hyster H135 - 155XL
WORKSHOP, SERVICE, REPAIR MANUAL - WIRING
HYSTER H135 - 155XL - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING - English Service Manual and Wiring Information to Hyster H135 - 155XL. CONTENTS: 01 GENERAL INFORMATION - Lift Truck Weights - Capacities - Tire Sizes - Tire Pressure - Electrical System - Wheel Nut Torque - Engine Specifications -Gasoline/Lpg - Hydraulic System - Mast Speeds - Transmission Oil Pressures - Torque Specifications 02 GM 4.3 LITRE V–6 AND 5.7 LITRE V–8 ENGINES - Gm 4.3 Litre V-6 And 5.7 Litre V-8 Engines - Description - Engine, Removal And Installation - Cylinder Head - Removal And Disassembly - Cleaning And Inspection - Repairs, Valve Guides And Seats - Studs For The Rocker Arms - Valve Springs - Assembly And Installation - Cylinder Block, Cleaning And Inspection - Piston Bore Prepartion - Engine Mounts - Lubrication System - Oil Pump, Removal And Disassembly - Cleaning And Inspection - Oil Pump, Assembly And Installation - Timing Cover, Timing Sprockets, Camshaft And Cam Followers - Timing Cover, Removal - Installation - Timing Sprockets, Removal - Timing Sprockets, Installation - Camshaft, Removal - Camshaft, Inspection - Camshaft, Installation - Hydraulic Valve Lifters, Removal - Hydraulic Valve Lifters, Disassembly - Hydraulic Valve Lifters, Cleaning And Inspection - Hydraulic Valve Lifters, Assembly - Crankshaft - Removal - Inspection And Repair - How To Check The Clearance Between The Main Bearings And Their Journals - Installation - Piston And Connecting Rod Assemblies - Connecting Rod Bearings, Replacement - Piston And Connecting Rod Assemblies, Removal - Disassembly - Piston, Cleaning And Inspection - Cylinder Bores, Inspection And Repair - Piston Rings - Assembly - Piston And Connecting Rod Assemblies, Installation - Flywheel And Flyweel Housing - Flywheel Repair For V-6 Engines - Flywheel For V-6 Engines, Installation - Flywheel Housing, H3.5-5.00xl (H70-110xl) - Engine Adapter, H6.00-7.00xl (H135-155xl) - Ring Gear Replacement (Flywheel) For V-8 Engines - Flywheel For V-8 Engines, Flywheel Housing - Coolant Pump - Fan Mount - Checks And Adjustements - Valve Clearance Adjustment - Engine Specifications - Engine Specifications - Engine Data - Cylinder Head - Hydraulic Valve Lifter - Camshaft - Pistons - Crankshaft - Connecting Rods - Cooling System - Lubrication System - Torque Specifications For Capscrews And Bolts - Troubleshooting 03 GM 4.3 LITRE V-6 ENGINE - Gm 4.3 Litre V-6 - Introduction - Description - Engine, Removal And Installation - Cylinder Head - Removal And Disassembly - Cleaning And Inspection - Repairs, Valve Guides And Seats - Repairs, Valves - Repairs, Valve Seats - Valve Springs - Studs For The Rocker Arms (Early Models) - Studs For The Rocker Arms (Late Models) - Assembly And Installation - Cylinder Block, Cleaning And Inspection - Piston Bore Preparation - Engine Mounts - Lubrication System - Oil Pump, Removal And Disassembly - Cleaning And Inspection - Oil Pump, Assembly And Installation - Oil Sump, Installation - Timing Cover, Timing Sprockets, Camshaft And Valve Lifters - Timing Cover, Removal - Installation - Timing Sprockets, Removal - Timing Sprockets, Installation - Camshaft, Removal - Camshaft, Inspection - Camshaft, Installation - Balance Shaft, Removal - Balance Shaft, Installation - Hydraulic Valve Lifters, Removal - Hydraulic Valve Lifters, Disassembly - Hydraulic Valve Lifters, Cleaning And Inspection - Hydraulic Valve Lifters, Assembly - Hydraulic Valve Lifters, Installation - Crankshaft - Removal - Inspection And Repair - How To Check The Clearance Between The Main Bearings And Their Journals - Installation - Piston And Connecting Rod Assemblies - Connecting Rod Bearings, Replacement - Piston And Connecting Rod Assemblies, Removal - Disassembly - Piston, Cleaning And Inspection - Cylinder Bores, Inspection And Repair - Piston Rings - Assembly - Piston And Connecting Rod Assemblies, Installation - Flywheel And Flywheel Housing - Flywheel Repairs - Flywheel, Installation - Flywheel Housing - Engine Adapter - Coolant Pump - Thermostat - Fan Mount, Early Models - Fan Mount Assembly, Late Models - Drive Belt, Installation - Checks And Adjustments - Valve Clearance Adjustment, Early Models - Valve Clearance Adjustment, New Models - Check The Compression - Engine Specifications - Engine Data - Engine Data - Cylinder Head - Hydraulic Valve Lifter - Camshaft - Pistons - Crankshaft - Connecting Rods - Connecting Rods - Balance Shaft - Cooling System - Lubrication System - Torque Specifications - Troubleshooting 04 PERKINS 4.236 AND PERKINS 4.2482 DIESEL ENGINES - Introduction - General - Description - Engine Serial Number Codes - Removal And Installation - Engine - Cylinder Head - Removal - Installation - Cylinder Head Repairs - Oil Pump - Removal - Disassembly - Inspection - Assembly - Installation - Relief Valve - Timing Gear Case And Timing Gears - Removal - Installation - Pistons And Connecting Rods - Removal - Disassembly - Inspection - Assembly - Installation - Crankshaft And Main Bearings - Removal - Inspection - Assembly - Camshaft And Cam Followers - Removal - Inspection - Assembly - Flywheel And Flywheel Housing - Removal - Repairs - Installation - Steering Pump Drive - Removal - Installation - Pcv Valve - Fuel System - Fuel Pump - Removal - Disassembly - Assembly - Installation - Fuel Injection Pump - Removal - Repairs - Installation - Fuel Injectors - Removal - Repairs - Installation - Cold Start Aid - Description - Removal - Installation - Cooling System - Thermostat - Removal - Inspection - Installation - Water Pump - Removal - Disassembly - Assembly - Installation - Checks And Adjustments - Checking The Injectors - Repairs - Installation - Removing Air From The Fuel System - Checking The Timing Marks - Method A - Method B - Checking The Timing Angle Of The Fuel Injection Pump With The Special Tool - Valve Clearance Adjustment - Adjusting The Throttle Linkage - Troubleshooting - Specifications - Torque Specifications 05 PERKINS 1004-42 (AR) , 1006-60 (YG) , 1006-60T (YH) DIESEL ENGINES - Perkins Diesel Engines, 1004-42 (Ar), 1006-60 (Yg), 1006-60t (Yh) - General - General Safety Rules - Description - Engine Serial Number Codes - Engine Data - 1004-42 (Ar) Engine (Low Governed Speed) - 1004-42 (Ar) Engine (High Governed Speed) - 1006-60 (Yg) Engine - 1006-60 (Yh) Engine - Removal And Installation - Lifting The Engine - Cylinder Head Assembly - Valve Cover - Removal - Installation - Rocker Arm Assembly - Removal - Installation - Disassembly - Inspection - Assembly - Valve Clearance Adjustments - Four Cylinder Engines - Six Cylinder Engines - Valve Springs - Cylinder Head Assembly - Removal - Installation - Valves And Valve Springs - Removal - Inspection - Installation - Valve Guides - Inspection - Removal - Installation - Cylinder Head And Valve Seats - Inspection - Repair - Installation Of New Valve Seats - Piston And Connecting Rod Assemblies - Rod Bearings - Removal - Installation - Piston And Connecting Rod Assembly - Service Note - Removal - Installation - Piston Rings - Removal - Inspection - Installation - Piston And Connecting Rod - Disassembly - Inspection - How To Select The Correct Replacements - Installation - Piston Cooling Jets - Removal - Installation - Crankshaft Assembly - General - Crankshaft Pulley - Removal, Engine Ar - Removal, Engine Yg And Yh - Inspection - Installation, Engine Ar - Installation, Engine Yg And Yh - Rear Oil Seal - Replacement - Main Bearings - Removal - Inspection - Installation - Thrust Washers - Check The Axial Movement Of The Crankshaft - Removal - Installation - Crankshaft - Removal - Inspection - Installation - Flywheel - Removal - Ring Gear (Replacement) - Installation - Flywheel Housing - Removal - Installation - Timing Case And Timing Gears - General - Timing Case Cover - Removal - Installation - Front Oil Seal - Removal - Installation - Crankshaft Pulley Wear Sleeve - Installation - Idler Gear And Hub - Removal - Installation - Air Compressor Drive, Bendix - Disassembly - Compressor Drive, Assembly - Gear For The Fuel Injection Pump - Removal - Installation - Camshaft Gear - Removal - Installation - Crankshaft Gear - Removal - Installation - Timing Case - Removal - Installation - Camshaft And Tappets - Removal - Installation - Cylinder Block Assembly - Description - Cylinder Block - Disassembly - Inspection - Assembly - Cylinder Bore (4-Cylinder Engines) - Cylinder Bore (6-Cylinder Engines) - Inspection - To Check The Condition Of A Cylinder Liner - Removal - Installation (Service Liner) - Installation (Partially Finished Liner) - Engine Timing - General Description - How To Set Number 1 Piston To Tdc On The Compression Stroke - How To Set Number 1 Piston To Tdc On The Compression Stroke (Alternate Procedure) - Check The Valve Timing - Check The Timing Of The Fuel Injection Pump - Turbocharger, Engine Yh - General - Removal - Installation - Clean The Impeller And Compressor Housing - Lubrication System - General - Oil Filter, Replacement - Filter Head - To Remove And To Install - Oil Sump - Removal - Installation - Oil Pump - Removal - Inspection - Installation - Relief Valve - Removal - Disassembly - Inspection - Assembly - Installation - Idler Gear Shaft, Replacement - Removal - Removal, Alternative - Installation - Installation, Alternative - Installation, Alternative For 4-Cylinder Engines Only - Fuel System - Description - Fuel Injection Pump - Removal - Installation - Fuel Injection Pump, Checks And Adjustments - Remove Air From The Fuel System - Fuel Filter (Replacement) - Canister Type - Quick Release Canister Type - Fuel Injectors - Removal - Inspection - Installation - Fuel Pump - Removal - Disassembly - Assembly - Installation - Test - Cooling System - General - Thermostat - Thermostats - Remove - Install - Test - Coolant Pump - Removal - Disassembly - Assembly - Installation - Fan And Fan Drive - Removal - Installation - Oil Cooler (6-Cylinder Engines) - Removal - Disassembly And Assembly - Installation - By-Pass Valve, Oil Cooler - Electrical Equipment - Drive Belts - Alternator - Removal - Installation - Starter Motor - Removal - Installation - Cold Start Aid - Air Compressor, Engines Yg And Yh - General - Air Compressor, Removal - Air Compressor, Installation - Engine Specifications - Cylinder Head Assembly - Cylinder Head - Valve Guides - Inlet Valve - Exhaust Valves - Valve Springs - Tappets - Rocker Arm Shaft - Rocker Arms And Bushings - Piston And Connecting Rods - Pistons (Engine AR) - Pistons (Engine YG and YH) - Piston Rings (Engine AR) - Piston Rings (Engines YG and YH) - Piston Pins - Connecting Rods - Small End Bushings - Connecting Rod,Bearings, Engines AR And YG - Connecting Rod,Bearings, Engines YH - Piston Cooling Jets - Crankshaft Assembly - Crankshaft - Main Bearings - Crankshaft Thrust Washers - Crankshaft Heat Treatment - Crankshaft Overhaul - Timing Case And Drive Assembly - Camshaft - Camshaft Thrust Washer - Camshaft Gear - Gear For Fuel Injection Pump - Crankshaft Gear - Idler Gear And Hub - Engine Block Assembly - Cylinder Block (Engine AR) - Cylinder Bore Specifications (Engine AR) - Cylinder Block (Engine YG and YH) - Cylinder LIners (Engine YG and YH) - Cylinder Liner Specifications (Partially Finished) - Turbocharger - Lubrication System - Oil Pump, Engine AR - Oil Pump, Engine YG and YH - Idler Gear for Oil Pump - Relief Valve - Oil Filter - Fuel System - Lucas Fuel Injection Pump - Fuel Injector Codes - Fuel Pump, Engine AR - Fuel Pump, Engines YG And YH - Fuel Filter - Cooling System - Coolant Pump - Thermostat - Fan Drive Housing - Flywheel And Housing - Limits for Flywheel "Run Out" and Alignment (Total Indicator Reading) - Electrical Equipment - Alternator - Starter Motor - Cold Start Aid - Torque Specifications - Special Torque Specifications - Special Tools - Troubleshooting - List Of Possible Causes 06 LPG FUEL SYSTEM - Introduction - General - Description And Operation - Fuel Tank - Fuel Filter And Fuel Valve Unit - Vaporizer - Carburetor - Governor - Repairs - Lpg Tank - Removal - Installation - Hydrostatic Relief Valve - Removal And Installation - Filter Unit - Replacement Of The Fuel Filter Element - Replacement Of The Diaphragm And Fuel Valve - Replacement Of The Hoses - Vaporizer - Removal - Vaporizer Disassembly - Cleaning - Inspection - Vaporizer Assembly - Installation - Carburetor - Removal - Disassembly - Cleaning - Assembly - Installation - Governor - Checks And Adjustments - Check The Filter Unit - Check The Vaporizer - Pressure Reducer Valve - Vapor Valve - Adjust The Carburetor - Idle Mixture - Idle Speed - Power Mixture - Adjust The Throttle Linkage - Troubleshooting 07 WEBER CARBURETOR WITH GOVERNOR - Weber Carburetor With Governor - General - Description - Carburetor - Governor - Operation - Carburetor, Float System - Carburetor, Idle System - Carburetor, Main Metering System - Carburetor, Power System - Carburetor, Accelerator Pump System - Carburetor, Choke System - Governor - Repairs - Carburetor - Removal - Disassembly - Cleaning - Assembly - Installation - Governor - Checks And Adjustments - General - Choke System - Electric Choke - Idle Mixture Adjustment - Idle Speed Adjustment - Throttle Linkage Adjustment - Troubleshooting 08 ELECTRONIC CONTROL MODULE (ECM) - Introduction - General - Description And Operation - General - Electronic Control Module (Ecm) - Diagnostic Connector - How The Ecm Begins Operation - Electronic Engine Control - What The Ecm Does - Distributor - Ignition Module - When The Engine Is Being Started - When The Engine Is Running - Electronic Control Module (Ecm) With Ignition Module Distributor, Corrections - Fuel Control - Throttle Body Injection - Fuel Injectors - Fuel Pressure Regulator - Throttle Position Sensor - Idle Air Control - Gm 4.3l Engine Governor System - Gm 3.0l Engine Governor System - Vacuum Ports - Fuel Pump - Ecm Sensors And Controllers - Manifold Absolute Pressure (Map) - Engine Coolant Temperature (Ect) Sensor 09 ELECTRONIC ENGINE CONTROL - Introduction - General - Troubleshooting Procedure - How This Section Is Arranged - Where Do I Start - Visual/Physical Inspection - Knowledge/Tools Required - Damage From Static Discharge (Static Electricity) - Troulbleshooting Information - Malfunction Indicator Lamp (Mil) - Reading Diagnostic Trouble Codes (Dtc) - Clearing Diagnostic Trouble Codes (Dtc) - Table 1. Ecm Diagnostic Codes Available - Diagnostic Mode - Field Service Mode - Ecm Learning Ability - Table 2. Scan Tool Information - On-Board Diagnostic (Obd) System Check - Troubleshooting Charts - General - Tools And Test Equipment - Chart A-1 No Malfuntion Indicator Lamp - Circuit Description - Chart A-2 - No Scan Data, No Dtc12, Malfunction Indicator Lamp On - Circuit Description - Chart A-3 - The Starter Rotates The Engine, Engine Will Not Run - Circuit Description - Chart A-4 - Fuel Injector Circuit - Circuit Description - Chart A-5 - Fuel Pump Relay Circuit - Circuit Description - Chart A-6 - Fuel System Troubleshooting (1 Of 3) - Circuit Description - Fuel Pressure Check - Chart A-7 - Ingition System Troubleshooting - Dtc 14 Engine Coolant Temperature Sensor Circuit (Low Temperature Indicated) - CIRCUIT DESCRIPTION - Dtc 15 Engine Coolant Temperature Sensor Circuit (High Temperature Indicated) - CIRCUIT DESCRIPTION - CODE 15 - Engine Coolant Temperature Sensor Circuit (High Temperature Indicated) - Dtc 21 Throttle Position Sensor Circuit (Signal Voltage High) - CIRCUIT DESCRIPTION - CODE 21 - Throttle Position Sensor Circuit (Signal Voltage High) - Dtc 22 Throttle Position Sensor Circuit (Signal Voltage Low) - CIRCUIT DESCRIPTION - Dtc 31 Engine Governor Circuit - CIRCUIT DESCRIPTION - Dtc 33 Manifold Absolute Pressure (Map) Sensor Circuit (Signal Voltage High - Low Vacuum) - CIRCUIT DESCRIPTION - Dct 34 Manifold Absolute Pressure (Map) Sensor Circuit (Signal Voltage - High Vacuum) - CIRCUIT DESCRIPTION - Dtc 41 Electronic Spark Timing (Est) - Open Est Circuit - CIRCUIT DESCRIPTION - Dtc 42 - Electronic Spark Timing (Est) - Grounded Est Circuit, Open Or Grounded Bypass Circuit - CIRCUIT DESCRIPTION - Dtc 51 Ecm Failure - CIRCUIT DESCRIPTION - Troubleshooting, Performance - GENERAL - Make A Careful Visual Check - FAULT: Codes Or Performance That Is Not Regular - Fault: Loss Of Diagnostic Trouble Code (DTC) Memory - FAULT: Engine Quits While Driving - Additional Checks - FAULT: Engine Is Difficult To Start - FAULT: Variation In Engine Power When The Throttle Is Held Steady - FAULT: Decreased Engine Power - FAULT: Detonation - FAULT Engine Momentarily Does Not Increase Power When Throttle Changes - FAULT: One Or More Cylinders Do Not Operate Correctly. The Engine Does Not Idle Correctly - FAULT: Rough Idle Or Engine Stalls During Idle - FAULT: Fuel Usage Too High - FAULT: Dieseling - FAULT: Backfire - System Test Charts - GENERAL - ENGINE COOLANT TEMPERATURE (ECT) SENSOR TEST - THROTTLE POSITION (TP) SENSOR CHECK - MINIMUN IDLE SPEED - Adjustment - Chart B-1 Idle Air Control (Iac) System Check - CIRCUIT DESCRIPTION - Chart B-2 Manifold Absolute Pressure (Map) Sensor Output Test - CIRCUIT DESCRIPTION - Chart B-3 Check The Governor System - GOVERNOR SYSTEM NOT OPERATING CORRECTLY - Check The Function Of Governor System - CHECK THE PVC SYSTEM - Repairs - FUEL SYSTEM COMPONENTS - General - Fuel Pressure Relief Procedure - Fuel Pump Replacement - TBI Unit, Removal - TBI Unit, Cleaning and Inspection - TBI Unit, Installation - Fuel Meter Body, Removal - Fuel Meter Body, Installation - Fuel Injector, Removal - Fuel Injector, Installation - Pressure Regulator, Removal - Pressure Regulator, Inspection - Pressure Regulator, Installation - Throttle Position Sensor (TPS), Removal - Throttle Position Sensor (TPS), Installation - Idle Air Control (IAC) Valve, Removal - Cleaning and Inspection - Idle Air Control (IAC) Valve, Installation - GOVERNOR SYSTEM (3.0L ENGINE) - Governor Module Replacement - Governor Motor Replacement - Throttle Cables, Installation and Adjustment - CHECK THE MONOTROL PEDAL - GOVERNOR SYSTEM (4.3L ENGINE) - Governor Throttle Drive Assembly, Removal - Governor Throttle Drive Assembly, Inspection - Governor Throttle Drive Assembly, Installation - Governor Drive Motor, Removal - Governor Drive Motor, Cleaning and Lubrication - Governor Drive Motor, Installation - Governor Drive Motor, Inspection - IGNITION SYSTEM COMPONENTS - ECM Replacement - Function Check - Distributor, Removal - Distributor, Disassembly - Distributor, Inspection - Distributor, Assembly - Distributor, Installation - Firing Order - Distributor, Ignition Timing - IGNITION MODULE - Test For A Fault - Replacement - Sensing Coil Test - Sensing Coil Replacement - Ignition Coil Test - Ignition Coil, Removal - Ignition Coil, Installation - SENSORS - Engine Coolant Temperature (ECT) Sensor Replacement - MAP Sensor Replacement - PCV SYSTEM - Replacement - WIRING - Connectors And Terminals - Procedures For Spark Plugs, Spark Plug Wires, And Boots - WIRING DIAGRAM - Troubleshooting Of Spark Plugs - ECM CONNECTOR J1 IDENTIFICATION - ECM CONNECTOR J2 IDENTIFICATION - Special Tools 10 ELECTRONIC ENGINE CONTROL, TROUBLESHOOTING AND REPAIR - Electronic Engine Control, Troubleshooting And Repair - General - Engine Data - Light Bulb Check - System Check - Troubleshooting With The Fault Monitor System In The Ecm - How To Clear A Code - Fault In The Ecm - Fault In The Prom - Calpak Not Installed - Fuel Control - Idle Air Control (Iac) - Fuel Pump Circuit - Coolant Temperature Sensor (Cts) - Manifold Absolute Pressuer Sensor (Map) - Throttle Position Sensodr (Tps) - Output Check, Throttle Position Sensor - Electronic Spark Timing - Engine Crank Signal - Distributor Reference Signal - Troubleshooting Charts - Chart A-1-No "Check Engine" Light - Circuit Description, "Check Engine" Light - Chart A-1-No "Check Engine" Light - Chart A-2-No Aldl Data Or No Code 12 From "Check Engine" Light. The "Check Engine" Light Is Continuosly Illuminated - Circuit Description, "Check Engine" Light - Chart A-2-No Aldl Data Or No Code 12 From "Check Engine" Light. The "Check Engine" Light Is Continuously Illuminated - Chart A-3-Starter Cranks The Engine, But Will Not Run - Circuit Description - Chart A-4-Fuel Injector Circuit - Circuit Description - Chart A-5-Fuel Pump Relay Circuit - Circuit Description - Chart A-6-Fuel System Pressure Test - Circuit Description - Chart A-7-Map Output Check - Circuit Description - Chart A-8-Engine Crank Signal Check - Circuit Description - Chart A-9-Ignition System Troubleshooting - Chart A-9 Ignition System Troubleshooting Chart - Chart A-10-Idle Air Control (Iac) System - Circuit Description - Fault Codes - Code 14-Coolant Temperature Sensor Circuit (Indicates High Temperature) - Circuit Description - Code 15-Coolant Temperature Sensor Circuit (Indicates Low Temperature - Circuit Description - Code 21-Throttle Position Sensor Circuit (Signal Voltage High) - Circuit Description - Code 22-Throttle Position Sensor Circuit (Signal Voltage Low) - Circuit Description - Code 31-Engine Governor Circuit - Circuit Description - Code 33-Map Sensor Circuit, Signal Voltage High (Low Vacuum - Circuit Description - Code 34-Map Sensor Circuit, Signal Voltage Low (High Vacuum) - Circuit Description - Code 42-Electronic Spark Timing (Est) - Circuit Description - Code 54-Fuel Pump Circuit (Low Voltage) - Circuit Description - Code 51-Prom In The Ecm Has A Fault - Code 52-Fuel Calpak Is Missing - Code 55-Ecm Has A Fault - Troubleshooting, Poor Operation - General - Make A Careful Visual Check - Fault: Fuel Usage Too High - Fault: Codes Or Performance That Is Not Regular - Fault: "Dieseling" - Fault: "Backfire" - Fault: Rough Idle Or Engine Stalls During Idle - Fault: Smoke In The Exhaust Gases - Fault: Engine Is Difficult To Start - Fault: Variation In Engine Power When The Throttle Is Held Steady - Fault: Decreased Engine Power - Fault: "Detontion" - Fault: Engine Momentarily Does Not Increase Power When Throttle Changes - Fault: One Cylinder In The Engine Does Not Operate Correctly. The Engine Does Not Idle Correctly - Repairs, Fuel System Components - General - Vacuum Ports - Throttle Body Injection (Tbi) Unit - Tbi Unit, Removal - Tbi Unit, Cleaning And Inspection - Tbi Unit, Installation - Cover For Fuel Meter Body, Replacement - Fuel Injectors - Fuel Injectors, Removal - Fuel Injectors, Installation - Pressure Regulator, Removal - Pressure Regulator, Inspection - Pressure Regulator, Installation - Fuel Meter Body, Removal - Fuel Meter Body, Installation - Throttle Position Sensor (Tps), Removal - Throttle Position Sensor (Tps), Installation - Idle Air Control (Iac) Valve, Removal - Cleaning And Inspection - Idle Air Control (Iac) Valve, Installation - Governor Throttle Drive Assembly, Removal - Governor Throttle Drive Assembly, Inspection - Cleaning And Lubrication - Governor Throttle Drive Assembly, Installation - Governor Drive Motor, Removal - Governor Drive Motor, Cleaning And Lubrication - Governor Drive Motor, Installation - Governor Drive Motor, Inspection - Throttle Body, Removal And Disassembly - Throttle Body, Inspection - Throttle Body, Assembly And Installation - Fuel Pump, Removal And Disassembly - Fuel Pump, Inspection - Repairs, Electrical Components - General - Ignition Coil Test - Ignition Module Test - Distributor, Removal - Distributor, Disassembly - Distributor, Assembly - Distributor, Installation - Firing Order - Ignition Timing - Ignition Coil, Removal - Ignition Coil, Installation - Procedures For Spark Plugs, Spark Plug Wires And Boots - Troubleshooting Of Spark Plugs - Coolant Temperature Sensor (Cts), Replacement - Manifold Absolute Pressure (Map) Sensor, Replacement - Oil Pressure Switch, Replacement - Coolant Temperature Sender, Replacement - Wire Harness - Connectors And Terminals - Electronic Control Module (Ecm) - Ecm Connector A-B Identification - Ecm Connector C-D Identification - Special Tools 11 MICROPROCESSOR SPARK TIMING SYSTEM (MSTS) - Introduction - General - Description - What Msts Does - How Msts Begins Operation - Operation - Distributor - Ignition Coil - Ignition Module - When The Engine Is Being Started - When The Engine Is Running - Manifold Absolute Pressure (Map) Sensor - Engine Coolant Temperature (Ect) Sensor - Msts Module Corrections - Troubleshooting - General - Tools And Equipment - Msts - Troubleshooting Procedure - Where To Start - Visual/Physical Inspection - Knowledge/Tools Required - Damage From Static Discharge (Static Electricity) - Troubleshooting Information - Malfunction Indicator Lamp (Mil) - Connecting The Codemate Tester - Reading Diagnostic Trouble Codes (Dtc) - Clearing Diagnostic Trouble Codes (Dtc's) - On-Board Diagnostic (Odb) System Check - No Malfunction Indicator Lamp - Circuit Description - Test Description - No Dtc-12, Malfunction Indicator Lamp On - Circuit Description - Test Description - Starter Rotates Engine, Engine Does Not Run - Test Description - Dtc-14 Engine Coolant Temperature Sensor (Ect) (Low Temperature Indicated) - Circuit Description - Test Description - Dtc-15 Engine Coolant Temperature Sensor (Ect) (High Temperature Indicated) - Circuit Description - Test Description - Dtc-34 Manifold Absolute Pressure (Map) Sensor - Circuit Description - Test Description - Dtc-41 Electronic Spark Timing (Est Open Circuit) - Circuit Description - Test Description - Dtc-42 Electronic Spark Timing (Est Grounded Circuit) - Circuit Description - Test Description - Dtc 51 Msts Failure - Circuit Description - Repairs - Distributor - Removal - Disassembly - Inspection - Assembly - Installation - Ignition Timing - Ignition Module - Test For A Fault - Ignition Module Replacement - Sensing Coil - Test For A Fault - Sensing Coil Replacement - Ignition Coil - Test For A Fault - Removal - Installation - Msts Module - Removal - Installation - Ect Sensor Replacement - Map Sensor Replacement 12 HIGH ENERGY IGNITION (HEI) - High Energy Ignition (Hei) - Description - Repairs - Distributor - Removal - Disassembly - Assembly - Installation, If The Crankshaft Was Not Rotated When Distributor Was Removed - Nstallation, If The Crankshaft Was Rotated When The Distributor Was Removed - Ignition Coil - Removal, Some 4 And 6 Cylinder Models - Installation, Some 4 And 6 Cylinder Models - Removal, V8, Some 4 And 6 Cylinder Models - Installation, V8, Some 4 And 6 Cylinder Models - Electronic Module - Removal - Installation - Sensing Coil - Removal - Installation - Spark Plugs - Removal - Installation - Checks And Adjustments - Visual Checks - Check The High Voltage Wires - Checking The Ignition Coil - Coil In Distributor Cap Design - Separate Coil Design - Checking The Sensing Coil - Check The Electronic Module - Ignition Timing Adjustment - Ignition System, Gm V8-366 (6-Litre) - Ignition Timing And Idle Speed Adjustment, Gm V6-Lpg (4.3-Litre) - Specifications - Troubleshooting 13 COOLING SYSTEM - Cooling System - Introduction - Description - Radiator - Radiator Cap - Thermostat - Water Pump - Fan And Fan Shroud - Repairs - Cooling System Checks - Exhaust Leaks - Radiator - Checks - Cleaning The Radiator - Drain The Cooling System - Fill The Cooling System - Water Pump - Checks - Thermostat - Checks - Fan And Fan Shroud - Troubleshooting 14 DIFFERENTIAL - Differential - General - Description - Repairs - Removal - Disassembly - Assembly - Assemble The Pinion, Bearings And Pinion Carrier - Adjust Preload For Pinion Bearings - Adjust Thickness Of Shim Set For The Pinion Carrier (Depth Of Pinion) - Assemble The Differential And Ring Gear - Assemble Differential Pinion And Side Gear Assembly - Check The Rotating Torque Of Differential Gears - Install The Differential And Ring Gear Assembly - Adjust Preload Of The Differential Bearings - Check Runout Of Ring Gear - Adjust The Gear Clearance - Check Tooth Contact Pattern Of The Gear Set - Installation Into The Axle Housing - Specifications - Table 1. General Specifications - Table 2. Rivet Installation Pressure - Table 3. Pinion Preload Pressure - Table 4. Pinion Adjustment - Table 5. Torque Specifications - Table 6. Torque Specifications For Metric Hardware - Troubleshooting 15 CLUTCH ASSEMBLY AND MANUAL TRANSMISSION - Introduction - General - Description - Oil Clutch Assembly, H6.00-7.00xl (H135-155xl) - Manual Transmission - Repairs - Oil Clutch Assembly - Removal And Disassembly - Cleaning - Inspection - Assembly And Installation - Transmission - Removal, H6.00-7.00xl (H135-155xl) - Disassembly - Cleaning - Inspection - Assembly - Installation, H6.00-7.00xl (H135-155xl) - Checks And Adjustments - Adjusting The Clutch Pedal Linkage, H6.00-7.00xl (H135-155xl) - Troubleshooting-Oil Clutch Assembly - Troubleshooting-Manual Transmission 16 TWO-SPEED POWERSHIFT TRANSMISSION (HYSTER T-40) 01 - Two-Speed Powershift Transmission (Hyster T-40) Description And Operation - General - Mechanical Description - Torque Converter - Transmission Pump - Shaft Assemblies - Input Shaft - Forward Clutch Shaft - Clutch Assemblies - Forward Low And High Clutch Assemblies - Reverse Low And High Clutch Assemblies - Countershaft - Output Shaft - Hydraulic Operation - Torque Converter - Seal Rings - Control Valve - System Pressure Regulator - Clutch Pressure Regulator - Torque Converter Regulator - Inching Spool - Direction Spool, Direction Control Lever - Direction Spool, Monotrol Pedal - Range Spool - Drain Spool - Accumulator - Modulator Spool - Operation (See - Lubrication Circuit - Monotrol Pedal - Oil Flow Diagrams - Neutral - Forward-Low - Forward-Low-Inching - Reverse Low 17 TWO-SPEED POWERSHIFT TRANSMISSION (HYSTER T-40) 02 - Two-Speed Powershift Transmission (Hyster T-40) - General - Transmission - Removal, Transmission And Torque Converter - Transmission, Disassembly - Reverse-Low Clutch, Disassembly - Reverse-High Clutch, Disassembly - Forward-Low Clutch, Disassembly - Forward-High Clutch, Disassembly - Cleaning And Inspection - Assembly, Forward Low And High Clutches - Forward Clutches, Assembly - Reverse-Low Clutch, Assembly - Reverse Clutches, Assembly - Transmission, Assembly - Torque Converter, Installation - Control Valve - Removal - Disassembly - Assembly - Installation - Monotrol Pedal - Removal And Disassembly - Assembly And Installation - Checks And Adjustments - Stall Test - Linkage Adjustments - Linkage For The Inching Pedal, H6.00-7.00xl (H135-155xl) - Linkage For The Inching Pedal, S6.00-7.00xl (S135-155xl) - Linkage For The Range Lever H6.00-7.00xl (H135-155xl) - Linkage For The Direction Control Lever, H6.00-7.00xl (H135-155xl) - Linkage For The Range Lever, S6.00-7.00xl (S135-155xl) - Linkage For The Direction Control Lever S6.00-7.00xl (S135-155xl) - Check The Oil Pressure For The Transmission - System Pressure Check Port - Torque Converter Check Port - Clutch Pressure Check Port - Inching Pressure - Solenoid Check Ports (Monotrol Control Only) - Lubrication Pressure Check Ports - Specifications - Troubleshooting 18 SPEED REDUCER - Introduction - General - Description - Operation - Repairs - Removal - Disassembly - Cleaning And Inspection - Assembly - Installation - Checks And Adjustments - Adjust The Direction Control Linkage 19 BRAKE SYSTEM - Introduction - General - Description - Operation - Brake Booster And Master Cylinder - Service Brake Assembly - Parking Brake - Repairs - Brake Shoe Assemblies - Removal And Disassembly - Cleaning And Inspection - Assembly And Installation - Master Cylinder - Removal - Disassembly - Assembly - Installation - Brake Booster - Removal - Disassembly - Cleaning And Inspection - Assembly - Installation - Checks And Adjustments - Remove Air From The Brake System - Adjust The Brake Pedal - Adjust The Brake Shoes - Adjust The Parking Brake - Adjust The Parking Brake Switch - Check The Relief Valve On The Brake Booster - Troubleshooting 20 DRIVE AXLES, HUBS AND WHEELS - Introduction - General - Description - Repairs - Disassembly - Cleaning - Assembly - Troubleshooting 21 STEERING AXLE - Steering Axle - General - Description - Repairs - Steering Axle, H3.50-5.50xl (H70-110xl) And S3.50-5.50xl (S70-120xl), E3.50-5.50xl (E70-120xl, E70-120xl3) - Removal - Installation - Steering Axle, H6.00-7.00xl (H135-155xl) H8.00-16.00xl (H165-360l) - Removal - Installation - Wheels And Hubs, All Units - Removal And Disassembly - Cleaning - Assembly And Installation - Spindles And Bearings, All Units - Removal - Cleaning - Assembly And Installation - Tie Rods, All Units - Removal - Cleaning - Installation - Steering Cylinder - Removal And Disassembly - Cleaning And Inspection - Assembly And Installation - Troubleshooting 22 STEERING HOUSING AND THE STEERING CONTROL - Introduction - General - Description - Operation - Repairs - Steering Wheel And Column Assembly - Type "A" Steering Column Assembly - Removal And Disassembly - Assembly And Installation - Type "A" Steering Column - Type "A" Steering Column - Type "B" Steering Column - Removal And Disassembly - Assembly And Installation - Type "B" Steering Column - Disassembly Of Steering Control Unit - Cleaning Of Steering Control Unit - Assembly Of Steering Control Unit - Checks And Adjustments - Remove Air From The System - Troubleshooting 23 FRAME - Introduction - General - Description - Repairs - Counterweight - Removal - Installation - Hood - Removal - Installation - Overhead Guard - Removal - Installation - Operator Restraint System - Hydraulic Tank - Removal - Inspection - Repairs, Small Leaks - Repairs, Large Leaks - Cleaning - Steam Method Of Cleaning - Chemical Solution Method Of Cleaning - Other Methods Of Preparation For Repair - Installation - Fuel Tank - Removal - Repairs - Installation - Radiator - Removal - Installation - Engine - Removal - Installation - Safety Labels - Cab - Cab Replacement - Window Replacement - Windshield Wipers And Heater 24 HYDRAULIC SYSTEM - Introduction - General - Description And Operation - Hydraulic Pumps - Main Control Valve - Steering Control Unit - Brake Valve - Oil Clutch - Troubleshooting 25 HYDRAULIC VANE PUMPS - Introduction - General - Description - Operation - Pump - Relief Valve - Repairs - Removal - Disassembly - Assembly - Installation - Checks And Adjustments - Checking The Relief Pressure Of The Relief Valve - Lift Trucks With Internal Combustion Engines - Electric Lift Trucks - Electric Lift Trucks With Adjustable Relief Valve - Specifications - Troubleshooting 26 HYDRAULIC SCHEMATIC - Electrical Schematic (Gasoline & Lpg) - Electrical Schematic (Diesel, Perkins 4.2482) - Electrical Schematic (Diesel, Perkins 1004.4) - Hydraulic Schematic - Hydraulic Schematic, Powershift Transmission With Manual Control - Hydraulic Schematic, Powershift Transmission With Monotrol Pedal 27 CONTROL VALVE FOR THE HYDRAULIC SYSTEM - Introduction - General - Description - Operation - Lift Spool - Tilt Spool - Relief Valve, Single–Stage - Relief Valve, Two–Stage - Repairs - Removal And Disassembly - Cleaning And Inspection - Assembly - Installation - Checks And Adjustments - Adjust The Single–Stage Relief Valve - Adjust The Two–Stage Relief Valve - Adjust The Relief Valve On The Auxiliary Control Valve, H60–110e Only - Troubleshooting 28 GEAR PUMPS - Introduction - Description - Operation - Flow Control Valve - Relief Valve - Repairs - Removal - Disassembly - Cleaning - Inspection - Assembly - Installation - Checks And Adustments - Check The Output Of The Pump - Check For Air In The Hydraulic System - Troubleshooting 29 NEAR THE MAST - Safety Procedures When Working Near The Mast - Safety Procedures When Working Near The Mast - Lift Cylinders - General - Description - Lowering Control Valve - Cylinders (General) - Cylinders (H520-620b,H700-800a) - Cylinders (H360-460b) - Cylinders (Two-Speed) - Repairs - Removal Of The Lift Cylinder Without Removing The Mast - Standard Masts With The Main Lift Cylinder Fastened To The Crossmember Of The Inner Mast - Standard And Full Free-Lift Masts With The Lift Cylinder To A Crosshead - Masts That Have Two Cylinders, A Main Lift Cylinder And A Free-Lift Cylinder - Disassembly - Assembly - Installation Of The Lift Cylinder In The Mast - Standard Masts With The Main Lift Cylinder Fastened To The Crossmember Of The Inner Mast - Standard And Full-Free-Lift Masts With The Lift Cylinder Fastened To A Crosshead - Chevron Packing - Lift Cylinders For Vista Masts - Description - Lowering Control Valve - Removal - Disassembly - Assembly - Installation - Main Lift Cylinders - Free-Lift Cylinders - Checks And Adjustments - Check For Leaks In Lift System - Troubleshooting - Specifications 30 TILT CYLINDERS - Introduction - General - Description - Repairs - Removal - Disassembly - Cleaning - Assembly - Tilt Cylinders With O-Rings Or Single Lip Seals - Tilt Cylinders For The Xm And Xms Models - Tilt Cylinders For H700 800a And Early Model H700 920b - Installation - Tilt Cylinders Using Chevron Packing - Checks And Adjustments - Check The Tilt Cylinders For Leaks - Adjust The Tilt Cylinder Stroke And The Mast Tilt Angle - Table 1. Movement Rates (Maximum) For Tilt Cylinders - Table 2. Torque Specifications For The Tilt Cylinders - Troubleshooting 31 VISTA MASTS - Introduction - General - Description And Operation - General - Safety Procedure When Working Near The Mast - Two-Stage Mast - Three-Stage Mast - Repairs - Carriage - Removal - Disassembly,Side Shift Carriage - Assembly, Side Shift Carriage - Installation - Two-Stage Mast - Removal - Disassembly - Cleaning And Inspection - Assembly - Installation - Three-Stage Mast - Removal - Disassembly - Cleaning And Inspection - Assembly - Installation - Checks And Adjustments - Check The Operation Of The Mast - Check For Leaks In The Lift And Tilt System - Lift System - Tilt System - Adjust The Tilt Cylinder Stroke And The Backward Tilt Angle - Lift Chain Adjustment - Mast Adjustment - Carriage Adjustment - Troubleshooting 32 STARTER, THE SOLENOID, AND THE SOLENOID SWITCH - Introduction - General - Description And Operation - Repairs - Removal - Dissasembly - Cleaning - Assembly - Installation - Checks And Adjustments - General - Troubleshooting 33 ALTERNATOR WITH A VOLTAGE REGULATOR - Introduction - General - Description - Repairs - General - Removal And Disassembly (Type A) - Cleaning - Assembly (Type A) - Removal And Disaassembly (Type B) - Cleaning - Assembly (Type B) - Installation (Type A And Type B) - Checks And Adjustments - General - Check The Alternator For Low Output (Type A Or Type B) - Check The Alternator For High Output (Type A Or Type B) - Check The Circuit For The Brushes - Delco Alternators - Motorola Alternators - Check The Diodes - Check The Diode Bridge - Delco And Leece–Neville Alternators - Motorola Alternators - Check The Field Winding For The Rotor - Check The Windings In The Stator - Check The Voltage Regulator - Troubleshooting 34 GAUGES, METERS AND INDICATORS - Introduction - General - Description - General - Steering Column Gauges, Meters And Indicators - Led Display Panel - Battery Discharge Indicators - Brush Wear Indicators - Motor Temperature Indicators - "Lx" Series Display Panel - Hourmeter Functions - Battery Indicator Function - Status Code Function - "Zx" Series Display Panels - Display Panel - Basic Display Panels - Performance Display - Brush Wear Indicators - Checks And Adjustments - General - Replacement - General - Meter Replacement - Sender Replacement - Fuel Level Sender - Pressure And Temperature Sender - I.T.W. Display Panel - Removal - Display Panels For The Ev - 100/200zx Motor Controllers, Column Mount - Removal - Replacing Display Panel Assembly - Indicator Leds - Battery Indicators - Digital Display (Performance Disply Panel Only) - Status Code Or Performance Level Switches And Indicator Leds (Performance Display Panel Only) - Replacing Parts Of The Basic Display Panel - Replacing Parts Of The Performance Display Panel - Display Panels For The Ev-100/200zx Motor Controllers, Dash Mount - Removal And Replacement - Specifications - Troubleshooting 35 WIRING DIAGRAMS
Hyster H135 - 155XL - Service Manual - Wiring Information
inicio - index
coche - car
moto
4x4
quad - buggy
camión - truck
e-mail