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 (Part No. B024)

• Covers 1990–2005 Hyster H3.50-5.50XM, H6.00-7.00XL, S3.50-5.50XM, S6.00-7.00XL, and S135-155XL2 series forklifts, including specific F006, G006, B024, and C024 model configurations
• Official OEM publications: 1300 SRM 325, 2200 SRM 2, and 1800 SRM 452
• Contains 45 exploded-view diagrams, 3 detailed hydraulic and electrical schematics, and 4 torque-specification tables
• Functions as a 685-page authoritative, manufacturer-level reference for transmission, alternator, and brake systems across the listed Hyster production range

Component and System Documentation

This technical compilation provides deep insight into core heavy-equipment subsystems, saving you diagnostic time in the shop. The transmission section details the T-40 two-speed powershift unit. You will find specific breakdowns for the forward and reverse clutch assemblies, manifold block maintenance, and MONOTROL pedal calibration. Electrical documentation focuses heavily on Delco, Motorola, and Leece-Neville alternators. It outlines brush circuit continuity tests, diode bridge verification, and stator winding analysis. A third major segment covers the braking system. It details master cylinder rebuilding, booster relief valve checks, and the exact air-removal procedures needed to restore full stopping power.

Specification and Reference Highlights

Accurate tolerances are the difference between a successful rebuild and a comeback. This manual defines exact operational limits for the drivetrain and hydraulics. System pressure is calibrated to 1303 ±124 kPa (189 ±18 psi) at 2000 rpm, while torque converter pressure must hit 834 ±69 kPa (121 ±10 psi). For the transmission, clutch assembly clearance on new parts is specified tightly at 3.1 to 4.5 mm (0.121 to 0.178 in.). Electrical output specs confirm the alternator produces 110 amps under optimal load, and the brake system operates with a relief pressure of 2.275 MPa. Heavy equipment maintenance involves significant hazards, so always verify your shop setup against certified safety standards before turning wrenches or applying these specifications.

Document Reference: 1300 SRM 325, 2200 SRM 2, 1800 SRM 452, © 2003-2004 Hyster Company