Hyster S135-155XL (B024) Forklift Service Manual

Name: Hyster S135-155XL (B024) Forklift Service Manual
Brand: MidWestTech
SKU: 897335
Price: 149.73 USD
Availability: InStock

1,435 pages · Publication 897335

$149.73

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Models: S135-155XL (B024)
Manual type: Service Manual
Pages: 1,435
Publication: 897335
Condition: Brand new

Hyster S135-155XL (B024) Forklift Service Manual, publication 897335

What's inside

From the manual's own table of contents: 300 sections, 643 entries. See sample pages (PDF, 251 KB)

Search the contents

Two-Speed Powershift Transmission

Safety Precautions Maintenance and Repair

General

Mechanical Description8 topics

Torque Converter
Transmission Pump
Shaft Assemblies
Input Shaft
Forward Clutch Shaft
Clutch Assemblies
Countershaft
Output Shaft

Hydraulic Operation1 topic

Seal Rings

Control Valve11 topics

System Pressure Regulator
Clutch Pressure Regulator
Torque Converter Regulator
Inching Spool
Direction Spool, Direction Control Lever
Direction Spool, MONOTROL Pedal
Range Spool
Drain Spool
Accumulator
Modulator Spool
Operation

Lubrication Circuit

MONOTROL Pedal

Oil Flow Diagrams4 topics

Neutral
Forward-Low
Forward-Low-Inching
Reverse-Low

Transmission Repair7 topics

Transmission and Torque Converter, Remove
Transmission, Disassemble
Reverse-Low Clutch, Disassemble
Reverse-High Clutch, Disassemble
Forward-Low Clutch, Disassemble
Forward-High Clutch, Disassemble
Clean and Inspect

Forward Low and High Clutches Assembly5 topics

Forward Clutches, Assemble
Reverse-Low Clutch, Assemble
Reverse Clutches, Assemble
Transmission, Assemble
Torque Converter, Install

Control Valve Repair6 topics

Remove
Disassemble
Assemble
Install
Remove and Disassemble
Assemble and Install

Stall Test

Linkage Adjustments5 topics

Linkage for Range Lever - Early Model H6.00-7.00XL (H135-155XL)
Linkage for Direction Control Lever - Early Model H6.00-7.00XL (
Linkage for Range Lever - Later Model H6.00-7.00XL (H135-155XL
Linkage for Direction Control Lever - Later Model H6.00-7.00XL (
Linkage for Direction Control Lever S6.00-7.00XL (S135-155XL, S1

Oil Pressure Check6 topics

System Pressure Check Port
Torque Converter Check Port
Clutch Pressure Check Port
Inching Pressure
Solenoid Check Ports (MONOTROL Control Only)
Lubrication Pressure Check Ports

Specifications

Troubleshooting2 topics

Correct Solenoid Pressure (MONOTROL Only): 965 ±138 kPa ( 140 ±2
Lubrication Pressure: 83 ±21 kPa ( 12 ±3 psi)

Table 1. Stall Speed Specifications

Masts

Description and Operation4 topics

General
Safety Procedures When Working Near Mast
Two-Stage Mast
Three-Stage Mast

Carriage Repair2 topics

Sideshift Carriage, Disassemble
Sideshift Carriage, Assemble

Two-Stage Mast Repair

Three-Stage Mast Repair

Mast Operation Check

Show all 300 sections

Lift and Tilt System Leaks Check2 topics

Lift System
Tilt System

Tilt Cylinder Stroke and Backward Tilt Angle Adjustment

Lift Chain Adjustments

Mast Adjustments

Carriage Adjustment

Table 1. Mast Parts Weight

Table 2. Hook-Type Carriage Chain Adjustment

Table 3. Pin-Type Carriage Chain Adjustment

Oil Clutch Assembly

Description

Oil Clutch Assembly Repair

Clutch Pedal and Linkage Adjustment

Bypass Valve Adjustment for Cold Oil

Three-Speed Manual Transmission

Operation10 topics

Selector Rails and Forks, Disassemble
Gear Assemblies, Disassemble
Output Gear and Differential, Disassemble
Clean
Inspect
Shaft Assemblies, Assemble
Output Gear and Differential, Assemble
Input Yoke, Install
Transmission, Install Cover
Selector Rails and Forks, Install

Shift Linkage Adjustment

Differential Troubleshooting2 topics

Torque Specifications
Lubrication

Table 1. Pinion Assembly Shims Adjustment

Table 2. Ring and Pinion Tooth Contact Adjustment

Hydraulic Pump Drive Assembly

Hydraulic Pump Drive Assembly Repair

LPG Fuel System5 topics

Fuel Tank
Fuel Filter and Fuel Valve Unit
Vaporizer
Carburetor
Governor

LPG Tank Repair

Hydrostatic Relief Valve Repair1 topic

Remove and Install

Filter Unit Repair2 topics

Fuel Filter Element, Replace
Diaphragm and Fuel Valve, Replace

Hoses Replacement

Vaporizer Repair

Carburetor Repair

Governor Repair

Filter Unit Check

Vaporizer Check2 topics

Pressure Reducer Valve
Vapor Valve

Carburetor Adjustment3 topics

Idle Mixture
Idle Speed
Power Mixture

Throttle Linkage Adjustment

Periodic Maintenance3 topics

Serial Number Data
How to Move Disabled Lift Truck
How to Put Lift Truck on Blocks

Maintenance Schedule

Safety Procedures When Working Near Mast

Maintenance Procedures Every 8 Hours or Daily2 topics

How to Make Checks With Engine Stopped
How to Make Checks With Engine Running

Maintenance Procedures Every 250 Hours or 6 Weeks5 topics

Engine Oil and Filter, GM V-6
Mast, Lubrication
Lift Chains, Lubrication
Crankcase Breather, GM V-6 Engine
Air Filter GM V-6 EPA Compliant Engine

Maintenance Procedures Every 350 Hours or 2 Months9 topics

Drive Belts
Forks, Wear and Damage Check
Lift Chains, Wear Check
Hydraulic Tank Breather, Clean and Check
Brake Fluid
Fuel System, Checks and Adjustments
Steering Axle, Lubrication
Cooling System, Clean Debris from Radiator Core
Air Filter

Maintenance Procedures Every 500 Hours or 3 Months3 topics

Engine Oil and Filter, Perkins Diesel Engine
Crankcase Breather, Perkins Diesel Engine
PCV Valve, GM V-6

Maintenance Procedures Every 1000 Hours or 6 Months12 topics

Manifold Heat Valve, GM V-6
Crankcase Breather, GM V-6
Ignition System, GM V-6
Valve Clearance, Check and Adjust
Fuel Filter, Diesel Engine, Replace
Fuel System Air Removal, Perkins (1004.42 Diesel Engine)
Differential and Drive Axle, Oil Level Check
Control Levers and Pedals, Lubrication
Cooling System GM V-6 EPA Compliant Engine
LPG Fuel Filter GM V-6 EPA Compliant Engine, Replace
Inspect Engine Electrical System, Connectors, and FCVS Connectio
Spark Plug Replacement

Maintenance Procedures Every 2000 Hours or Yearly14 topics

Hydraulic System
Powershift Transmission (All Units), Oil Change and Oil Filter
Oil Clutch System S6.00-7.00XL (S135-155XL), Oil and Filter Chan
Differential and Drive Axle for Powershift Transmission (All Uni
Cooling System
Service Brakes
LPG Filter, Replace (Pre-2004)
Oxygen Sensor GM V-6 EPA Compliant Engine
Gasoline Fuel Filter, Replace
Air Filter Element, GM V-6 EPA Compliant Engine
Test LPG/GAS Regulator Pressure
Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks
Check Throttle Shaft for Sticking
Inspect Exhaust Manifold and Piping for Leaks

Hood Latch Check

Fuel Injectors Repair

Lift and Tilt System Leak Check2 topics

Lift Cylinders, Leak Check
Tilt Cylinders, Leak Check

Welding Repairs

Overhead Guard Changes

Wheel and Tire Replacement1 topic

Solid Rubber Tire, Change

Adhesives and Sealants

Hydraulic Oil, Lubricant, and Coolant Specifications

Table 1. Maintenance Schedule

Frame

Counterweight Repair

Hood Repair

Overhead Guard Repair

Operator Restraint System Repair

Fuel and Hydraulic Tanks Repair3 topics

Small Leaks, Repair
Large Leaks, Repair
Additional Preparations for Repair

Radiator Repair

Exhaust System Repair1 topic

Muffler, Remove

Engine Repair

Safety Labels

Drive Axle

Drive Axle Repair

Torque Specifications

Steering Axle

Steering Axle Assembly Repair

Wheels and Hubs Repair

Spindles, Bearings, and Tie Rods Repair

Steering Cylinder Repair

Brake System3 topics

Brake Booster and Master Cylinder
Service Brake Assembly
Parking Brake

Brake Shoe Assemblies Repair

Master Cylinder Repair

Brake Booster Repair

Brake System Air Removal

Brake Pedal Adjustment

Brake Shoes Adjustment

Parking Brake Adjustment

Brake Booster Relief Valve Check

Hydraulic System7 topics

Main Hydraulic Pump
Steering Pump
Main Control Valve
Control Valve Lever
Filter
Steering Control Unit
Brake Booster

Main Hydraulic Pump Repair6 topics

Hydraulic Tank
Hydraulic Oil
Relief Pressures*
Hydraulic Pump
Lift, Lower, and Tilt Circuit
Steering and Brake System

Capacities and Specifications

Lift Truck Weights

Tire Sizes

Electrical System

Engine Specifications

Transmission Oil Pressures

Upright Speeds11 topics

Frame
Engine - GM V-6
Engine - Perkins
Powershift Transmission
Manual Transmission
Oil Clutch Assembly
Steering System
Brake System
Tilt Cylinders
Upright
Drive Axle

Diagrams

GM Engines

Engine Removal and Installation

Cylinder Head Repair6 topics

Valve Guides and Seats, Repairs
Valves, Repair
Valve Seats, Repair
Valve Springs
Rocker Arm Studs (Early Models)
Rocker Arm Studs (Late Models)

Cylinder Block Cleaning and Inspection

Piston Bore Preparation

Engine Mounts Installation

Lubrication System Repair3 topics

Oil Pump, Remove and Disassemble
Oil Pump, Assemble and Install
Oil Sump, Install

Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters5 topics

Timing Cover
Timing Sprockets
Camshaft
Balance Shaft
Hydraulic Valve Lifters

Crankshaft Repair2 topics

Inspect and Repair
How to Check Clearance Between Main Bearings and Their Journals

Piston and Connecting Rod Assemblies Repair6 topics

Connecting Rod Bearings, Replace
Piston and Connecting Rod Assemblies, Remove
Piston, Clean and Inspect
Cylinder Bores, Inspect and Repair
Piston Rings
Piston and Connecting Rod Assemblies, Install

Flywheel and Flywheel Housing Repair2 topics

Flywheel, Repair
Flywheel, Install

Coolant Pump Repair

Thermostat Replacement

Fan Mount Repair (Early Models)

Fan Mount Assembly Repair (Late Models)

Drive Belt Installation

Valve Clearance Adjustment (Early Models)

Valve Clearance Adjustment (New Models)

Compression Check7 topics

Engine Data
Cylinder Head
Hydraulic Valve Lifter
Pistons
Crankshaft
Connecting Rods
Lubrication System

Table 1. Piston Rings Arrangement on Piston

Cooling System5 topics

Radiator
Radiator Cap
Thermostat
Water Pump
Fan and Fan Shroud

Cooling System Checks1 topic

Exhaust Leaks

Radiator Cleaning2 topics

Drain
Fill

Main Control Valve4 topics

Lift Spool
Tilt Spool
Single-Stage Relief Valve
Two-Stage Relief Valve

Main Control Valve Repair

Single-Stage Relief Valve Adjustment

Two-Stage Relief Valve

Auxiliary Control Valve Relief Valve Adjustment (H60-110E Only)

Table 1. Relief Pressures (Oil temperature at 55 to 66 C ( 131 t

Alternator with Regulator

Alternator Repair2 topics

Alternator Type A
Alternator Type B

General Check and Adjustment

Low Output Check (Type A or Type B)

High Output Check (Type A or Type B)

Brushes Circuit Check2 topics

Delco Alternators
Motorola Alternators

Diodes Check

Diode Bridge Check1 topic

Delco and Leece-Neville Alternators

Rotor Field Winding Check

Stator Windings Check

Voltage Regulator Check

High Energy Ignition (HEI) System

Distributor Repair2 topics

Install, If Crankshaft WAS NOT Rotated when Distributor was Remo
Install, If Crankshaft WAS Rotated when Distributor was Removed

Ignition Coil Replacement2 topics

Some Four- and Six-Cylinder Models
V8, Some Four- and Six-Cylinder Models

Electronic Module Replacement

Sensing Coil Replacement

Spark Plugs Replacement

Visual Check

High Voltage Wires Check

Ignition Coil Check3 topics

Coil in Distributor Cap Design
Separate Coil Design
Sensing Coil, Check

Electronic Module Check

Ignition Timing Adjustment

GM V8-366 (6-liter) Ignition System Check

GM V6-LPG (4.3 liter) GM V6-LPG (4.3 liter) Ignition Timing and

Differential

Differential Repair

Table 1. Ring Gear Backlash Adjustment Specifications

Table 3. General Specifications

Table 4. Rivet Installation Pressure

Table 5. Pinion Adjustment

Table 6. Pinion Preload Pressure

Table 7. Torque Specifications

Table 8. Torque Specifications for Metric Hardware

Table 9. Torque Specifications for Metric (Fine) Hardware

Steering Control Unit

Steering Wheel and Column Assembly Repair

Steering Column Assembly Repair2 topics

Type A Steering Column Assembly
Type B Steering Column Assembly

System Air Removal

Hydraulic Gear Pumps2 topics

Flow Control Valve
Relief Valve

Hydraulic Gear Pump Repair

Pump Output Check2 topics

Method No. 1
Method No. 2

Hydraulic System Air Check

Tilt Cylinders

Tilt Cylinder Repair

Tilt Cylinder Leak Check

Tilt Cylinder Stroke and Mast Tilt Angle Adjustment2 topics

Piston Rod Nut
Retainer

Table 1. Movement Rates (Maximum) for Tilt Cylinders

Starter

Starter Repair

General Checks and Adjustments

Instrument Panel Indicators and Senders4 topics

Steering Column Gauges, Meters, and Indicators
LED Display Panel
LX Series Display Panel
ZX Series Display Panels

Adjustments - General

Replacement - General Information

Meter Replacement

Sender Replacement2 topics

Fuel Level Sender
Pressure and Temperature Sender

ITW Display Panel Replacement

Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl7 topics

Display Panel Assembly, Replace
Indicator LEDs
Battery Indicators
Digital Display (Performance Display Panel Only)
Status Code or Performance Level Switches and Indicator LEDs (Pe
Basic Display Panel, Replace Parts
Performance Display Panel, Replace Parts

Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace4 topics

Remove and Replace
Meter Specifications
Sender Specifications
Meter

Lift Cylinders3 topics

Lowering Control Valve
Cylinders (General)
Cylinders (Two-Speed)

Lift Cylinder Repair3 topics

Lift Cylinder Removal Without Removing Mast
Lift Cylinder Installation in Mast
Chevron-Style Packing

Lift Cylinders for VISTA® Masts1 topic

Description

Lift System Leak Check

Table 1. Lift Trucks with Two-Speed Lift Cylinders

Table 2. Cylinder Retainer Torque Specifications and Weight Guid

Metric and Inch (SAE) Fasteners6 topics

Threaded Fasteners
Nomenclature, Threads
Strength Identification
Cotter (Split) Pins
Fastener Torque Tables
Conversion Table

Table 1. Bolts and Screws

Table 2. Studs and Nuts

Table 3. Torque Nuts

Table 4. Torque Nuts With Nylon Insert

Table 5. Torque Values for Metric Fasteners*

Table 6. Torque Values for Inch Fasteners*

Table 7. Conversion Table for Metric and English units

Table 8. Cotter Pin Dimensional Data

Perkins Diesel Engines3 topics

General Safety Rules
Engine Serial Number Codes
Lift Engine

Cylinder Head Assembly Repair11 topics

Valve Cover
Rocker Arm Assembly
Valve Clearance Adjustments
Cylinder Head Assembly
Valves and Valve Springs
Valve Guides
Cylinder Head and Valve Seats
Rod Bearings
Piston and Connecting Rod Assembly
Piston and Connecting Rod
Piston Cooling Jets

Crankshaft Assembly Repair6 topics

Crankshaft Pulley
Rear Oil Seal
Main Bearings
Thrust Washers
Flywheel
Flywheel Housing

Timing Case and Timing Gears Repair10 topics

Timing Case Cover
Front Oil Seal
Crankshaft Pulley Wear Sleeve
Idler Gear and Hub
Air Compressor Drive, Bendix
Fuel Injection Pump Gear
Camshaft Gear
Crankshaft Gear
Timing Case
Camshaft and Tappets

Cylinder Block Assembly Repair3 topics

Cylinder Block
Cylinder Bore (Four-Cylinder Engines)
Cylinder Liner (Six-Cylinder Engines)

Engine Timing

Turbocharger - Engine YH Repair5 topics

Oil Filter, Replace
Filter Head
Oil Sump
Oil Pump
Idler Gear Shaft, Replace

Fuel System Repair5 topics

Fuel Injection Pump
Fuel System, Remove Air
Fuel Filter, Replace
Fuel Injectors
Fuel Pump

Cooling System Repair3 topics

Coolant Pump
Fan and Fan Drive
Oil Cooler (Six-Cylinder Engines)

Electrical Equipment Repair3 topics

Alternator
Starter Motor
Cold Start Aid

Air Compressor - Engines YG and YH1 topic

Repair

Rotary Exhauster Replacement10 topics

Piston and Connecting Rods
Crankshaft Assembly
Timing Case and Drive Assembly
Engine Block Assembly
Turbocharger
Fuel System
Flywheel and Housing
Electrical Equipment
Piston and Connecting Rod Assemblies
Auxiliary Equipment

Special Torque Specifications

Special Tools

Table 1. Cylinder Head

Table 2. Valve Guides

Table 3. Inlet Valves

Table 4. Exhaust Valves

Table 5. Valve Springs

Table 6. Tappets

Table 7. Rocker Arm Shaft

Table 8. Rocker Arms and Bushings

Table 9. Pistons (Engine AR)

Table 10. Pistons (Engines YG and YH)

Table 11. Piston Rings (Engine AR)

Table 12. Piston Rings (Engines YG and YH)

Table 13. Piston Pins

Table 14. Connecting Rods

Table 15. Small End Bushings

Table 16. Connecting Rod Bearings (Engines AR and YG)

Table 17. Connecting Rod Bearings (Engine YH)

Table 18. Piston Cooling Jets

Table 19. Crankshaft

Table 20. Main Bearings

Table 21. Crankshaft Thrust Washers

Table 22. Crankshaft Heat Treatment

Table 23. Crankshaft Overhaul Specifications

Table 24. Maximum Variation (Run-out)

Table 25. Camshaft

Table 26. Camshaft Thrust Washer

Table 27. Camshaft Gear

Table 28. Gear for Fuel Injection Pump

Table 29. Crankshaft Gear

Table 30. Idler Gear and Hub

Table 31. Cylinder Block (Engine AR)

Table 32. Cylinder Bore Specifications

Table 33. Cylinder Block (Engines YG and YH)

Table 34. Cylinder Liners (Engines YG and YH)

Table 35. Cylinder Liner Specifications (Partially Finished)

Table 36. Oil Pump (Engine AR)

Table 37. Oil Pump (Engines YG and YH)

Table 38. Idler Gear for Oil Pump

Table 39. Relief Valve

Table 40. Oil Filter

Table 41. Lucas Fuel Injection Pump

Table 42. Fuel Pump (Engine AR)

Table 43. Fuel Pump (Engines YG and YH)

Table 44. Fuel Filter

Table 45. Fuel Injector Codes

Table 46. Coolant Pump

Table 47. Thermostat

Table 48. Fan Drive Housing

Table 49. Limits for Flywheel Run Out and Alignment (Total Indic

Table 50. Alternator

Table 51. Starter Motor

Table 52. Cold Start Aid

Table 53. List of Possible Causes

Microprocessor Spark Timing System (MSTS)15 topics

What MSTS Does
How MSTS Begins Operation
Distributor
Ignition Coil
Ignition Module
When Engine Is Being Started
When Engine Is Running
Manifold Absolute Pressure (MAP) Sensor
Engine Coolant Temperature (ECT) Sensor
MSTS Module Corrections
Tools and Test Equipment
MSTS
Troubleshooting Procedure
Troubleshooting Information
On-Board Diagnostic (OBD) System Check

No Malfunction Indicator Lamp2 topics

Circuit Description
Test Description

No DTC-12, Malfunction Indicator Lamp ON

Starter Rotates Engine, Engine Does Not Run

DTC-14 Engine Coolant Temperature (ECT) (Low Temperature Indicat

DTC-15 Engine Coolant Temperature Sensor (ECT) (High Temperature

DTC-34 Manifold Absolute Pressure (MAP) Sensor

DTC-41 Electronic Spark Timing (EST) Open Circuit

DTC-42 Electronic Spark Timing (EST) Grounded Circuit

DTC-51 MSTS Failure1 topic

Ignition Timing

Ignition Module Repair2 topics

Test For Fault
Replace

Sensing Coil Repair

Ignition Coil Repair

MSTS Module Repair

ECT Sensor Replacement

MAP Sensor Replacement

Table 1. MSTS Module Connections

Table 2. Pressure Conversion Chart

Table 3. MSTS Diagnostic Codes

Inside this manual

Real pages from this service manual (1,435 pages). Open the sample pages (PDF, 251 KB)

Sample pages from the Hyster S135-155XL (B024) Forklift Service Manual: Specifications, Troubleshooting, Diagram

Specifications, page 126: Linkage Adjustments
Troubleshooting, page 500: Troubleshooting
Diagram, page 764: Diagrams, Schematics, or Arrangements

This is a service manual

Here's how it compares to the other manual types.

This manual

Service manual

Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.

Operator's manual

Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.

What it's used for

Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.

Service shops and owner/operators who repair their own equipment

Identifying correct parts and seeing how assemblies come apart and go back together

Keeping equipment running with less downtime

Factory manual, 1,435 pages

Quantity one is the manual described above.

Fast free USA shipping

Ships in 1 business day.

60-day returns

Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy

Binder not included

Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.

Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).