Hyster H135 155XL - Service Repair Manual - Wiring Diagrams

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HYSTER H135 - 155XL - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING

- English Workshop Manual and Wiring Information to Hyster H135 155XL.

 

INDEX:



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

AND MORE....