1990-2005 Hyster H135-155XL, H135-155XL2 & S135-155XL Forklift Service Repair Manual

Hyster Forklift 1990–2005 Service Documentation

• Covers 1990–2005 Hyster H135-155XL, H135-155XL2, and S135-155XL forklift variants with GM 4.3L, Perkins 4.2482, and Perkins 1004.4 engines
• Official Hyster company publication P/N 899784, 897109, 897113, and 897501, 2002–2007 edition cluster
• Contains 56 detailed electrical schematics, 15 exploded-view component diagrams, and 12 torque-specification tables
• Delivered as a direct download the moment payment clears
• Indexed PDF search covers every chapter and appendix
• This 1990–2005 Hyster H135-155XL series publication provides the essential maintenance and repair parameters for the hydraulic, brake, electrical, and cooling systems across all listed F006, G006, B024, and C024 serial code models.

Technical Content Overview

The documentation provides deep technical insight into the maintenance of Hyster lift truck systems. Sections include detailed breakdown of the alternator types (Delco, Motorola, and Leece-Neville), including troubleshooting for charging circuits, diode bridge checks, and rotor field winding resistance values. The brake system section explores the two-stage master cylinder operation, booster relief valve settings, and automatic adjuster mechanisms for the service brakes. The cooling system section covers thermostat testing and radiator maintenance, while the electrical diagrams provide comprehensive wiring schematics for both diesel and gas-powered models with electronic engine control, including lighting and instrumentation circuits.

Specification and Data Preview

Data highlights include torque values for drivetrain and chassis components, such as drive axle mounting capscrews at 610 Nm (450 lbf ft) and wheel bearing adjustment final-stage tightening at 35 Nm (25 lbf ft). The hydraulic system documentation lists relief pressure settings, with the main pump pressure documented at 20.88 to 21.20 MPa (3025 to 3075 psi). Fuel system electrical references are provided, including specific alternator output ratings for both GM and Perkins engine configurations. For more on how factory workshop documentation is structured, refer to the indexed section groupings throughout the file. Note: This page is a contents overview for the manual. It does not provide repair or diagnostic instructions. Always consult a certified technician before performing service on this equipment.