Hyster H135-155XL, H135-155XL2 & S135-155XL 1990–2005 Forklift Service & Repair Manual (P/N 899784)

• Coverage and format: Covers the Hyster H6.00-7.00XL (H135-155XL and H135-155XL 2) design series F006 and G006 through 27 Hyster SRM section PDFs totaling 1,281 pages.
• Engine repair: Includes GM 4.3L V-6 and Perkins 1104 (RE) engine removal, cylinder-head and valve-train work, piston and crankshaft service, timing-system procedures, lubrication-system repair, cooling-system work, and engine troubleshooting.
• Electronic fuel and engine control: Covers the EPA-compliant GM 3.0L/4.3L LPG and gasoline systems, ECM diagnostics, DTC fault isolation, live data, graphing and logging, ignition/injector/throttle tests, fuel-pressure and leak checks, and harness/connector repair.
• Transmission and driveline: Details the two-speed powershift transmission, torque converter, clutch assemblies, control valve, MONOTROL controls, removal and overhaul work, stall and pressure testing, linkage adjustment, differential setup, and drive-axle repair.
• Hydraulics, mast, and steering: Provides gear-pump repair and output checks, main-control-valve service, steering-control-unit overhaul and bleeding, lift/tilt cylinder repair, mast and carriage disassembly, lift-chain adjustment, and hydraulic leak testing.
• Brakes, chassis, and electrical service: Addresses service and parking brakes, master cylinder and booster repair, steering axle work, frame and cab components, tanks and radiator, alternator and starter testing, instrument-panel senders, and operator-presence-system troubleshooting.
• Schematics and reference data: Includes production-specific wiring diagrams, connector views, diagnostic charts, powershift/oil-clutch schematics, maintenance schedules, capacities, wear and adjustment specifications, and component-specific torque tables.

Model and powertrain scope

The collection is centered on the H6.00-7.00XL family and its F006/G006 design-series identification. Several SRM sections also list other Hyster truck families because Hyster used the same component manual across multiple applications. Check the model and design-series line printed on each section cover before selecting a procedure.

Mechanical gasoline-engine repair is covered by the GM 4.3-liter V-6 section. The separate electronic fuel and ECM publications address both 3.0L and 4.3L EPA-compliant systems, including 3.0L throttle-body injection and 4.3L multi-point injection. Diesel coverage is the Perkins 1104 (RE), with internal engine repair, fuel-injection-pump timing, fuel-system air removal, and electrical fault diagnosis. This distinction matters: the collection does not include a separate 3.0L internal engine-overhaul section. The Perkins manual also identifies PD.1D valve-guide tooling, PD.41D/PD.208 measuring equipment, PD.170 seal tooling, PD.6118B valve-spring tooling, and PD.198/MS.1531 angle gauges.

Diagnostics and electrical documentation

The 330-page ECM troubleshooting section goes well beyond a code list. It explains MIL-based and laptop-based diagnosis, active and historical DTC handling, sensor and actuator data, graphing, data logging, ignition-output disabling, injector disabling, throttle testing, preliminary/intermittent checks, and dedicated GM 3.0L and 4.3L circuit charts. It identifies Spectrum Diagnostic Software P/N 2067944 and the Spectrum Special Tools Kit P/N 2067935.

The diagram section separates important production changes instead of presenting one generic circuit. Examples include the G006 diesel-engine wiring diagram after November 2005; GM V-6 gas/LPG electrical schematics for G006 before and after November 2005; U.S. and European G006 lighting circuits for both production periods; and powershift transmission, transmission, and oil-clutch schematics. The ignition manual adds crankshaft- and camshaft-position sensor service, distributor overhaul, coil and ignition-module replacement, spark-plug wire inspection, and Micro-Pack, Metri-Pack, and Weather-Pack terminal repair.

Mechanical repair depth

The transmission repair section covers removal of the transmission and torque converter, clutch-pack disassembly and reassembly, control-valve service, MONOTROL pedal work, stall testing, linkage setup, and checks at the system, converter, clutch, solenoid, and lubrication ports. The differential manual includes pinion depth, bearing preload, ring-gear runout and backlash, tooth-contact-pattern checks, and final installation. Hydraulic coverage continues through pump inspection, flow testing, air checks, relief-valve work, steering-system air removal, and cylinder leak diagnosis.

Mast coverage includes two- and three-stage assemblies, sideshift carriage service, lift-cylinder removal with the mast installed where applicable, lift-chain setup, roller and strip-bearing adjustment, and operational checks. The brake section adds shoe, master-cylinder, booster, bleeding, pedal, parking-brake, and relief-valve procedures.

A few details show why the factory text matters during repair. Transmission clutch parts are kept with their original assemblies and plate sequence, while piston-seal lips and shaft seal-ring lands must be protected during assembly; mixing or nicking these parts can create clutch-pressure and engagement faults. Differential carrier flanges and pinion components are not to be forced with pry bars or hammers because damaged sealing faces can leak and a distorted yoke can create driveline runout or imbalance. On the mast, roller shims are repositioned across the stub shaft rather than casually added or removed, and incorrect spacer or shim placement can misalign the carriage and accelerate roller and channel wear.

This is service and repair documentation, not an operator’s manual or parts catalog. Mast work, raised-truck support, pressurized LPG/gasoline systems, heavy drivetrain components, brakes, and electrical testing require the safety procedures, lifting equipment, isolation steps, and personal protective equipment specified for the job.