Complete service repair manual for Hyster Lift Trucks S135XL2-S155XL2 (C024), with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.
Hyster Service Manual S135-155XL2 (C024) 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.
1559945 – Hyster Service Manual S135-155XL2 (C024).pdf
Total Pages: 1,121 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 WITH FUEL INJECTION | 897800 | 0600 SRM 0590 | 11/03 |
| PERKINS DIESEL ENGINE 1104 (RE) | 1552002 | 0600 SRM 1070 | 12/03 |
| COOLING SYSTEM | 897934 | 0700 SRM 0626 | 11/01 |
| ELECTRONIC CONTROLLED LPG/GASOLINE FUEL SYSTEM GM 3.0L AND 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 | 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 |
| 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 INCE (SAE) FASTENERS | 910442 | 8000 SRM 0231 | 03/03 |
| CAPACITIES and SPECIFICATIONS | 897395 | 8000 SRM 0454 | 10/03 |
| PERIODIC MAINTENANCE | 897304 | 8000 SRM 0393 | 12/03 |
| DIAGRAMS-GM ELECTRONIC ENGINE CONTROL | 897501 | 8000 SRM 0519 | 12/03 |
| PART NO. 1559945 | |||
| 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-897106-10-03-srm0324…434
toc…434
Two-Speed Powershift Transmission…434
Safety Precautions Maintenance and Repair…435
General…438
Mechanical Description…438
Torque Converter…438
Transmission Pump…439
Shaft Assemblies…439
Input Shaft…440
Forward Clutch Shaft…440
Clutch Assemblies…440
Countershaft…447
Output Shaft…447
Hydraulic Operation…448
Torque Converter…448
Seal Rings…449
Control Valve…449
System Pressure Regulator…452
Clutch Pressure Regulator…452
Torque Converter Regulator…453
Inching Spool…453
Direction Spool, Direction Control Lever…453
Direction Spool, MONOTROL Pedal…454
Range Spool…454
Drain Spool…455
Accumulator…455
Modulator Spool…455
Operation…455
Lubrication Circuit…456
MONOTROL Pedal…456
Oil Flow Diagrams…458
Neutral…458
Forward-Low…459
Forward-Low-Inching…460
Reverse-Low…461
hyster-897107-10-03-srm0325…464
toc…464
Two-Speed Powershift Transmission…464
Safety Precautions Maintenance and Repair…465
General…468
Transmission Repair…468
Transmission and Torque Converter, Remove…468
Transmission, Disassemble…470
Reverse-Low Clutch, Disassemble…473
Reverse-High Clutch, Disassemble…476
Forward-Low Clutch, Disassemble…479
Forward-High Clutch, Disassemble…482
Clean and Inspect…484
Forward Low and High Clutches Assembly…485
Forward Clutches, Assemble…487
Reverse-Low Clutch, Assemble…493
Reverse Clutches, Assemble…495
Transmission, Assemble…502
Torque Converter, Install…509
Control Valve Repair…510
Remove…510
Disassemble…511
Assemble…512
Install…514
MONOTROL Pedal…514
Remove and Disassemble…514
Assemble and Install…514
Stall Test…517
Linkage Adjustments…518
Linkage for Inching Pedal H6.00-7.00XL (H135-155XL, H135-155XL 2…518
Linkage for Inching Pedal S6.00-7.00XL (S135-155XL, S135-155XL 2…521
Linkage for Range Lever – Early Model H6.00-7.00XL (H135-155XL) …524
Linkage for Direction Control Lever – Early Model H6.00-7.00XL (…524
Linkage for Range Lever – Later Model H6.00-7.00XL (H135-155XL, …526
Linkage for Direction Control Lever – Later Model H6.00-7.00XL (…528
Linkage for Range Lever S6.00-7.00XL (S135-155XL, S135-155XL 2 )…530
Linkage for Direction Control Lever S6.00-7.00XL (S135-155XL, S1…530
Oil Pressure Check…532
System Pressure Check Port…532
Torque Converter Check Port…532
Clutch Pressure Check Port…532
Inching Pressure…533
Solenoid Check Ports (MONOTROL Control Only)…533
Lubrication Pressure Check Ports…533
Specifications…534
Troubleshooting…534
Correct System Pressure: 1300 ±124 kPa ( 189 ±18 psi)…537
Correct Clutch Pressure: 924 ±69 kPa ( 134 ±10 psi)…538
Correct Solenoid Pressure (MONOTROL Only): 965 ±138 kPa ( 140 ±2…539
Torque Converter Pressure: 834 ±69 kPa ( 121 ±10 psi)…539
Lubrication Pressure: 83 ±21 kPa ( 12 ±3 psi)…539
tables…464
Table 1. Stall Speed Specifications…517
hyster-897111-10-03-srm0329…542
toc…542
Masts…542
Safety Precautions Maintenance and Repair…543
General…546
Description and Operation…546
General…546
Safety Procedures When Working Near Mast…547
Two-Stage Mast…547
Three-Stage Mast…549
Carriage Repair…551
Remove…551
Sideshift Carriage, Disassemble…551
Sideshift Carriage, Assemble…552
Install…552
Two-Stage Mast Repair…554
Remove…554
Disassemble…555
Clean and Inspect…556
Assemble…557
Install…557
Three-Stage Mast Repair…559
Remove…559
Disassemble…559
Clean and Inspect…559
Assemble…559
Install…561
Mast Operation Check…561
Lift and Tilt System Leaks Check…562
Lift System…562
Tilt System…562
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment…563
Lift Chain Adjustments…563
Mast Adjustments…566
Carriage Adjustment…566
Troubleshooting…568
tables…542
Table 1. Mast Parts Weight…555
Table 2. Hook-Type Carriage Chain Adjustment…564
Table 3. Pin-Type Carriage Chain Adjustment…564
hyster-897121-10-03-srm0339…572
toc…572
Hydraulic Pump Drive Assembly…572
Safety Precautions Maintenance and Repair…573
General…576
Description…576
Hydraulic Pump Drive Assembly Repair…578
Remove and Disassemble…578
Clean…579
Inspect…579
Assemble and Install…579
Troubleshooting…580
hyster-897304-12-03-srm0393…584
toc…584
Periodic Maintenance…584
Safety Precautions Maintenance and Repair…585
General…590
Serial Number Data…590
How to Move Disabled Lift Truck…590
How to Tow Lift Truck…590
How to Put Lift Truck on Blocks…591
How to Raise Drive Tires…591
How to Raise Steering Tires…591
Maintenance Schedule…592
Safety Procedures When Working Near Mast…603
Maintenance Procedures Every 8 Hours or Daily…605
How to Make Checks With Engine Stopped…605
Hydraulic System…605
Engine Oil…605
Drive Belts…605
Intake Manifold Rubber Cap…605
Cooling System…605
Air Filter…606
Fuel System…608
Primary Fuel Filter, Diesel Engine…608
Battery…608
Tires and Wheels…608
Forks…609
Adjust…609
Remove…609
Install…609
Forks, Mast, and Lift Chains, Inspect…611
Operator Restraint System…612
Safety Labels…613
How to Make Checks With Engine Running…614
Gauges, Lights, Horn, and Fuses…614
Oil Level, Powershift Transmission…615
Oil Level, Oil Clutch System, S6.00-7.00XL (S135-155XL)…615
Control Levers and Pedals…615
Lift System Operation…616
Inching/Brake Pedal…616
Service Brakes…616
Parking Brake…616
Steering System…617
Maintenance Procedures Every 250 Hours or 6 Weeks…617
Engine Oil and Filter, GM V-6…617
Mast, Lubrication…617
Lift Chains, Lubrication…618
Crankcase Breather, GM V-6 Engine…618
Drive Shafts, S6.00-7.00XL (S135-155XL)…618
Air Filter GM V-6 EPA Compliant Engine…618
Maintenance Procedures Every 350 Hours or 2 Months…619
Drive Belts…619
Perkins Diesel Engine…619
GM V-6 Engine, Early Models…619
GM V-6 Engine, Late Models…619
Forks, Wear and Damage Check…621
Lift Chains, Wear Check…622
Hydraulic Tank Breather, Clean and Check…622
Brake Fluid…622
Fuel System, Checks and Adjustments…622
Diesel Fuel System…622
LPG Carburetor…623
Gasoline Carburetor (Early Models)…623
Fuel Injection (Late Model GM V-6)…624
Steering Axle, Lubrication…624
Cooling System, Clean Debris from Radiator Core…624
Air Filter…624
Maintenance Procedures Every 500 Hours or 3 Months…625
Engine Oil and Filter, Perkins Diesel Engine…625
Crankcase Breather, Perkins Diesel Engine…625
PCV Valve, GM V-6…625
Maintenance Procedures Every 1000 Hours or 6 Months…625
Manifold Heat Valve, GM V-6…625
Crankcase Breather, GM V-6…625
Ignition System, GM V-6…625
Valve Clearance, Check and Adjust…626
Fuel Filter, Diesel Engine, Replace…626
Fuel System Air Removal, Perkins (1004.42 Diesel Engine)…626
Fuel Injection Pump With Vent Tube…626
Fuel Injection Pump With Vent Screw…627
Differential and Drive Axle, Oil Level Check…629
Differential S3.50-5.50XL (S70-120XL)…629
Differential and Drive Axle for Powershift Transmission S6.00-7…629
Differential, Speed Reducer, and Drive Axle for Manual Transmiss…629
Control Levers and Pedals, Lubrication…629
Cooling System GM V-6 EPA Compliant Engine…629
LPG Fuel Filter GM V-6 EPA Compliant Engine, Replace…630
Inspect Engine Electrical System, Connectors, and FCVS Connectio…630
Spark Plug Replacement…631
Remove…631
Install…631
Maintenance Procedures Every 2000 Hours or Yearly…632
Hydraulic System…632
Hydraulic Oil and Filter S3.50-5.50XL (S70-120XL), Replace…632
Hydraulic Oil and Filter S6.00-7.00XL (S135-155XL), Replace…632
Powershift Transmission (All Units), Oil Change and Oil Filter, …632
Manual Transmission and Differential S6.00-7.00XL (S135-155XL), …633
Oil Clutch System S6.00-7.00XL (S135-155XL), Oil and Filter Chan…633
Differential and Drive Axle for Powershift Transmission (All Uni…633
Cooling System…634
PCV Valve, GM V-6…634
Service Brakes…634
LPG Filter, Replace (Pre-2004)…634
Oxygen Sensor GM V-6 EPA Compliant Engine…635
Gasoline Fuel Filter, Replace…635
Air Filter Element, GM V-6 EPA Compliant Engine…635
Test LPG/GAS Regulator Pressure…635
Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks…635
Check Throttle Shaft for Sticking…636
Inspect Exhaust Manifold and Piping for Leaks…636
Hood Latch Check…637
Lift Chain Adjustments…637
Fuel Injectors Repair…639
Lift and Tilt System Leak Check…639
Lift Cylinders, Leak Check…639
Tilt Cylinders, Leak Check…639
Welding Repairs…640
Overhead Guard Changes…640
Wheel and Tire Replacement…641
Solid Rubber Tire, Change…641
Wheels, Install…642
SIT Tire, Change for S3.50-5.50XL (D004), and S6.00-7.00XL (B024…642
Remove SIT Solid Tire From Wheel…643
Install SIT Solid Tire on Wheel…644
Adhesives and Sealants…645
Hydraulic Oil, Lubricant, and Coolant Specifications…645
tables…584
Table 1. Maintenance Schedule…592
Table 2. Hook-Type Carriage Chain Adjustment…638
Table 3. Pin-Type Carriage Chain Adjustment…638
hyster-897390-12-03-srm0449…648
toc…648
Frame…648
Safety Precautions Maintenance and Repair…649
General…652
Description…652
Counterweight Repair…653
Remove…653
Install…654
Hood Repair…654
Remove…654
Install…654
Overhead Guard Repair…655
Remove…655
Install…655
Operator Restraint System Repair…656
Fuel and Hydraulic Tanks Repair…656
Inspect…656
Small Leaks, Repair…656
Large Leaks, Repair…656
Clean…657
Steam Method of Cleaning…657
Chemical Solution Method of Cleaning…657
Additional Preparations for Repair…657
Radiator Repair…658
Remove…658
Install…658
Exhaust System Repair…658
Muffler, Remove…658
Install…658
Engine Repair…662
Remove…662
Install…662
Safety Labels…664
hyster-897391-09-03-srm0450…668
toc…668
Drive Axle…668
Safety Precautions Maintenance and Repair…669
General…672
Description…672
Drive Axle Repair…673
Remove…673
Units With Manual Transmission…673
Units With Powershift Transmission…673
Disassemble…673
Clean…674
Inspect…674
Assemble…675
Install…675
Units With Manual Transmission…675
Units With Powershift Transmission…676
Torque Specifications…676
Troubleshooting…677
hyster-897392-09-03-srm0451…680
toc…680
Steering Axle…680
Safety Precautions Maintenance and Repair…681
General…684
Description…684
Steering Axle Assembly Repair…685
Remove…685
Install…685
Wheels and Hubs Repair…686
Remove and Disassemble…686
Clean…686
Assemble and Install…686
Spindles, Bearings, and Tie Rods Repair…687
Remove…687
Clean…687
Assemble and Install…687
Steering Cylinder Repair…688
Remove and Disassemble…688
Clean and Inspect…688
Assemble and Install…689
Troubleshooting…690
hyster-897393-02-04-srm0452…694
toc…694
Brake System…694
Safety Precautions Maintenance and Repair…695
General…698
Description and Operation…698
Brake Booster and Master Cylinder…698
Service Brake Assembly…700
Parking Brake…700
Brake Shoe Assemblies Repair…701
Remove and Disassemble…701
Clean…702
Inspect…702
Assemble and Install…702
Master Cylinder Repair…703
Remove…703
Disassemble…703
Clean and Inspect…704
Assemble…704
Install…705
Brake Booster Repair…705
Remove…705
Disassemble…705
Clean and Inspect…705
Assemble…706
Install…707
Brake System Air Removal…707
Brake Pedal Adjustment…707
Brake Shoes Adjustment…708
Parking Brake Adjustment…708
Brake Booster Relief Valve Check…708
Troubleshooting…709
hyster-897394-09-03-srm0453…714
toc…714
Hydraulic System…714
Safety Precautions Maintenance and Repair…715
General…718
Description and Operation…718
Main Hydraulic Pump…718
Steering Pump…718
Main Control Valve…718
Control Valve Lever…722
Filter…722
Steering Control Unit…722
Brake Booster…722
Main Hydraulic Pump Repair…723
Remove…723
Disassemble…723
Clean and Inspect…723
Assemble…724
Install…724
Specifications…724
Hydraulic System…724
Hydraulic Tank…724
Hydraulic Oil…724
Relief Pressures*…724
Hydraulic Pump…724
Steering Pump…724
Troubleshooting…725
Lift, Lower, and Tilt Circuit…726
Steering and Brake System…727
hyster-897395-10-03-srm0454…732
toc…732
Capacities and Specifications…732
Safety Precautions Maintenance and Repair…733
Lift Truck Weights…736
Hydraulic System…736
Tire Sizes…736
Electrical System…737
Engine Specifications…737
Transmission Oil Pressures…738
Upright Speeds…738
Torque Specifications…739
Frame…739
Engine – GM V-6…739
Engine – Perkins…739
Powershift Transmission…739
Manual Transmission…739
Oil Clutch Assembly…740
Steering System…740
Brake System…740
Hydraulic System…740
Main Control Valve…740
Tilt Cylinders…740
Upright…740
Drive Axle…740
hyster-897501-12-03-srm0519…744
toc…744
Diagrams…744
Safety Precautions Maintenance and Repair…745
hyster-897800-11-03-srm0590…808
toc…808
GM Engines…808
Safety Precautions Maintenance and Repair…809
General…812
Description…812
Engine Removal and Installation…813
Cylinder Head Repair…813
Remove and Disassemble…813
Clean and Inspect…813
Valve Guides and Seats, Repairs…814
Valves, Repair…814
Valve Seats, Repair…815
Valve Springs…816
Rocker Arm Studs (Early Models)…816
Rocker Arm Studs (Late Models)…817
Assemble and Install…817
Cylinder Block Cleaning and Inspection…821
Piston Bore Preparation…821
Engine Mounts Installation…821
Lubrication System Repair…822
Oil Pump, Remove and Disassemble…822
Clean and Inspect…822
Oil Pump, Assemble and Install…822
Oil Sump, Install…823
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters…824
Timing Cover…824
Remove…824
Install…826
Timing Sprockets…826
Remove…826
Install…826
Camshaft…827
Remove…827
Inspect…827
Install…827
Balance Shaft…828
Remove…828
Install…829
Hydraulic Valve Lifters…829
Remove…829
Disassemble…830
Clean and Inspect…830
Assemble…830
Install…831
Crankshaft Repair…832
Remove…832
Inspect and Repair…832
How to Check Clearance Between Main Bearings and Their Journals…833
Install…834
Piston and Connecting Rod Assemblies Repair…835
Connecting Rod Bearings, Replace…835
Piston and Connecting Rod Assemblies, Remove…836
Disassemble…836
Piston, Clean and Inspect…837
Cylinder Bores, Inspect and Repair…837
Piston Rings…838
Assemble…839
Piston and Connecting Rod Assemblies, Install…839
Flywheel and Flywheel Housing Repair…840
Flywheel, Repair…840
Flywheel, Install…840
H3.50-5.00XL (H70-110XL), S3.50-5.50XL (S70-120XL), S6.00-7.00XL…840
H6.00-7.00XL (H135-155XL)…840
Flywheel Housing H3.50-5.00XL (H70-110XL), H3.50-5.50XM (H70-120…840
Engine Adapter H6.00-7.00XL (H135-155XL)…840
Coolant Pump Repair…841
Thermostat Replacement…841
Fan Mount Repair (Early Models)…841
Fan Mount Assembly Repair (Late Models)…841
Drive Belt Installation…843
Valve Clearance Adjustment (Early Models)…844
Valve Clearance Adjustment (New Models)…845
Compression Check…845
Engine Specifications…845
Engine Data…845
Cylinder Head…846
Hydraulic Valve Lifter…846
Camshaft…846
Pistons…846
Crankshaft…847
Connecting Rods…848
Balance Shaft…848
Cooling System…848
Lubrication System…848
Torque Specifications…849
Troubleshooting…850
tables…808
Table 1. Piston Rings Arrangement on Piston…839
hyster-897934-11-01-srm0626…856
toc…856
Cooling System…856
Safety Precautions Maintenance and Repair…857
General…860
Description…861
Radiator…861
Radiator Cap…861
Thermostat…861
Water Pump…862
Fan and Fan Shroud…862
Cooling System Checks…862
Radiator…862
Thermostat…862
Water Pump…863
Exhaust Leaks…863
Fan and Fan Shroud…863
Radiator Cleaning…863
Drain…863
Clean…863
Fill…864
Troubleshooting…865
hyster-899783-10-03-srm0090…868
toc…868
Main Control Valve…868
Safety Precautions Maintenance and Repair…869
General…872
Description…872
Operation…875
Lift Spool…875
Tilt Spool…876
Tilt Backward…876
Tilt Forward…877
Single-Stage Relief Valve…879
Two-Stage Relief Valve…880
Main Control Valve Repair…881
Remove and Disassemble…881
Clean and Inspect…881
Assemble…881
Install…882
Single-Stage Relief Valve Adjustment…882
Two-Stage Relief Valve…883
Auxiliary Control Valve Relief Valve Adjustment (H60-110E Only)…883
Troubleshooting…884
tables…868
Table 1. Relief Pressures (Oil temperature at 55 to 66 C ( 131 t…882
hyster-899784-10-03-srm0002…888
toc…888
Alternator with Regulator…888
Safety Precautions Maintenance and Repair…889
General…892
Description…892
Alternator Repair…894
Alternator Type A…894
Remove and Disassemble…894
Clean…895
Assemble…896
Install…896
Alternator Type B…899
Remove and Disassemble…899
Clean…899
Assemble…900
Install…901
General Check and Adjustment…902
Low Output Check (Type A or Type B)…902
High Output Check (Type A or Type B)…904
Brushes Circuit Check…905
Delco Alternators…905
Motorola Alternators…906
Diodes Check…907
Diode Bridge Check…907
Delco and Leece-Neville Alternators…907
Motorola Alternators…907
Rotor Field Winding Check…908
Stator Windings Check…909
Voltage Regulator Check…909
Troubleshooting…909
hyster-910072-11-03-srm0046…914
toc…914
Differential…914
Safety Precautions Maintenance and Repair…915
General…918
Description…918
Differential Repair…918
Remove…918
Differential Carrier From Axle Housing, Remove…918
Differential and Ring Gear From Differential Carrier, Remove…922
Drive Pinion and Pinion Carrier From Differential Carrier, Remov…924
Disassemble…925
Differential and Ring Gear Assembly, Disassemble…925
Drive Pinion and Pinion Carrier, Disassemble…927
Clean and Inspect…929
Assemble…930
Pinion, Bearings, and Pinion Carrier, Assemble…930
Pinion Bearings, Adjust Preload…931
Press Method…931
Yoke or Flange Method…931
Triple-Lip Seal, Install…932
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)…933
Differential and Ring Gear, Assemble…935
Differential Gears Rotating Torque, Check…938
Differential and Ring Gear Assembly, Install…939
Differential Bearings, Preload Adjust…940
Ring Gear, Runout Check…941
Ring Gear Backlash, Adjust…941
Gear Set, Tooth Contact Pattern Check…943
Thrust Screw, Install and Adjust…945
Install…946
Differential Assembly Into Axle Housing, Install…946
Specifications…948
Troubleshooting…952
tables…914
Table 1. Ring Gear Backlash Adjustment Specifications…942
Table 2. Ring and Pinion Tooth Contact Adjustment…944
Table 3. General Specifications…948
Table 4. Rivet Installation Pressure…948
Table 5. Pinion Adjustment…948
Table 6. Pinion Preload Pressure…949
Table 7. Torque Specifications…950
Table 8. Torque Specifications for Metric Hardware…951
Table 9. Torque Specifications for Metric (Fine) Hardware…951
hyster-910076-10-03-srm0054…956
toc…956
Steering Control Unit…956
Safety Precautions Maintenance and Repair…957
General…960
Description…960
Operation…960
Steering Wheel and Column Assembly Repair…962
Steering Column Assembly Repair…962
Type A Steering Column Assembly…962
Remove and Disassemble…962
Assemble and Install…964
Type B Steering Column Assembly…966
Remove and Disassemble…966
Assemble and Install…966
Steering Control Unit…969
Disassemble…969
Clean…972
Assemble…973
System Air Removal…978
Troubleshooting…978
hyster-910091-10-03-srm0097…982
toc…982
Hydraulic Gear Pumps…982
Safety Precautions Maintenance and Repair…983
Description…986
Operation…987
Flow Control Valve…987
Relief Valve…988
Hydraulic Gear Pump Repair…988
Remove…988
Disassemble…989
Clean…989
Inspect…990
Assemble…993
Install…995
Pump Output Check…995
Method No. 1…995
Method No. 2…996
Hydraulic System Air Check…997
Troubleshooting…998
hyster-910102-10-03-srm0103…1004
toc…1004
Tilt Cylinders…1004
Safety Precautions Maintenance and Repair…1005
General…1008
Description…1008
Tilt Cylinder Repair…1008
Remove…1008
Disassemble…1008
Clean…1008
Assemble…1009
Tilt Cylinders With O-Ring or Single-Lip Seals…1009
Tilt Cylinders for XM and XMS Models…1010
Tilt Cylinders for H700-800A and Early Model H700-920B…1011
Install…1012
Tilt Cylinders Using Chevron Packing…1013
Install…1014
Tilt Cylinder Leak Check…1016
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment…1017
Torque Specifications…1018
Piston Rod Nut…1018
Retainer…1019
Troubleshooting…1021
tables…1004
Table 1. Movement Rates (Maximum) for Tilt Cylinders…1017
hyster-910107-02-01-srm0106…1024
toc…1024
Starter…1024
Safety Precautions Maintenance and Repair…1025
General…1028
Description and Operation…1028
Starter Repair…1030
Remove…1030
Disassemble…1030
Clean…1031
Assemble…1031
Install…1032
General Checks and Adjustments…1032
Troubleshooting…1035
hyster-910110-12-03-srm0143…1040
toc…1040
Instrument Panel Indicators and Senders…1040
Safety Precautions Maintenance and Repair…1041
General…1044
Description…1045
Steering Column Gauges, Meters, and Indicators…1045
LED Display Panel…1045
Battery Discharge Indicators…1045
Brush Wear Indicators…1052
Motor Temperature Indicators…1052
LX Series Display Panel…1054
Hourmeter Functions…1054
Battery Indicator Function…1055
Status Code Function…1056
ZX Series Display Panels…1056
Display Panel…1056
Basic Display Panels…1056
Performance Display…1059
Brush Wear Indicators…1062
Adjustments – General…1063
Replacement – General Information…1063
Meter Replacement…1064
Sender Replacement…1065
Fuel Level Sender…1065
Pressure and Temperature Sender…1065
ITW Display Panel Replacement…1066
Remove…1066
Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl…1067
Remove…1067
Display Panel Assembly, Replace…1067
Indicator LEDs…1068
Battery Indicators…1068
Digital Display (Performance Display Panel Only)…1068
Status Code or Performance Level Switches and Indicator LEDs (Pe…1068
Basic Display Panel, Replace Parts…1068
Performance Display Panel, Replace Parts…1070
Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace…1071
Remove and Replace…1071
Specifications…1071
Meter Specifications…1071
Sender Specifications…1072
Troubleshooting…1072
Meter…1072
hyster-910119-10-03-srm0135…1076
toc…1076
Lift Cylinders…1076
Safety Precautions Maintenance and Repair…1077
Safety Procedures When Working Near Mast…1080
General…1084
Description…1084
Lowering Control Valve…1084
Cylinders (General)…1087
Cylinders (H520-620B, H700-800A)…1087
Retainer, Install…1087
Cylinders (H360-460B)…1089
Cylinders (Two-Speed)…1091
Lift Cylinder Repair…1093
Lift Cylinder Removal Without Removing Mast…1093
Standard Masts With Main Lift Cylinder Fastened to Crossmember o…1093
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to…1093
Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift …1093
Disassemble…1095
Assemble…1095
Lift Cylinder Installation in Mast…1097
Standard Masts With Main Lift Cylinder Fastened to Crossmember o…1097
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to…1097
Chevron-Style Packing…1097
Chevron-Style Packing Installation on Piston…1098
Chevron-Style Packing Installation in Packing Gland…1100
Lift Cylinders for VISTA® Masts…1101
Description…1101
Lowering Control Valve…1101
Remove…1103
Disassemble…1104
Assemble…1105
Install…1106
Main Lift Cylinders…1106
Free-Lift Cylinder…1106
Lift System Leak Check…1107
Specifications…1108
Troubleshooting…1109
tables…1076
Table 1. Lift Trucks with Two-Speed Lift Cylinders…1092
Table 2. Cylinder Retainer Torque Specifications and Weight Guid…1108
hyster-910442-03-03-srm0231…1112
toc…1112
Metric and Inch (SAE) Fasteners…1112
Safety Precautions Maintenance and Repair…1113
General…1116
Threaded Fasteners…1116
Nomenclature, Threads…1116
Strength Identification…1117
Cotter (Split) Pins…1117
Fastener Torque Tables…1122
Conversion Table…1124
tables…1112
Table 1. Bolts and Screws…1118
Table 2. Studs and Nuts…1119
Table 3. Torque Nuts…1120
Table 4. Torque Nuts With Nylon Insert…1121
Table 5. Torque Values for Metric Fasteners*…1122
Table 6. Torque Values for Inch Fasteners*…1123
Table 7. Conversion Table for Metric and English units…1124
Table 8. Cotter Pin Dimensional Data…1125
Hyster S135-155XL2 (C024) Repair Service Manual