Yale Forklift A875 (GDP050-060TG) 02.2023 Service Manual - PDF

Yale Forklift A875 (GDP050-060TG) 02.2023 Service Manual – PDF DOWNLOAD

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Yale Forklift A875 (GDP050-060TG) 02.2023 Service Manual – PDF DOWNLOAD

Language : English
Pages : 2222
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TABLE OF CONTENTS:

Yale Forklift A875 (GDP050-060TG) 02.2023 Service Manual – PDF DOWNLOAD

524150775 0700YRM0626 (03 2003) US EN 1
toc 1
Cooling System 1
Safety Precautions Maintenance and Repair 2
General 5
Description 6
Radiator 6
Radiator Cap 6
Thermostat 6
Water Pump 7
Fan and Fan Shroud 7
Cooling System Checks 7
Radiator 7
Thermostat 7
Water Pump 8
Exhaust Leaks 8
Fan and Fan Shroud 8
Radiator Cleaning 8
Drain 8
Clean 8
Fill 9
Troubleshooting 10
524150790 2100YRM0103 (03 2007) US EN 13
toc 13
Tilt Cylinders 13
Safety Precautions Maintenance and Repair 14
General 17
Description 17
Tilt Cylinder Repair 17
Remove 17
Disassemble 17
Clean 17
Assemble 18
Tilt Cylinders With O-Ring or Single-Lip Seals 18
Tilt Cylinders 19
Install 20
Tilt Cylinder Leak Check 22
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment 23
Torque Specifications 23
Piston Rod Nut 23
Retainer 23
Troubleshooting 24
tables 13
Table 1 Movement Rates (Maximum) for Tilt Cylinders 22
524150791 2200YRM0002 (01 2016) US EN 29
General 33
Description 34
Alternator Repair 36
Alternator Type A 36
Remove and Disassemble 36
Clean 38
Assemble 38
Install 39
Alternator Type B 42
Remove and Disassemble 42
Clean 42
Assemble 43
Install 44
General Check and Adjustment 44
Low Output Check (Type A or Type B) 45
High Output Check (Type A or Type B) 48
Brushes Circuit Check 49
Delco Alternators 49
Motorola Alternators 49
Diodes Check 50
Diode Bridge Check 50
Delco and Leece-Neville Alternators 50
Motorola Alternators 50
Rotor Field Winding Check 51
Stator Windings Check 52
Voltage Regulator Check 52
Troubleshooting 52
524150792 2200YRM0106 (01 2016) US EN 57
General 61
Description and Operation 62
Starter Repair 66
Remove 66
Disassemble 66
Clean 67
Assemble 67
Install 68
General Checks and Adjustments 68
Troubleshooting 70
524150797 8000YRM0231 (02 2023) US EN 77
General 83
Threaded Fasteners 83
Nomenclature, Threads 83
Strength Identification 84
Cotter (Split) Pins 85
Fastener Torque Tables 90
Conversion Table 92
524150797 8000YRM0231 (03 2020) US EN 99
General 103
Threaded Fasteners 103
Nomenclature, Threads 103
Strength Identification 104
Cotter (Split) Pins 105
Fastener Torque Tables 110
Conversion Table 112
524150797 8000YRM0231 (12 2021) US EN 119
General 123
Threaded Fasteners 123
Nomenclature, Threads 123
Strength Identification 124
Cotter (Split) Pins 125
Fastener Torque Tables 130
Conversion Table 132
524153914 2200YRM0107 (03 2008) US EN 139
toc 139
High Energy Ignition (HEI) System 139
Safety Precautions Maintenance and Repair 140
Description 143
Distributor Repair 145
Remove 145
Disassemble 145
Assemble 151
Install, If Crankshaft WAS NOT Rotated when Distributor was Remo 152
Install, If Crankshaft WAS Rotated when Distributor was Removed 152
Ignition Coil Replacement 154
Some Four- and Six-Cylinder Models 154
Remove 154
Install 154
V8, Some Four- and Six-Cylinder Models 155
Remove 155
Install 155
Electronic Module Replacement 156
Remove 156
Install 156
Sensing Coil Replacement 158
Remove 158
Install 158
Spark Plugs Replacement 158
Remove 158
Install 159
Visual Check 159
High Voltage Wires Check 159
Ignition Coil Check 160
Coil in Distributor Cap Design 160
Separate Coil Design 160
Sensing Coil, Check 161
Electronic Module Check 161
Ignition Timing Adjustment 162
GM V8-366 (6-liter) Ignition System Check 163
GM V6-LPG (4 3 liter) GM V6-LPG (4 3 liter) Ignition Timing and 163
Specifications 163
Troubleshooting 164
524153916 2200YRM0765 (03 2003) US EN 169
toc 169
Microprocessor Spark Timing System (MSTS) 169
Safety Precautions Maintenance and Repair 170
General 173
Description 174
What MSTS Does 174
How MSTS Begins Operation 174
Operation 175
Distributor 175
Ignition Coil 176
Ignition Module 176
When Engine Is Being Started 176
When Engine Is Running 178
Manifold Absolute Pressure (MAP) Sensor 179
Engine Coolant Temperature (ECT) Sensor 179
MSTS Module Corrections 180
Troubleshooting 181
General 181
Tools and Test Equipment 183
MSTS 184
Troubleshooting Procedure 184
Where to Start 184
Visual/Physical Inspection 184
Knowledge/Tools Required 184
Damage From Static Discharge (Static Electricity) 185
Troubleshooting Information 185
Malfunction Indicator Lamp (MIL) 185
Connecting CodeMate Tester 185
Reading Diagnostic Trouble Codes (DTC) 186
Clearing Diagnostic Trouble Codes (DTC’s) 187
On-Board Diagnostic (OBD) System Check 187
Test Description 187
No Malfunction Indicator Lamp 189
Circuit Description 189
Test Description 189
No DTC-12, Malfunction Indicator Lamp ON 191
Circuit Description 191
Test Description 191
Starter Rotates Engine, Engine Does Not Run 192
Test Description 192
DTC-14 Engine Coolant Temperature (ECT) (Low Temperature Indicat 196
Circuit Description 196
Test Description 196
DTC-15 Engine Coolant Temperature Sensor (ECT) (High Temperature 198
Circuit Description 198
Test Description 198
DTC-34 Manifold Absolute Pressure (MAP) Sensor 200
Circuit Description 200
Test Description 200
DTC-41 Electronic Spark Timing (EST) Open Circuit 203
Circuit Description 203
Test Description 203
DTC-42 Electronic Spark Timing (EST) Grounded Circuit 205
Circuit Description 205
Test Description 205
DTC-51 MSTS Failure 207
Circuit Description 207
Distributor Repair 207
Remove 207
Disassemble 208
Inspect 208
Assemble 208
Install 209
Ignition Timing 209
Ignition Module Repair 210
Test For Fault 210
Replace 210
Sensing Coil Repair 211
Test For Fault 211
Replace 211
Ignition Coil Repair 212
Test For Fault 212
Remove 212
Install 212
MSTS Module Repair 213
Remove 213
Install 213
ECT Sensor Replacement 213
MAP Sensor Replacement 214
tables 169
Table 1 MSTS Module Connections 182
Table 2 Pressure Conversion Chart 183
Table 3 MSTS Diagnostic Codes 185
524153917 2200YRM0781 (03 2003) US EN 217
toc 217
Electronic Engine Control 217
Safety Precautions Maintenance and Repair 218
General 221
Description and Operation 221
General 221
Electronic Control Module (ECM) 221
Diagnostic Connector 221
How ECM Begins Operation 225
Electronic Engine Control 226
What ECM Does 226
Distributor 228
Ignition Module 228
When Engine Is Being Started 229
When Engine Is Running 230
Electronic Control Module (ECM) with Ignition Module Distributor 230
Fuel Control 231
Throttle Body Injection (TBI) 232
Fuel Injectors 232
Fuel Pressure Regulator 232
Throttle Position Sensor (TPS) 233
Idle Air Control (IAC) 233
GM 4 3L Engine Governor System 234
GM 3 0L Engine Governor System 234
Vacuum Ports 236
Fuel Pump 236
ECM Sensors and Controllers 238
Manifold Absolute Pressure (MAP) 238
Engine Coolant Temperature (ECT) Sensor 238
524153918 2200YRM0782 (03 2003) US EN 241
toc 241
Electronic Engine Control 241
Safety Precautions Maintenance and Repair 242
General 247
Troubleshooting Procedure 247
How This Section Is Arranged 247
Where Do I Start? 247
Visual/Physical Inspection 247
Knowledge/Tools Required 247
Damage From Static Discharge (Static Electricity) 247
Troubleshooting Information 248
Malfunction Indicator Lamp (MIL) 248
Reading Diagnostic Trouble Codes (DTC) 248
Clearing Diagnostic Trouble Codes (DTCs) 252
ECM Diagnostic Codes Available 253
Diagnostic Mode 253
Field Service Mode 253
ECM Learning Ability 253
SCAN Tool Information 254
On-Board Diagnostic (OBD) System Check 255
Test Description 255
Troubleshooting Charts 257
General 257
Tools and Test Equipment 257
Troubleshooting Chart Description Summary 258
A-1 – No Malfunction Indicator Lamp 258
Circuit Description 258
Test Description 259
Other Troubleshooting Checks 259
A-2 – No Scan Data, No DTC 12, Malfunction Indicator Lamp ON 261
Circuit Description 261
Test Description 261
A-3 – Starter Rotates Engine, Engine Will Not Run 263
Circuit Description 263
Test Description 263
Other Troubleshooting Checks 263
A-4 – Fuel Injector Circuit 265
Test Description 265
A-5 – Fuel Pump Relay Circuit 267
Circuit Description 267
Test Description 267
Other Troubleshooting Checks 267
A-6 – Fuel System Troubleshooting 269
Circuit Description 269
Test Description 269
Other Troubleshooting Checks 269
Test Description 271
Fuel Pressure Check 273
A-7 – Ignition System Troubleshooting 273
Test Description 274
DTC 14 Engine Coolant Temperature Sensor Circuit (Low Temperatur 277
Circuit Description 277
Test Description 277
Other Troubleshooting Checks 277
DTC 15 Engine Coolant Temperature Sensor Circuit (High Temperatu 279
Circuit Description 279
Test Description 279
Other Troubleshooting Checks 279
DTC 21 Throttle Position Sensor Circuit (Signal Voltage High) 281
Circuit Description 281
Test Description 281
Other Troubleshooting Checks 281
DTC 22 Throttle Position Sensor Circuit (Signal Voltage Low) 283
Circuit Description 283
Test Description 283
Other Troubleshooting Checks 283
DTC 31 Engine Governor Circuit 285
Circuit Description 285
Test Description 285
Other Troubleshooting Checks 285
DTC 33 Manifold Absolute Pressure (MAP) Sensor Circuit (Signal V 287
Circuit Description 287
Test Description 287
Other Troubleshooting Checks 287
DTC 34 Manifold Absolute Pressure (MAP) Sensor Circuit (Signal V 289
Circuit Description 289
Test Description 289
Other Troubleshooting Checks 289
DTC 41 Electronic Spark Timing (EST) – Open EST Circuit 291
Circuit Description 291
Test Description 291
Other Troubleshooting Checks 291
DTC 42 EST – Grounded EST Circuit, Open or Grounded Bypass Circu 293
Circuit Description 293
Test Description 294
Other Troubleshooting Checks 294
DTC 51 ECM Failure 296
Circuit Description 296
Other Troubleshooting Checks 296
Troubleshooting, Poor Operation 297
General 297
Make a Careful Visual Check 297
FAULT: Codes or Performance That Is Not Regular 297
FAULT: Loss of Diagnostic Trouble Code (DTC) Memory 297
FAULT: Engine Quits While Driving 297
Additional Checks 297
FAULT: Engine Is Difficult to Start 297
FAULT: Variation in Engine Power When Throttle Is Held Steady 298
FAULT: Decreased Engine Power 298
FAULT: Detonation 299
FAULT: Engine Momentarily Does Not Increase Power When Throttle 299
FAULT: One or More Cylinders Do Not Operate Correctly – Engine D 300
FAULT: Rough Idle or Engine Stalls During Idle 300
FAULT: Fuel Usage Too High 300
FAULT: Dieseling 301
FAULT: Backfire 301
System Test Charts 301
General 301
Engine Coolant Temperature (ECT) Sensor Test 301
Throttle Position (TP) Sensor Check 302
Minimum Idle Speed 302
Adjustment 303
B-1 – Idle Air Control (IAC) System Check 304
Circuit Description 304
Other Troubleshooting Checks 304
B-2 – Manifold Absolute Pressure (MAP) Sensor Output Test 306
Circuit Description 306
Test Description 306
B-3 – Check Governor System 308
Governor System Not Operating Correctly 308
Check Function of Governor System 308
Check PCV System 309
Fuel System Components Repair 309
General 309
Fuel Pressure Relief Procedure 309
Fuel Pump Replacement 309
Throttle Body Injection Unit (TBI) 310
Remove 310
Clean and Inspect 311
Install 311
Fuel Meter Body 311
Remove 311
Install 314
Fuel Injector 314
Remove 314
Install 315
Pressure Regulator 315
Remove 315
Inspect 315
Install 315
Throttle Position Sensor (TPS) 316
Remove 316
Install 316
Idle Air Control (IAC) Valve 316
Remove 316
Clean and Inspect 316
Install 317
Governor System 3 0L Engine Repair 317
Governor Module, Replace 317
Governor Motor, Replace 317
Throttle Cables, Install and Adjust 317
Foot Directional Control Pedal, Check 318
Governor System 4 3L Engine Repair 319
Governor Throttle Drive Assembly 319
Remove 319
Inspect 320
Install 320
Governor Drive Motor 320
Remove 320
Clean and Lubricate 320
Install 321
Inspect 322
Ignition System Components Repair 322
ECM Replacement 322
Function Check 322
Distributor 322
Remove 322
Disassemble 322
Inspect 323
Assemble 323
Install 323
Firing Order 324
Ignition Timing 324
Ignition Module Repair 324
Test For Fault 324
Replace 325
Sensing Coil 325
Test 325
Replace 326
Ignition Coil 326
Test 326
Remove 326
Install 327
Sensors Repair 327
Engine Coolant Temperature (ECT) Sensor, Replace 327
MAP Sensor, Replace 327
PCV System Repair 328
Replace 328
Wiring 328
Connectors and Terminals 328
Procedures for Spark Plugs, Spark Plug Wires, and Boots 331
Wiring Diagram 331
Spark Plugs Troubleshooting 336
Special Tools 337
tables 241
Table 1 ECM Diagnostic Codes Available 253
Table 2 SCAN Tool Information 254
Table 3 Troubleshooting Chart Description Summary 258
Table 4 ECT Sensor – Temperature vs Resistance 279
Table 5 ECT Sensor – Temperature vs Resistance 302
Table 6 ECM Connector J1 Identification 334
Table 7 ECM Connector J2 Identification 335
524158636 0100YRM0505 (06 2004) US EN 341
toc 341
Frame 341
Safety Precautions Maintenance and Repair 342
General 345
Description 345
Operator Module Repair 345
Remove 345
Install 345
Hood and Side Covers Repair 347
Remove 347
Install and Adjust 347
Overhead Guard Repair 349
Remove and Install 349
LED Backup and Brake Lights, Replace 350
Remove 350
Install 350
Counterweight Repair 351
Remove 351
Install 352
Exhaust System Repair 353
Muffler, Replace 354
Radiator and Cooling System Repair 360
Remove 360
Install 360
Operator Restraint System Repair 362
Engine Repair 363
Remove Engine Only 363
Remove Engine and Transmission 363
Install Engine Only 364
Install Engine and Transmission 365
Fuel and Hydraulic Tanks Repair 365
Inspect 365
Small Leaks, Repair 365
Large Leaks, Repair 365
Clean 366
Steam Method of Cleaning 366
Chemical Solution Method of Cleaning 366
Additional Preparations for Repair 366
Safety Labels 367
tables 341
Table 1 Weight of Counterweights 352
524158637 0600YRM1020 (10 2006) US EN 373
toc 373
GM Engine Repair 373
Safety Precautions Maintenance and Repair 374
General 377
Description 377
Engine Removal and Installation 385
Cylinder Head and Valve Mechanism Repair 385
Cylinder Head, Remove 385
Cylinder Head, Disassemble 387
Clean and Inspect 387
Valves and Valve Seats 390
Studs for Rocker Arms 390
Hydraulic Valve Lifters 391
Replace 391
Clean and Inspect 391
Cylinder Head, Assemble 391
Cylinder Head, Install 392
Valve Clearance, Adjust 393
Rocker Arm Cover, Install 393
Timing Gear Cover Repair 394
Remove 394
Install 394
Timing Wheel Repair 395
Timing Wheel, Removal 395
Timing Wheel, Install 395
Air Gap Adjustment 396
Camshaft Repair 398
Camshaft, Remove 398
Camshaft, Clean and Inspect 398
Camshaft Bearings, Remove 400
Camshaft Bearings, Clean and Inspect 400
Camshaft Bearings, Install 400
Camshaft, Install 401
Distributor Repair 401
Remove 401
Install 402
Lubrication System Repair 403
Oil Pan 403
Remove 403
Install 403
Oil Pump 403
Remove 403
Disassemble 404
Clean and Inspect 405
Assemble 405
Install 405
Piston and Piston Rod Assemblies Repair 405
Piston Rod Bearings, Replace 405
Piston and Piston Rod Assemblies, Remove 407
Piston and Piston Rod Assemblies, Disassemble 407
Pistons, Clean and Inspect 408
Cylinder Bores, Inspect and Repair 408
Piston Rings, Inspect 409
Piston and Piston Rod Assemblies, Assemble 410
Piston and Piston Rod Assemblies, Install 410
Crankshaft Repair 411
Main Bearings, Replace 411
Oil Seal for Rear Main Bearing, Replace 412
Crankshaft, Remove 412
Inspect and Repair 413
Main Bearing and Journal Clearance, Check 414
Crankshaft, Install 415
Flywheel and Flywheel Housing Repair 415
Flywheel, Remove 416
Ring Gear, Replace 417
Flywheel, Install 417
Cooling System Repair 417
Water Pump 417
Remove 417
Inspect 417
Install 418
Thermostat 418
Remove and Install 418
Alternator Repair 418
Starter Repair 418
Checks and Adjustments 420
Engine Compression Test 420
Test Procedure 420
Test Results 420
Engine Noise Diagnostic Test 420
Description 420
Test Procedure 420
Engine Specifications 422
Engine Data 422
Cylinder Bore 422
Piston 422
Piston Rings 422
Wrist Pin 423
Crankshaft 423
Piston Rod 424
Camshaft 424
Hydraulic Valve System 424
Cylinder Head Warpage 425
Lubrication System 425
Cooling System 425
Torque Specifications 426
Troubleshooting 427
524158742 0600YRM0496 (01 2011) US EN 433
toc 433
Mazda Engine 433
Safety Precautions Maintenance and Repair 434
General 437
Description 437
Engine Removal and Installation 437
Cylinder Head, Camshaft, and Valve Mechanism Repair 438
Remove 438
Clean 439
Inspect and Repair 440
Cylinder Head 440
Rocker Shaft Assembly 440
Camshaft 440
Valve Guides 441
Valve Seats 442
Valves 442
Valve Springs 443
Install 443
Crankshaft and Main Bearings Repair 446
Remove 446
Inspect and Repair 446
Crankshaft 446
Main Bearings 446
Install 447
Pistons and Connecting Rods Repair 448
Remove and Disassemble 448
Clean 448
Inspect and Repair 448
Pistons 448
Piston Rings 449
Connecting Rods and Bearings 449
Assemble and Install 450
Cylinder Block Repair 451
Oil Pump Repair 451
Remove 451
Disassemble 452
Clean 452
Inspect 452
Assemble 453
Install 454
Cooling System Repair 454
Thermostat 454
Replace 454
Fan Assembly 454
Remove and Disassemble 454
Assemble and Install 455
Water Pump 455
Remove and Disassemble 455
Assemble and Install 456
Distributor Repair 457
Remove 457
Install 457
Flywheel and Ring Gear Repair 458
Remove 458
Ring Gear, Replace 458
Install 458
Flywheel Repair 459
Remove 459
Install 459
Valve Adjustment 460
Compression Pressure Check 460
Engine Timing Adjustment 461
Throttle Linkage Adjustment 461
Gasoline Engines 461
LPG Engines (IMPCO) 461
LPG Engines (AISAN) 462
Engine Specifications 462
Engine Data 462
Thermostat 462
Cylinder Head 462
Valve Mechanism 462
Camshaft 463
Crankshaft 463
Connecting Rods 464
Cylinder Block 464
Pistons 464
Oil Pump 464
Torque Specifications 465
Troubleshooting 466
524158744 0900YRM0498 (12 2003) US EN 471
toc 471
LPG Fuel System 471
Safety Precautions Maintenance and Repair 472
General 475
Description and Operation 475
Fuel Tank 476
Fuel Filter and Fuel Valve Unit 476
Vaporizer 476
Carburetor 478
Solenoid Valve 479
Idle Control Actuator 480
Governor System 480
Hose Replacement 480
LPG Tank Repair 481
Remove 481
Install 481
Hydrostatic Relief Valve Repair 482
Remove and Install 482
Filter Unit Repair 482
Fuel Filter Element, Replace 482
Diaphragm and Fuel Valve, Replace 484
Vaporizer Repair 484
Remove 484
Disassemble 484
Clean 484
Inspect 484
Assemble 486
Install 490
Carburetor Repair 490
Remove 490
Disassemble 490
Clean 490
Assemble 492
Install 492
Solenoid Valve Repair 492
Governor System Check 493
Filter Unit Check 493
Vaporizer Check 494
Pressure Reducer Valve 494
Vapor Valve 494
Carburetor Adjustment 494
Idle, Adjust 494
Power Mixture 495
Throttle Linkage Adjustment 496
Foot Directional Control Pedal, Check 497
Troubleshooting 498
524158745 0900YRM0502 (12 2003) US EN 505
toc 505
Gasoline Fuel System 505
Safety Precautions Maintenance and Repair 506
General 509
Description 509
Carburetor 509
Governor 510
Carburetor Operation 510
Float System 510
Idle System 511
Idle Control Actuator 511
Idle Compensator Valve 511
Idle Metering System 511
Solenoid Valve (Shutoff Valve) 512
Main Metering System 512
Choke System 512
Vacuum Diaphragm 513
Temperature Sensor System 513
Choke-Release Mechanism 513
Power System 513
Accelerator Pump System 513
Governor Operation 514
Governor Repair 514
Carburetor Repair 514
Remove 514
Disassemble 515
Clean 515
Inspect 517
Assemble 517
Install 518
Carburetor Adjustment 519
Idle Speed and Mixture, Adjust 519
Throttle Linkage Adjustment 520
Foot Directional Control Pedal, Check 521
Governor Adjustment 522
Troubleshooting 523
524158746 0900YRM0523 (12 2003) US EN 529
toc 529
LPG Fuel System 529
Safety Precautions Maintenance and Repair 530
General 533
Description and Operation 533
Fuel Tank 535
Fuel Filter and Fuel Valve Unit 535
Vaporizer 536
Carburetor 538
Solenoid Valve 540
Idle Control Actuator 540
Governor 540
Hose Replacement 540
LPG Tank Repair 541
Remove 541
Install 541
Hydrostatic Relief Valve Repair 542
Remove and Install 542
Filter Unit Repair 542
Fuel Filter Element, Replace 542
Diaphragm and Fuel Valve, Replace 544
Vaporizer Repair 544
Remove 544
Disassemble 544
Clean 544
Inspect 544
Assemble 546
Install 549
Carburetor Repair 550
Remove 550
Disassemble 550
Clean 550
Assemble 553
Install 553
Solenoid Valve Repair 553
Governor Repair 553
Filter Unit Check 554
Vaporizer Check 554
Pressure Reducer Valve 554
Vapor Valve 554
Carburetor Adjustment 554
Idle Mixture 554
Idle, Adjust 554
Power Mixture, Adjust 555
Governor Check and Adjustment 556
Check 556
Adjust 556
Throttle Linkage Adjustment GC/GLC040-065RG/TG/ZG and GP/GLP/GDP 557
Throttle Linkage Adjustment GP/GLP/GDP16-20AF/BF (GP/GLP/GDP030- 558
Foot Directional Control Pedal Check 559
Troubleshooting 560
524158747 0900YRM0925 (12 2003) US EN 567
toc 567
LPG Fuel System 567
Safety Precautions Maintenance and Repair 568
General 571
Description and Operation 571
Fuel Tank 572
Regulator 572
Start Mode 574
Idle Mode 574
Run Mode 574
Resonator 574
Carburetor 575
Start Mode 575
Idle Mode 575
Run Mode 575
Governor 576
Hoses Replacement 577
LPG Tank Repair 577
Remove 577
Install 577
Relief Valve Repair 578
Remove and Install 578
Carburetor Repair 578
Remove 578
Disassemble 578
Clean 579
Assemble 579
Install 580
Governor Repair 580
Remove 580
Inspect 580
Install 580
Regulator Repair 581
Remove 581
Disassemble 581
Clean 581
Inspect 581
Assemble 583
Install 584
Regulator Adjustment 584
Regulator Height Adjustment 584
Regulator Assembly Air Tightness Test 585
Carburetor Adjustment 586
Idle Speed and Fuel Mixture 586
Idle Control Adjustment 586
Governor Adjustment 587
Checks 587
Adjustments 587
Throttle Linkage Adjustment 588
Foot Directional Control Pedal Check 589
Throttle Linkage Adjustment 590
Troubleshooting 591
tables 567
Table 1 Power Adjusting Screw 580
Table 2 Air Adjusting Screw 580
Table 3 Idle Mixture Adjusting Screw 583
Table 4 Idle Mixture Adjusting Screw 586
524158748 0900YRM0948 (10 2006) US EN 599
toc 599
LPG Fuel System 599
Safety Precautions Maintenance and Repair 600
General 603
Description and Operation 603
Fuel Tank 603
Oxygen Sensor 603
Regulator 603
Start Mode 606
Idle Mode 609
Run Mode 609
Resonator 609
Carburetor 609
Start Mode 609
Idle Mode 610
Run Mode 610
Governor 611
Hoses Replacement 611
LPG Tank Repair 612
Remove 612
Install 612
Relief Valve Repair 613
Remove and Install 613
Carburetor Repair 613
Remove 613
Disassemble 613
Clean 614
Assemble 614
Install 615
Fuel Injector Repair 615
Remove 615
Clean and Inspect 615
Install 615
Governor Repair 616
Remove 616
Inspect 616
Install 616
Regulator Repair 616
Remove 616
Install 616
Oxygen Sensor Repair 616
Remove and Install 616
Vacuum Switches Repair 617
Remove and Install 617
Inspect 617
Resistor Repair 617
Remove and Install 617
Inspect 617
Carburetor and New Regulator Adjustment 617
Idle Speed and Fuel Mixture 617
Idle Control Adjustment 618
Governor Checks and Adjustments 619
Checks 619
Adjustments 619
Throttle Linkage Adjustment 619
Foot Directional Control Pedal Check 621
Check Engine Light 621
Inspect Warning Lamp 621
Check Feedback Operation 621
Check VAC1 and VAC2 Signals 621
Check Resistor 621
Check Fuel Injector 621
Check Oxygen Sensor 622
Check Vacuum Switch 1 622
Check Vacuum Switch 2 622
After Completing Checks 622
Troubleshooting 622
tables 599
Table 1 Adjusting Screw 615
524158749 1300YRM0500 (08 2003) US EN 631
toc 631
Single-Speed Powershift Transmission 631
Safety Precautions Maintenance and Repair 632
General 635
Description and Operation 635
General 635
Torque Converter 636
Description 636
Operation 636
Clutch Assemblies 638
Description 638
Operation 639
Hydraulic System 642
General 642
Control Valve 643
General 643
Clutch Pressure Regulator 644
Inching Spool Assembly 645
Direction Spool 645
Modulator Circuit 645
Torque Converter Regulator 645
Foot Directional Control Pedal 645
Foot Directional Control Pedal Start Circuit 646
Direction Control Lever 646
Differential 646
Oil Flow Diagrams 648
Neutral 648
Modulator Operation 648
Forward 652
Forward-Inching 652
524158750 1300YRM0501 (03 2004) US EN 659
toc 659
Single-Speed Powershift Transmission 659
Safety Precautions Maintenance and Repair 660
General 663
Transmission Removal 667
Torque Converter and Housing Repair 667
Remove 667
Install 667
Transmission Pump Repair 669
Remove 669
Repair 669
Install 669
Front Cover and Pump Drive Repair 669
Remove and Disassemble 669
Assemble and Install 669
Clutch Assemblies Repair 672
Remove and Disassemble 675
Inspect 677
Assemble 678
Install 683
Differential Repair 684
Remove and Disassemble 684
Inspect 685
Assemble and Install 686
Control Valve Repair 693
Remove and Disassemble 693
Inspect 693
Assemble and Install 693
Foot Directional Control Pedal Repair 696
Remove and Disassemble 696
Assemble and Install 696
Direction Control Lever Repair 699
Remove and Disassemble 699
Assemble and Install 699
Stall Test 700
Inching/Brake Pedal Adjustment 701
Neutral Start Switch, Foot Directional Control Pedal Adjustment 705
Neutral Start Switch, Foot Directional Control Pedal Adjustment 706
Neutral Start Switch Test, Foot Directional Control Pedal 707
Oil Pressure Checks 707
Relief Valve for Transmission Pump Check, TEST PORT 1 707
Clutch Pressure Check, TEST PORTS 2 and 3 707
Torque Converter Regulator Check, TEST PORT 4 708
Lubrication Circuit Oil Pressure Check, TEST PORT 5 708
Modulator Pressure Check, TEST PORT 6 708
Troubleshooting 709
Troubleshooting – Pressure Tests 712
tables 659
Table 1 Adjustment of Shims for Pinion Assembly 686
Table 2 Ring and Pinion Tooth Contact Adjustment 687
Table 3 Stall Speeds 701
Table 4 Transmission Oil Pressures Test Ports 708
524158751 1400YRM0499 (10 2004) US EN 717
toc 717
Drive Axle 717
Safety Precautions Maintenance and Repair 718
General 721
Description 721
Drive Axle Repair 721
Remove and Disassemble 721
Clean and Inspect 723
Assemble and Install 723
Torque Specifications 725
GP2 00-3 00RF/TF (GP040-060RG/TG/ZG) 725
GC040-065TF/RF 725
Troubleshooting 726
524158752 1600YRM0316 (08 2006) US EN 729
toc 729
Steering Axle 729
Safety Precautions Maintenance and Repair 730
General 733
Description 733
Steering Axle Assembly Repair 734
Remove 734
Install 734
Wheels and Hubs Repair 735
Remove and Disassemble 735
Clean 735
Assemble and Install 735
Spindles, Bearings, and Tie Rods Repair 737
Remove 737
Install 737
Steering Cylinder Repair 738
Remove and Disassemble 738
Clean and Inspect 739
Assemble and Install 739
Torque Specifications 739
Troubleshooting 740
524158753 1600YRM0720 (11 2006) US EN 745
toc 745
Steering Housing and Control Unit 745
Safety Precautions Maintenance and Repair 746
General 749
Description 749
Operation 750
Steering Wheel and Column Assembly Repair 751
Assembly Components, Remove 751
Steering Control Unit, Disassemble 756
Steering Control Unit, Clean 756
Steering Control Unit, Assemble 756
Assembly Components, Install 758
System Air Removal 760
Troubleshooting 760
524158754 1800YRM0506 (05 2005) US EN 765
toc 765
Brake System 765
Safety Precautions Maintenance and Repair 766
General 769
Description and Operation 769
Service Brakes 769
Master Cylinder 769
Parking Brake 771
Service Brakes Repair 771
Remove and Disassemble 771
Clean 773
Inspect 773
Assemble and Install 775
Adjust 779
Parking Brake Repair 779
Remove and Disassemble 779
Assemble and Install 779
Adjust 779
Master Cylinder Repair 781
Remove 781
Clean and Inspect 781
Repair 782
Install 784
Service Brakes Adjustment 784
Brake System Air Removal 785
Parking Brake Not Applied Switch Test 785
Parking Brake Switch Test (Foot Directional Control Pedal Only) 785
Inching/Brake Pedal Adjustment 786
Neutral Start Switch Adjustment, Foot Directional Control Pedal 790
Neutral Start Switch Adjustment, Foot Directional Control Pedal 791
Neutral Start Switch Test (Foot Directional Control Pedal) 792
Torque Specifications 792
GP2 00-3 00RF/TF (GP040-060RG/TG/ZG) 792
GC040-065RG/TG/ZG 792
Troubleshooting 792
524158755 1900YRM0513 (06 2004) US EN 799
toc 799
Hydraulic System 799
Safety Precautions Maintenance and Repair 800
General 803
Description 803
Hydraulic System 803
Gear Pump Assembly 803
Flow Control Valve 803
Relief Valve 803
Operation 810
Hydraulic System 810
Gear Pump 810
Flow Control Valve 810
Relief Valve 810
Gear Pump Assembly Repair 812
Remove and Disassemble 812
Assemble and Install 813
Steering Relief Pressure Check and Adjustment 813
Gear Pump Flow Check 814
Troubleshooting 814
524158756 2000YRM0516 (12 2003) US EN 819
toc 819
Main Control Valve 819
Safety Precautions Maintenance and Repair 820
General 823
Description 823
Operation 824
Lift Section 824
Tilt Section 824
Tilt Backward 824
Tilt Forward 824
Relief Valve 828
Main Control Valve Repair 829
Remove 829
Disassemble 829
Clean and Inspect 829
Assemble 829
Install 835
Pressure Relief Valve Check and Adjustment 836
Primary Relief Valve 836
Secondary Relief Valve 836
Troubleshooting 837
524158757 2200YRM0514 (01 2004) US EN 841
toc 841
Instrument Cluster 841
Safety Precautions Maintenance and Repair 842
General 845
Description 845
Instrument Cluster Display Panel, Internal Combustion Lift Truck 845
Instrument Cluster Display Panel, Electric Lift Truck Models 852
Optional Basic Display Panel 852
Features of the Optional Basic Display Panel 852
Description of Features on the Optional Basic Display Panel 852
Standard Display Panel 853
Features of the Standard Display Panel 853
Description of Features on the Standard Display Panel 853
Premium Display Panel 854
Features on the Premium Display Panel 854
Description of Features on the Premium Display Panel 855
Curtis 1215 Display Panel 857
Description and Features 857
Operation 858
Cluster-Type Display Panel (Internal Combustion) Replacement 859
Remove 859
Install 859
Cluster Display Panel (Electric Lift Truck) Replacement 862
Curtis 1215 Display Panel Replacement 867
Remove 867
Install 867
tables 841
Table 1 Instrument Cluster, Internal Combustion 846
524158758 2200YRM0524 (12 2003) US EN 871
toc 871
Electrical System 871
Safety Precautions Maintenance and Repair 872
General 875
Description 875
Starting System 875
Ignition System 875
Charging System 876
Starter Repair 877
Remove and Disassemble 877
Assemble and Install 877
Coil Replacement 879
Distributor Repair 880
Remove and Disassemble 880
Assemble and Install 880
Distributor Repair 882
Remove and Disassemble 882
Assemble and Install 884
Alternator Repair 884
Remove and Disassemble 884
Assemble and Install 885
General Checks and Adjustments 886
Starter Checks 886
Operation, Check 886
Brush Holder, Check 887
Armature, Check 887
Field Windings, Check 887
Clutch and Bearing, Check 887
Ignition System Check and Adjustment 888
Engine Timing, Adjust 888
Spark Plugs, Check 888
Charging Circuit Checks 889
Low Output, Check 889
High Output, Check 890
Diodes, Check 890
Rotor Field Winding, Check 891
Stator Windings, Check 891
Brushes and Bearings, Check 891
Voltage Regulator, Check 891
Troubleshooting 892
524158759 2200YRM0603 (12 2003) US EN 897
toc 897
Microprocessor Spark Timing System (MSTS) 897
Safety Precautions Maintenance and Repair 898
General 901
Description 901
What MSTS Does 901
How MSTS Begins Operation 901
Operation 902
Distributor 902
Ignition Module 903
When Engine is Being Started 904
When Engine is Running 904
Manifold Absolute Pressure (MAP) Sensor 905
Engine Coolant Temperature (ECT) Sensor 906
MSTS Module Corrections 906
Initial Timing Connector 908
Governor System Operation 908
Troubleshooting 910
General 910
Tools and Test Equipment 911
MSTS 911
Test Description 911
Ignition System 913
Test Description 913
Electronic Spark Timing (EST) 916
Circuit Description 916
Test Description 917
Manifold Absolute Pressure (MAP) Sensor 920
Circuit Description 920
Test Description 920
Test 1 921
Test 2 922
Engine Coolant Temperature (ECT) Sensor 923
Circuit Description 923
Test Description 923
Distributor Repair 925
Remove 925
Disassemble 925
Inspect 926
Assemble 926
Install 926
Ignition Timing 926
Ignition Module Replacement 927
Test for a Fault 927
Replace 928
Sensing Coil Replacement 928
Test for a Fault 928
Replace 928
Ignition Coil Replacement 929
Test for a Fault 929
Remove 929
Install 929
MSTS Module Replacement 930
Remove 930
Install 930
ECT Sensor Replacement 930
MAP Sensor Replacement 931
tables 897
Table 1 MSTS Module Connections 908
Table 2 Voltage and Pressure for MAP Sensor Troubleshooting 921
Table 3 Pressure Conversion Chart 922
524158885 2200YRM0611 (12 2003) US EN 935
toc 935
Electronic Engine Control 935
Safety Precautions Maintenance and Repair 936
General 941
Troubleshooting Procedure 941
Where Do I Start? 941
Visual/Physical Inspection 941
Knowledge/Tools Required 941
Damage From Static Discharge (Static Electricity) 941
Troubleshooting Information 941
Malfunction Indicator Lamp (MIL) 942
Reading Diagnostic Trouble Codes (DTCs) 942
Clearing Diagnostic Trouble Codes (DTC’s) 943
Diagnostic Mode 943
Field Service Mode 943
ECM Learning Ability 944
On-Board Diagnostic (OBD) System Check 944
Troubleshooting Charts 947
Tools and Test Equipment 947
A-1 – No Malfunction Indicator Lamp 948
Circuit Description 948
Test Description 948
Other Troubleshooting Checks 948
A-2 – No SCAN Data, No DTC 12, Malfunction Indicator Lamp On 951
Circuit Description 951
Test Description 951
A-3 – Starter Rotates the Engine, Engine Will Not Run 953
Circuit Description 953
Test Description 953
Other Troubleshooting Checks 954
A-4 – Fuel Injector Circuit 956
Circuit Description 956
Test Description 956
A-5 – Fuel Pump Relay Circuit 958
Circuit Description 958
Test Description 958
Other Troubleshooting Checks 958
A-7 – Fuel System Troubleshooting 960
Circuit Description 960
Test Description 961
Other Troubleshooting Checks 961
Test Description 961
Fuel Pressure Check 964
A-8 Ignition System Troubleshooting 965
Test Description 965
DTC 14 – Engine Coolant Temperature Sensor Circuit (High Tempera 969
Circuit Description 969
Test Description 969
Other Troubleshooting Checks 969
DTC 15 – Engine Coolant Temperature Sensor Circuit (Low Temperat 971
Circuit Description 971
Test Description 971
Other Troubleshooting Checks 971
DTC 21 – Throttle Position Sensor Circuit (Signal Voltage High) 973
Circuit Description 973
Test Description 973
Other Troubleshooting Checks 973
DTC 22 – Throttle Position Sensor Circuit (Signal Voltage Low) 975
Circuit Description 975
Test Description 975
Other Troubleshooting Checks 975
DTC 31 – Engine Governor Circuit 977
Circuit Description 977
Test Description 977
Other Troubleshooting Checks 977
DTC 33 – Manifold Absolute Pressure (MAP) Sensor Circuit (Signal 979
Circuit Description 979
Test Description 979
Other Troubleshooting Checks 979
DTC 34 – Manifold Absolute Pressure (MAP) Sensor Circuit (Signal 981
Circuit Description 981
Test Description 981
Other Troubleshooting Checks 981
DTC 42 – Electronic Spark Timing (EST) 983
Circuit Description 983
Test Description 984
Other Troubleshooting Checks 984
DTC 51 – ECM Failure 986
Circuit Description 986
Other Troubleshooting Checks 986
Troubleshooting, Poor Operation 986
General 986
Make a Careful Visual Check 986
FAULT: Codes or Performance That is Not Regular 986
Definition: 986
Check: 987
FAULT: Loss Of Diagnostic Trouble Code (DTC) Memory 987
FAULT: Engine Quits While Driving 987
Additional Checks 987
FAULT: Engine Is Difficult To Start 987
Definition: 987
Check: 987
FAULT: Variation In Engine Power When The Throttle Is Held Stead 988
Definition: 988
Check: 988
FAULT: Decreased Engine Power 988
Definition: 988
Check: 988
FAULT: Detonation 988
Definition: 988
Check: 988
FAULT: Engine Momentarily Does Not Increase Power When Throttle 989
Definition: 989
Check: 989
FAULT: One Or More Cylinders Do Not Operate Correctly The Engin 989
Definition: 989
Check: 989
FAULT: Rough Idle Or Engine Stalls During Idle 990
Definition: 990
Checks: 990
FAULT: Fuel Usage Too High 990
Definition: 990
Check: 990
FAULT: Dieseling 990
Definition: 990
Checks: 991
FAULT: Backfire 991
Definition: 991
Check: 991
Engine Coolant Temperature (ECT) Sensor Test 991
Throttle Position (TP) Sensor Check 992
Minimum Idle Speed Adjustment 993
Adjust 993
C-1 – Idle Air Control (IAC) System Check 994
Circuit Description 994
Other Troubleshooting Checks 994
C-2 – Manifold Absolute Pressure (MAP) Sensor Output Test 996
Circuit Description 996
Test Description: 996
PCV System Check 998
Governor System Check 998
Governor System Not Operating Correctly 998
Governor System Function, Check 999
Fuel System Components Repair 999
General 999
Fuel Pressure Relief Procedure 999
Fuel Pump, Replace 999
TBI Unit 1000
Remove 1000
Clean and Inspect 1001
Install 1001
Fuel Meter Body 1002
Remove 1002
Install 1002
Fuel Injector 1003
Remove 1003
Install 1003
Pressure Regulator 1004
Remove 1004
Inspect 1004
Install 1004
Throttle Position Sensor (TPS) 1004
Remove 1004
Install 1004
Idle Air Control (IAC) Valve 1005
Remove 1005
Clean and Inspect 1005
Install 1005
Throttle Body 1006
Remove and Disassemble 1006
Inspect 1006
Assemble and Install 1006
Oil Pressure Switch, Replace 1006
Governor System Repair 1008
Governor Module, Replace 1008
Governor Motor, Replace 1008
Throttle Cables, Install and Adjust 1009
Foot Directional Control Pedal, Check 1010
Ignition System Components Repair 1010
ECM, Replace 1010
Function, Check 1010
Distributor 1010
Remove 1010
Disassemble 1011
Inspect 1011
Assemble 1011
Install 1012
Ignition Timing 1012
Ignition Module Repair 1012
Test For a Fault 1012
Ignition Module, Replace 1013
Sensing Coil 1014
Test 1014
Replace 1014
Ignition Coil 1014
Test 1014
Remove 1015
Install 1015
Sensors Repair 1015
Engine Coolant Temperature (ECT) Sensor, Replace 1015
MAP Sensor Replacement 1015
PCV System Repair 1016
Replace 1016
Wiring Repair 1016
Connectors and Terminals 1016
Procedures for Spark Plugs, Spark Plug Wires, and Boots 1019
Spark Plug Troubleshooting 1020
Wiring Diagrams 1021
Special Tools 1026
tables 935
Table 1 ECM Diagnostic Codes Available 943
Table 2 SCAN Tool Information 945
Table 3 ECT Sensor – Temp vs Resistance 969
Table 4 ECT Sensor – Temp vs Resistance 971
Table 5 ECM Failure 986
Table 6 ECT Sensor – Temperature vs Resistance 991
524158887 2200YRM0612 (12 2003) US EN 1031
toc 1031
Electronic Engine Control 1031
Safety Precautions Maintenance and Repair 1032
General 1035
Description and Operation 1035
General 1035
Electronic Control Module (ECM) 1035
How ECM Begins Operation 1037
Electronic Engine Control 1037
What ECM Does 1037
Distributor 1038
Ignition Module 1038
When the Engine is Being Started 1039
When the Engine is Running 1040
Electronic Control Module (ECM) Corrections 1040
What the ECM Does 1041
Fuel Control Operation 1041
Starting Mode 1041
Clear Excess Fuel (clear flood) Mode 1041
Run Mode 1042
Acceleration Mode 1042
Deceleration Mode 1042
Fuel Cutoff Mode 1042
Fuel System Components 1042
Fuel Pump Electrical Circuit 1042
Throttle Body Injection 1042
Throttle Position (TP) Sensor 1042
Idle Air Control (IAC) Valve 1043
Fuel Injector 1044
Fuel Pressure Regulator 1044
Idle Speed Control 1044
Maximum RPM Control 1044
Governor System 1044
ECM Sensors and Controllers 1045
Manifold Absolute Pressure (MAP) Sensor 1045
Engine Coolant Temperature (ECT) Sensor 1046
Positive Crankcase Ventilation 1046
524158890 4000YRM0521 (03 2006) US EN 1049
toc 1049
Mast 1049
Safety Precautions Maintenance and Repair 1050
General 1053
Description and Operation 1053
Carriages 1053
Mast Mounts 1055
Two-Stage Mast, Limited Free-Lift (LFL) 1056
Description and Operation 1056
Two-Stage Mast, Full Free-Lift (FFL) 1058
Description and Operation 1058
Three-Stage Mast, Full Free-Lift (FFL) 1060
Description and Operation 1060
Four-Stage Mast 1062
Description and Operation 1062
Cylinder Cushion During Lifting Sequence 1066
Cylinder Cushion During Lowering Sequence 1067
524158891 4000YRM0522 (07 2010) US EN 1071
toc 1071
Mast 1071
Safety Precautions Maintenance and Repair 1072
General 1075
Safety Procedures When Working Near Mast 1076
Fork Repair 1078
Remove 1078
Install 1078
Carriages Repair 1080
Standard Carriage, Remove 1080
Hang-On Sideshift Carriage, Remove 1081
Standard Carriage and Hang-On Sideshift Carriage, Repair 1082
Standard Carriage, Install 1083
Hang-On Sideshift Carriage, Install 1084
Integral Sideshift Carriage 1084
Remove 1084
Clean and Inspect 1088
Repair 1089
Install 1090
Mast Repair 1091
Remove 1091
Two-Stage LFL and Two-Stage FFL Masts, Disassemble 1093
Three-Stage FFL Mast 1101
Disassemble 1101
Mast and Chains, Clean and Inspect 1104
Two-Stage LFL and Two-Stage FFL Mast, Assemble 1105
Three-Stage FFL Mast, Assemble 1106
Install 1107
Lift Cylinders Repair 1109
Main Lift Cylinders, Remove 1109
Free-Lift Cylinder, Remove 1109
Cylinders, Disassemble 1110
Two-Stage Full Free-Lift Mast, Right-Hand Main Lift Cylinder 1110
Two-Stage Full Free-Lift Mast, Left-Hand Main Lift Cylinder 1112
Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift 1112
Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift 1113
Two-Stage Full Free-Lift Mast and Three-Stage Full Free-Lift Mas 1114
Clean and Inspect 1115
Cylinders, Assemble 1115
Two-Stage Full Free-Lift Mast, Right-Hand Main Lift Cylinder 1115
Two-Stage Full Free-Lift Mast, Left-Hand Main Lift Cylinder 1116
Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift 1117
Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift 1117
Two-Stage Full Free-Lift Mast and Three-Stage Full Free-Lift Mas 1118
Main Lift Cylinders, Install 1119
Free-Lift Cylinder, Install 1119
Header Hose Arrangements 1120
Two-Stage LFL Mast, New Hose Install 1120
Two-Stage LFL Mast, Adjust Hoses After Installation 1125
Two-Stage FFL Mast, New Hose Install 1125
Two-Stage FFL Mast, Adjust Hoses After Installation 1133
Three-Stage FFL Mast, New Hose Install 1133
Three-Stage FFL Mast, Adjust Hoses After Installation 1144
Header Hose Arrangement 1145
Two-Stage LFL Mast, New Hose Install 1145
Two-Stage LFL Mast, Adjust Hoses After Installation 1150
Two-Stage FFL Mast, New Hose Install 1150
Two-Stage FFL Mast, Adjust Hoses After Installation 1156
Three-Stage FFL Mast, New Hose Install 1156
Three-Stage FFL Mast, Adjust Hoses After Install 1165
Lift and Tilt System Leak Check 1166
Lift Cylinders Leak Check 1166
Tilt Cylinders Leak Check 1166
Tilt Cylinders Adjustment 1167
Lift Chains Adjustment 1169
Mast Adjustment 1171
Carriage Adjustment 1173
Troubleshooting 1174
tables 1071
Table 1 Hook-Type Carriage Chain Adjustment 1169
Table 2 Pin-Type Carriage Chain Adjustment 1170
524158900 8000YRM0707 (06 2009) US EN 1177
toc 1177
Periodic Maintenance 1177
Safety Precautions Maintenance and Repair 1178
General 1183
Serial Number 1183
How to Move Disabled Lift Truck 1183
How to Tow Lift Truck 1183
How to Put Lift Truck on Blocks 1184
How to Raise Drive Tires 1184
How to Raise Steering Tires 1184
Maintenance Schedule 1185
Maintenance Procedures Every 8 Hours or Daily 1194
How to Make Checks With Engine Stopped 1194
Tires and Wheels 1194
Forks 1195
Adjust 1195
Remove 1195
Install 1197
Forks, Mast, and Lift Chains, Inspect 1197
Safety Labels 1198
Operator Restraint System 1198
Steering Column Latch 1198
Fuel, Oil, or Coolant Leaks, Check 1198
Drive Belt 1199
Intake Manifold Rubber Cap 1199
Powershift Transmission Oil Temperature 1199
Powershift Transmission Oil Level 1200
Engine Oil 1200
Hydraulic System 1200
Air Filter 1202
How to Make Checks With Engine Running 1202
Gauges, Indicator Lights, Horn, Fuses, and Relays 1202
Check Engine Light (Mazda and GM LPG Closed Loop with Low-Emissi 1203
Malfunction Indicator Lamp (GM 3 0L Gasoline Engine) 1204
Engine Oil Pressure 1204
Cooling System 1204
Steering System 1205
Service Brakes 1205
Brake Fluid Level 1205
Operation, Check 1205
Parking Brake 1205
Water Separator, Diesel Engine 1206
Drain Water from Water Separator 1206
Fuel Filter, Diesel Engine 1206
Diesel Fuel System, Remove Air 1206
Control Levers and Pedals 1206
Lift System, Operate 1206
Cooling System 1207
Maintenance Procedures Every 250 Hours or 6 Weeks 1208
Air Filter 1208
Drive Belt 1208
Mazda FE and F2 Engines 1208
Fan and Alternator Drive Belt 1208
Timing Belt 1209
GM 3 0L 1209
Mazda XA and HA Diesel Engines 1210
Engine Oil Filter 1210
Brake Fluid 1210
Hydraulic Tank Breather 1210
Battery 1210
Forks 1211
Lift Chains 1211
Lubrication 1211
Wear, Check 1211
Mast 1212
Steering Axle 1212
Fuel System 1212
Engine Speed, Diesel, Mazda XA and HA Engines 1212
Engine Speed, LPG Carburetor, Mazda and GM (Aisan Open-Loop and 1213
Engine Speed, LPG Carburetor, Mazda (Impco) 1213
Engine Speed, LPG Carburetor, GM 3 0L (Impco) 1214
Engine Speed, Mazda Gasoline Carburetor 1215
Hydraulic System 1215
Cooling System, Clean Debris From Radiator Core 1216
Maintenance Procedures Every 500 Hours or 3 Months 1216
Drain Tar From Aisan LPG Regulator 1216
PCV Valve 1216
Maintenance Procedures Every 1000 Hours or 6 Months 1217
Diesel Fuel System 1217
Fuel Filter, Replace 1217
Check Water Sensor 1218
Diesel Fuel System Air Removal 1218
Differential and Drive Axle, Powershift Transmission 1218
Valve Clearance, Check and Adjust 1218
Ignition System 1218
GM 3 0L LPG (IMPCO) 1218
GM 3 0L LPG (Aisan) 1219
Mazda FE and F2 1219
Mazda XA and HA Diesel Engines 1219
Aisan Regulator Pressure/Diaphragm and O-Ring Checks 1220
PCV Valve 1220
Integral Sideshift Carriage, Check Bearings 1220
Control Levers and Pedals 1220
Cooling System, GM 3 0L EPA Compliant Engine 1221
LPG Fuel Filter (IMPCO), GM 3 0L EPA Compliant Engine, Replace 1221
Inspect Engine Electrical System, Connectors, and FCVS Connectio 1222
Maintenance Procedures Every 2000 Hours or Yearly 1222
Hydraulic System 1222
Hydraulic Oil and Filter, Replace 1222
Powershift Transmission Oil and Filter 1222
Replace 1222
Cooling System 1223
Service Brakes 1223
Differential 1224
LPG Fuel Filter, Replace (Pre-2004) 1224
Gasoline Fuel Filter 1224
Fuel Filter, Replace (Aisan LPG System) 1224
LPG Fuel Injector (Aisan Closed-Loop Low Emission System) 1225
Integral Sideshift Carriage, Replace Bearings 1225
Oxygen Sensor, GM 3 0L EPA Compliant Engine 1225
Air Filter Element, GM 3 0L EPA Compliant Engine 1225
Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks 1225
Check Throttle Shaft for Sticking 1226
Inspect Exhaust Manifold and Piping for Leaks 1226
Test LPG/GAS Regulator Pressure 1226
Safety Procedures When Working Near Mast 1227
Hood Latch Check 1229
Lift Chain Adjustments 1230
Lift and Tilt System Leak Check 1233
Lift Cylinder, Leak Check 1233
Tilt Cylinder, Leak Check 1233
Charging Battery 1233
Diesel Engine Fuel Injector Check 1234
Welding Repairs 1234
Overhead Guard Changes 1235
Wheel and Tire Replacement 1235
Solid Rubber Tire, Change GC/GLC040-065RG/TG/ZG Models 1235
Remove and Install Tire on Wheel 1235
Pneumatic Tire, Repair GP/GLP/GDP040-060RG/TG/ZG Models 1236
Remove Wheels From Lift Truck 1236
Remove Wheel From Tire 1236
Remove Tire From Two-Piece Wheel 1237
Remove Tire From Three- and Four-Piece Wheels 1238
Install Wheel on Tire 1239
Install Tire on Three- or Four-Piece Wheels 1239
Install Three-Piece or Four-Piece Wheel in Tire 1240
Install Tire on Two-Piece Wheel 1241
Install Two-Piece Wheel in Tire 1241
Add Air to Pneumatic Tires 1242
Wheels, Install 1242
Dual Drive Wheels, Install 1242
Solid Rubber Tire, Change GP/GLP/GDP040-060RG/TG/ZG Models 1243
Remove Wheel From Tire 1243
Install Wheel in Tire 1245
tables 1177
Table 1 Maintenance Schedule 1186
Table 2 Hook-Type Carriage Chain Adjustment 1231
Table 3 Pin-Type Carriage Chain Adjustment 1231
524158901 8000YRM0708 (01 2011) US EN 1249
toc 1249
Capacities and Specifications 1249
Safety Precautions Maintenance and Repair 1250
Lift Truck Weights 1253
Tire Pressure 1253
Tire Sizes 1254
Capacities 1254
Electrical System 1255
Gasoline/LPG 1255
Diesel 1255
Transmission Oil Pressures 1256
Hydraulic System 1256
Stall Speeds 1257
Engine Specifications 1257
Gasoline/LPG 1257
Diesel 1259
Mast Speeds 1260
Gasoline/LPG Engines (US Models) 1260
Diesel Engines (US Models) 1264
Gasoline/LPG Engines (US Models) 1266
Gasoline/LPG Engines (European Models) 1271
Diesel Engines (European Models) 1275
Torque Specifications 1276
Frame 1276
Brake System 1277
Mast 1277
Steering System 1277
Drive Axle 1277
Transmission and Differential 1277
Engine – Mazda FE and F2 1278
Engine – GM 3 0L 1279
Engine – Mazda XA and HA Diesel 1279
524158902 8000YRM0709 (10 2004) US EN 1283
toc 1283
Diagrams 1283
Safety Precautions Maintenance and Repair 1284
524162461 0600YRM1019 (01 2011) US EN 1349
toc 1349
Mazda XA and HA Diesel Engines 1349
Safety Precautions Maintenance and Repair 1350
General 1355
Description 1355
Engine Removal and Installation 1355
Cylinder Head and Valve Mechanism Repair 1357
Remove 1357
Clean 1357
Inspect and Repair 1358
Cylinder Head 1358
Rocker Shaft Assembly 1358
Valve Guides 1359
Valve Seats 1359
Valves 1360
Valve Springs 1360
Push Rods 1361
Cylinder Head, Assemble 1361
Cylinder Head, Install 1362
Timing Gears Repair 1363
Remove 1363
Clean and Inspect 1363
Install 1364
Camshaft Repair 1365
Remove 1365
Inspect and Repair 1365
Install 1366
Crankshaft and Main Bearings Repair 1366
Remove 1366
Inspect and Repair 1366
Crankshaft 1366
Main Bearings 1367
Install 1367
Piston and Connecting Rods Repair 1368
Remove and Disassemble 1368
Clean 1368
Inspect and Repair 1368
Pistons 1368
Piston Rings 1369
Connecting Rods and Bearings 1369
Assemble and Install 1370
Cylinder Block and Liners Repair 1371
Inspect and Repair 1371
Lubrication System Repair 1373
Oil Pump 1373
Remove 1373
Disassemble 1373
Clean 1373
Inspect 1373
Assemble 1374
Install 1375
Oil Filter Mount 1375
Remove 1375
Install 1375
Oil Cooler 1376
Remove 1376
Clean and Inspect 1376
Install 1376
Cooling System Repair 1376
Thermostat 1376
Remove and Install 1376
Water Pump 1377
Remove 1377
Disassemble 1377
Inspect 1378
Assemble 1378
Install 1379
Fuel System Repair 1380
Description and Operation 1380
Fuel Injection Pump 1380
Remove 1380
Install 1381
Fuel Filter 1382
Filter, Replace 1382
Water Sensor Check 1383
Fuel System Air Removal 1383
Fuel Injectors 1384
Remove and Disassemble 1384
Clean and Inspect 1384
Assemble 1384
Inspect and Adjust 1384
Install 1385
Flywheel and Ring Gear Repair 1385
Flywheel, Remove 1385
Ring Gear, Replace 1385
Flywheel, Install 1386
Flywheel, Remove 1386
Flywheel, Install 1386
Alternator Repair 1387
Starting System Repair 1388
Cold Start Aid 1388
Description and Operation 1388
Glow Plugs, Replace 1388
Glow Plugs, Check 1389
Fuse 1389
Relay and Controller 1389
Checks and Adjustments 1390
Valves, Adjust 1390
Compression Pressure Check 1390
Throttle Linkage, Adjust 1391
Fuel Injection Pump Timing Check 1392
Engine Specifications 1393
Engine Data 1393
Cylinder Head 1393
Camshaft 1394
Crankshaft 1395
Connecting Rods 1396
Cylinder Block 1397
Pistons 1397
Oil Pump 1397
Torque Specifications 1398
Special Tools 1399
Troubleshooting 1401
tables 1349
Table 1 Camshaft Journal Diameters 1365
Table 2 Crankshaft Journal Diameters 1367
Table 3 Piston Diameters 1369
Table 4 Cylinder Liner Diameters 1371
524162462 2200YRM1016 (10 2004) US EN 1409
toc 1409
Electronic Engine Control 1409
Safety Precautions Maintenance and Repair 1410
General 1413
Description and Operation 1413
General 1413
Electronic Control Module (ECM) 1413
Diagnostic Connector 1413
How ECM Begins Operation 1417
Electronic Engine Control 1418
What ECM Does 1418
Distributor 1419
Ignition Module 1420
When Engine Is Being Started 1421
When Engine Is Running 1422
Electronic Control Module (ECM) with Ignition Module Distributor 1423
Fuel Control 1423
Throttle Body Injection (TBI) 1424
Fuel Injectors 1424
Fuel Pressure Regulator 1424
Throttle Position Sensor (TPS) 1425
Idle Air Control (IAC) 1425
GM 4 3L Engine Governor System 1426
GM 3 0L Engine Governor System 1426
Vacuum Ports 1428
Fuel Pump 1428
ECM Sensors and Controllers 1430
Manifold Absolute Pressure (MAP) 1430
Engine Coolant Temperature (ECT) Sensor 1430
524162463 2200YRM1017 (10 2004) US EN 1433
toc 1433
Electronic Engine Control 1433
Safety Precautions Maintenance and Repair 1434
General 1441
Troubleshooting Procedure 1441
How This Section Is Arranged 1441
Where Do I Start? 1441
Visual/Physical Inspection 1441
Knowledge/Tools Required 1441
Damage From Static Discharge (Static Electricity) 1441
Troubleshooting Information 1442
Malfunction Indicator Lamp (MIL) 1442
Reading Diagnostic Trouble Codes (DTC) 1442
Clearing Diagnostic Trouble Codes (DTCs) 1446
ECM Diagnostic Codes Available 1447
Diagnostic Mode 1447
Field Service Mode 1447
ECM Learning Ability 1447
SCAN Tool Information 1448
On-Board Diagnostic (OBD) System Check 1450
Test Description 1450
Troubleshooting Charts 1451
General 1451
Tools and Test Equipment 1452
Presssure Conversion Chart 1453
Troubleshooting Chart Description Summary 1454
A-1 No Malfunction Indicator Lamp 1455
Circuit Description 1455
Diagnostic Aids 1455
Test Description 1455
A-2 No Scan Data, No DTC-12, Malfunction Indicator Lamp ON 1457
Circuit Description 1457
Diagnostic Aids 1457
Test Description 1457
A-3 Engine Cranks but Does Not Run 1459
Circuit Description 1459
Diagnostic Aids 1459
Test Description 1459
A-4 Fuel Injector Circuit 1462
Circuit Description 1462
Test Description 1462
A-5 Fuel Pump Relay Circuit 1464
Circuit Description 1464
Diagnostic Aids 1465
Test Description 1465
A-6 Fuel System Troubleshooting 1467
Circuit Description 1467
Diagnostic Aids 1468
Test Description 1468
Test Description 1470
A-7 Ignition System Troubleshooting 1472
Circuit Description 1472
Diagnostic Aids 1472
Test Description 1472
DTC 14 ECT Sensor Circuit – Low Temp Indicated (Scan Diagnostics 1477
Circuit Description 1477
Diagnostic Aids 1477
Test Description 1478
DTC 15 Engine Coolant Temperature (ECT) Sensor Circuit High Temp 1479
Circuit Description 1479
Diagnostic Aids 1479
Test Description 1479
DTC 21 Throttle Position (TP) Sensor Circuit Signal Voltage High 1481
Circuit Description 1481
Diagnostic Aids 1481
Test Description 1481
DTC 22 Throttle Position (TP) Sensor Circuit Signal Voltage Low 1483
Circuit Description 1483
Diagnostic Aids 1483
Test Description 1483
DTC 31 Engine Governor Circuit 1485
Circuit Description 1485
Diagnostic Aids 1485
Test Description 1485
DTC 33 Manifold Absolute Pressure (MAP) Sensor Circuit Signal Vo 1487
Circuit Description 1487
Diagnostic Aids 1488
Test Description 1488
DTC 34 Manifold Absolute Pressure (MAP) Sensor Circuit Signal Vo 1490
Circuit Description 1490
Diagnostic Aids 1490
Test Description 1490
DTC 41 Electronic Spark Timing (EST) – Open EST Circuit 1492
Circuit Description 1492
Diagnostic Aids 1493
Test Description 1493
DTC 42 EST – Grounded EST Circuit, Open or Grounded Bypass Circu 1494
Circuit Description 1494
Diagnostic Aids 1494
Test Description 1494
DTC 51 Calibration Checksum Failure 1496
Circuit Description 1496
Diagnostic Aids 1496
Test Description 1496
DTC 81 Fuel Pump Relay Driver Circuit High, Low, or Open 1497
Circuit Description 1497
Diagnostic Aids 1498
Test Description 1498
DTC 81 5-Volt Reference Circuit Out of Range 1500
Circuit Description 1500
Diagnostic Aids 1500
Test Description 1500
DTC 81 FPRSENSE Circuit Fault 1502
Circuit Description 1502
Diagnostic Aids 1502
Test Description 1502
Troubleshooting, Poor Operation 1503
General 1503
Make a Careful Visual Check 1503
FAULT: Codes or Performance That Is Abnormal 1504
FAULT: Loss of Diagnostic Trouble Code (DTC) Memory 1504
FAULT: Engine Quits While Driving 1504
Additional Checks 1504
FAULT: Engine Is Difficult to Start 1504
FAULT: Variation in Engine Power When Throttle Is Held Steady 1505
FAULT: Decreased Engine Power 1505
FAULT: Detonation/Spark Knock 1505
FAULT: Engine Momentarily Does Not Increase Power When Throttle 1506
FAULT: One or More Cylinders Do Not Operate Correctly – Engine D 1506
FAULT: Rough Idle or Engine Stalls During Idle 1507
FAULT: Fuel Usage Too High 1507
FAULT: Dieseling 1507
FAULT: Backfire 1508
System Test Charts 1508
General 1508
Engine Coolant Temperature (ECT) Sensor Test 1508
Throttle Position (TP) Sensor Check 1509
Minimum Idle Speed 1509
Adjustment 1509
B-1 – Idle Air Control (IAC) System Check 1510
Circuit Description 1510
Diagnostic Aids 1511
B-2 – Manifold Absolute Pressure (MAP) Sensor Output Test 1512
Circuit Description 1512
Test Description 1512
B-3 – Check Governor System 1514
Governor System Not Operating Correctly 1514
Check Function of Governor System 1514
Check PCV System 1515
Fuel System Components Repair 1515
General 1515
Fuel Pressure Relief Procedure 1515
Fuel Pump Replacement 1515
Throttle Body Injection Unit (TBI) 1516
Remove 1516
Clean and Inspect 1516
Install 1517
Fuel Meter Body 1517
Remove 1517
Install 1520
Fuel Injector 1520
Remove 1520
Install 1521
Pressure Regulator 1521
Remove 1521
Inspect 1521
Install 1521
Throttle Position Sensor (TPS) 1522
Remove 1522
Install 1522
Idle Air Control (IAC) Valve 1522
Remove 1522
Clean and Inspect 1523
Install 1523
Governor System 3 0L Engine Repair 1523
Governor Module, Replace 1523
Governor Motor, Replace 1523
Throttle Cables, Install and Adjust 1523
Foot Directional Control Pedal, Check 1524
Governor System 4 3L Engine Repair 1525
Governor Throttle Drive Assembly 1525
Remove 1525
Inspect 1526
Install 1526
Governor Drive Motor 1526
Remove 1526
Clean and Lubricate 1527
Install 1527
Inspect 1527
Foot Directional Control Pedal, Check 1528
Ignition System Components Repair 1529
ECM Replacement 1529
Function Check 1529
Distributor 1529
Remove 1529
Disassemble 1529
Inspect 1530
Assemble 1530
Install 1530
Firing Order 1531
Ignition Timing 1531
Ignition Module Repair 1531
Test For Fault 1531
Replace 1532
Sensing Coil 1532
Test 1532
Replace 1533
Ignition Coil 1533
Test 1533
Remove 1533
Install 1534
Sensors Repair 1534
Engine Coolant Temperature (ECT) Sensor, Replace 1534
MAP Sensor, Replace 1534
PCV System Repair 1535
Replace 1535
Wiring 1535
Connectors and Terminals 1535
Procedures for Spark Plugs, Spark Plug Wires, and Boots 1538
Wiring Diagram 1538
Spark Plugs Troubleshooting 1542
Special Tools 1544
tables 1433
Table 1 ECM Diagnostic Codes Available 1447
Table 2 Rinda SCAN Tool Information 1448
Table 3 TECH 1 SCAN Tool Information 1448
Table 4 On-Board Diagnostic System Checks 1451
Table 5 Voltage and Pressure Chart 1453
Table 6 Troubleshooting Chart Description Summary 1454
Table 7 No Malfunction Indicator Lamp (GM 3 0L Engine Only) 1456
Table 8 No Scan Data, No DTC-12, Malfunction Indicator Lamp ON 1458
Table 9 Engine Cranks but Does Not Run 1460
Table 10 Fuel Injector Circuit 1462
Table 11 Fuel Pump Relay Circuit 1465
Table 12 A-6A Fuel System Troubleshooting 1468
Table 13 A-6B Fuel system Troubleshooting 1470
Table 14 Ignition System Troubleshooting 1473
Table 15 Engine Coolant Temperature Sensor 1477
Table 16 DTC 14 Engine Coolant Temperature (ECT) Sensor Circuit 1478
Table 17 Engine Coolant Temperature Sensor Table 1480
Table 18 DTC 15 Engine Coolant Temperature (ECT) Sensor Circuit 1480
Table 19 DTC 21 Throttle Position (TP) Sensor Circuit Signal Vo 1482
Table 20 DTC 22 Throttle Position (TP) Sensor Circuit Signal Vo 1484
Table 21 DTC 31 Engine Governor Circuit 1486
Table 22 DTC 33 Manifold Absolute Pressure (MAP) Sensor Circuit 1488
Table 23 DTC 34 Manifold Absolute Pressure (MAP) Sensor Circuit 1491
Table 24 DTC 41 Electronic Spark Timing (EST) – Open EST Circui 1493
Table 25 DTC 42 Electronic Spark Timing (EST) – Grounded EST Ci 1495
Table 26 DTC 51 Calibration Checksum Failure 1497
Table 27 DTC 81 Fuel Pump Relay Driver Circuit High, Low, or Op 1498
Table 28 DTC 81 5 Volt Reference Circuit Out of Range 1501
Table 29 DTC 81 FPRSENSE Circuit Fault 1503
Table 30 ECT Sensor – Temperature vs Resistance 1508
Table 31 Idle Air Control (IAC) System Check 1511
Table 32 Altitude Voltage Chart 1513
Table 33 Manifold Absolute Pressure (MAP) Sensor Output Test 1513
Table 34 Weather-Pack Terminal Repair 1538
Table 35 ECM Connector J1 Identification 1540
Table 36 ECM Connector J2 Identification 1541
524208004 0900YRM1088 (05 2006) US EN 1549
toc 1549
Electronic Controlled LPG/Gasoline Fuel System 1549
Safety Precautions Maintenance and Repair 1550
General 1555
Fuel System Warnings and Cautions 1555
Glossary 1556
Description and Operation of LPG Fuel System 1560
Propane Fuel System 1560
LPG Fuel Tank 1562
Service Line 1562
Fuel Filter 1562
Low Pressure Lock-Off (LPL) 1562
Low Pressure Regulator (LPR) 1563
Air Fuel Mixer 1563
Throttle Control Device 1564
Drive By Cable 1564
Three-Way Catalytic (TWC) Muffler 1565
Electronic Control Module (ECM) 1565
Heated Exhaust Gas Oxygen (HEGO) Sensor 1566
Description and Operation of Gasoline Fuel System 1568
Gasoline Fuel System Throttle Body Injection (TBI), 3 0L Engine 1568
Gasoline Multi-Point Fuel Injection (MPFI) System, 4 3L Only 1568
Gasoline Fuel Storage Tank 1568
Gasoline Fuel Pump 1568
Fuel Filter 1568
Fuel Pressure Regulator, 3 0L Only 1571
Fuel Rail and Pressure Regulator, 4 3L Only 1572
Fuel Injector 1572
Throttle Control Device 1572
Drive By Cable 1572
Three-Way Catalytic Muffler 1573
Electronic Control Module (ECM) 1573
Heated Exhaust Gas Oxygen (HEGO) Sensor 1575
LPG Fuel System Repair 1575
Propane Fuel System Pressure Relief 1575
Propane Fuel System Leak Test 1575
Propane Fuel Filter Replacement 1576
Remove 1576
Install 1576
Low Pressure Lock-Off (LPL) Replacement 1576
Remove 1576
Install 1576
Pressure Trim Valve (PTV) Replacement 1578
Remove 1578
Install 1578
Low Pressure Regulator 1578
Remove 1578
Install 1578
Fuel Trim Valve (FTV) Solenoid Replacement 1579
Remove 1579
Install 1579
Temperature Manifold Absolute Pressure (TMAP) 1579
Remove 1579
Install 1579
Throttle Body Replacement 1581
Remove 1581
Install 1581
Mixer Replacement 1583
Remove 1583
Install 1583
Coolant Hose Replacement 1583
Remove 1583
Install 1584
Vapor Hose Replacement 1584
Remove 1584
Install 1584
Balance Line Hose Replacement 1584
Remove 1584
Install 1584
PTV Hose Replacement 1584
Remove 1584
Install 1584
FTV Hose Replacement 1585
Remove 1585
Install 1585
Throttle Position Sensor (TPS) Replacement 1585
Foot Pedal Position (FPP) Sensor Replacement 1587
Electronic Control Module (ECM) Replacement 1590
Remove 1590
Install 1590
Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement 1590
Remove 1590
Install 1591
Three-Way Catalytic Muffler (TWC) Replacement 1591
Remove 1591
Install 1591
Restricted Exhaust System Diagnosis 1591
Exhaust System Description 1591
Tools Required 1591
Diagnostic Tool 1591
Check at Heated Exhaust Gas Oxygen Sensor (HEGO) 1591
Gasoline Fuel System Repair 1592
Gasoline MPFI and TBI Fuel System Pressure Relief 1592
Gasoline Fuel System Leak Test 1593
Throttle Body Injector (TBI) Assembly Replacement, 3 0L Only 1593
Remove 1593
Install 1593
Throttle Body Assembly Replacement, 3 0L Only 1595
Remove 1595
Install 1595
Throttle Body Assembly Replacement, 4 3L Only 1596
Remove 1596
Install 1596
Fuel Rail Replacement, Gasoline 4 3L Only 1597
Remove 1597
Install 1597
Injector Replacement, Gasoline 4 3L Only 1597
Remove 1597
Install 1597
Injector Replacement, Gasoline 3 0L Only 1599
Remove 1599
Install 1599
Temperature Manifold Absolute Pressure (TMAP) Replacement 1599
Remove 1599
Install 1599
Throttle Position Sensor (TPS) Replacement 1599
Foot Pedal Position (FPP) Sensor Replacement 1602
Electronic Control Module (ECM) Replacement 1605
Remove 1605
Install 1605
Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement 1606
Remove 1606
Install 1606
Three-Way Catalytic Muffler (TWC) Replacement 1606
Remove 1606
Install 1606
Restricted Exhaust System Diagnosis 1606
Exhaust System Description 1606
Tools Required 1606
Diagnostic Tool 1606
Check at Heated Exhaust Gas Oxygen Sensor (HEGO) 1607
LPG System Diagnosis 1607
Fuel System Description 1607
Diagnostic Aids 1608
Tools Required 1608
Duty Cycle Monitoring Tool 1608
Diagnostic Tool 1608
Pressure Gauges 1608
Test Description 1608
Gasoline System Diagnosis 1616
Fuel System Description, 3 0L Only 1616
Fuel System Description, 4 3L Only 1616
Diagnostic Aids 1617
Tools Required 1617
Diagnostic Tool 1617
Test Description 1617
LPG Symptom Diagnosis 1624
Gasoline Symptom Diagnosis 1638
Wire Harness Repair 1649
On Vehicle Service Wiring Harness Repair 1649
Connectors and Terminals 1649
Twisted/Shielded Cable Repair 1650
Twisted Leads Repair 1651
Micro-Pack 1652
Metri-Pack 1652
Remove 1652
Weather-Pack 1654
Weather-Pack Terminal Repair 1655
tables 1549
Table 1 TPS Replacement Procedure 1585
Table 2 FPP Replacement Procedure 1588
Table 3 TPS Replacement Procedure 1600
Table 4 FPP Replacement Procedure 1603
Table 5 LPG Fuel System Diagnosis 1608
Table 6 Fuel Control Diagnosis 1612
Table 7 Gasoline Fuel System Diagnosis, 3 0L Only 1618
Table 8 Gasoline Fuel System Diagnosis, 4 3L Only 1621
Table 9 Preliminary Checks 1624
Table 10 Intermittent 1625
Table 11 No Start 1626
Table 12 Hard Start 1628
Table 13 Cuts Out or Misses 1629
Table 14 Hesitation, Sag, or Stumble 1630
Table 15 Backfire 1631
Table 16 Lack of Power, Sluggishness, or Sponginess 1632
Table 17 Poor Fuel Economy 1633
Table 18 Rough, Unstable, Incorrect Idle, or Stalling 1635
Table 19 Surges or Chuggles 1637
Table 20 Preliminary Checks 1638
Table 21 Intermittent 1639
Table 22 No Start 1640
Table 23 Hard Start 1641
Table 24 Cuts Out or Misses 1642
Table 25 Hesitation, Sag, or Stumble 1643
Table 26 Backfire 1644
Table 27 Lack of Power, Sluggishness, or Sponginess 1645
Table 28 Poor Fuel Economy 1646
Table 29 Rough, Unstable, Incorrect Idle, or Stalling 1647
Table 30 Surges or Chuggles 1648
524208009 2200YRM1090 (04 2005) US EN 1659
toc 1659
Electronic Control Module (ECM) Diagnostic Troubleshooting 1659
Safety Precautions Maintenance and Repair 1660
General 1669
Description of ECM Based Diagnostics 1669
Definition of Terms 1669
Diagnostics Overview of the Spectrum Fuel System 1669
Malfunction Indicator Lamp (MIL) 1669
Spectrum Diagnostic Trouble Codes (DTC) 1670
Using a Laptop Computer to Diagnose the Spectrum System 1670
Installing the Spectrum Diagnostic Software 1670
Connecting a Laptop Computer to the Spectrum System 1670
Diagnostic Communication Error 1671
Diagnostic Trouble Codes 1671
Checking Diagnostic Trouble Codes 1672
Clearing Diagnostic Trouble Codes 1672
DATA Stream 1672
Reading Sensor and Actuator Values 1672
Graphing and Data Logging 1673
Ignition System Test 1674
Disabling Ignition Outputs 1674
Injector Test 1675
Disabling Injectors 1675
Throttle Test 1676
Using a Diagnostic Jumper to Diagnose the ECI System 1677
On-Board Diagnostics System Check/Malfunction Indicator Lamp 1678
Circuit Description 1678
Preliminary and Intermittent Checks 1681
GM 3 0L Wiring Schematics and Connectors 1683
GM 3 0L Diagnostic Trouble Codes 1697
DTC 111 – IAT High Voltage Motorola® TMAP 1697
Circuit Description 1697
Conditions for Setting the DTC 1697
DTC 112 – IAT Low Voltage Motorola® TMAP 1700
Circuit Description 1700
Conditions for Setting the DTC 1700
DTC 113 – IAT Higher Than Expected 1 Motorola® TMAP 1703
Circuit Description 1703
Conditions for Setting the DTC 1703
Diagnostic Aids 1703
DTC 114 – IAT Higher Than Expected 2 Motorola® TMAP 1704
Circuit Description 1704
Conditions for Setting the DTC 1704
Diagnostic Aids 1704
DTC 115 – Oil Pressure Low 1705
Circuit Description 1705
Conditions for Setting the DTC 1705
DTC 121 – ECT Voltage High 1708
Circuit Description 1708
Conditions for Setting the DTC 1709
DTC 122 – ECT Voltage Low 1712
Circuit Description 1712
Conditions for Setting the DTC 1712
DTC 123 – ECT Higher Than Expected 1 1714
Circuit Description 1714
Conditions for Setting the DTC 1714
DTC 124 – ECT Higher Than Expected 2 1716
Circuit Description 1716
Conditions for Setting the DTC 1716
DTC 131 – MAP High Pressure Motorola® TMAP 1718
Circuit Description 1718
Conditions for Setting the DTC 1718
Diagnostic Aids 1718
DTC 132 – MAP Low Voltage Motorola® TMAP 1720
Circuit Description 1720
Conditions for Setting the DTC 1720
DTC 134 – BP High Pressure Motorola® TMAP 1724
Circuit Description 1724
Conditions for Setting the DTC 1724
DTC 135 – BP Low Pressure Motorola® TMAP 1726
Circuit Description 1726
Conditions for Setting the DTC 1726
DTC 142 – Crank Sync Noise 1730
Circuit Description 1730
Conditions for setting the DTC 1730
DTC 143 – Never Crank Synced At Start 1733
Circuit Description 1733
Conditions for Setting the DTC 1733
DTC 144 – Camshaft Sensor Loss 1736
Circuit Description 1736
Conditions for Setting the DTC 1736
DTC 145 – Camshaft Sensor Noise 1739
Circuit Description 1739
Conditions for Setting the DTC 1739
DTC 211 – Closed Loop Multiplier High (LPG) 1742
Circuit Description 1742
Conditions for Setting the DTC 1742
Diagnostic Aids 1742
DTC 212 – HO 2 S Open/Inactive 1744
Circuit Description 1744
Conditions for Setting the DTC 1744
DTC 221 – Closed Loop Multiplier High (Gasoline) 1748
Circuit Description 1748
Conditions for Setting the DTC 1748
Diagnostic Aids 1749
DTC 222 – Closed Loop Multiplier Low (Gasoline) 1750
Circuit Description 1750
Conditions for Setting the DTC 1750
Diagnostic Aids 1750
DTC 224 – Closed Loop Multiplier Low (LPG) 1752
Circuit Description 1752
Conditions for Setting the DTC 1752
Diagnostic Aids 1753
DTC 241 – Adaptive Lean Fault (High Limit-Gasoline) 1754
Circuit Description 1754
Conditions for Setting the DTC 1754
Diagnostic Aids 1755
DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline) 1758
Circuit Description 1758
Conditions for Setting the DTC 1758
Diagnostic Aids 1758
DTC 243 – Adaptive Learn High (LPG) 1760
Circuit Description 1760
Conditions for Setting the DTC 1760
Diagnostic Aids 1760
DTC 244 – Adaptive Learn Low (LPG) 1764
Circuit Description 1764
Conditions for Setting the DTC 1764
Diagnostic Aids 1764
DTC 261 – System Voltage High 1766
Circuit Description 1766
Conditions for Setting the DTC 1766
DTC 262 – System Voltage Low 1768
Circuit Description 1768
Conditions for Setting the DTC 1768
DTC 411 – Injector Driver 1 Open 1771
Circuit Description 1771
Conditions for Setting the DTC 1771
DTC 412 – Injector Driver 1 Shorted 1774
Circuit Description 1774
Conditions for Setting the DTC 1774
DTC 511 – COP Failure 1777
Circuit Description 1777
Conditions for Setting the DTC 1777
DTC 512 – Invalid Interrupt 1779
Circuit Description 1779
Conditions for Setting the DTC 1779
DTC 513 – A/D Loss 1781
Circuit Description 1781
Conditions for Setting the DTC 1781
DTC 514 – RTI 1 Loss 1783
Circuit Description 1783
Conditions for Setting the DTC 1783
DTC 515 – Flash Checksum Invalid 1785
Circuit Description 1785
Conditions for Setting the DTC 1785
DTC 516 – Ram Failure 1787
Circuit Description 1787
Conditions for Setting the DTC 1787
DTC 531 – External 5V Ref Lower Than Expected 1789
Circuit Description 1789
Conditions for Setting the DTC 1789
DTC 532 – External 5V Ref Higher Than Expected 1792
Circuit Description 1792
Conditions for Setting the DTC 1792
DTC 555 – RTI 2 Loss 1794
Circuit Description 1794
Conditions for Setting the DTC 1794
DTC 556 – RTI 3 Loss 1796
Circuit Description 1796
Conditions for Setting the DTC 1796
DTC 611 – FPP High Voltage 1798
Circuit Description 1798
Conditions for Setting the DTC 1798
DTC 612 – FPP Low Voltage 1801
Circuit Description 1801
Conditions for Setting the DTC 1801
DTC 631 – TPS1 Signal Voltage High 1805
Circuit Description 1805
Conditions for Setting the DTC 1805
DTC 632 – TPS1 Signal Voltage Low 1808
Circuit Description 1808
Conditions for Setting the DTC 1808
DTC 638 – Throttle Unable To Close 1810
Circuit Description 1810
Conditions for Setting the DTC 1810
Diagnostic Aids 1810
DTC 651 – Maximum Govern Speed Override 1814
Circuit Description 1814
Conditions for Setting the DTC 1814
Diagnostic Aids 1814
DTC 652 – Fuel Rev Limit 1816
Circuit Description 1816
Conditions for Setting the DTC 1816
Diagnostic Aids 1816
DTC 653 – Spark Rev Limit 1819
Circuit Description 1819
Conditions for Setting the DTC 1819
Diagnostic Aids 1819
GM 4 3L Wiring Schematics and Connectors 1822
GM 4 3L Diagnostic Trouble Codes 1839
DTC 111 – IAT High Voltage Bosch® TMAP 1839
Circuit Description 1839
Conditions for Setting the DTC 1839
DTC 111 – IAT High Voltage Motorola® TMAP 1842
Circuit Description 1842
Conditions for Setting the DTC 1842
DTC 112 – IAT Low Voltage Bosch® TMap 1844
Circuit Description 1844
Conditions for Setting the DTC 1844
DTC 112 – IAT Low Voltage Motorola® TMAP 1847
Circuit Description 1847
Conditions for Setting the DTC 1847
DTC 113 – IAT Higher Than Expected 1 Bosch® TMAP 1850
Circuit Description 1850
Conditions for Setting the DTC 1850
Diagnostic Aids 1850
DTC 113 – IAT Higher Than Expected 1 Motorola® TMAP 1851
Circuit Description 1851
Conditions for Setting the DTC 1851
Diagnostic Aids 1851
DTC 114 – IAT Higher Than Expected 2 Bosch® TMAP€ 1852
Circuit Description 1852
Conditions for Setting the DTC 1852
Diagnostic Aids 1852
DTC 114 – IAT Higher Than Expected 2 Motorola® TMAP 1853
Circuit Description 1853
Conditions for Setting the DTC 1853
Diagnostic Aids 1853
DTC 115 – Oil Pressure Low 1854
Circuit Description 1854
Conditions for Setting the DTC 1854
DTC 121 – ECT Voltage High 1857
Circuit Description 1857
Conditions for Setting the DTC 1858
DTC 122 – ECT Voltage Low 1860
Circuit Description 1860
Conditions for Setting the DTC 1860
DTC 123 – ECT Higher Than Expected 1 1863
Circuit Description 1863
Conditions for Setting the DTC 1863
DTC 124 – ECT Higher Than Expected 2 1865
Circuit Description 1865
Conditions for Setting the DTC 1865
DTC 131 – MAP High Pressure Bosch® TMAP 1866
Circuit Description 1866
Conditions for Setting the DTC 1866
Diagnostic Aids 1866
DTC 131 – MAP High Pressure Motorola® TMAP 1870
Circuit Description 1870
Conditions for Setting the DTC 1870
Diagnostic Aids 1870
DTC 132 – MAP Low Voltage Bosch® TMAP 1873
Circuit Description 1873
Conditions for Setting the DTC 1873
DTC 132 – MAP Low Voltage Motorola® TMAP 1876
Circuit Description 1876
Conditions for Setting the DTC 1876
DTC 134 – BP High Pressure Bosch® TMAP 1880
Circuit Description 1880
Conditions for Setting the DTC 1880
DTC 134 – BP High Pressure Motorola® TMAP 1882
Circuit Description 1882
Conditions for Setting the DTC 1882
DTC 135 – BP Low Pressure Bosch® TMAP 1884
Circuit Description 1884
Conditions for Setting the DTC 1884
DTC 135 – BP Low Pressure Motorola® TMAP 1888
Circuit Description 1888
Conditions for Setting the DTC 1888
DTC 142 – Crank Sync Noise 1892
Circuit Description 1892
Conditions for setting the DTC 1892
DTC 143 – Never Crank Synced At Start 1895
Circuit Description 1895
Conditions for Setting the DTC 1895
DTC 144 – Camshaft Sensor Loss 1898
Circuit Description 1898
Conditions for Setting the DTC 1898
DTC 145 – Camshaft Sensor Noise 1901
Circuit Description 1901
Conditions for Setting the DTC 1901
DTC 211 – Closed Loop Multiplier High (LPG) 1904
Circuit Description 1904
Conditions for Setting the DTC 1904
Diagnostic Aids 1904
DTC 212 – HO 2 S Open/Inactive 1906
Circuit Description 1906
Conditions for Setting the DTC 1906
DTC 221 – Closed Loop Multiplier High (Gasoline) 1910
Circuit Description 1910
Conditions for Setting the DTC 1910
Diagnostic Aids 1910
DTC 222 – Closed Loop Multiplier Low (Gasoline) 1912
Circuit Description 1912
Conditions for Setting the DTC 1912
Diagnostic Aids 1913
DTC 224 – Closed Loop Multiplier Low (LPG) 1914
Circuit Description 1914
Conditions for Setting the DTC 1914
Diagnostic Aids 1915
DTC 241 – Adaptive Lean Fault (High Limit-Gasoline) 1916
Circuit Description 1916
Conditions for Setting the DTC 1916
Diagnostic Aids 1917
DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline) 1920
Circuit Description 1920
Conditions for Setting the DTC 1920
Diagnostic Aids 1921
DTC 243 – Adaptive Learn High (LPG) 1923
Circuit Description 1923
Conditions for Setting the DTC 1923
Diagnostic Aids 1924
DTC 244 – Adaptive Learn Low (LPG) 1926
Circuit Description 1926
Conditions for Setting the DTC 1926
Diagnostic Aids 1927
DTC 261 – System Voltage High 1928
Circuit Description 1928
Conditions for Setting the DTC 1928
DTC 262 – System Voltage Low 1930
Circuit Description 1930
Conditions for Setting the DTC 1930
DTC 511 – COP Failure 1933
Circuit Description 1933
Conditions for Setting the DTC 1933
DTC 512 – Invalid Interrupt 1935
Circuit Description 1935
Conditions for Setting the DTC 1935
DTC 513 – A/D Loss 1937
Circuit Description 1937
Conditions for Setting the DTC 1937
DTC 514 – RTI 1 Loss 1939
Circuit Description 1939
Conditions for Setting the DTC 1939
DTC 515 – Flash Checksum Invalid 1941
Circuit Description 1941
Conditions for Setting the DTC 1941
DTC 516 – Ram Failure 1943
Circuit Description 1943
Conditions for Setting the DTC 1943
DTC 531 – External 5V Ref Lower Than Expected 1945
Circuit Description 1945
Conditions for Setting the DTC 1945
DTC 532 – External 5V Ref Higher Than Expected 1948
Circuit Description 1948
Conditions for Setting the DTC 1948
DTC 555 – RTI 2 Loss 1950
Circuit Description 1950
Conditions for Setting the DTC 1950
DTC 556 – RTI 3 Loss 1952
Circuit Description 1952
Conditions for Setting the DTC 1952
DTC 611 – FPP High Voltage 1954
Circuit Description 1954
Conditions for Setting the DTC 1954
DTC 612 – FPP Low Voltage 1958
Circuit Description 1958
Conditions for Setting the DTC 1958
DTC 631 – TPS1 Signal Voltage High 1962
Circuit Description 1962
Conditions for Setting the DTC 1962
DTC 632 – TPS1 Signal Voltage Low 1965
Circuit Description 1965
Conditions for Setting the DTC 1965
DTC 638 – Throttle Unable To Close 1968
Circuit Description 1968
Conditions for Setting the DTC 1968
Diagnostic Aids 1969
DTC 651 – Maximum Govern Speed Override 1971
Circuit Description 1971
Conditions for Setting the DTC 1971
Diagnostic Aids 1971
DTC 652 – Fuel Rev Limit 1974
Circuit Description 1974
Conditions for Setting the DTC 1974
Diagnostic Aids 1974
DTC 653 – Spark Rev Limit 1976
Circuit Description 1976
Conditions for Setting the DTC 1976
Diagnostic Aids 1976
Wire Harness Repair 1979
On Vehicle Service Wiring Harness Repair 1979
Connectors and Terminals 1979
Twisted/Shielded Cable Repair 1980
Twisted Leads Repair 1981
Micro-Pack 1982
Metri-Pack 1982
Remove 1982
Weather-Pack 1984
Weather-Pack Terminal Repair 1984
tables 1659
Table 1 OBD System Check 1679
Table 2 Preliminary Checks 1681
Table 3 Intermittent Checks 1682
Table 4 Communication Port C002 1683
Table 5 Coil Connector C003 1683
Table 6 Fuel System Interface C004 1683
Table 7 Oil Pressure Connector C005 1684
Table 8 Distributor Connector C006 1684
Table 9 Magnetic Pickup Connector C007 1684
Table 10 Heated Oxygen Sensor C008 1684
Table 11 Throttle Position Sensor Connector C009 1685
Table 12 Foot Pedal Position Connector C010 1685
Table 13 Governor Motor Connector C011 1685
Table 14 TMAP Connector C012 1685
Table 15 Starter Solenoid C013 1686
Table 16 Engine Coolant Temperature C014 1686
Table 17 Battery Connector C015 1686
Table 18 Alternator Connection C016 1686
Table 19 Battery Connector C017 1686
Table 20 Alternator Connector C018 1687
Table 21 Instrument Panel Connector C019 1687
Table 22 Instrument Panel Connector C020 1687
Table 23 Instrument Panel Connector C021 1688
Table 24 Fuel Trim Valve Connector C022 1688
Table 25 Fuel Lockoff Connector C023 1688
Table 26 Pressure Trim Valve Connector C024 1689
Table 27 Throttle Body Injector Connector C025 1689
Table 28 Relay and Fuse Center 1689
Table 29 DTC 111 – IAT Voltage High (Motorola® TMAP) 1698
Table 30 DTC 112 – IAT Low Voltage (Motorola® TMAP) 1701
Table 31 DTC 115 – Oil Pressure Low 1706
Table 32 Temperature Resistance 1708
Table 33 DTC 121 – ECT VOLTAGE HIGH 1709
Table 34 DTC 122 – ECT Voltage Low 1713
Table 35 DTC 123 – ECT Higher Than Expected 1 1715
Table 36 DTC 124 – ECT Higher Than Expected 2 1717
Table 37 DTC 131 – MAP HIGH PRESSURE (Motorola® TMAP) 1719
Table 38 DTC 132 – MAP Low Voltage (Motorola® TMAP) 1721
Table 39 DTC 134 – BP High Pressure (Motorola® TMAP) 1725
Table 40 DTC 135 – BP Low Pressure (Motorola® TMAP) 1726
Table 41 DTC 142 – Crank Sync Noise 1730
Table 42 DTC 143 – Never Crank Synced At Start 1733
Table 43 DTC 144 – Camshaft Sensor Loss 1736
Table 44 DTC 145 – Camshaft Sensor Noise 1739
Table 45 DTC 211 – Closed Loop Multiplier High (LPG) 1743
Table 46 DTC 212 – HO 2 S Open/Inactive 1745
Table 47 DTC 221 – Closed Loop Multiplier High (Gasoline) 1749
Table 48 DTC 222 – Closed Loop Multiplier Low (Gasoline) 1752
Table 49 DTC 224 – Closed Loop Multiplier Low (LPG) 1754
Table 50 DTC 241 – Adaptive Lean Fault (High Limit-Gasoline) 1756
Table 51 DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline) 1759
Table 52 DTC 243 – Adaptive Learn High (LPG) 1762
Table 53 DTC 244 – Adaptive Learn Low (LPG) 1765
Table 54 DTC 261 – System Voltage High 1767
Table 55 DTC 262 – System Voltage Low 1769
Table 56 DTC 411 – Injector Driver 1 Open 1772
Table 57 DTC 412 – Injector Driver 1 Shorted 1775
Table 58 DTC 511 – COP Failure 1778
Table 59 DTC 512 – Invalid Interrupt 1780
Table 60 DTC 513 – A/D Loss 1782
Table 61 DTC 514 – RTI 1 Loss 1784
Table 62 DTC 515 – Flash Checksum Invalid 1786
Table 63 DTC 516 – Ram Failure 1788
Table 64 DTC 531 – External 5V Ref Lower Than Expected 1790
Table 65 DTC 532 – External 5 V Ref Higher Than Expected 1792
Table 66 DTC 555 – RTI 2 Loss 1795
Table 67 DTC 556 – RTI 3 Loss 1797
Table 68 DTC 611 – FPP High Voltage 1798
Table 69 DTC 612 – FPP Low Voltage 1802
Table 70 DTC 631 – TPS1 Signal Voltage High 1806
Table 71 DTC 632 – TPS1 Signal Voltage Low 1809
Table 72 DTC 638 – Throttle Unable To Close 1811
Table 73 DTC 651 – Maximum Govern Speed Override 1815
Table 74 DTC 652 – Fuel Rev Limit 1817
Table 75 DTC 653 – Spark Rev Limit 1820
Table 76 Communication Port C002 1822
Table 77 Injector Connector C003 1822
Table 78 Injector Connector C004 1822
Table 79 Oil Pressure Connector C005 1823
Table 80 Throttle Position Sensor 1 Connector C006 1823
Table 81 Foot Pedal Position Connector C006A 1823
Table 82 Coil Connector C007 1823
Table 83 Module Connector C008 1824
Table 84 Crank Sensor Connector C009 1824
Table 85 EGO Sensor Connector C010 1824
Table 86 Cam Connector C011 1824
Table 87 Throttle Connector C012 1825
Table 88 Bosch TMAP Connector C013 (Gasoline Fuel System Only) 1825
Table 89 Motorola TMAP Connector C013 (LPG Fuel System Only) 1825
Table 90 Starter Solenoid Connector C014 1825
Table 91 ECT Connector C015 1826
Table 92 Starter Relay C016 1826
Table 93 Power Relay C017 1826
Table 94 Fuel Pump Relay C018 1826
Table 95 Battery Connector C019 1826
Table 96 Alternator Connector C020 1826
Table 97 Alternator Connector C021 1827
Table 98 Instrument Panel Connector C022 1827
Table 99 Instrument Panel Connector C023 1827
Table 100 Instrument Panel Connector C024 1828
Table 101 Fuel Trim Valve Connector C025 1828
Table 102 Fuel Lockoff Connector C026 1828
Table 103 Pressure Trim Valve Connector C027 1829
Table 104 Injector 1 Connector C028 1829
Table 105 Injector 2 Connector C029 1829
Table 106 Injector 3 Connector C030 1829
Table 107 Injector 4 Connector C031 1830
Table 108 Injector 5 Connector C032 1830
Table 109 Injector 6 Connector C033 1830
Table 110 Relay and Fuse Center 1831
Table 111 DTC 111 – IAT Voltage High (Bosch® TMAP) 1840
Table 112 DTC 111 – IAT Voltage High (Motorola® TMAP) 1843
Table 113 DTC 112 – IAT Low Voltage (Bosch® TMAP) 1845
Table 114 DTC 112 – IAT Low Voltage (Motorola® TMAP) 1848
Table 115 DTC 115 – Oil Pressure Low 1855
Table 116 Temperature Resistance 1857
Table 117 DTC 121 – ECT VOLTAGE HIGH 1858
Table 118 DTC 122 – ECT Voltage Low 1861
Table 119 DTC 123 – ECT Higher Than Expected 1 1864
Table 120 DTC 124 – ECT Higher Than Expected 2 1866
Table 121 DTC 131 – MAP High Pressure (Bosch® TMAP) 1867
Table 122 DTC 131 – MAP HIGH PRESSURE (Motorola® TMAP) 1871
Table 123 DTC 132 – MAP Low Voltage (Bosch® TMAP) 1874
Table 124 DTC 132 – MAP Low Voltage (Motorola® TMAP) 1877
Table 125 DTC 134 – BP High Pressure (Bosch® TMAP) 1881
Table 126 DTC 134 – BP High Pressure (Motorola® TMAP) 1883
Table 127 DTC 135 – BP Low Pressure (Bosch® TMAP) 1884
Table 128 DTC 135 – BP Low Pressure (Motorola® TMAP) 1888
Table 129 DTC 142 – Crank Sync Noise 1892
Table 130 DTC 143 – Never Crank Synced At Start 1895
Table 131 DTC 144 – Camshaft Sensor Loss 1898
Table 132 DTC 145 – Camshaft Sensor Noise 1901
Table 133 DTC 211 – Closed Loop Multiplier High (LPG) 1905
Table 134 DTC 212 – HO 2 S Open/Inactive 1907
Table 135 DTC 221 – Closed Loop Multiplier High (Gasoline) 1911
Table 136 DTC 222 – Closed Loop Multiplier Low (Gasoline) 1914
Table 137 DTC 224 – Closed Loop Multiplier Low (LPG) 1916
Table 138 DTC 241 – Adaptive Lean Fault (High Limit-Gasoline) 1918
Table 139 DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline) 1921
Table 140 DTC 243 – Adaptive Learn High (LPG) 1924
Table 141 DTC 244 – Adaptive Learn Low (LPG) 1927
Table 142 DTC 261 – System Voltage High 1929
Table 143 DTC 262 – System Voltage Low 1931
Table 144 DTC 511 – COP Failure 1934
Table 145 DTC 512 – Invalid Interrupt 1936
Table 146 DTC 513 – A/D Loss 1938
Table 147 DTC 514 – RTI 1 Loss 1940
Table 148 DTC 515 – Flash Checksum Invalid 1942
Table 149 DTC 516 – Ram Failure 1944
Table 150 DTC 531 – External 5V Ref Lower Than Expected 1946
Table 151 DTC 532 – External 5 V Ref Higher Than Expected 1948
Table 152 DTC 555 – RTI 2 Loss 1951
Table 153 DTC 556 – RTI 3 Loss 1953
Table 154 DTC 611 – FPP High Voltage 1955
Table 155 DTC 612 – FPP Low Voltage 1959
Table 156 DTC 631 – TPS1 Signal Voltage High 1963
Table 157 DTC 632 – TPS1 Signal Voltage Low 1966
Table 158 DTC 638 – Throttle Unable To Close 1969
Table 159 DTC 651 – Maximum Govern Speed Override 1972
Table 160 DTC 652 – Fuel Rev Limit 1975
Table 161 DTC 653 – Spark Rev Limit 1977
524214123 2200YRM1104 (03 2004) US EN 1989
toc 1989
Electrical System 1989
Safety Precautions Maintenance and Repair 1990
Ignition System 1993
General 1993
Ignition Timing Adjustment 1993
Spark Plugs Check 1993
Spark Plug Wires Check 1994
Distributor Repair 1994
Remove 1994
Disassemble 1994
Inspect 1995
Assemble 1995
Install 1996
Ignition Coil Check 1996
Primary Coil Winding 1996
Secondary Coil Winding 1996
Starter Repair 1997
General 1997
Remove 1997
No-Load Test 1998
Magnetic Switch Test 1999
Pull-Out Test 1999
Holding Coil Test 1999
Return Test 1999
Inspection of the Pinion Movement 1999
Disassemble 2000
Inspect 2001
Armature 2001
Brush and Brush Holder 2002
Magnetic Switch Check 2002
Assemble 2003
Alternator Repair 2004
General 2004
Charging System Inspection 2004
Output Current Check 2005
No-Load Adjusted Voltage Check 2005
Remove and Disassemble 2005
Inspection 2007
Stator Coil Check 2007
Rotor Check 2007
Rectifier Check 2008
Brushes and Springs 2008
Bearings Inspection 2008
Assemble and Install 2009
Troubleshooting 2009
Battery and Related Parts 2009
Magnetic Switch and Related Parts 2010
tables 1989
Table 1 Engine Specification Table 1993
Table 2 Spark Plug Wire Table 1994
Table 3 Starter Specifications 1997
Table 4 Problem Diagnosis Chart 1998
Table 5 Rectifier Check Table 2008
524214124 0900YRM1089 (04 2004) US EN 2015
toc 2015
Gasoline Fuel System 2015
Safety Precautions Maintenance and Repair 2016
General 2023
Description of Operation 2023
Intake-Air System 2024
Throttle Body 2025
Idle Air Control (IAC) Valve 2025
Electronic Governor 2025
Fuel System 2027
Fuel Injector 2028
Pressure Regulator 2029
Exhaust System 2029
Three Way Catalytic Converter (TWC) 2031
Control System 2031
Intake Air Temperature (IAT) Sensor 2033
Mass Air Flow (MAF) Sensor 2034
Throttle Position (TP) Sensor 2035
Camshaft Position (CMP) Sensor 2036
Engine Coolant Temperature (ECT) Sensor 2037
Boost Sensor 2038
Heated Oxygen Sensor (HO 2 S) 2039
Electronic Governor Sensor 2040
Engine Control Unit (ECU) 2041
Diagnosis System 2043
Service Code Check 2043
Procedure After the Failure Correction 2043
Service Code P0102 MAF Sensor Signals: Too Low Input Voltage to 2046
Failure Detection Condition 2046
Fail/Safe 2046
Possible Sources 2046
Service Code P0103 MAF Sensor Signals: Too High Input Voltage to 2047
Failure Detection Condition 2047
Fail/Safe 2047
Possible Sources 2047
Service Code P0112 IAT Sensor Signals: Too Low Input Voltage to 2048
Failure Detection Condition 2048
Fail/Safe 2048
Possible Sources 2048
Service Code P0113 IAT Sensor Signals: Too High Input Voltage to 2049
Failure Detection Condition 2049
Fail/Safe 2049
Possible Sources 2049
Service Code P0117 ECT Sensor Signals: Too Low Input Voltage to 2050
Failure Detection Condition 2050
Fail/Safe 2050
Possible Sources 2050
Service Code P0118 ECT Sensor Signals: Too High Input Voltage to 2051
Failure Detection Condition 2051
Fail/Safe 2051
Possible Sources 2051
Service Code P0122 TP Sensor Signals: Too Low Input Voltage to E 2052
Failure Detection Condition 2052
Fail/Safe 2052
Possible Sources 2052
Service Code P0123 TP Sensor Signals: Too High Input Voltage to 2053
Failure Detection Condition 2053
Fail/Safe 2053
Possible Sources 2053
Service Code P0131 HO 2 S Signals: Too Low Input Voltage to ECU 2054
Failure Detection Condition 2054
Fail/Safe 2054
Possible Sources 2054
Service Code P0132 HO 2 S Signals: Too High Input Voltage to ECU 2055
Failure Detection Conditions 2055
Fail/Safe 2055
Possible Sources 2055
Service Code P0134 HO 2 S Signals: Inactive 2056
Failure Detection Condition 2056
Fail/Safe 2056
Possible Sources 2056
Service Code P0171 Fuel Injection Control System: A/F Ratio Lean 2060
Failure Detection Condition 2060
Possible Sources 2060
Service Code P0172 Fuel Injection Control System: A/F Rich 2064
Failure Detection Condition 2064
Possible Sources 2064
Service Code P0340 CMP Sensor Signals 2066
Failure Detection Condition 2066
Fail/Safe 2066
Possible sources 2066
Service Code P1504 IAC System 2067
Failure Detection Condition 2067
Fail/Safe 2067
Possible Sources 2067
Service Code P1562 Battery Backup Power Supply 2068
Failure Detection Condition 2068
Possible Sources 2068
Service Code P1608 ECU Internal Circuit Breakage 2068
Failure Detection Condition 2068
Possible Sources 2068
Data Monitor 2069
Data Monitor Check 2069
Freeze Frame Data 2071
Simulation Check 2071
Drive Cycle 2072
Pending Code 2073
Engine Tune-up 2073
Engine Tune-Up Preparation 2073
Idle Speed Adjustment 2073
Idle-Up Speed Check 2073
Idle Mixture Check 2074
Intake-Air System 2074
Intake-Air System Manifold Vacuum Check 2074
Throttle Body 2074
Remove 2076
Install 2076
Electronic Governor 2076
Resistance Check 2076
Remove 2076
Install 2076
Intake-Air Control (IAC) Valve 2077
Resistance Check 2077
Remove 2077
Install 2077
Intake Manifold 2077
Remove 2077
Install 2078
Fuel System 2078
Before Repair Procedure 2078
Fuel Line Safety Procedure 2078
After Repair Procedure 2079
Fuel Hose, Install 2079
Fuel Leakage Check 2080
Fuel Line Pressure Check 2080
Fuel Injector 2081
Remove 2081
Install 2082
Resistance, Inspect 2082
Fuel Leakage Test 2082
Volume Test 2083
Pressure Regulator 2083
Remove 2083
Install 2084
Operation Check 2084
Exhaust System 2084
Exhaust System, Inspect 2084
Three Way Catalytic (TWC) Converter 2084
Remove and Install 2084
Exhaust Manifold 2084
Remove 2084
Install 2086
Positive Crankcase Ventilation (PCV) Valve 2086
Remove 2086
Inspect 2086
Install 2086
Control System 2086
Engine Control Unit (ECU) 2086
Remove 2086
Install 2087
ECU, Inspect 2087
Using a Voltmeter 2087
Using an Oscilloscope (Reference) 2090
Intake Air Temperature (IAT) Sensor 2093
Remove 2093
Inspect 2093
Install 2093
Mass Air Flow (MAF) Sensor 2093
Inspect 2093
Voltage Check 2093
Remove 2094
Install 2094
Throttle Position (TP) Sensor 2094
Resistance Check 2094
TP Sensor, Adjust 2094
Remove 2095
Install 2095
Engine Coolant Temperature (ECT) Sensor 2095
Resistance Check 2095
Remove 2096
Install 2096
Camshaft Position (CMP) Sensor 2096
Voltage Check 2096
Heated Oxygen Sensor (HO 2 S) 2097
Voltage Check 2097
Heater Resistance Check 2097
Boost Sensor 2097
Inspect 2097
Remove 2098
Install 2098
Electronic Governor Sensor Check 2098
Troubleshooting 2099
Intermittent Concern Troubleshooting 2099
Vibration Method 2099
Inspection Method for Switch Connectors or Wires 2099
Inspection Method for Sensor Connectors or Wires 2099
Inspection Method for Sensors 2100
Inspection Method for Actuators or Relays 2100
Water Sprinkling Method 2100
Symptom Diagnostics 2100
Engine Control System Operation Inspection 2104
Input Signal System Investigation Procedure 2104
Finding Unusual Signals 2104
Locating the Source of Unusual Signals 2104
Investigate the Input Signal System for Variable Resistance Type 2104
Investigate the Standard Power Supply System for Variable Resist 2105
Investigate the Ground (GND) System for Variable Resistance Type 2105
Investigate the Input Signal System for Variable Resistance Type 2105
Investigate the Electrical Supply System for Variable Resistance 2106
Investigate the Ground (GND) System for Variable Resistance Type 2106
Investigate the Input Signal System for Thermistor Type 2106
Investigate the Ground (GND) System for Thermistor Type 2106
Technical Data 2107
tables 2015
Table 1 Specifications 2024
Table 2 Specifications 2028
Table 3 Specifications 2029
Table 4 Specifications 2031
Table 5 Specifications 2031
Table 6 Engine Control Unit (ECU) Functions 2041
Table 7 Engine Control System Relation 2042
Table 8 Service Codes 2044
Table 9 Diagnosis Procedure 2057
Table 10 Diagnosis Procedure 2060
Table 11 Diagnosis Procedure 2064
Table 12 Monitor Item Chart 2069
Table 13 Freeze Frame Data Monitor Chart 2071
Table 14 Simulation Item Chart 2071
Table 15 Drive Cycle Chart 2073
Table 16 Specification 2073
Table 17 PCV Valve Specifications 2086
Table 18 ECU Terminal Voltage (Reference) 2088
Table 19 SGT Signal 2090
Table 20 HO 2 S Signal 2091
Table 21 IGT Signal 2091
Table 22 Fuel Injection Control Signal 2092
Table 23 IAC Signal 2092
Table 24 Specification 2093
Table 25 Closed Throttle Position Specifications 2095
Table 26 Specifications 2096
Table 27 Specifications 2097
Table 28 Specifications 2098
Table 29 Troubleshooting 2101
Table 30 List of Possible Causes 2103
Table 31 Gasoline Fuel Systems Technical Data 2107
524217573 2200YRM1092 (04 2005) US EN 2111
toc 2111
Governor Electronic Control Module (ECM) Diagnostic Troubleshoot 2111
Safety Precautions Maintenance and Repair 2112
General 2117
Description of ECM Based Diagnostics 2117
Definition of Terms 2117
Diagnostics Overview of the Spectrum System 2117
Malfunction Indicator Lamp (MIL) 2117
Spectrum Diagnostic Trouble Codes (DTC) 2118
Using a Laptop Computer to Diagnose the Spectrum System 2118
Installing the Spectrum Diagnostic Software 2118
Connecting a Laptop Computer to the Spectrum System 2118
Diagnostic Trouble Codes 2119
Checking Diagnostic Trouble Codes 2119
Clearing Diagnostic Trouble Codes 2119
DATA Stream 2120
Reading Sensor and Actuator Values 2120
Graphing and Data Logging 2121
Throttle Test 2122
Using a Diagnostic Jumper to Diagnose the ECM System 2122
On-Board Diagnostics System Check/Malfunction Indicator Lamp 2123
Circuit Description 2123
Preliminary and Intermittent Checks 2126
DTC 115 – Oil Pressure Low 2128
Circuit Description 2128
Conditions for Setting the DTC 2128
DTC 121 – ECT Voltage High 2131
Circuit Description 2131
Conditions for Setting the DTC 2131
DTC 122 – ECT Low Voltage 2134
Circuit Description 2134
Conditions for Setting the DTC 2134
DTC 123 – ECT Higher Than Expected 1 2137
Circuit Description 2137
Conditions for Setting the DTC 2137
DTC 131 – MAP High Pressure 2139
Circuit Description 2139
Conditions for Setting the DTC 2139
Diagnostic Aids 2139
DTC 132 – MAP Low Voltage 2142
Circuit Description 2142
Conditions for Setting the DTC 2142
DTC 134 – BP High Pressure 2146
Circuit Description 2146
Conditions for Setting the DTC 2146
DTC 135 – BP Low Pressure 2148
Circuit Description 2148
Conditions for Setting the DTC 2148
DTC 261 – System Voltage Low 2152
Circuit Description 2152
Conditions for Setting the DTC 2152
DTC 262 – System Voltage High 2154
Circuit Description 2154
Conditions for Setting the DTC 2154
DTC 511 – COP Failure 2156
Circuit Description 2156
Conditions for Setting the DTC 2156
DTC 512 – Invalid Interrupt 2158
Circuit Description 2158
Conditions for Setting the DTC 2158
DTC 513 – A/D Loss 2160
Circuit Description 2160
Conditions for Setting the DTC 2160
DTC 514 – RTI 1 Loss 2162
Circuit Description 2162
Conditions for Setting the DTC 2162
DTC 515 – Flash Checksum Invalid 2164
Circuit Description 2164
Conditions for Setting the DTC 2164
DTC 516 – Ram Failure 2166
Circuit Description 2166
Conditions for Setting the DTC 2166
DTC 531 – External 5V Ref Lower Than Expected 2168
Circuit Description 2168
Conditions for Setting the DTC 2168
DTC 532 – External 5V Ref Higher Than Expected 2170
Circuit Description 2170
Conditions for Setting the DTC 2170
DTC 555 – RTI 2 Loss 2172
Circuit Description 2172
Conditions for Setting the DTC 2172
DTC 556 – RTI 3 Loss 2174
Circuit Description 2174
Conditions for Setting the DTC 2174
DTC 611 – FPP High Voltage 2176
Circuit Description 2176
Conditions for Setting the DTC 2176
DTC 612 – FPP Low Voltage 2180
Circuit Description 2180
Conditions for Setting the DTC 2180
DTC 631 – TPS1 Signal Voltage High 2184
Circuit Description 2184
Conditions for Setting the DTC 2184
DTC 632 – TPS1 Signal Voltage Low 2187
Circuit Description 2187
Conditions for Setting the DTC 2187
DTC 633 – TPS2 Signal Voltage High 2190
Circuit Description 2190
Conditions for Setting the DTC 2190
DTC 634 – TPS2 Signal Voltage Low 2193
Circuit Description 2193
Conditions for Setting the DTC 2193
DTC 635 – TPS1 Higher Than TPS2 2196
Circuit Description 2196
Conditions for Setting the DTC 2196
DTC 636 – TPS1 Lower Than TPS2 2199
Circuit Description 2199
Conditions for Setting the DTC 2199
DTC 637 – Throttle Unable To Open 2202
Circuit Description 2202
Conditions for Setting the DTC 2202
DTC 638 – Throttle Unable To Close 2205
Circuit Description 2205
Conditions for Setting the DTC 2205
DTC 652 – Rev Limit 2208
Circuit Description 2208
Conditions for Setting the DTC 2208
DTC 653 – Rev Limit 2210
Circuit Description 2210
Conditions for Setting the DTC 2210
DTC 712 – External Fault Input Low 2213
Circuit Description 2213
Conditions for Setting the DTC 2213
Diagnostic Aids 2213
Wire Harness Repair 2214
On Vehicle Service Wiring Harness Repair 2214
Connectors and Terminals 2214
Twisted/Shielded Cable Repair 2215
Twisted Leads Repair 2216
Micro-Pack 2217
Metri-Pack 2217
Remove 2217
Weather-Pack 2219
Weather-Pack Terminal Repair 2219
tables 2111
Table 1 OBD System Check 2124
Table 2 Preliminary Checks 2126
Table 3 Intermittent Checks 2127
Table 4 DTC 115 – Oil Pressure Low 2129
Table 5 Temperature Resistance 2131
Table 6 DTC 121 – ECT Voltage High 2132
Table 7 DTC 122 – ECT Low Voltage 2135
Table 8 DTC 123 – ECT Higher Than Expected 1 2138
Table 9 DTC 131 – MAP High Pressure 2140
Table 10 DTC 132 – MAP Low Voltage 2142
Table 11 DTC 134 – BP High Pressure 2147
Table 12 DTC 135 – BP Low Pressure 2148
Table 13 DTC 261 – System Voltage Low 2152
Table 14 DTC 262 – System Voltage High 2155
Table 15 DTC 511 – COP Failure 2157
Table 16 DTC 512 – Invalid Interrupt 2159
Table 17 DTC 513 – A/D Loss 2161
Table 18 DTC 514 – RTI 1 Loss 2163
Table 19 DTC 515 – Flash Checksum Invalid 2165
Table 20 DTC 516 – Ram Failure 2167
Table 21 DTC 531 – External 5V Ref Lower Than Expected 2168
Table 22 DTC 532 – External 5 V Ref Higher Than Expected 2170
Table 23 DTC 555 – RTI 2 Loss 2173
Table 24 DTC 556 – RTI 3 Loss 2175
Table 25 DTC 611 – FPP High Voltage 2177
Table 26 DTC 612 – FPP Low Voltage 2181
Table 27 DTC 631 – TPS1 Signal Voltage High 2185
Table 28 DTC 632 – TPS1 Signal Voltage Low 2188
Table 29 DTC 633 – TPS2 Signal Voltage High 2191
Table 30 DTC 634 – TPS2 Signal Voltage Low 2194
Table 31 DTC 635 – TPS1 Higher Than TPS2 2197
Table 32 DTC 636 – TPS1 Lower Than TPS2 2200
Table 33 DTC 637 – Throttle Unable To Open 2203
Table 34 DTC 638 – Throttle Unable To Close 2206
Table 35 DTC 652 – Rev Limit 2209
Table 36 DTC 653 – Rev Limit 2211