Hyster H6.00-7.00XL (H135-155XL) Frame Maintenance And Repair

Description

• Model List:
  • H6.00-7.00XL (H135-155XL) Frame

• 1. RM0322-(02-2007)-UK-EN
• 1.1. Safety Precautions Maintenance and Repair
• 1.2. General
• 1.3. Description
• 1.4. Counterweight Repair
• 1.5. Install
• 1.6. Hood Repair
• 1.7. Install
• 1.8. Overhead Guard Repair
• 1.9. Install
• 1.10. Operator Restraint System Repair
• 1.11. Automatic Locking Retractor (ALR)
• 1.12. Emergency Locking Retractor (ELR)
• 1.13. Hydraulic Tank Repair
• 1.14. Inspect
• 1.15. Small Leaks Repair
• 1.16. Large Leaks Repair
• 1.17. Steam Method
• 1.18. Chemical Solution Method
• 1.19. Other Methods of Preparation for Repair
• 1.20. Install
• 1.21. Fuel Tank Repair
• 1.22. Install
• 1.23. Radiator Repair
• 1.24. Install
• 1.25. Engine Repair
• 1.26. Install
• 1.27. Throttle Pedal Adjustment
• 1.28. Perkins 1104C-44(RE) Diesel Engine
• 1.29. Safety Labels
• 1.30. Cab Repair
• 1.31. Cab, Replace
• 1.32. Window, Replace
• 1.33. Windshield Wipers and Heater
• 1.34. Table 1. Material Specifications for Cab Windows
• 2. RM0324-(10-2003)-UK-EN
• 2.1. Two-Speed Powershift Transmission
• 2.2. Safety Precautions Maintenance and Repair
• 2.3. General
• 2.4. Mechanical Description
• 2.5. Torque Converter
• 2.6. Transmission Pump
• 2.7. Shaft Assemblies
• 2.8. Input Shaft
• 2.9. Forward Clutch Shaft
• 2.10. Clutch Assemblies
• 2.11. Countershaft
• 2.12. Output Shaft
• 2.13. Hydraulic Operation
• 2.14. Torque Converter
• 2.15. Seal Rings
• 2.16. Control Valve
• 2.17. System Pressure Regulator
• 2.18. Clutch Pressure Regulator
• 2.19. Torque Converter Regulator
• 2.20. Inching Spool
• 2.21. Direction Spool, Direction Control Lever
• 2.22. Direction Spool, MONOTROL Pedal
• 2.23. Range Spool
• 2.24. Drain Spool
• 2.25. Accumulator
• 2.26. Modulator Spool
• 2.27. Operation
• 2.28. Lubrication Circuit
• 2.29. MONOTROL Pedal
• 2.30. Oil Flow Diagrams
• 2.31. Neutral
• 2.32. Forward-Low
• 2.33. Forward-Low-Inching
• 2.34. Reverse-Low
• 3. RM0325-(10-2003)-UK-EN
• 3.1. Two-Speed Powershift Transmission
• 3.2. Safety Precautions Maintenance and Repair
• 3.3. General
• 3.4. Transmission Repair
• 3.5. Transmission and Torque Converter, Remove
• 3.6. Transmission, Disassemble
• 3.7. Reverse-Low Clutch, Disassemble
• 3.8. Reverse-High Clutch, Disassemble
• 3.9. Forward-Low Clutch, Disassemble
• 3.10. Forward-High Clutch, Disassemble
• 3.11. Clean and Inspect
• 3.12. Forward Low and High Clutches Assembly
• 3.13. Forward Clutches, Assemble
• 3.14. Reverse-Low Clutch, Assemble
• 3.15. Reverse Clutches, Assemble
• 3.16. Transmission, Assemble
• 3.17. Torque Converter, Install
• 3.18. Control Valve Repair
• 3.19. Disassemble
• 3.20. Assemble
• 3.21. Install
• 3.22. MONOTROL Pedal
• 3.23. Remove and Disassemble
• 3.24. Assemble and Install
• 3.25. Stall Test
• 3.26. Linkage Adjustments
• 3.27. Linkage for Inching Pedal H6.00-7.00XL (H135-155XL, H135-155XL 2
• 3.28. Linkage for Inching Pedal S6.00-7.00XL (S135-155XL, S135-155XL 2
• 3.29. Linkage for Range Lever – Early Model H6.00-7.00XL (H135-155XL)
• 3.30. Linkage for Direction Control Lever – Early Model H6.00-7.00XL (
• 3.31. Linkage for Range Lever – Later Model H6.00-7.00XL (H135-155XL,
• 3.32. Linkage for Direction Control Lever – Later Model H6.00-7.00XL (
• 3.33. Linkage for Range Lever S6.00-7.00XL (S135-155XL, S135-155XL 2 )
• 3.34. Linkage for Direction Control Lever S6.00-7.00XL (S135-155XL, S1
• 3.35. Oil Pressure Check
• 3.36. System Pressure Check Port
• 3.37. Torque Converter Check Port
• 3.38. Clutch Pressure Check Port
• 3.39. Inching Pressure
• 3.40. Solenoid Check Ports (MONOTROL Control Only)
• 3.41. Lubrication Pressure Check Ports
• 3.42. Specifications
• 3.43. Troubleshooting
• 3.44. Correct System Pressure 1300 124 kPa ( 189 18 psi)
• 3.45. Correct Clutch Pressure 924 69 kPa ( 134 10 psi)
• 3.46. Correct Solenoid Pressure (MONOTROL Only) 965 138 kPa ( 140 2
• 3.47. Torque Converter Pressure 834 69 kPa ( 121 10 psi)
• 3.48. Lubrication Pressure 83 21 kPa ( 12 3 psi)
• 3.49. Table 1. Stall Speed Specifications
• 4. RM0326-(03-2007)-UK-EN
• 4.1. General
• 4.2. Description
• 4.3. Steering Axle Assembly Repair
• 4.4. Wheels and Hubs Repair (All Units)
• 4.5. Spindles and Bearings Repair (All Units)
• 4.6. Tie Rods Repair (All Units)
• 4.7. Steering Cylinder Repair
• 4.8. Troubleshooting
• 5. RM0327-(09-2003)-UK-EN
• 5.1. Brake System
• 5.2. Safety Precautions Maintenance and Repair
• 5.3. General
• 5.4. Description
• 5.5. Operation
• 5.6. Brake Booster and Master Cylinder
• 5.7. Brake Booster
• 5.8. Master Cylinder
• 5.9. Service Brake Assembly
• 5.10. Parking Brake
• 5.11. Brake Shoe Assemblies Repair
• 5.12. Remove and Disassemble
• 5.13. Clean and Inspect
• 5.14. Cleaning Procedures
• 5.15. Inspect
• 5.16. Assemble and Install
• 5.17. Master Cylinder Repair
• 5.18. Disassemble
• 5.19. Assemble
• 5.20. Install
• 5.21. Brake Booster Repair
• 5.22. Disassemble
• 5.23. Clean and Inspect
• 5.24. Assemble
• 5.25. Install
• 5.26. Brake System Air Removal
• 5.27. Brake Pedal Adjustment
• 5.28. Brake Shoes Adjustment
• 5.29. Parking Brake Adjustment
• 5.30. Parking Brake Switch Adjustment
• 5.31. Brake Booster Relief Valve Check
• 5.32. Troubleshooting
• 6. RM0328-(09-2003)-UK-EN
• 6.1. Hydraulic System
• 6.2. Safety Precautions Maintenance and Repair
• 6.3. General
• 6.4. Description and Operation
• 6.5. Hydraulic Pumps
• 6.6. Main Control Valve
• 6.7. Control Valve Lever
• 6.8. Steering Control Unit
• 6.9. Brake Valve
• 6.10. Oil Clutch, H6.00-7.00XL (H135-155XL) (F006)
• 6.11. Troubleshooting
• 6.12. Lift, Lower, and Tilt Circuit
• 6.13. Steering, Brake, and Oil Clutch System
• 7. RM0329-(09-2010)-UK-EN
• 7.1. Safety Precautions Maintenance and Repair
• 7.2. General
• 7.3. Description and Operation
• 7.4. General
• 7.5. Safety Procedures When Working Near Mast
• 7.6. Two-Stage Mast
• 7.7. Three-Stage Mast
• 7.8. Carriage Repair
• 7.9. Sideshift Carriage, Disassemble
• 7.10. Sideshift Carriage, Assemble
• 7.11. Install
• 7.12. Two-Stage Mast Repair
• 7.13. Disassemble
• 7.14. Clean and Inspect
• 7.15. Assemble
• 7.16. Install
• 7.17. Three-Stage Mast Repair
• 7.18. Disassemble
• 7.19. Clean and Inspect
• 7.20. Assemble
• 7.21. Install
• 7.22. Mast Operation Check
• 7.23. Lift and Tilt System Leaks Check
• 7.24. Lift System
• 7.25. Tilt System
• 7.26. Tilt Cylinder Stroke and Backward Tilt Angle Adjustment
• 7.27. Lift Chain Adjustments
• 7.28. Mast Adjustments
• 7.29. Carriage Adjustment
• 7.30. Troubleshooting
• 7.31. Table 1. Mast Parts Weight
• 7.32. Table 2. Hook-Type Carriage Chain Adjustment
• 7.33. Table 3. Pin-Type Carriage Chain Adjustment
• 8. RM0331-(09-2003)-UK-EN
• 8.1. Capacities and Specifications
• 8.2. Safety Precautions Maintenance and Repair
• 8.3. Lift Truck Weights
• 8.4. Capacities
• 8.5. Tire Sizes
• 8.6. Tire Pressure
• 8.7. Electrical System
• 8.8. Wheel Nut Torque
• 8.9. Engine Specifications
• 8.10. Hydraulic System
• 8.11. Mast Speeds
• 8.12. Transmission Oil Pressures
• 8.13. Torque Specifications
• 8.14. Engine – GM 4.3L V-6
• 8.15. Engine – Perkins 4.2482
• 8.16. Engine – Perkins 1004.4
• 8.17. Manual Transmission
• 8.18. Powershift Transmission
• 8.19. Speed Reducer
• 8.20. Drive Axle
• 8.21. Steering System
• 8.22. Brake System
• 8.23. Hydraulic System
• 8.24. Tilt Cylinder
• 9. RM0332-(09-1997)-UK-EN
• 9.1. ELECTRICAL SCHEMATIC (GASOLINE LPG)
• 9.2. ELECTRICAL SCHEMATIC (DIESEL, PERKINS 4.2482)
• 9.3. ELECTRICAL SCHEMATIC (DIESEL, PERKINS 1004.4)
• 9.4. HYDRAULIC SCHEMATIC
• 9.5. HYDRAULIC SCHEMATIC, POWERSHIFT TRANSMISSION WITH MANUAL CONTROL
• 9.6. HYDRAULIC SCHEMATIC, POWERSHIFT TRANSMISSION WITH MONOTROL PEDAL
• 10. RM0341-(06-2009)-UK-EN
• 10.1. Periodic Maintenance
• 10.2. Safety Precautions Maintenance and Repair
• 10.3. General
• 10.4. Serial Number Data
• 10.5. How to Move Disabled Truck
• 10.6. How to Tow Lift Truck
• 10.7. How to Put Lift Truck on Blocks
• 10.8. How to Raise Drive Tires
• 10.9. How to Raise Steering Tires
• 10.10. Maintenance Schedule
• 10.11. Maintenance Procedures Every 8 Hours or Daily
• 10.12. How to Make Checks With Engine Stopped
• 10.13. Hydraulic System Oil
• 10.14. Engine Oil
• 10.15. Drive Belts
• 10.16. Intake Manifold Rubber Cap
• 10.17. Cooling System
• 10.18. Air Filter
• 10.19. Fuel System
• 10.20. Primary Fuel Filter, Diesel Engine
• 10.21. Battery
• 10.22. Tires and Wheels
• 10.23. Forks, Mast, and Lift Chains, Inspect
• 10.24. Operator Restraint System
• 10.25. Safety Labels
• 10.26. How to Make Checks With Engine Running
• 10.27. Gauges, Lights, Horn, and Fuses
• 10.28. Oil Level, Powershift Transmission
• 10.29. Oil Level, Oil Clutch System, H3.50-5.00XL (H70-110XL)
• 10.30. Control Levers and Pedals
• 10.31. Lift System Operation
• 10.32. Inching/Brake Pedal
• 10.33. Service Brakes
• 10.34. Parking Brake
• 10.35. Steering System
• 10.36. Maintenance Procedures Every 250 Hours or 6 Weeks
• 10.37. Engine Oil and Filter, GM V-6 Engine
• 10.38. Lift Chains, Lubrication
• 10.39. Drive Shafts
• 10.40. Mast Lubrication
• 10.41. Crankcase Breather, GM V-6
• 10.42. Air Filter, GM V-6 EPA Compliant Engine
• 10.43. Maintenance Procedures Every 350 Hours or 2 Months
• 10.44. Engine Oil and Filter, Perkins 4.2482 Diesel Engine
• 10.45. Drive Belts
• 10.46. Perkins Diesel Engine
• 10.47. GM V-6 Engine (Early Models)
• 10.48. GM V-6 Engine (Late Models)
• 10.49. Brake Fluid
• 10.50. Lift Chains Wear Check
• 10.51. Forks Wear and Damage Check
• 10.52. Steering Axle Lubrication
• 10.53. Fuel System, Checks and Adjustments
• 10.54. Diesel Fuel System
• 10.55. LPG Carburetor (Early Models)
• 10.56. Gasoline Carburetor (Early Models)
• 10.57. Fuel Injection (Late Models)
• 10.58. Crankcase Breather, Perkins 4.2482 Diesel Engine
• 10.59. Hydraulic Tank Breather
• 10.60. Cooling System, Clean Debris from Radiator Core
• 10.61. Maintenance Procedures Every 500 Hours or 3 Months
• 10.62. Engine Oil and Filter, Perkins Diesel Engine
• 10.63. Crankcase Breather, Perkins Diesel Engine
• 10.64. PCV Valve, GM V-6
• 10.65. Maintenance Procedures Every 1000 Hours or 6 Months
• 10.66. Manifold Heat Valve, GM V-6 (Early Models)
• 10.67. Ignition System, GM V-6
• 10.68. Valve Clearance Adjustment
• 10.69. Fuel Filter, Replace (Diesel Engine)
• 10.70. Fuel System Air Removal (Perkins 1004-4 Diesel Engine)
• 10.71. Fuel Injection Pump With Vent Tube
• 10.72. Fuel Injection Pump With Vent Screw
• 10.73. Fuel System Air Removal (Perkins 4.2482 Diesel Engine)
• 10.74. Oil Level Check in Transmission
• 10.75. Manual Transmission, H3.50-5.00XL (H70-110XL)
• 10.76. Speed Reducer for Powershift Transmission, H3.50-5.00XL (H70-110
• 10.77. Manual Transmission, H6.00-7.00XL (H135-155XL)
• 10.78. Differential and Drive Axle for Powershift Transmission, H6.00-7
• 10.79. Differential, Speed Reducer, and Drive Axle for Manual Transmiss
• 10.80. Control Levers and Pedals, Lubricate
• 10.81. Crankcase Breather, Replace
• 10.82. Cooling System, GM V-6 EPA Compliant Engine
• 10.83. Spark Plug Replacement
• 10.84. Install
• 10.85. LPG Fuel Filter GM V-6 EPA Compliant Engine, Replace
• 10.86. Inspect Engine Electrical System, Connectors, and FCVS Connectio
• 10.87. Maintenance Procedures Every 2000 Hours or Yearly
• 10.88. Hydraulic System
• 10.89. Hydraulic Oil and Filter, H3.50-5.00XL (H70-110XL), Replace
• 10.90. Hydraulic Oil and Filter, H6.00-7.00XL (H135-155XL, H135-155XL 2
• 10.91. Oil Change and Oil Filter Replacement, Powershift Transmission,
• 10.92. Oil Change, Manual Transmission, H3.50-5.00XL (H70-110XL)
• 10.93. Oil Change, Manual Transmission, H6.00-7.00XL (H135-155XL)
• 10.94. Oil Change, Speed Reducer, Powershift Transmission, H3.50-5.00XL
• 10.95. Oil and Filter Change, Oil Clutch System, H3.50-5.00XL (H70-110X
• 10.96. Oil Change, Differential and Drive Axle, Powershift Transmission
• 10.97. Oil Change, Differential, Speed Reducer, and Drive Axle, Manual
• 10.98. Cooling System
• 10.99. PCV Valve, GM V-6
• 10.100. Service Brakes
• 10.101. LPG Filter, Replace
• 10.102. Gasoline Fuel Filter, Replace
• 10.103. Hood Latch Check, H3.50-5.00XL (H70-110XL)
• 10.104. Air Filter Element, GM V-6 EPA Compliant Engine
• 10.105. Oxygen Sensor GM V-6 EPA Compliant Engine
• 10.106. Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks
• 10.107. Check Throttle Shaft for Sticking
• 10.108. Inspect Exhaust Manifold and Piping for Leaks
• 10.109. Test LPG/GAS Regulator Pressure
• 10.110. Safety Procedures When Working Near Mast
• 10.111. Lift Chain Adjustments
• 10.112. Fuel Injectors Repair
• 10.113. Lift and Tilt System Leak Check
• 10.114. Lift Cylinders, Leak Check