1990–2005 Hyster Forklift Service Manuals for H3.50-5.50XM, H6.00-7.00XL, S3.50-5.50XM, S6.00-7.00XL, S135-155XL2 (P/N B024)

• Primary machine coverage: Hyster S6.00-7.00XL trucks sold as S135-155XL, S155XLS, and S135-155XL 2 under the B024 and C024 model codes. Several shared factory sections also name H6.00-7.00XL F006/G006, H3.50-5.50XM, and S3.50-5.50XM applications, but only those shared sections apply. The B024/C024 frame, brake, hydraulic, steering-axle, and specification chapters make this primarily an S-series set, not a complete manual package for the other trucks named on individual covers.
• Transmission and axle repair: Covers the Hyster T-40 two-speed powershift unit from operating theory through removal, clutch-pack disassembly and assembly, control-valve repair, torque-converter installation, MONOTROL pedal work, stall testing, pressure-port diagnosis, and model-specific linkage adjustment. For the S6.00-7.00XL range, the three-speed manual-transmission section applies to B024 and adds selector-rail, fork, gearset, differential, shift-linkage, and clutch-pedal procedures, backed by separate differential and drive-axle repair chapters.
• Engine and ignition service: Provides internal repair coverage for the GM 4.3-liter V-6 and the Perkins 1004-42 (AR), 1006-60 (YG), and 1006-60T (YH) diesel family. Major work includes cylinder-head service, valves, pistons, crankshaft, camshaft and timing gears, lubrication and cooling systems, fuel-injection-pump timing, turbocharger service for the YH engine, and engine specifications. The late-model LPG MSTS section supplies DTC-based troubleshooting, MAP/ECT/EST circuit checks, ignition timing, and use of the CodeMate Tester, Hyster P/N 3071579.
• Hydraulic, steering, and brake systems: Details main and steering pump operation, hydraulic gear-pump rebuilding and output checks, main control-valve disassembly and relief-valve adjustment, steering-column and control-unit repair, system air removal, steering-axle service, brake-shoe and master-cylinder repair, booster overhaul and relief-valve checking, brake bleeding, pedal and parking-brake adjustment, and hydraulic troubleshooting.
• Mast, carriage, cylinders, and chassis: Covers two-stage and three-stage mast removal and repair, sideshift-carriage service, lift-chain and carriage adjustment, lift/tilt leak checks, older-mast lift cylinders, tilt-cylinder resealing, counterweight and overhead-guard work, operator-restraint components, tank and radiator repair, exhaust components, and engine removal/installation at the truck level.
• Electrical diagnosis and diagrams: An 85-page diagrams publication contains 28 named drawings: 22 electrical and lighting schematics, three hydraulic schematics, and three transmission/oil-clutch drawings. Alternator diagnosis covers Delco, Motorola, and Leece-Neville brush circuits, diodes and diode bridges, rotor fields, stator windings, and regulators. The instrument section adds gauges, senders, the seat sensor, and Operator Presence System module troubleshooting on applicable C024 trucks.
• Reference package: The 852-page PDF set contains 25 Hyster factory service sections, with periodic maintenance, fastener data, capacities, system-specific torque tables, hydraulic and transmission pressure-test specifications, electrical test values, wear limits, adjustments, troubleshooting tables, and numerous exploded and section views.

Coverage and configuration details

The build splits in 8000 SRM 519 help identify the correct schematic for the truck's engine and electrical configuration. The publication separates diesel wiring before and after 1995; GM gasoline fuel-injection circuits for early production, 1992-1998, and 1999-and-later builds; LPG/MSTS circuits for 1993-1997 and 1998-and-later builds; and C024/G006 engine and lighting diagrams before and after November 2005. B024 hydraulic drawings are divided into early-model, later-model, and B024 1999-2003/C024 arrangements.

Configuration limits are also clear. The three-speed manual-transmission publication applies to B024, and the included Perkins 1000-series overhaul publication lists B024 rather than C024. C024 trucks with the Perkins 1104C-44(RE) engine are represented in the wiring, maintenance, fuse/relay, and throttle-adjustment material, but the separately referenced Perkins Diesel Engines, 1104 (RE), 600 SRM 1070 internal-engine publication is not part of this set. The files provide oil-clutch maintenance data and an Oil Clutch Schematic, but not the separately referenced Oil Clutch System 1200 SRM 334 repair section. MSTS coverage is for spark timing and related electronic diagnosis; the separately referenced LPG Fuel System 900 SRM 348 and Electronic Controlled LPG/Gasoline Fuel System 900 SRM 1088 sections are not included.

The Perkins engine publication also has a dedicated special-tools section for valve-guide, cylinder-liner, crankshaft-seal, timing-case, piston, and valve-seat work. Its Lucas injection-pump timing procedure identifies timing pin PD.246, while the MSTS chapter specifies the CodeMate diagnostic tester noted above.

Representative drawings include Diesel Engine Wiring Schematic for US Models B024, F006, GM V-6 Gas and LPG Engine Electrical Schematic (C024, G006), Before November 2005, Schematic for Lights Option (U.S.) for B024 Trucks, Hydraulic System Schematic for B024 US/EUR (Early Model Trucks), Powershift Transmission Diagram, and Oil Clutch Schematic.

The factory repair notes identify specific failure points. Incorrect torque-converter hub engagement can damage the powershift transmission oil pump, and incorrect hose-port connections at the steering control unit can cause unexpected steering action. Because the set covers raised-mast work, pressurized hydraulics, brake repair, heavy drivetrain components, and live electrical testing, use the manual's blocking, pressure-release, lifting, and battery-isolation precautions before beginning service.

Included Hyster publications - 852 PDF pages total