Hyster S135-155XL2 (C024) Forklift Service Manual

Name: Hyster S135-155XL2 (C024) Forklift Service Manual
Brand: MidWestTech
SKU: 1559945
Price: 119.57 USD
Availability: InStock

1,128 pages · Publication 1559945

$119.57

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Models: S135-155XL2 (C024)
Manual type: Service Manual
Pages: 1,128
Publication: 1559945
Condition: Brand new

Hyster S135-155XL2 (C024) Forklift Service Manual, publication 1559945

What's inside

From the manual's own table of contents: 334 sections, 700 entries. See sample pages (PDF, 236 KB)

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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 334 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

Hydraulic Pump Drive Assembly

Description

Hydraulic Pump Drive Assembly Repair2 topics

Clean
Inspect

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 Valve

Operation4 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

Differential

Differential Repair

Table 1. Ring Gear Backlash Adjustment Specifications

Table 2. Ring and Pinion Tooth Contact Adjustment

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 Engines2 topics

General Safety Rules
Engine Serial Number Codes

Cylinder Head Assembly Repair11 topics

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

Crankshaft Assembly Repair8 topics

Crankshaft Pulley
Rear Oil Seal
Crankshaft Flange Wear Sleeve
Main Bearings
Thrust Washers
Crankshaft Timing Ring
Flywheel
Flywheel Housing

Timing Case and Timing Gears Repair10 topics

Timing Case Cover
Front Oil Seal
Crankshaft Pulley Wear Sleeve, Install
Fuel Pump Gear
Idler Gear and Hub
Camshaft Gear
Crankshaft Gear
Timing Case
Power Take-Off (PTO) Adaptor
Camshaft and Tappets

Cylinder Block Assembly Repair2 topics

Cylinder Block
Cylinder Bore

Engine Timing9 topics

How to Set Number One Piston to TDC on Compression Stroke
Fuel Injection Pump Timing, Check
Fuel Injection Pump Timing, Adjust
Oil Filter, Replace
Oil Filter Head
Oil Sump
Oil Pump
Oil Strainer and Suction Pipe
Dipstick Tube

Fuel System Repair6 topics

Cold Start Advance Unit (KSB)
Typical Fuel System
Fuel Filter
Fuel Injectors
Fuel System Air Removal
Bosch EVPE Fuel Injection Pump

Cooling System Repair4 topics

Coolant Pump
Fan Drive
Oil Cooler
Coolant By-Pass Hose

Electrical Equipment Repair13 topics

Drive Belt
Alternator
Starter Motor
Starting Aid
Pressure Sensor
Temperature Sensor
Piston and Connecting Rods
Crankshaft Assembly
Timing Case and Drive Assembly
Engine Block Assembly
Fuel System
Flywheel and Housing
Electrical Equipment

Special Torque Specifications1 topic

Piston and Connecting Rod Assemblies

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

Table 10. Piston Rings

Table 11. Piston Pins

Table 12. Connecting Rods

Table 13. Small End Bushings

Table 14. Connecting Rod Bearings

Table 15. Piston Cooling Jets

Table 16. Crankshaft Overhaul Specifications

Table 17. Maximum Variation (Run-out)

Table 18. Camshaft

Table 19. Camshaft Thrust Washer

Table 20. Camshaft Gear

Table 21. Gear for Fuel Pump

Table 22. Crankshaft Gear

Table 23. Idler Gear and Hub

Table 24. Timing Gear Backlash Values

Table 25. Cylinder Block

Table 26. Oil Pump

Table 27. Idler Gear for Oil Pump

Table 28. Relief Valve

Table 29. Oil Filter

Table 30. Bosch Fuel Injection Pump

Table 31. Fuel Injector Settings

Table 32. Fuel Pump

Table 33. Fuel Filter

Table 34. Coolant Pump

Table 35. Thermostat

Table 36. Fan Drive Housing

Table 37. Limits for Flywheel Run Out and Alignment (Total Indic

Table 38. Alternator

Table 39. Starter Motor

Table 40. Starting Aids

Table 41. List of Possible Causes

Electronic Controlled LPG/Gasoline Fuel System1 topic

Fuel System Warnings and Cautions

Glossary

Description and Operation of LPG Fuel System10 topics

Propane Fuel System
LPG Fuel Tank
Service Line
Low Pressure Lock-Off (LPL)
Low Pressure Regulator (LPR)
Air Fuel Mixer
Throttle Control Device
Three-Way Catalytic (TWC) Muffler
Electronic Control Module (ECM)
Heated Exhaust Gas Oxygen (HEGO) Sensor

Description and Operation of Gasoline Fuel System8 topics

Gasoline Fuel System Throttle Body Injection (TBI), 3.0L Engine
Gasoline Multi-Point Fuel Injection (MPFI) System, 4.3L Only
Gasoline Fuel Storage Tank
Gasoline Fuel Pump
Fuel Pressure Regulator, 3.0L Only
Fuel Rail and Pressure Regulator, 4.3L Only
Fuel Injector
Three-Way Catalytic Muffler

LPG Fuel System Repair21 topics

Propane Fuel System Pressure Relief
Propane Fuel System Leak Test
Propane Fuel Filter Replacement
Low Pressure Lock-Off (LPL) Replacement
Pressure Trim Valve (PTV) Replacement
Low Pressure Regulator
Fuel Trim Valve (FTV) Solenoid Replacement
Temperature Manifold Absolute Pressure (TMAP)
Throttle Body Replacement
Mixer Replacement
Coolant Hose Replacement
Vapor Hose Replacement
Balance Line Hose Replacement
PTV Hose Replacement
FTV Hose Replacement
Throttle Position Sensor (TPS) Replacement
Foot Pedal Position (FPP) Sensor Replacement
Electronic Control Module (ECM) Replacement
Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement
Three-Way Catalytic Muffler (TWC) Replacement
Restricted Exhaust System Diagnosis

Gasoline Fuel System Repair9 topics

Gasoline MPFI and TBI Fuel System Pressure Relief
Gasoline Fuel System Leak Test
Throttle Body Injector (TBI) Assembly Replacement, 3.0L Only
Throttle Body Assembly Replacement, 3.0L Only
Throttle Body Assembly Replacement, 4.3L Only
Fuel Rail Replacement, Gasoline 4.3L Only
Injector Replacement, Gasoline 4.3L Only
Injector Replacement, Gasoline 3.0L Only
Temperature Manifold Absolute Pressure (TMAP) Replacement

LPG System Diagnosis2 topics

Fuel System Description
Diagnostic Aids

Gasoline System Diagnosis2 topics

Fuel System Description, 3.0L Only
Fuel System Description, 4.3L Only

LPG Symptom Diagnosis

Gasoline Symptom Diagnosis

Wire Harness Repair2 topics

On Vehicle Service Wiring Harness Repair
Connectors and Terminals

Table 1. LPG Fuel System Diagnosis

Table 2. Fuel Control Diagnosis

Table 3. Gasoline Fuel System Diagnosis, 3.0L Only

Table 4. Gasoline Fuel System Diagnosis, 4.3L Only

Table 5. Preliminary Checks

Table 6. Intermittent

Table 7. No Start

Table 8. Hard Start

Table 9. Cuts Out or Misses

Table 10. Hesitation, Sag, or Stumble

Table 11. Backfire

Table 12. Lack of Power, Sluggishness, or Sponginess

Table 13. Poor Fuel Economy

Table 14. Rough, Unstable, Incorrect Idle, or Stalling

Table 15. Surges or Chuggles

Table 16. Preliminary Checks

Table 17. Intermittent

Table 18. No Start

Table 19. Hard Start

Table 20. Cuts Out or Misses

Table 21. Hesitation, Sag, or Stumble

Table 22. Backfire

Table 23. Lack of Power, Sluggishness, or Sponginess

Table 24. Poor Fuel Economy

Table 25. Rough, Unstable, Incorrect Idle, or Stalling

Table 26. Surges or Chuggles

Electronic Control Module (ECM) Diagnostic Troubleshooting

Description of ECM Based Diagnostics10 topics

Definition of Terms
Diagnostics Overview of the Spectrum Fuel System
Malfunction Indicator Lamp (MIL)
Spectrum Diagnostic Trouble Codes (DTC)
Using a Laptop Computer to Diagnose the Spectrum System
Diagnostic Trouble Codes
DATA Stream
Ignition System Test
Injector Test
Throttle Test

On-Board Diagnostics System Check/Malfunction indicator lamp1 topic

Circuit Description

Preliminary and Intermittent Checks

DTC 111 - IAT High Voltage Bosch® TMAP1 topic

Conditions for Setting the DTC

DTC 111 - IAT High Voltage Motorola® TMAP

DTC 112 - IAT Low Voltage Bosch® TMap

DTC 112 - IAT Low Voltage Motorola® TMAP

DTC 113 - IAT Higher Than Expected 1 Bosch® TMAP

DTC 113 - IAT Higher Than Expected 1 Motorola® TMAP

DTC 114 - IAT Higher Than Expected 2 Bosch® TMAP

DTC 114 - IAT Higher Than Expected 2 Motorola® TMAP

DTC 115 - Oil Pressure Low

DTC 121 - ECT Voltage High

DTC 122 - ECT Low Voltage

DTC 123 - ECT Higher Than Expected 1

DTC 124 - ECT Higher Than Expected 2

DTC 131 - MAP High Pressure Bosch® TMAP

DTC 131 - MAP High Pressure Motorola® TMAP

DTC 132 - MAP Low Voltage Bosch® TMAP

DTC 132 - MAP Low Voltage Motorola® TMAP

DTC 134 - BP High Pressure Bosch® TMAP

DTC 134 - BP High Pressure Motorola® TMAP

DTC 135 - BP Low Pressure Bosch® TMAP

DTC 135 - BP Low Pressure Motorola® TMAP

DTC 142 - Crank Sync Noise

DTC 143 - Never Crank Synced At Start

DTC 144 - Camshaft Sensor Loss

DTC 145 - Camshaft Sensor Noise

DTC 211 - Closed Loop Multiplier High (LPG)

DTC 212 - HO 2 S Open/Inactive

DTC 213 - HO 2 S Open/Inactive (Post-Cat)

DTC 221 - Closed Loop Multiplier High (Gasoline)

DTC 222 - Closed Loop Multiplier Low (Gasoline)

DTC 224 - Closed Loop Multiplier Low (LPG)

DTC 241 - Adaptive Lean Fault (High Limit-Gasoline)

DTC 242 - Adaptive Rich Fault (Low Limit-Gasoline)

DTC 243 - Adaptive Learn High (LPG)

DTC 244 - Adaptive Learn Low (LPG)

DTC 261 - System Voltage Low

DTC 262 - System Voltage High

DTC 411 - Injector Driver 1 Open (3.0L only)

DTC 412 - Injector Driver 1 Shorted (3.0L only)

DTC 511 - COP Failure

DTC 512 - Invalid Interrupt

DTC 515 - Flash Checksum Invalid

DTC 516 - Ram Failure

DTC 531 - External 5V Ref Lower Than Expected

DTC 532 - External 5V Ref Higher Than Expected

DTC 611 - FPP High Voltage

DTC 612 - FPP Low Voltage

DTC 631 - TPS1 Signal Voltage High

DTC 632 - TPS1 Signal Voltage Low

DTC 637 - Throttle Unable To Open

DTC 638 - Throttle Unable To Close

DTC 651 - Maximum Govern Speed Override

DTC 652 - Fuel Rev Limit

DTC 653 - Spark Rev Limit

Table 1. OBD System Check

Table 2. Preliminary Checks

Table 3. Intermittent Checks

Table 4. DTC 111 - IAT Voltage High (Bosch® TMAP)

Table 5. DTC 111 - IAT Voltage High (Motorola® TMAP)

Table 6. DTC 112 - IAT Low Voltage (Bosch® TMAP)

Inside this manual

Real pages from this service manual (1,128 pages). Open the sample pages (PDF, 235 KB)

Sample pages from the Hyster S135-155XL2 (C024) Forklift Service Manual: Diagram, Troubleshooting, Specifications

Diagram, page 354: Diagrams, Schematics, or Arrangements
Troubleshooting, page 422: Troubleshooting
Specifications, page 677: Specifications

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, 1,128 pages

Quantity one is the manual described above.

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