In-Depth Hyster H135-155XL, H135-155XL2 & S135-155XL Forklift Service Repair Manual 1990-2005
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Models Covered & Key Technical Specifications
Hyster-Yale Materials Handling, Inc.
Hyster G006 Series
- H135XL (1990-2005)
- H155XL (1990-2005)
- H135XL2 (2000-2005)
- H155XL2 (2000-2005)
- H70XL (1988-1996)
- H80XL (1988-1996)
- H90XL (1988-1996)
- H100XL (1988-1996)
- H110XL (1988-1996)
- S135XL (1991-2005)
- S155XL (1991-2005)
- S155XLS (1998-2005)
- S135XL2 (2000-2005)
- S155XL2 (2000-2005)
- S70XL (1987-1996)
- S80XL (1987-1996)
- S100XL (1987-1996)
- S120XL (1987-1996)
- H70XM (1996-2004)
- H80XM (1996-2004)
- H90XM (1996-2004)
- H100XM (1996-2004)
- H110XM (1996-2004)
- H120XM (1996-2004)
- S70XM (1996-2004)
- S80XM (1996-2004)
- S100XM (1996-2004)
- S120XM (1996-2004)
Professional Workshop Service Manual & Technical Specifications
Hyster H135-155XL, H135-155XL2 & S135-155XL Forklift Service Repair Manual
This comprehensive Service Repair Manual (SRM) provides professional-grade instructions for the maintenance, assembly, and troubleshooting of Hyster’s heavy-duty XL and XL2 series forklifts. Designed for technicians and fleet owners, this manual covers the G006 and F006 internal pneumatic tire series, as well as the B024 and C024 cushion tire series.
Whether you are performing a routine 8-hour inspection or a complete engine overhaul on a GM 4.3L V6, this documentation offers the technical depth required to minimize downtime and ensure operator safety.
Model Coverage & Serial Number Groups
This manual is specifically authored for the following Hyster models and their respective design codes:
- H135XL & H155XL (Design Code F006)
- H135XL2 & H155XL2 (Design Code G006)
- S135XL & S155XL (Design Code B024)
- S135XL2, S155XL2 & S155XLS (Design Code C024)
Complete Technical Content
This manual is organized into specialized Service Repair Manual (SRM) sections, including:
Engine and Electronic Systems
- GM 4.3L V6 Engine: Full repair procedures for cylinder heads, valves, and internal components.
- Electronic Controlled LPG/Gasoline Fuel System: Detailed diagnosis for EPA-compliant Spectrum fuel systems.
- High Voltage Switch (HVS) Ignition: Troubleshooting for the electronic ignition systems used on GM engines.
- ECM Diagnostics: Comprehensive fault code (DTC) lists and laptop-based diagnostic procedures.
Drive Train and Chassis
- Drive Axle & Differential: Overhaul instructions for the heavy-duty drive assemblies, including torque specs for ring and pinion gears.
- Brake System: Complete coverage of the master cylinder, brake booster, and service/parking brake adjustments.
- Cooling System: Maintenance for radiators, thermostats, and water pumps to prevent engine overheating.
Hydraulics and Mast
- Main Control Valve: Adjustment procedures for single and two-stage relief valves.
- Hydraulic Gear Pumps: Performance testing and repair for the main hydraulic supply.
- Lift & Tilt Cylinders: Seal replacement and troubleshooting for internal/external leaks.
- Two-Stage and Three-Stage Masts: Maintenance of weldments, carriages, and sideshift assemblies.
Electrical and Maintenance
- Diagrams and Schematics: Full electrical and hydraulic fold-outs for serial codes F006, G006, B024, and C024.
- Instrument Panel: Diagnosis of indicators, senders, and the Operator Presence System (OPS).
- Periodic Maintenance: Scheduled service intervals from daily 8-hour checks to 2000-hour major overhauls.
Value for the Technician
- Mobile-Friendly Layout: Clear section headings and indexed tables of contents make it easy to find specific torque values or wiring paths on a tablet or smartphone in the shop.
- Detailed Specifications: Includes dedicated sections for Metric and SAE (Inch) fasteners, fluid capacities, and tire pressures.
- Professional Troubleshooting: Step-by-step logic charts help isolate issues in the hydraulic, electrical, and fuel systems quickly.
Keep your Hyster equipment operating at peak performance with the exact technical data used by factory-certified mechanics.
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