Hyster S135XL, S150XL, S155XL Forklift Trucks Service Manual

This complete factory manual offers expert-level technical documentation for servicing and maintaining Hyster S135XL, S150XL, and S155XL forklift trucks. Featuring detailed overhaul procedures for GM 4.3L V6 and Perkins 1000 Series diesel engines, the manual includes two-speed power-shift and manual transmissions, MSTS and ECM electronic controls, differential systems, drive axles, hydraulic gear pumps, mast assemblies, tilt and lift cylinders, fuel systems (gasoline, LPG, diesel), and full diagnostic guides. Designed for professional mechanics, it provides wiring diagrams, torque specs, troubleshooting charts, and scheduled service intervals to ensure reliable machine performance.

Model Covers:

Hyster S135XL Forklift Trucks

Hyster S150XL Forklift Trucks

Hyster S155XL Forklift Trucks

File Format: PDF

Size: 50.26 MB

No. of pages: 984

Language: English

Delivery Method: Instant Download - Access your file immediately after purchase.

📑 Table of Contents Overview:

Engines - GM 4.3L & Perkins 1000 Series

• Full disassembly and rebuild for cylinder heads, crankshafts, camshafts, pistons, cooling and oil systems
• Turbocharger servicing, fuel injector calibration, glow plug and starting aid systems
• Timing gear adjustment, lubrication system specs, coolant flow diagnostics

Fuel Systems (LPG, Gasoline, Diesel)

• Weber carburetor with governor repair, IMPCO LPG vaporizer, injector pumps and timing
• Fuel tank valve inspection, cold start system, dual-fuel configurations and filter element servicing

Transmission & Clutch Systems

• Two-speed power-shift (T-40), manual three-speed, clutch disassembly and Monotrol pedal checks
• Linkage adjustment, stall testing, hydraulic valve servicing and solenoid diagnostics

Differentials & Axles

• Gear clearance, backlash settings, preload torque specs, housing alignment and pinion depth tuning
• Drive axle disassembly, stub shafts, and bearing service

Hydraulic Systems

• Gear pump flow tests, main control valve repair, tilt and lift cylinder leak testing
• Hydraulic pump drive unit servicing, solenoid valve installation and pressure checks

Electrical & MSTS Controls

• HEI ignition system, distributor diagnostics, MAP/CTS sensor troubleshooting
• ECM testing, CodeMate interface usage, DTC charts and spark control modules

Brake & Steering Systems

• Brake booster and master cylinder repair, booster valve adjustments, park brake and inching pedal setup
• Steering axle, hub assembly, cylinder calibration and control unit diagnostics

Mast & Cylinder Systems

• Two-stage and three-stage mast installation, fork carriage rebuild, lift chain tensioning
• Vista mast disassembly and tilt cylinder seal servicing

Maintenance & Technical Specs

• Daily to annual maintenance schedules, fluid checks, torque values, part replacement intervals
• Lubrication charts, special tools list, and flywheel alignment standards

This Hyster S135XL, S150XL, S155XL Forklift Trucks Service Manual is an invaluable tool for field engineers and workshop technicians performing precision repairs and preventative maintenance on heavy-duty forklifts.