Hyster H135 - 155XL - Service Manual - Wiring Information

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