packing Gland….1407
Lift Cylinders for VISTA® Masts….1408
Description….1408
Lowering Control Valve….1408
Remove….1410
Disassemble….1411
Assemble….1412
Install….1413
Main Lift Cylinders….1413
Free-Lift Cylinder….1413
Lift System Leak Check….1414
Specifications….1415
Troubleshooting….1416
tables….1383
Table 1. Lift Trucks with Two-Speed Lift Cylinders….1399
Table 2. Cylinder Retainer Torque Specifications and Weight Guid….1415
hyster-910442-03-03-srm0231….1419
toc….1419
Metric and Inch (SAE) Fasteners….1419
Safety Precautions Maintenance and Repair….1420
General….1423
Threaded Fasteners….1423
Nomenclature, Threads….1423
Strength Identification….1424
Cotter (Split) Pins….1424
Fastener Torque Tables….1429
Conversion Table….1431
tables….1419
Table 1. Bolts and Screws….1425
Table 2. Studs and Nuts….1426
Table 3. Torque Nuts….1427
Table 4. Torque Nuts With Nylon Insert….1428
Table 5. Torque Values for Metric Fasteners*….1429
Table 6. Torque Values for Inch Fasteners*….1430
Table 7. Conversion Table for Metric and English units….1431
Table 8. Cotter Pin Dimensional Data….1432
Hyster S135-155XL (B024) Repair Service Manual