Yale Forklift A875 (GPGLP050-060TG) Service Manual – PDF DOWNLOAD

Yale Forklift A875 (GPGLP050-060TG) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift A875 (GPGLP050-060TG) Service Manual – PDF DOWNLOAD

Language : English
Pages : 2202
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift A875 (GPGLP050-060TG) 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
524153914 2200YRM0107 (03 2008) US EN 119
toc 119
High Energy Ignition (HEI) System 119
Safety Precautions Maintenance and Repair 120
Description 123
Distributor Repair 125
Remove 125
Disassemble 125
Assemble 131
Install, If Crankshaft WAS NOT Rotated when Distributor was Remo 132
Install, If Crankshaft WAS Rotated when Distributor was Removed 132
Ignition Coil Replacement 134
Some Four- and Six-Cylinder Models 134
Remove 134
Install 134
V8, Some Four- and Six-Cylinder Models 135
Remove 135
Install 135
Electronic Module Replacement 136
Remove 136
Install 136
Sensing Coil Replacement 138
Remove 138
Install 138
Spark Plugs Replacement 138
Remove 138
Install 139
Visual Check 139
High Voltage Wires Check 139
Ignition Coil Check 140
Coil in Distributor Cap Design 140
Separate Coil Design 140
Sensing Coil, Check 141
Electronic Module Check 141
Ignition Timing Adjustment 142
GM V8-366 (6-liter) Ignition System Check 143
GM V6-LPG (4 3 liter) GM V6-LPG (4 3 liter) Ignition Timing and 143
Specifications 143
Troubleshooting 144
524153916 2200YRM0765 (03 2003) US EN 149
toc 149
Microprocessor Spark Timing System (MSTS) 149
Safety Precautions Maintenance and Repair 150
General 153
Description 154
What MSTS Does 154
How MSTS Begins Operation 154
Operation 155
Distributor 155
Ignition Coil 156
Ignition Module 156
When Engine Is Being Started 156
When Engine Is Running 158
Manifold Absolute Pressure (MAP) Sensor 159
Engine Coolant Temperature (ECT) Sensor 159
MSTS Module Corrections 160
Troubleshooting 161
General 161
Tools and Test Equipment 163
MSTS 164
Troubleshooting Procedure 164
Where to Start 164
Visual/Physical Inspection 164
Knowledge/Tools Required 164
Damage From Static Discharge (Static Electricity) 165
Troubleshooting Information 165
Malfunction Indicator Lamp (MIL) 165
Connecting CodeMate Tester 165
Reading Diagnostic Trouble Codes (DTC) 166
Clearing Diagnostic Trouble Codes (DTC’s) 167
On-Board Diagnostic (OBD) System Check 167
Test Description 167
No Malfunction Indicator Lamp 169
Circuit Description 169
Test Description 169
No DTC-12, Malfunction Indicator Lamp ON 171
Circuit Description 171
Test Description 171
Starter Rotates Engine, Engine Does Not Run 172
Test Description 172
DTC-14 Engine Coolant Temperature (ECT) (Low Temperature Indicat 176
Circuit Description 176
Test Description 176
DTC-15 Engine Coolant Temperature Sensor (ECT) (High Temperature 178
Circuit Description 178
Test Description 178
DTC-34 Manifold Absolute Pressure (MAP) Sensor 180
Circuit Description 180
Test Description 180
DTC-41 Electronic Spark Timing (EST) Open Circuit 183
Circuit Description 183
Test Description 183
DTC-42 Electronic Spark Timing (EST) Grounded Circuit 185
Circuit Description 185
Test Description 185
DTC-51 MSTS Failure 187
Circuit Description 187
Distributor Repair 187
Remove 187
Disassemble 188
Inspect 188
Assemble 188
Install 189
Ignition Timing 189
Ignition Module Repair 190
Test For Fault 190
Replace 190
Sensing Coil Repair 191
Test For Fault 191
Replace 191
Ignition Coil Repair 192
Test For Fault 192
Remove 192
Install 192
MSTS Module Repair 193
Remove 193
Install 193
ECT Sensor Replacement 193
MAP Sensor Replacement 194
tables 149
Table 1 MSTS Module Connections 162
Table 2 Pressure Conversion Chart 163
Table 3 MSTS Diagnostic Codes 165
524153917 2200YRM0781 (03 2003) US EN 197
toc 197
Electronic Engine Control 197
Safety Precautions Maintenance and Repair 198
General 201
Description and Operation 201
General 201
Electronic Control Module (ECM) 201
Diagnostic Connector 201
How ECM Begins Operation 205
Electronic Engine Control 206
What ECM Does 206
Distributor 208
Ignition Module 208
When Engine Is Being Started 209
When Engine Is Running 210
Electronic Control Module (ECM) with Ignition Module Distributor 210
Fuel Control 211
Throttle Body Injection (TBI) 212
Fuel Injectors 212
Fuel Pressure Regulator 212
Throttle Position Sensor (TPS) 213
Idle Air Control (IAC) 213
GM 4 3L Engine Governor System 214
GM 3 0L Engine Governor System 214
Vacuum Ports 216
Fuel Pump 216
ECM Sensors and Controllers 218
Manifold Absolute Pressure (MAP) 218
Engine Coolant Temperature (ECT) Sensor 218
524153918 2200YRM0782 (03 2003) US EN 221
toc 221
Electronic Engine Control 221
Safety Precautions Maintenance and Repair 222
General 227
Troubleshooting Procedure 227
How This Section Is Arranged 227
Where Do I Start? 227
Visual/Physical Inspection 227
Knowledge/Tools Required 227
Damage From Static Discharge (Static Electricity) 227
Troubleshooting Information 228
Malfunction Indicator Lamp (MIL) 228
Reading Diagnostic Trouble Codes (DTC) 228
Clearing Diagnostic Trouble Codes (DTCs) 232
ECM Diagnostic Codes Available 233
Diagnostic Mode 233
Field Service Mode 233
ECM Learning Ability 233
SCAN Tool Information 234
On-Board Diagnostic (OBD) System Check 235
Test Description 235
Troubleshooting Charts 237
General 237
Tools and Test Equipment 237
Troubleshooting Chart Description Summary 238
A-1 – No Malfunction Indicator Lamp 238
Circuit Description 238
Test Description 239
Other Troubleshooting Checks 239
A-2 – No Scan Data, No DTC 12, Malfunction Indicator Lamp ON 241
Circuit Description 241
Test Description 241
A-3 – Starter Rotates Engine, Engine Will Not Run 243
Circuit Description 243
Test Description 243
Other Troubleshooting Checks 243
A-4 – Fuel Injector Circuit 245
Test Description 245
A-5 – Fuel Pump Relay Circuit 247
Circuit Description 247
Test Description 247
Other Troubleshooting Checks 247
A-6 – Fuel System Troubleshooting 249
Circuit Description 249
Test Description 249
Other Troubleshooting Checks 249
Test Description 251
Fuel Pressure Check 253
A-7 – Ignition System Troubleshooting 253
Test Description 254
DTC 14 Engine Coolant Temperature Sensor Circuit (Low Temperatur 257
Circuit Description 257
Test Description 257
Other Troubleshooting Checks 257
DTC 15 Engine Coolant Temperature Sensor Circuit (High Temperatu 259
Circuit Description 259
Test Description 259
Other Troubleshooting Checks 259
DTC 21 Throttle Position Sensor Circuit (Signal Voltage High) 261
Circuit Description 261
Test Description 261
Other Troubleshooting Checks 261
DTC 22 Throttle Position Sensor Circuit (Signal Voltage Low) 263
Circuit Description 263
Test Description 263
Other Troubleshooting Checks 263
DTC 31 Engine Governor Circuit 265
Circuit Description 265
Test Description 265
Other Troubleshooting Checks 265
DTC 33 Manifold Absolute Pressure (MAP) Sensor Circuit (Signal V 267
Circuit Description 267
Test Description 267
Other Troubleshooting Checks 267
DTC 34 Manifold Absolute Pressure (MAP) Sensor Circuit (Signal V 269
Circuit Description 269
Test Description 269
Other Troubleshooting Checks 269
DTC 41 Electronic Spark Timing (EST) – Open EST Circuit 271
Circuit Description 271
Test Description 271
Other Troubleshooting Checks 271
DTC 42 EST – Grounded EST Circuit, Open or Grounded Bypass Circu 273
Circuit Description 273
Test Description 274
Other Troubleshooting Checks 274
DTC 51 ECM Failure 276
Circuit Description 276
Other Troubleshooting Checks 276
Troubleshooting, Poor Operation 277
General 277
Make a Careful Visual Check 277
FAULT: Codes or Performance That Is Not Regular 277
FAULT: Loss of Diagnostic Trouble Code (DTC) Memory 277
FAULT: Engine Quits While Driving 277
Additional Checks 277
FAULT: Engine Is Difficult to Start 277
FAULT: Variation in Engine Power When Throttle Is Held Steady 278
FAULT: Decreased Engine Power 278
FAULT: Detonation 279
FAULT: Engine Momentarily Does Not Increase Power When Throttle 279
FAULT: One or More Cylinders Do Not Operate Correctly – Engine D 280
FAULT: Rough Idle or Engine Stalls During Idle 280
FAULT: Fuel Usage Too High 280
FAULT: Dieseling 281
FAULT: Backfire 281
System Test Charts 281
General 281
Engine Coolant Temperature (ECT) Sensor Test 281
Throttle Position (TP) Sensor Check 282
Minimum Idle Speed 282
Adjustment 283
B-1 – Idle Air Control (IAC) System Check 284
Circuit Description 284
Other Troubleshooting Checks 284
B-2 – Manifold Absolute Pressure (MAP) Sensor Output Test 286
Circuit Description 286
Test Description 286
B-3 – Check Governor System 288
Governor System Not Operating Correctly 288
Check Function of Governor System 288
Check PCV System 289
Fuel System Components Repair 289
General 289
Fuel Pressure Relief Procedure 289
Fuel Pump Replacement 289
Throttle Body Injection Unit (TBI) 290
Remove 290
Clean and Inspect 291
Install 291
Fuel Meter Body 291
Remove 291
Install 294
Fuel Injector 294
Remove 294
Install 295
Pressure Regulator 295
Remove 295
Inspect 295
Install 295
Throttle Position Sensor (TPS) 296
Remove 296
Install 296
Idle Air Control (IAC) Valve 296
Remove 296
Clean and Inspect 296
Install 297
Governor System 3 0L Engine Repair 297
Governor Module, Replace 297
Governor Motor, Replace 297
Throttle Cables, Install and Adjust 297
Foot Directional Control Pedal, Check 298
Governor System 4 3L Engine Repair 299
Governor Throttle Drive Assembly 299
Remove 299
Inspect 300
Install 300
Governor Drive Motor 300
Remove 300
Clean and Lubricate 300
Install 301
Inspect 302
Ignition System Components Repair 302
ECM Replacement 302
Function Check 302
Distributor 302
Remove 302
Disassemble 302
Inspect 303
Assemble 303
Install 303
Firing Order 304
Ignition Timing 304
Ignition Module Repair 304
Test For Fault 304
Replace 305
Sensing Coil 305
Test 305
Replace 306
Ignition Coil 306
Test 306
Remove 306
Install 307
Sensors Repair 307
Engine Coolant Temperature (ECT) Sensor, Replace 307
MAP Sensor, Replace 307
PCV System Repair 308
Replace 308
Wiring 308
Connectors and Terminals 308
Procedures for Spark Plugs, Spark Plug Wires, and Boots 311
Wiring Diagram 311
Spark Plugs Troubleshooting 316
Special Tools 317
tables 221
Table 1 ECM Diagnostic Codes Available 233
Table 2 SCAN Tool Information 234
Table 3 Troubleshooting Chart Description Summary 238
Table 4 ECT Sensor – Temperature vs Resistance 259
Table 5 ECT Sensor – Temperature vs Resistance 282
Table 6 ECM Connector J1 Identification 314
Table 7 ECM Connector J2 Identification 315
524158636 0100YRM0505 (06 2004) US EN 321
toc 321
Frame 321
Safety Precautions Maintenance and Repair 322
General 325
Description 325
Operator Module Repair 325
Remove 325
Install 325
Hood and Side Covers Repair 327
Remove 327
Install and Adjust 327
Overhead Guard Repair 329
Remove and Install 329
LED Backup and Brake Lights, Replace 330
Remove 330
Install 330
Counterweight Repair 331
Remove 331
Install 332
Exhaust System Repair 333
Muffler, Replace 334
Radiator and Cooling System Repair 340
Remove 340
Install 340
Operator Restraint System Repair 342
Engine Repair 343
Remove Engine Only 343
Remove Engine and Transmission 343
Install Engine Only 344
Install Engine and Transmission 345
Fuel and Hydraulic Tanks Repair 345
Inspect 345
Small Leaks, Repair 345
Large Leaks, Repair 345
Clean 346
Steam Method of Cleaning 346
Chemical Solution Method of Cleaning 346
Additional Preparations for Repair 346
Safety Labels 347
tables 321
Table 1 Weight of Counterweights 332
524158637 0600YRM1020 (10 2006) US EN 353
toc 353
GM Engine Repair 353
Safety Precautions Maintenance and Repair 354
General 357
Description 357
Engine Removal and Installation 365
Cylinder Head and Valve Mechanism Repair 365
Cylinder Head, Remove 365
Cylinder Head, Disassemble 367
Clean and Inspect 367
Valves and Valve Seats 370
Studs for Rocker Arms 370
Hydraulic Valve Lifters 371
Replace 371
Clean and Inspect 371
Cylinder Head, Assemble 371
Cylinder Head, Install 372
Valve Clearance, Adjust 373
Rocker Arm Cover, Install 373
Timing Gear Cover Repair 374
Remove 374
Install 374
Timing Wheel Repair 375
Timing Wheel, Removal 375
Timing Wheel, Install 375
Air Gap Adjustment 376
Camshaft Repair 378
Camshaft, Remove 378
Camshaft, Clean and Inspect 378
Camshaft Bearings, Remove 380
Camshaft Bearings, Clean and Inspect 380
Camshaft Bearings, Install 380
Camshaft, Install 381
Distributor Repair 381
Remove 381
Install 382
Lubrication System Repair 383
Oil Pan 383
Remove 383
Install 383
Oil Pump 383
Remove 383
Disassemble 384
Clean and Inspect 385
Assemble 385
Install 385
Piston and Piston Rod Assemblies Repair 385
Piston Rod Bearings, Replace 385
Piston and Piston Rod Assemblies, Remove 387
Piston and Piston Rod Assemblies, Disassemble 387
Pistons, Clean and Inspect 388
Cylinder Bores, Inspect and Repair 388
Piston Rings, Inspect 389
Piston and Piston Rod Assemblies, Assemble 390
Piston and Piston Rod Assemblies, Install 390
Crankshaft Repair 391
Main Bearings, Replace 391
Oil Seal for Rear Main Bearing, Replace 392
Crankshaft, Remove 392
Inspect and Repair 393
Main Bearing and Journal Clearance, Check 394
Crankshaft, Install 395
Flywheel and Flywheel Housing Repair 395
Flywheel, Remove 396
Ring Gear, Replace 397
Flywheel, Install 397
Cooling System Repair 397
Water Pump 397
Remove 397
Inspect 397
Install 398
Thermostat 398
Remove and Install 398
Alternator Repair 398
Starter Repair 398
Checks and Adjustments 400
Engine Compression Test 400
Test Procedure 400
Test Results 400
Engine Noise Diagnostic Test 400
Description 400
Test Procedure 400
Engine Specifications 402
Engine Data 402
Cylinder Bore 402
Piston 402
Piston Rings 402
Wrist Pin 403
Crankshaft 403
Piston Rod 404
Camshaft 404
Hydraulic Valve System 404
Cylinder Head Warpage 405
Lubrication System 405
Cooling System 405
Torque Specifications 406
Troubleshooting 407
524158742 0600YRM0496 (01 2011) US EN 413
toc 413
Mazda Engine 413
Safety Precautions Maintenance and Repair 414
General 417
Description 417
Engine Removal and Installation 417
Cylinder Head, Camshaft, and Valve Mechanism Repair 418
Remove 418
Clean 419
Inspect and Repair 420
Cylinder Head 420
Rocker Shaft Assembly 420
Camshaft 420
Valve Guides 421
Valve Seats 422
Valves 422
Valve Springs 423
Install 423
Crankshaft and Main Bearings Repair 426
Remove 426
Inspect and Repair 426
Crankshaft 426
Main Bearings 426
Install 427
Pistons and Connecting Rods Repair 428
Remove and Disassemble 428
Clean 428
Inspect and Repair 428
Pistons 428
Piston Rings 429
Connecting Rods and Bearings 429
Assemble and Install 430
Cylinder Block Repair 431
Oil Pump Repair 431
Remove 431
Disassemble 432
Clean 432
Inspect 432
Assemble 433
Install 434
Cooling System Repair 434
Thermostat 434
Replace 434
Fan Assembly 434
Remove and Disassemble 434
Assemble and Install 435
Water Pump 435
Remove and Disassemble 435
Assemble and Install 436
Distributor Repair 437
Remove 437
Install 437
Flywheel and Ring Gear Repair 438
Remove 438
Ring Gear, Replace 438
Install 438
Flywheel Repair 439
Remove 439
Install 439
Valve Adjustment 440
Compression Pressure Check 440
Engine Timing Adjustment 441
Throttle Linkage Adjustment 441
Gasoline Engines 441
LPG Engines (IMPCO) 441
LPG Engines (AISAN) 442
Engine Specifications 442
Engine Data 442
Thermostat 442
Cylinder Head 442
Valve Mechanism 442
Camshaft 443
Crankshaft 443
Connecting Rods 444
Cylinder Block 444
Pistons 444
Oil Pump 444
Torque Specifications 445
Troubleshooting 446
524158744 0900YRM0498 (12 2003) US EN 451
toc 451
LPG Fuel System 451
Safety Precautions Maintenance and Repair 452
General 455
Description and Operation 455
Fuel Tank 456
Fuel Filter and Fuel Valve Unit 456
Vaporizer 456
Carburetor 458
Solenoid Valve 459
Idle Control Actuator 460
Governor System 460
Hose Replacement 460
LPG Tank Repair 461
Remove 461
Install 461
Hydrostatic Relief Valve Repair 462
Remove and Install 462
Filter Unit Repair 462
Fuel Filter Element, Replace 462
Diaphragm and Fuel Valve, Replace 464
Vaporizer Repair 464
Remove 464
Disassemble 464
Clean 464
Inspect 464
Assemble 466
Install 470
Carburetor Repair 470
Remove 470
Disassemble 470
Clean 470
Assemble 472
Install 472
Solenoid Valve Repair 472
Governor System Check 473
Filter Unit Check 473
Vaporizer Check 474
Pressure Reducer Valve 474
Vapor Valve 474
Carburetor Adjustment 474
Idle, Adjust 474
Power Mixture 475
Throttle Linkage Adjustment 476
Foot Directional Control Pedal, Check 477
Troubleshooting 478
524158745 0900YRM0502 (12 2003) US EN 485
toc 485
Gasoline Fuel System 485
Safety Precautions Maintenance and Repair 486
General 489
Description 489
Carburetor 489
Governor 490
Carburetor Operation 490
Float System 490
Idle System 491
Idle Control Actuator 491
Idle Compensator Valve 491
Idle Metering System 491
Solenoid Valve (Shutoff Valve) 492
Main Metering System 492
Choke System 492
Vacuum Diaphragm 493
Temperature Sensor System 493
Choke-Release Mechanism 493
Power System 493
Accelerator Pump System 493
Governor Operation 494
Governor Repair 494
Carburetor Repair 494
Remove 494
Disassemble 495
Clean 495
Inspect 497
Assemble 497
Install 498
Carburetor Adjustment 499
Idle Speed and Mixture, Adjust 499
Throttle Linkage Adjustment 500
Foot Directional Control Pedal, Check 501
Governor Adjustment 502
Troubleshooting 503
524158746 0900YRM0523 (12 2003) US EN 509
toc 509
LPG Fuel System 509
Safety Precautions Maintenance and Repair 510
General 513
Description and Operation 513
Fuel Tank 515
Fuel Filter and Fuel Valve Unit 515
Vaporizer 516
Carburetor 518
Solenoid Valve 520
Idle Control Actuator 520
Governor 520
Hose Replacement 520
LPG Tank Repair 521
Remove 521
Install 521
Hydrostatic Relief Valve Repair 522
Remove and Install 522
Filter Unit Repair 522
Fuel Filter Element, Replace 522
Diaphragm and Fuel Valve, Replace 524
Vaporizer Repair 524
Remove 524
Disassemble 524
Clean 524
Inspect 524
Assemble 526
Install 529
Carburetor Repair 530
Remove 530
Disassemble 530
Clean 530
Assemble 533
Install 533
Solenoid Valve Repair 533
Governor Repair 533
Filter Unit Check 534
Vaporizer Check 534
Pressure Reducer Valve 534
Vapor Valve 534
Carburetor Adjustment 534
Idle Mixture 534
Idle, Adjust 534
Power Mixture, Adjust 535
Governor Check and Adjustment 536
Check 536
Adjust 536
Throttle Linkage Adjustment GC/GLC040-065RG/TG/ZG and GP/GLP/GDP 537
Throttle Linkage Adjustment GP/GLP/GDP16-20AF/BF (GP/GLP/GDP030- 538
Foot Directional Control Pedal Check 539
Troubleshooting 540
524158747 0900YRM0925 (12 2003) US EN 547
toc 547
LPG Fuel System 547
Safety Precautions Maintenance and Repair 548
General 551
Description and Operation 551
Fuel Tank 552
Regulator 552
Start Mode 554
Idle Mode 554
Run Mode 554
Resonator 554
Carburetor 555
Start Mode 555
Idle Mode 555
Run Mode 555
Governor 556
Hoses Replacement 557
LPG Tank Repair 557
Remove 557
Install 557
Relief Valve Repair 558
Remove and Install 558
Carburetor Repair 558
Remove 558
Disassemble 558
Clean 559
Assemble 559
Install 560
Governor Repair 560
Remove 560
Inspect 560
Install 560
Regulator Repair 561
Remove 561
Disassemble 561
Clean 561
Inspect 561
Assemble 563
Install 564
Regulator Adjustment 564
Regulator Height Adjustment 564
Regulator Assembly Air Tightness Test 565
Carburetor Adjustment 566
Idle Speed and Fuel Mixture 566
Idle Control Adjustment 566
Governor Adjustment 567
Checks 567
Adjustments 567
Throttle Linkage Adjustment 568
Foot Directional Control Pedal Check 569
Throttle Linkage Adjustment 570
Troubleshooting 571
tables 547
Table 1 Power Adjusting Screw 560
Table 2 Air Adjusting Screw 560
Table 3 Idle Mixture Adjusting Screw 563
Table 4 Idle Mixture Adjusting Screw 566
524158748 0900YRM0948 (10 2006) US EN 579
toc 579
LPG Fuel System 579
Safety Precautions Maintenance and Repair 580
General 583
Description and Operation 583
Fuel Tank 583
Oxygen Sensor 583
Regulator 583
Start Mode 586
Idle Mode 589
Run Mode 589
Resonator 589
Carburetor 589
Start Mode 589
Idle Mode 590
Run Mode 590
Governor 591
Hoses Replacement 591
LPG Tank Repair 592
Remove 592
Install 592
Relief Valve Repair 593
Remove and Install 593
Carburetor Repair 593
Remove 593
Disassemble 593
Clean 594
Assemble 594
Install 595
Fuel Injector Repair 595
Remove 595
Clean and Inspect 595
Install 595
Governor Repair 596
Remove 596
Inspect 596
Install 596
Regulator Repair 596
Remove 596
Install 596
Oxygen Sensor Repair 596
Remove and Install 596
Vacuum Switches Repair 597
Remove and Install 597
Inspect 597
Resistor Repair 597
Remove and Install 597
Inspect 597
Carburetor and New Regulator Adjustment 597
Idle Speed and Fuel Mixture 597
Idle Control Adjustment 598
Governor Checks and Adjustments 599
Checks 599
Adjustments 599
Throttle Linkage Adjustment 599
Foot Directional Control Pedal Check 601
Check Engine Light 601
Inspect Warning Lamp 601
Check Feedback Operation 601
Check VAC1 and VAC2 Signals 601
Check Resistor 601
Check Fuel Injector 601
Check Oxygen Sensor 602
Check Vacuum Switch 1 602
Check Vacuum Switch 2 602
After Completing Checks 602
Troubleshooting 602
tables 579
Table 1 Adjusting Screw 595
524158749 1300YRM0500 (08 2003) US EN 611
toc 611
Single-Speed Powershift Transmission 611
Safety Precautions Maintenance and Repair 612
General 615
Description and Operation 615
General 615
Torque Converter 616
Description 616
Operation 616
Clutch Assemblies 618
Description 618
Operation 619
Hydraulic System 622
General 622
Control Valve 623
General 623
Clutch Pressure Regulator 624
Inching Spool Assembly 625
Direction Spool 625
Modulator Circuit 625
Torque Converter Regulator 625
Foot Directional Control Pedal 625
Foot Directional Control Pedal Start Circuit 626
Direction Control Lever 626
Differential 626
Oil Flow Diagrams 628
Neutral 628
Modulator Operation 628
Forward 632
Forward-Inching 632
524158750 1300YRM0501 (03 2004) US EN 639
toc 639
Single-Speed Powershift Transmission 639
Safety Precautions Maintenance and Repair 640
General 643
Transmission Removal 647
Torque Converter and Housing Repair 647
Remove 647
Install 647
Transmission Pump Repair 649
Remove 649
Repair 649
Install 649
Front Cover and Pump Drive Repair 649
Remove and Disassemble 649
Assemble and Install 649
Clutch Assemblies Repair 652
Remove and Disassemble 655
Inspect 657
Assemble 658
Install 663
Differential Repair 664
Remove and Disassemble 664
Inspect 665
Assemble and Install 666
Control Valve Repair 673
Remove and Disassemble 673
Inspect 673
Assemble and Install 673
Foot Directional Control Pedal Repair 676
Remove and Disassemble 676
Assemble and Install 676
Direction Control Lever Repair 679
Remove and Disassemble 679
Assemble and Install 679
Stall Test 680
Inching/Brake Pedal Adjustment 681
Neutral Start Switch, Foot Directional Control Pedal Adjustment 685
Neutral Start Switch, Foot Directional Control Pedal Adjustment 686
Neutral Start Switch Test, Foot Directional Control Pedal 687
Oil Pressure Checks 687
Relief Valve for Transmission Pump Check, TEST PORT 1 687
Clutch Pressure Check, TEST PORTS 2 and 3 687
Torque Converter Regulator Check, TEST PORT 4 688
Lubrication Circuit Oil Pressure Check, TEST PORT 5 688
Modulator Pressure Check, TEST PORT 6 688
Troubleshooting 689
Troubleshooting – Pressure Tests 692
tables 639
Table 1 Adjustment of Shims for Pinion Assembly 666
Table 2 Ring and Pinion Tooth Contact Adjustment 667
Table 3 Stall Speeds 681
Table 4 Transmission Oil Pressures Test Ports 688
524158751 1400YRM0499 (10 2004) US EN 697
toc 697
Drive Axle 697
Safety Precautions Maintenance and Repair 698
General 701
Description 701
Drive Axle Repair 701
Remove and Disassemble 701
Clean and Inspect 703
Assemble and Install 703
Torque Specifications 705
GP2 00-3 00RF/TF (GP040-060RG/TG/ZG) 705
GC040-065TF/RF 705
Troubleshooting 706
524158752 1600YRM0316 (08 2006) US EN 709
toc 709
Steering Axle 709
Safety Precautions Maintenance and Repair 710
General 713
Description 713
Steering Axle Assembly Repair 714
Remove 714
Install 714
Wheels and Hubs Repair 715
Remove and Disassemble 715
Clean 715
Assemble and Install 715
Spindles, Bearings, and Tie Rods Repair 717
Remove 717
Install 717
Steering Cylinder Repair 718
Remove and Disassemble 718
Clean and Inspect 719
Assemble and Install 719
Torque Specifications 719
Troubleshooting 720
524158753 1600YRM0720 (11 2006) US EN 725
toc 725
Steering Housing and Control Unit 725
Safety Precautions Maintenance and Repair 726
General 729
Description 729
Operation 730
Steering Wheel and Column Assembly Repair 731
Assembly Components, Remove 731
Steering Control Unit, Disassemble 736
Steering Control Unit, Clean 736
Steering Control Unit, Assemble 736
Assembly Components, Install 738
System Air Removal 740
Troubleshooting 740
524158754 1800YRM0506 (05 2005) US EN 745
toc 745
Brake System 745
Safety Precautions Maintenance and Repair 746
General 749
Description and Operation 749
Service Brakes 749
Master Cylinder 749
Parking Brake 751
Service Brakes Repair 751
Remove and Disassemble 751
Clean 753
Inspect 753
Assemble and Install 755
Adjust 759
Parking Brake Repair 759
Remove and Disassemble 759
Assemble and Install 759
Adjust 759
Master Cylinder Repair 761
Remove 761
Clean and Inspect 761
Repair 762
Install 764
Service Brakes Adjustment 764
Brake System Air Removal 765
Parking Brake Not Applied Switch Test 765
Parking Brake Switch Test (Foot Directional Control Pedal Only) 765
Inching/Brake Pedal Adjustment 766
Neutral Start Switch Adjustment, Foot Directional Control Pedal 770
Neutral Start Switch Adjustment, Foot Directional Control Pedal 771
Neutral Start Switch Test (Foot Directional Control Pedal) 772
Torque Specifications 772
GP2 00-3 00RF/TF (GP040-060RG/TG/ZG) 772
GC040-065RG/TG/ZG 772
Troubleshooting 772
524158755 1900YRM0513 (06 2004) US EN 779
toc 779
Hydraulic System 779
Safety Precautions Maintenance and Repair 780
General 783
Description 783
Hydraulic System 783
Gear Pump Assembly 783
Flow Control Valve 783
Relief Valve 783
Operation 790
Hydraulic System 790
Gear Pump 790
Flow Control Valve 790
Relief Valve 790
Gear Pump Assembly Repair 792
Remove and Disassemble 792
Assemble and Install 793
Steering Relief Pressure Check and Adjustment 793
Gear Pump Flow Check 794
Troubleshooting 794
524158756 2000YRM0516 (12 2003) US EN 799
toc 799
Main Control Valve 799
Safety Precautions Maintenance and Repair 800
General 803
Description 803
Operation 804
Lift Section 804
Tilt Section 804
Tilt Backward 804
Tilt Forward 804
Relief Valve 808
Main Control Valve Repair 809
Remove 809
Disassemble 809
Clean and Inspect 809
Assemble 809
Install 815
Pressure Relief Valve Check and Adjustment 816
Primary Relief Valve 816
Secondary Relief Valve 816
Troubleshooting 817
524158757 2200YRM0514 (01 2004) US EN 821
toc 821
Instrument Cluster 821
Safety Precautions Maintenance and Repair 822
General 825
Description 825
Instrument Cluster Display Panel, Internal Combustion Lift Truck 825
Instrument Cluster Display Panel, Electric Lift Truck Models 832
Optional Basic Display Panel 832
Features of the Optional Basic Display Panel 832
Description of Features on the Optional Basic Display Panel 832
Standard Display Panel 833
Features of the Standard Display Panel 833
Description of Features on the Standard Display Panel 833
Premium Display Panel 834
Features on the Premium Display Panel 834
Description of Features on the Premium Display Panel 835
Curtis 1215 Display Panel 837
Description and Features 837
Operation 838
Cluster-Type Display Panel (Internal Combustion) Replacement 839
Remove 839
Install 839
Cluster Display Panel (Electric Lift Truck) Replacement 842
Curtis 1215 Display Panel Replacement 847
Remove 847
Install 847
tables 821
Table 1 Instrument Cluster, Internal Combustion 826
524158758 2200YRM0524 (12 2003) US EN 851
toc 851
Electrical System 851
Safety Precautions Maintenance and Repair 852
General 855
Description 855
Starting System 855
Ignition System 855
Charging System 856
Starter Repair 857
Remove and Disassemble 857
Assemble and Install 857
Coil Replacement 859
Distributor Repair 860
Remove and Disassemble 860
Assemble and Install 860
Distributor Repair 862
Remove and Disassemble 862
Assemble and Install 864
Alternator Repair 864
Remove and Disassemble 864
Assemble and Install 865
General Checks and Adjustments 866
Starter Checks 866
Operation, Check 866
Brush Holder, Check 867
Armature, Check 867
Field Windings, Check 867
Clutch and Bearing, Check 867
Ignition System Check and Adjustment 868
Engine Timing, Adjust 868
Spark Plugs, Check 868
Charging Circuit Checks 869
Low Output, Check 869
High Output, Check 870
Diodes, Check 870
Rotor Field Winding, Check 871
Stator Windings, Check 871
Brushes and Bearings, Check 871
Voltage Regulator, Check 871
Troubleshooting 872
524158759 2200YRM0603 (12 2003) US EN 877
toc 877
Microprocessor Spark Timing System (MSTS) 877
Safety Precautions Maintenance and Repair 878
General 881
Description 881
What MSTS Does 881
How MSTS Begins Operation 881
Operation 882
Distributor 882
Ignition Module 883
When Engine is Being Started 884
When Engine is Running 884
Manifold Absolute Pressure (MAP) Sensor 885
Engine Coolant Temperature (ECT) Sensor 886
MSTS Module Corrections 886
Initial Timing Connector 888
Governor System Operation 888
Troubleshooting 890
General 890
Tools and Test Equipment 891
MSTS 891
Test Description 891
Ignition System 893
Test Description 893
Electronic Spark Timing (EST) 896
Circuit Description 896
Test Description 897
Manifold Absolute Pressure (MAP) Sensor 900
Circuit Description 900
Test Description 900
Test 1 901
Test 2 902
Engine Coolant Temperature (ECT) Sensor 903
Circuit Description 903
Test Description 903
Distributor Repair 905
Remove 905
Disassemble 905
Inspect 906
Assemble 906
Install 906
Ignition Timing 906
Ignition Module Replacement 907
Test for a Fault 907
Replace 908
Sensing Coil Replacement 908
Test for a Fault 908
Replace 908
Ignition Coil Replacement 909
Test for a Fault 909
Remove 909
Install 909
MSTS Module Replacement 910
Remove 910
Install 910
ECT Sensor Replacement 910
MAP Sensor Replacement 911
tables 877
Table 1 MSTS Module Connections 888
Table 2 Voltage and Pressure for MAP Sensor Troubleshooting 901
Table 3 Pressure Conversion Chart 902
524158885 2200YRM0611 (12 2003) US EN 915
toc 915
Electronic Engine Control 915
Safety Precautions Maintenance and Repair 916
General 921
Troubleshooting Procedure 921
Where Do I Start? 921
Visual/Physical Inspection 921
Knowledge/Tools Required 921
Damage From Static Discharge (Static Electricity) 921
Troubleshooting Information 921
Malfunction Indicator Lamp (MIL) 922
Reading Diagnostic Trouble Codes (DTCs) 922
Clearing Diagnostic Trouble Codes (DTC’s) 923
Diagnostic Mode 923
Field Service Mode 923
ECM Learning Ability 924
On-Board Diagnostic (OBD) System Check 924
Troubleshooting Charts 927
Tools and Test Equipment 927
A-1 – No Malfunction Indicator Lamp 928
Circuit Description 928
Test Description 928
Other Troubleshooting Checks 928
A-2 – No SCAN Data, No DTC 12, Malfunction Indicator Lamp On 931
Circuit Description 931
Test Description 931
A-3 – Starter Rotates the Engine, Engine Will Not Run 933
Circuit Description 933
Test Description 933
Other Troubleshooting Checks 934
A-4 – Fuel Injector Circuit 936
Circuit Description 936
Test Description 936
A-5 – Fuel Pump Relay Circuit 938
Circuit Description 938
Test Description 938
Other Troubleshooting Checks 938
A-7 – Fuel System Troubleshooting 940
Circuit Description 940
Test Description 941
Other Troubleshooting Checks 941
Test Description 941
Fuel Pressure Check 944
A-8 Ignition System Troubleshooting 945
Test Description 945
DTC 14 – Engine Coolant Temperature Sensor Circuit (High Tempera 949
Circuit Description 949
Test Description 949
Other Troubleshooting Checks 949
DTC 15 – Engine Coolant Temperature Sensor Circuit (Low Temperat 951
Circuit Description 951
Test Description 951
Other Troubleshooting Checks 951
DTC 21 – Throttle Position Sensor Circuit (Signal Voltage High) 953
Circuit Description 953
Test Description 953
Other Troubleshooting Checks 953
DTC 22 – Throttle Position Sensor Circuit (Signal Voltage Low) 955
Circuit Description 955
Test Description 955
Other Troubleshooting Checks 955
DTC 31 – Engine Governor Circuit 957
Circuit Description 957
Test Description 957
Other Troubleshooting Checks 957
DTC 33 – Manifold Absolute Pressure (MAP) Sensor Circuit (Signal 959
Circuit Description 959
Test Description 959
Other Troubleshooting Checks 959
DTC 34 – Manifold Absolute Pressure (MAP) Sensor Circuit (Signal 961
Circuit Description 961
Test Description 961
Other Troubleshooting Checks 961
DTC 42 – Electronic Spark Timing (EST) 963
Circuit Description 963
Test Description 964
Other Troubleshooting Checks 964
DTC 51 – ECM Failure 966
Circuit Description 966
Other Troubleshooting Checks 966
Troubleshooting, Poor Operation 966
General 966
Make a Careful Visual Check 966
FAULT: Codes or Performance That is Not Regular 966
Definition: 966
Check: 967
FAULT: Loss Of Diagnostic Trouble Code (DTC) Memory 967
FAULT: Engine Quits While Driving 967
Additional Checks 967
FAULT: Engine Is Difficult To Start 967
Definition: 967
Check: 967
FAULT: Variation In Engine Power When The Throttle Is Held Stead 968
Definition: 968
Check: 968
FAULT: Decreased Engine Power 968
Definition: 968
Check: 968
FAULT: Detonation 968
Definition: 968
Check: 968
FAULT: Engine Momentarily Does Not Increase Power When Throttle 969
Definition: 969
Check: 969
FAULT: One Or More Cylinders Do Not Operate Correctly The Engin 969
Definition: 969
Check: 969
FAULT: Rough Idle Or Engine Stalls During Idle 970
Definition: 970
Checks: 970
FAULT: Fuel Usage Too High 970
Definition: 970
Check: 970
FAULT: Dieseling 970
Definition: 970
Checks: 971
FAULT: Backfire 971
Definition: 971
Check: 971
Engine Coolant Temperature (ECT) Sensor Test 971
Throttle Position (TP) Sensor Check 972
Minimum Idle Speed Adjustment 973
Adjust 973
C-1 – Idle Air Control (IAC) System Check 974
Circuit Description 974
Other Troubleshooting Checks 974
C-2 – Manifold Absolute Pressure (MAP) Sensor Output Test 976
Circuit Description 976
Test Description: 976
PCV System Check 978
Governor System Check 978
Governor System Not Operating Correctly 978
Governor System Function, Check 979
Fuel System Components Repair 979
General 979
Fuel Pressure Relief Procedure 979
Fuel Pump, Replace 979
TBI Unit 980
Remove 980
Clean and Inspect 981
Install 981
Fuel Meter Body 982
Remove 982
Install 982
Fuel Injector 983
Remove 983
Install 983
Pressure Regulator 984
Remove 984
Inspect 984
Install 984
Throttle Position Sensor (TPS) 984
Remove 984
Install 984
Idle Air Control (IAC) Valve 985
Remove 985
Clean and Inspect 985
Install 985
Throttle Body 986
Remove and Disassemble 986
Inspect 986
Assemble and Install 986
Oil Pressure Switch, Replace 986
Governor System Repair 988
Governor Module, Replace 988
Governor Motor, Replace 988
Throttle Cables, Install and Adjust 989
Foot Directional Control Pedal, Check 990
Ignition System Components Repair 990
ECM, Replace 990
Function, Check 990
Distributor 990
Remove 990
Disassemble 991
Inspect 991
Assemble 991
Install 992
Ignition Timing 992
Ignition Module Repair 992
Test For a Fault 992
Ignition Module, Replace 993
Sensing Coil 994
Test 994
Replace 994
Ignition Coil 994
Test 994
Remove 995
Install 995
Sensors Repair 995
Engine Coolant Temperature (ECT) Sensor, Replace 995
MAP Sensor Replacement 995
PCV System Repair 996
Replace 996
Wiring Repair 996
Connectors and Terminals 996
Procedures for Spark Plugs, Spark Plug Wires, and Boots 999
Spark Plug Troubleshooting 1000
Wiring Diagrams 1001
Special Tools 1006
tables 915
Table 1 ECM Diagnostic Codes Available 923
Table 2 SCAN Tool Information 925
Table 3 ECT Sensor – Temp vs Resistance 949
Table 4 ECT Sensor – Temp vs Resistance 951
Table 5 ECM Failure 966
Table 6 ECT Sensor – Temperature vs Resistance 971
524158887 2200YRM0612 (12 2003) US EN 1011
toc 1011
Electronic Engine Control 1011
Safety Precautions Maintenance and Repair 1012
General 1015
Description and Operation 1015
General 1015
Electronic Control Module (ECM) 1015
How ECM Begins Operation 1017
Electronic Engine Control 1017
What ECM Does 1017
Distributor 1018
Ignition Module 1018
When the Engine is Being Started 1019
When the Engine is Running 1020
Electronic Control Module (ECM) Corrections 1020
What the ECM Does 1021
Fuel Control Operation 1021
Starting Mode 1021
Clear Excess Fuel (clear flood) Mode 1021
Run Mode 1022
Acceleration Mode 1022
Deceleration Mode 1022
Fuel Cutoff Mode 1022
Fuel System Components 1022
Fuel Pump Electrical Circuit 1022
Throttle Body Injection 1022
Throttle Position (TP) Sensor 1022
Idle Air Control (IAC) Valve 1023
Fuel Injector 1024
Fuel Pressure Regulator 1024
Idle Speed Control 1024
Maximum RPM Control 1024
Governor System 1024
ECM Sensors and Controllers 1025
Manifold Absolute Pressure (MAP) Sensor 1025
Engine Coolant Temperature (ECT) Sensor 1026
Positive Crankcase Ventilation 1026
524158890 4000YRM0521 (03 2006) US EN 1029
toc 1029
Mast 1029
Safety Precautions Maintenance and Repair 1030
General 1033
Description and Operation 1033
Carriages 1033
Mast Mounts 1035
Two-Stage Mast, Limited Free-Lift (LFL) 1036
Description and Operation 1036
Two-Stage Mast, Full Free-Lift (FFL) 1038
Description and Operation 1038
Three-Stage Mast, Full Free-Lift (FFL) 1040
Description and Operation 1040
Four-Stage Mast 1042
Description and Operation 1042
Cylinder Cushion During Lifting Sequence 1046
Cylinder Cushion During Lowering Sequence 1047
524158891 4000YRM0522 (07 2010) US EN 1051
toc 1051
Mast 1051
Safety Precautions Maintenance and Repair 1052
General 1055
Safety Procedures When Working Near Mast 1056
Fork Repair 1058
Remove 1058
Install 1058
Carriages Repair 1060
Standard Carriage, Remove 1060
Hang-On Sideshift Carriage, Remove 1061
Standard Carriage and Hang-On Sideshift Carriage, Repair 1062
Standard Carriage, Install 1063
Hang-On Sideshift Carriage, Install 1064
Integral Sideshift Carriage 1064
Remove 1064
Clean and Inspect 1068
Repair 1069
Install 1070
Mast Repair 1071
Remove 1071
Two-Stage LFL and Two-Stage FFL Masts, Disassemble 1073
Three-Stage FFL Mast 1081
Disassemble 1081
Mast and Chains, Clean and Inspect 1084
Two-Stage LFL and Two-Stage FFL Mast, Assemble 1085
Three-Stage FFL Mast, Assemble 1086
Install 1087
Lift Cylinders Repair 1089
Main Lift Cylinders, Remove 1089
Free-Lift Cylinder, Remove 1089
Cylinders, Disassemble 1090
Two-Stage Full Free-Lift Mast, Right-Hand Main Lift Cylinder 1090
Two-Stage Full Free-Lift Mast, Left-Hand Main Lift Cylinder 1092
Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift 1092
Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift 1093
Two-Stage Full Free-Lift Mast and Three-Stage Full Free-Lift Mas 1094
Clean and Inspect 1095
Cylinders, Assemble 1095
Two-Stage Full Free-Lift Mast, Right-Hand Main Lift Cylinder 1095
Two-Stage Full Free-Lift Mast, Left-Hand Main Lift Cylinder 1096
Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift 1097
Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift 1097
Two-Stage Full Free-Lift Mast and Three-Stage Full Free-Lift Mas 1098
Main Lift Cylinders, Install 1099
Free-Lift Cylinder, Install 1099
Header Hose Arrangements 1100
Two-Stage LFL Mast, New Hose Install 1100
Two-Stage LFL Mast, Adjust Hoses After Installation 1105
Two-Stage FFL Mast, New Hose Install 1105
Two-Stage FFL Mast, Adjust Hoses After Installation 1113
Three-Stage FFL Mast, New Hose Install 1113
Three-Stage FFL Mast, Adjust Hoses After Installation 1124
Header Hose Arrangement 1125
Two-Stage LFL Mast, New Hose Install 1125
Two-Stage LFL Mast, Adjust Hoses After Installation 1130
Two-Stage FFL Mast, New Hose Install 1130
Two-Stage FFL Mast, Adjust Hoses After Installation 1136
Three-Stage FFL Mast, New Hose Install 1136
Three-Stage FFL Mast, Adjust Hoses After Install 1145
Lift and Tilt System Leak Check 1146
Lift Cylinders Leak Check 1146
Tilt Cylinders Leak Check 1146
Tilt Cylinders Adjustment 1147
Lift Chains Adjustment 1149
Mast Adjustment 1151
Carriage Adjustment 1153
Troubleshooting 1154
tables 1051
Table 1 Hook-Type Carriage Chain Adjustment 1149
Table 2 Pin-Type Carriage Chain Adjustment 1150
524158900 8000YRM0707 (06 2009) US EN 1157
toc 1157
Periodic Maintenance 1157
Safety Precautions Maintenance and Repair 1158
General 1163
Serial Number 1163
How to Move Disabled Lift Truck 1163
How to Tow Lift Truck 1163
How to Put Lift Truck on Blocks 1164
How to Raise Drive Tires 1164
How to Raise Steering Tires 1164
Maintenance Schedule 1165
Maintenance Procedures Every 8 Hours or Daily 1174
How to Make Checks With Engine Stopped 1174
Tires and Wheels 1174
Forks 1175
Adjust 1175
Remove 1175
Install 1177
Forks, Mast, and Lift Chains, Inspect 1177
Safety Labels 1178
Operator Restraint System 1178
Steering Column Latch 1178
Fuel, Oil, or Coolant Leaks, Check 1178
Drive Belt 1179
Intake Manifold Rubber Cap 1179
Powershift Transmission Oil Temperature 1179
Powershift Transmission Oil Level 1180
Engine Oil 1180
Hydraulic System 1180
Air Filter 1182
How to Make Checks With Engine Running 1182
Gauges, Indicator Lights, Horn, Fuses, and Relays 1182
Check Engine Light (Mazda and GM LPG Closed Loop with Low-Emissi 1183
Malfunction Indicator Lamp (GM 3 0L Gasoline Engine) 1184
Engine Oil Pressure 1184
Cooling System 1184
Steering System 1185
Service Brakes 1185
Brake Fluid Level 1185
Operation, Check 1185
Parking Brake 1185
Water Separator, Diesel Engine 1186
Drain Water from Water Separator 1186
Fuel Filter, Diesel Engine 1186
Diesel Fuel System, Remove Air 1186
Control Levers and Pedals 1186
Lift System, Operate 1186
Cooling System 1187
Maintenance Procedures Every 250 Hours or 6 Weeks 1188
Air Filter 1188
Drive Belt 1188
Mazda FE and F2 Engines 1188
Fan and Alternator Drive Belt 1188
Timing Belt 1189
GM 3 0L 1189
Mazda XA and HA Diesel Engines 1190
Engine Oil Filter 1190
Brake Fluid 1190
Hydraulic Tank Breather 1190
Battery 1190
Forks 1191
Lift Chains 1191
Lubrication 1191
Wear, Check 1191
Mast 1192
Steering Axle 1192
Fuel System 1192
Engine Speed, Diesel, Mazda XA and HA Engines 1192
Engine Speed, LPG Carburetor, Mazda and GM (Aisan Open-Loop and 1193
Engine Speed, LPG Carburetor, Mazda (Impco) 1193
Engine Speed, LPG Carburetor, GM 3 0L (Impco) 1194
Engine Speed, Mazda Gasoline Carburetor 1195
Hydraulic System 1195
Cooling System, Clean Debris From Radiator Core 1196
Maintenance Procedures Every 500 Hours or 3 Months 1196
Drain Tar From Aisan LPG Regulator 1196
PCV Valve 1196
Maintenance Procedures Every 1000 Hours or 6 Months 1197
Diesel Fuel System 1197
Fuel Filter, Replace 1197
Check Water Sensor 1198
Diesel Fuel System Air Removal 1198
Differential and Drive Axle, Powershift Transmission 1198
Valve Clearance, Check and Adjust 1198
Ignition System 1198
GM 3 0L LPG (IMPCO) 1198
GM 3 0L LPG (Aisan) 1199
Mazda FE and F2 1199
Mazda XA and HA Diesel Engines 1199
Aisan Regulator Pressure/Diaphragm and O-Ring Checks 1200
PCV Valve 1200
Integral Sideshift Carriage, Check Bearings 1200
Control Levers and Pedals 1200
Cooling System, GM 3 0L EPA Compliant Engine 1201
LPG Fuel Filter (IMPCO), GM 3 0L EPA Compliant Engine, Replace 1201
Inspect Engine Electrical System, Connectors, and FCVS Connectio 1202
Maintenance Procedures Every 2000 Hours or Yearly 1202
Hydraulic System 1202
Hydraulic Oil and Filter, Replace 1202
Powershift Transmission Oil and Filter 1202
Replace 1202
Cooling System 1203
Service Brakes 1203
Differential 1204
LPG Fuel Filter, Replace (Pre-2004) 1204
Gasoline Fuel Filter 1204
Fuel Filter, Replace (Aisan LPG System) 1204
LPG Fuel Injector (Aisan Closed-Loop Low Emission System) 1205
Integral Sideshift Carriage, Replace Bearings 1205
Oxygen Sensor, GM 3 0L EPA Compliant Engine 1205
Air Filter Element, GM 3 0L EPA Compliant Engine 1205
Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks 1205
Check Throttle Shaft for Sticking 1206
Inspect Exhaust Manifold and Piping for Leaks 1206
Test LPG/GAS Regulator Pressure 1206
Safety Procedures When Working Near Mast 1207
Hood Latch Check 1209
Lift Chain Adjustments 1210
Lift and Tilt System Leak Check 1213
Lift Cylinder, Leak Check 1213
Tilt Cylinder, Leak Check 1213
Charging Battery 1213
Diesel Engine Fuel Injector Check 1214
Welding Repairs 1214
Overhead Guard Changes 1215
Wheel and Tire Replacement 1215
Solid Rubber Tire, Change GC/GLC040-065RG/TG/ZG Models 1215
Remove and Install Tire on Wheel 1215
Pneumatic Tire, Repair GP/GLP/GDP040-060RG/TG/ZG Models 1216
Remove Wheels From Lift Truck 1216
Remove Wheel From Tire 1216
Remove Tire From Two-Piece Wheel 1217
Remove Tire From Three- and Four-Piece Wheels 1218
Install Wheel on Tire 1219
Install Tire on Three- or Four-Piece Wheels 1219
Install Three-Piece or Four-Piece Wheel in Tire 1220
Install Tire on Two-Piece Wheel 1221
Install Two-Piece Wheel in Tire 1221
Add Air to Pneumatic Tires 1222
Wheels, Install 1222
Dual Drive Wheels, Install 1222
Solid Rubber Tire, Change GP/GLP/GDP040-060RG/TG/ZG Models 1223
Remove Wheel From Tire 1223
Install Wheel in Tire 1225
tables 1157
Table 1 Maintenance Schedule 1166
Table 2 Hook-Type Carriage Chain Adjustment 1211
Table 3 Pin-Type Carriage Chain Adjustment 1211
524158901 8000YRM0708 (01 2011) US EN 1229
toc 1229
Capacities and Specifications 1229
Safety Precautions Maintenance and Repair 1230
Lift Truck Weights 1233
Tire Pressure 1233
Tire Sizes 1234
Capacities 1234
Electrical System 1235
Gasoline/LPG 1235
Diesel 1235
Transmission Oil Pressures 1236
Hydraulic System 1236
Stall Speeds 1237
Engine Specifications 1237
Gasoline/LPG 1237
Diesel 1239
Mast Speeds 1240
Gasoline/LPG Engines (US Models) 1240
Diesel Engines (US Models) 1244
Gasoline/LPG Engines (US Models) 1246
Gasoline/LPG Engines (European Models) 1251
Diesel Engines (European Models) 1255
Torque Specifications 1256
Frame 1256
Brake System 1257
Mast 1257
Steering System 1257
Drive Axle 1257
Transmission and Differential 1257
Engine – Mazda FE and F2 1258
Engine – GM 3 0L 1259
Engine – Mazda XA and HA Diesel 1259
524158902 8000YRM0709 (10 2004) US EN 1263
toc 1263
Diagrams 1263
Safety Precautions Maintenance and Repair 1264
524162461 0600YRM1019 (01 2011) US EN 1329
toc 1329
Mazda XA and HA Diesel Engines 1329
Safety Precautions Maintenance and Repair 1330
General 1335
Description 1335
Engine Removal and Installation 1335
Cylinder Head and Valve Mechanism Repair 1337
Remove 1337
Clean 1337
Inspect and Repair 1338
Cylinder Head 1338
Rocker Shaft Assembly 1338
Valve Guides 1339
Valve Seats 1339
Valves 1340
Valve Springs 1340
Push Rods 1341
Cylinder Head, Assemble 1341
Cylinder Head, Install 1342
Timing Gears Repair 1343
Remove 1343
Clean and Inspect 1343
Install 1344
Camshaft Repair 1345
Remove 1345
Inspect and Repair 1345
Install 1346
Crankshaft and Main Bearings Repair 1346
Remove 1346
Inspect and Repair 1346
Crankshaft 1346
Main Bearings 1347
Install 1347
Piston and Connecting Rods Repair 1348
Remove and Disassemble 1348
Clean 1348
Inspect and Repair 1348
Pistons 1348
Piston Rings 1349
Connecting Rods and Bearings 1349
Assemble and Install 1350
Cylinder Block and Liners Repair 1351
Inspect and Repair 1351
Lubrication System Repair 1353
Oil Pump 1353
Remove 1353
Disassemble 1353
Clean 1353
Inspect 1353
Assemble 1354
Install 1355
Oil Filter Mount 1355
Remove 1355
Install 1355
Oil Cooler 1356
Remove 1356
Clean and Inspect 1356
Install 1356
Cooling System Repair 1356
Thermostat 1356
Remove and Install 1356
Water Pump 1357
Remove 1357
Disassemble 1357
Inspect 1358
Assemble 1358
Install 1359
Fuel System Repair 1360
Description and Operation 1360
Fuel Injection Pump 1360
Remove 1360
Install 1361
Fuel Filter 1362
Filter, Replace 1362
Water Sensor Check 1363
Fuel System Air Removal 1363
Fuel Injectors 1364
Remove and Disassemble 1364
Clean and Inspect 1364
Assemble 1364
Inspect and Adjust 1364
Install 1365
Flywheel and Ring Gear Repair 1365
Flywheel, Remove 1365
Ring Gear, Replace 1365
Flywheel, Install 1366
Flywheel, Remove 1366
Flywheel, Install 1366
Alternator Repair 1367
Starting System Repair 1368
Cold Start Aid 1368
Description and Operation 1368
Glow Plugs, Replace 1368
Glow Plugs, Check 1369
Fuse 1369
Relay and Controller 1369
Checks and Adjustments 1370
Valves, Adjust 1370
Compression Pressure Check 1370
Throttle Linkage, Adjust 1371
Fuel Injection Pump Timing Check 1372
Engine Specifications 1373
Engine Data 1373
Cylinder Head 1373
Camshaft 1374
Crankshaft 1375
Connecting Rods 1376
Cylinder Block 1377
Pistons 1377
Oil Pump 1377
Torque Specifications 1378
Special Tools 1379
Troubleshooting 1381
tables 1329
Table 1 Camshaft Journal Diameters 1345
Table 2 Crankshaft Journal Diameters 1347
Table 3 Piston Diameters 1349
Table 4 Cylinder Liner Diameters 1351
524162462 2200YRM1016 (10 2004) US EN 1389
toc 1389
Electronic Engine Control 1389
Safety Precautions Maintenance and Repair 1390
General 1393
Description and Operation 1393
General 1393
Electronic Control Module (ECM) 1393
Diagnostic Connector 1393
How ECM Begins Operation 1397
Electronic Engine Control 1398
What ECM Does 1398
Distributor 1399
Ignition Module 1400
When Engine Is Being Started 1401
When Engine Is Running 1402
Electronic Control Module (ECM) with Ignition Module Distributor 1403
Fuel Control 1403
Throttle Body Injection (TBI) 1404
Fuel Injectors 1404
Fuel Pressure Regulator 1404
Throttle Position Sensor (TPS) 1405
Idle Air Control (IAC) 1405
GM 4 3L Engine Governor System 1406
GM 3 0L Engine Governor System 1406
Vacuum Ports 1408
Fuel Pump 1408
ECM Sensors and Controllers 1410
Manifold Absolute Pressure (MAP) 1410
Engine Coolant Temperature (ECT) Sensor 1410
524162463 2200YRM1017 (10 2004) US EN 1413
toc 1413
Electronic Engine Control 1413
Safety Precautions Maintenance and Repair 1414
General 1421
Troubleshooting Procedure 1421
How This Section Is Arranged 1421
Where Do I Start? 1421
Visual/Physical Inspection 1421
Knowledge/Tools Required 1421
Damage From Static Discharge (Static Electricity) 1421
Troubleshooting Information 1422
Malfunction Indicator Lamp (MIL) 1422
Reading Diagnostic Trouble Codes (DTC) 1422
Clearing Diagnostic Trouble Codes (DTCs) 1426
ECM Diagnostic Codes Available 1427
Diagnostic Mode 1427
Field Service Mode 1427
ECM Learning Ability 1427
SCAN Tool Information 1428
On-Board Diagnostic (OBD) System Check 1430
Test Description 1430
Troubleshooting Charts 1431
General 1431
Tools and Test Equipment 1432
Presssure Conversion Chart 1433
Troubleshooting Chart Description Summary 1434
A-1 No Malfunction Indicator Lamp 1435
Circuit Description 1435
Diagnostic Aids 1435
Test Description 1435
A-2 No Scan Data, No DTC-12, Malfunction Indicator Lamp ON 1437
Circuit Description 1437
Diagnostic Aids 1437
Test Description 1437
A-3 Engine Cranks but Does Not Run 1439
Circuit Description 1439
Diagnostic Aids 1439
Test Description 1439
A-4 Fuel Injector Circuit 1442
Circuit Description 1442
Test Description 1442
A-5 Fuel Pump Relay Circuit 1444
Circuit Description 1444
Diagnostic Aids 1445
Test Description 1445
A-6 Fuel System Troubleshooting 1447
Circuit Description 1447
Diagnostic Aids 1448
Test Description 1448
Test Description 1450
A-7 Ignition System Troubleshooting 1452
Circuit Description 1452
Diagnostic Aids 1452
Test Description 1452
DTC 14 ECT Sensor Circuit – Low Temp Indicated (Scan Diagnostics 1457
Circuit Description 1457
Diagnostic Aids 1457
Test Description 1458
DTC 15 Engine Coolant Temperature (ECT) Sensor Circuit High Temp 1459
Circuit Description 1459
Diagnostic Aids 1459
Test Description 1459
DTC 21 Throttle Position (TP) Sensor Circuit Signal Voltage High 1461
Circuit Description 1461
Diagnostic Aids 1461
Test Description 1461
DTC 22 Throttle Position (TP) Sensor Circuit Signal Voltage Low 1463
Circuit Description 1463
Diagnostic Aids 1463
Test Description 1463
DTC 31 Engine Governor Circuit 1465
Circuit Description 1465
Diagnostic Aids 1465
Test Description 1465
DTC 33 Manifold Absolute Pressure (MAP) Sensor Circuit Signal Vo 1467
Circuit Description 1467
Diagnostic Aids 1468
Test Description 1468
DTC 34 Manifold Absolute Pressure (MAP) Sensor Circuit Signal Vo 1470
Circuit Description 1470
Diagnostic Aids 1470
Test Description 1470
DTC 41 Electronic Spark Timing (EST) – Open EST Circuit 1472
Circuit Description 1472
Diagnostic Aids 1473
Test Description 1473
DTC 42 EST – Grounded EST Circuit, Open or Grounded Bypass Circu 1474
Circuit Description 1474
Diagnostic Aids 1474
Test Description 1474
DTC 51 Calibration Checksum Failure 1476
Circuit Description 1476
Diagnostic Aids 1476
Test Description 1476
DTC 81 Fuel Pump Relay Driver Circuit High, Low, or Open 1477
Circuit Description 1477
Diagnostic Aids 1478
Test Description 1478
DTC 81 5-Volt Reference Circuit Out of Range 1480
Circuit Description 1480
Diagnostic Aids 1480
Test Description 1480
DTC 81 FPRSENSE Circuit Fault 1482
Circuit Description 1482
Diagnostic Aids 1482
Test Description 1482
Troubleshooting, Poor Operation 1483
General 1483
Make a Careful Visual Check 1483
FAULT: Codes or Performance That Is Abnormal 1484
FAULT: Loss of Diagnostic Trouble Code (DTC) Memory 1484
FAULT: Engine Quits While Driving 1484
Additional Checks 1484
FAULT: Engine Is Difficult to Start 1484
FAULT: Variation in Engine Power When Throttle Is Held Steady 1485
FAULT: Decreased Engine Power 1485
FAULT: Detonation/Spark Knock 1485
FAULT: Engine Momentarily Does Not Increase Power When Throttle 1486
FAULT: One or More Cylinders Do Not Operate Correctly – Engine D 1486
FAULT: Rough Idle or Engine Stalls During Idle 1487
FAULT: Fuel Usage Too High 1487
FAULT: Dieseling 1487
FAULT: Backfire 1488
System Test Charts 1488
General 1488
Engine Coolant Temperature (ECT) Sensor Test 1488
Throttle Position (TP) Sensor Check 1489
Minimum Idle Speed 1489
Adjustment 1489
B-1 – Idle Air Control (IAC) System Check 1490
Circuit Description 1490
Diagnostic Aids 1491
B-2 – Manifold Absolute Pressure (MAP) Sensor Output Test 1492
Circuit Description 1492
Test Description 1492
B-3 – Check Governor System 1494
Governor System Not Operating Correctly 1494
Check Function of Governor System 1494
Check PCV System 1495
Fuel System Components Repair 1495
General 1495
Fuel Pressure Relief Procedure 1495
Fuel Pump Replacement 1495
Throttle Body Injection Unit (TBI) 1496
Remove 1496
Clean and Inspect 1496
Install 1497
Fuel Meter Body 1497
Remove 1497
Install 1500
Fuel Injector 1500
Remove 1500
Install 1501
Pressure Regulator 1501
Remove 1501
Inspect 1501
Install 1501
Throttle Position Sensor (TPS) 1502
Remove 1502
Install 1502
Idle Air Control (IAC) Valve 1502
Remove 1502
Clean and Inspect 1503
Install 1503
Governor System 3 0L Engine Repair 1503
Governor Module, Replace 1503
Governor Motor, Replace 1503
Throttle Cables, Install and Adjust 1503
Foot Directional Control Pedal, Check 1504
Governor System 4 3L Engine Repair 1505
Governor Throttle Drive Assembly 1505
Remove 1505
Inspect 1506
Install 1506
Governor Drive Motor 1506
Remove 1506
Clean and Lubricate 1507
Install 1507
Inspect 1507
Foot Directional Control Pedal, Check 1508
Ignition System Components Repair 1509
ECM Replacement 1509
Function Check 1509
Distributor 1509
Remove 1509
Disassemble 1509
Inspect 1510
Assemble 1510
Install 1510
Firing Order 1511
Ignition Timing 1511
Ignition Module Repair 1511
Test For Fault 1511
Replace 1512
Sensing Coil 1512
Test 1512
Replace 1513
Ignition Coil 1513
Test 1513
Remove 1513
Install 1514
Sensors Repair 1514
Engine Coolant Temperature (ECT) Sensor, Replace 1514
MAP Sensor, Replace 1514
PCV System Repair 1515
Replace 1515
Wiring 1515
Connectors and Terminals 1515
Procedures for Spark Plugs, Spark Plug Wires, and Boots 1518
Wiring Diagram 1518
Spark Plugs Troubleshooting 1522
Special Tools 1524
tables 1413
Table 1 ECM Diagnostic Codes Available 1427
Table 2 Rinda SCAN Tool Information 1428
Table 3 TECH 1 SCAN Tool Information 1428
Table 4 On-Board Diagnostic System Checks 1431
Table 5 Voltage and Pressure Chart 1433
Table 6 Troubleshooting Chart Description Summary 1434
Table 7 No Malfunction Indicator Lamp (GM 3 0L Engine Only) 1436
Table 8 No Scan Data, No DTC-12, Malfunction Indicator Lamp ON 1438
Table 9 Engine Cranks but Does Not Run 1440
Table 10 Fuel Injector Circuit 1442
Table 11 Fuel Pump Relay Circuit 1445
Table 12 A-6A Fuel System Troubleshooting 1448
Table 13 A-6B Fuel system Troubleshooting 1450
Table 14 Ignition System Troubleshooting 1453
Table 15 Engine Coolant Temperature Sensor 1457
Table 16 DTC 14 Engine Coolant Temperature (ECT) Sensor Circuit 1458
Table 17 Engine Coolant Temperature Sensor Table 1460
Table 18 DTC 15 Engine Coolant Temperature (ECT) Sensor Circuit 1460
Table 19 DTC 21 Throttle Position (TP) Sensor Circuit Signal Vo 1462
Table 20 DTC 22 Throttle Position (TP) Sensor Circuit Signal Vo 1464
Table 21 DTC 31 Engine Governor Circuit 1466
Table 22 DTC 33 Manifold Absolute Pressure (MAP) Sensor Circuit 1468
Table 23 DTC 34 Manifold Absolute Pressure (MAP) Sensor Circuit 1471
Table 24 DTC 41 Electronic Spark Timing (EST) – Open EST Circui 1473
Table 25 DTC 42 Electronic Spark Timing (EST) – Grounded EST Ci 1475
Table 26 DTC 51 Calibration Checksum Failure 1477
Table 27 DTC 81 Fuel Pump Relay Driver Circuit High, Low, or Op 1478
Table 28 DTC 81 5 Volt Reference Circuit Out of Range 1481
Table 29 DTC 81 FPRSENSE Circuit Fault 1483
Table 30 ECT Sensor – Temperature vs Resistance 1488
Table 31 Idle Air Control (IAC) System Check 1491
Table 32 Altitude Voltage Chart 1493
Table 33 Manifold Absolute Pressure (MAP) Sensor Output Test 1493
Table 34 Weather-Pack Terminal Repair 1518
Table 35 ECM Connector J1 Identification 1520
Table 36 ECM Connector J2 Identification 1521
524208004 0900YRM1088 (05 2006) US EN 1529
toc 1529
Electronic Controlled LPG/Gasoline Fuel System 1529
Safety Precautions Maintenance and Repair 1530
General 1535
Fuel System Warnings and Cautions 1535
Glossary 1536
Description and Operation of LPG Fuel System 1540
Propane Fuel System 1540
LPG Fuel Tank 1542
Service Line 1542
Fuel Filter 1542
Low Pressure Lock-Off (LPL) 1542
Low Pressure Regulator (LPR) 1543
Air Fuel Mixer 1543
Throttle Control Device 1544
Drive By Cable 1544
Three-Way Catalytic (TWC) Muffler 1545
Electronic Control Module (ECM) 1545
Heated Exhaust Gas Oxygen (HEGO) Sensor 1546
Description and Operation of Gasoline Fuel System 1548
Gasoline Fuel System Throttle Body Injection (TBI), 3 0L Engine 1548
Gasoline Multi-Point Fuel Injection (MPFI) System, 4 3L Only 1548
Gasoline Fuel Storage Tank 1548
Gasoline Fuel Pump 1548
Fuel Filter 1548
Fuel Pressure Regulator, 3 0L Only 1551
Fuel Rail and Pressure Regulator, 4 3L Only 1552
Fuel Injector 1552
Throttle Control Device 1552
Drive By Cable 1552
Three-Way Catalytic Muffler 1553
Electronic Control Module (ECM) 1553
Heated Exhaust Gas Oxygen (HEGO) Sensor 1555
LPG Fuel System Repair 1555
Propane Fuel System Pressure Relief 1555
Propane Fuel System Leak Test 1555
Propane Fuel Filter Replacement 1556
Remove 1556
Install 1556
Low Pressure Lock-Off (LPL) Replacement 1556
Remove 1556
Install 1556
Pressure Trim Valve (PTV) Replacement 1558
Remove 1558
Install 1558
Low Pressure Regulator 1558
Remove 1558
Install 1558
Fuel Trim Valve (FTV) Solenoid Replacement 1559
Remove 1559
Install 1559
Temperature Manifold Absolute Pressure (TMAP) 1559
Remove 1559
Install 1559
Throttle Body Replacement 1561
Remove 1561
Install 1561
Mixer Replacement 1563
Remove 1563
Install 1563
Coolant Hose Replacement 1563
Remove 1563
Install 1564
Vapor Hose Replacement 1564
Remove 1564
Install 1564
Balance Line Hose Replacement 1564
Remove 1564
Install 1564
PTV Hose Replacement 1564
Remove 1564
Install 1564
FTV Hose Replacement 1565
Remove 1565
Install 1565
Throttle Position Sensor (TPS) Replacement 1565
Foot Pedal Position (FPP) Sensor Replacement 1567
Electronic Control Module (ECM) Replacement 1570
Remove 1570
Install 1570
Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement 1570
Remove 1570
Install 1571
Three-Way Catalytic Muffler (TWC) Replacement 1571
Remove 1571
Install 1571
Restricted Exhaust System Diagnosis 1571
Exhaust System Description 1571
Tools Required 1571
Diagnostic Tool 1571
Check at Heated Exhaust Gas Oxygen Sensor (HEGO) 1571
Gasoline Fuel System Repair 1572
Gasoline MPFI and TBI Fuel System Pressure Relief 1572
Gasoline Fuel System Leak Test 1573
Throttle Body Injector (TBI) Assembly Replacement, 3 0L Only 1573
Remove 1573
Install 1573
Throttle Body Assembly Replacement, 3 0L Only 1575
Remove 1575
Install 1575
Throttle Body Assembly Replacement, 4 3L Only 1576
Remove 1576
Install 1576
Fuel Rail Replacement, Gasoline 4 3L Only 1577
Remove 1577
Install 1577
Injector Replacement, Gasoline 4 3L Only 1577
Remove 1577
Install 1577
Injector Replacement, Gasoline 3 0L Only 1579
Remove 1579
Install 1579
Temperature Manifold Absolute Pressure (TMAP) Replacement 1579
Remove 1579
Install 1579
Throttle Position Sensor (TPS) Replacement 1579
Foot Pedal Position (FPP) Sensor Replacement 1582
Electronic Control Module (ECM) Replacement 1585
Remove 1585
Install 1585
Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement 1586
Remove 1586
Install 1586
Three-Way Catalytic Muffler (TWC) Replacement 1586
Remove 1586
Install 1586
Restricted Exhaust System Diagnosis 1586
Exhaust System Description 1586
Tools Required 1586
Diagnostic Tool 1586
Check at Heated Exhaust Gas Oxygen Sensor (HEGO) 1587
LPG System Diagnosis 1587
Fuel System Description 1587
Diagnostic Aids 1588
Tools Required 1588
Duty Cycle Monitoring Tool 1588
Diagnostic Tool 1588
Pressure Gauges 1588
Test Description 1588
Gasoline System Diagnosis 1596
Fuel System Description, 3 0L Only 1596
Fuel System Description, 4 3L Only 1596
Diagnostic Aids 1597
Tools Required 1597
Diagnostic Tool 1597
Test Description 1597
LPG Symptom Diagnosis 1604
Gasoline Symptom Diagnosis 1618
Wire Harness Repair 1629
On Vehicle Service Wiring Harness Repair 1629
Connectors and Terminals 1629
Twisted/Shielded Cable Repair 1630
Twisted Leads Repair 1631
Micro-Pack 1632
Metri-Pack 1632
Remove 1632
Weather-Pack 1634
Weather-Pack Terminal Repair 1635
tables 1529
Table 1 TPS Replacement Procedure 1565
Table 2 FPP Replacement Procedure 1568
Table 3 TPS Replacement Procedure 1580
Table 4 FPP Replacement Procedure 1583
Table 5 LPG Fuel System Diagnosis 1588
Table 6 Fuel Control Diagnosis 1592
Table 7 Gasoline Fuel System Diagnosis, 3 0L Only 1598
Table 8 Gasoline Fuel System Diagnosis, 4 3L Only 1601
Table 9 Preliminary Checks 1604
Table 10 Intermittent 1605
Table 11 No Start 1606
Table 12 Hard Start 1608
Table 13 Cuts Out or Misses 1609
Table 14 Hesitation, Sag, or Stumble 1610
Table 15 Backfire 1611
Table 16 Lack of Power, Sluggishness, or Sponginess 1612
Table 17 Poor Fuel Economy 1613
Table 18 Rough, Unstable, Incorrect Idle, or Stalling 1615
Table 19 Surges or Chuggles 1617
Table 20 Preliminary Checks 1618
Table 21 Intermittent 1619
Table 22 No Start 1620
Table 23 Hard Start 1621
Table 24 Cuts Out or Misses 1622
Table 25 Hesitation, Sag, or Stumble 1623
Table 26 Backfire 1624
Table 27 Lack of Power, Sluggishness, or Sponginess 1625
Table 28 Poor Fuel Economy 1626
Table 29 Rough, Unstable, Incorrect Idle, or Stalling 1627
Table 30 Surges or Chuggles 1628
524208009 2200YRM1090 (04 2005) US EN 1639
toc 1639
Electronic Control Module (ECM) Diagnostic Troubleshooting 1639
Safety Precautions Maintenance and Repair 1640
General 1649
Description of ECM Based Diagnostics 1649
Definition of Terms 1649
Diagnostics Overview of the Spectrum Fuel System 1649
Malfunction Indicator Lamp (MIL) 1649
Spectrum Diagnostic Trouble Codes (DTC) 1650
Using a Laptop Computer to Diagnose the Spectrum System 1650
Installing the Spectrum Diagnostic Software 1650
Connecting a Laptop Computer to the Spectrum System 1650
Diagnostic Communication Error 1651
Diagnostic Trouble Codes 1651
Checking Diagnostic Trouble Codes 1652
Clearing Diagnostic Trouble Codes 1652
DATA Stream 1652
Reading Sensor and Actuator Values 1652
Graphing and Data Logging 1653
Ignition System Test 1654
Disabling Ignition Outputs 1654
Injector Test 1655
Disabling Injectors 1655
Throttle Test 1656
Using a Diagnostic Jumper to Diagnose the ECI System 1657
On-Board Diagnostics System Check/Malfunction Indicator Lamp 1658
Circuit Description 1658
Preliminary and Intermittent Checks 1661
GM 3 0L Wiring Schematics and Connectors 1663
GM 3 0L Diagnostic Trouble Codes 1677
DTC 111 – IAT High Voltage Motorola® TMAP 1677
Circuit Description 1677
Conditions for Setting the DTC 1677
DTC 112 – IAT Low Voltage Motorola® TMAP 1680
Circuit Description 1680
Conditions for Setting the DTC 1680
DTC 113 – IAT Higher Than Expected 1 Motorola® TMAP 1683
Circuit Description 1683
Conditions for Setting the DTC 1683
Diagnostic Aids 1683
DTC 114 – IAT Higher Than Expected 2 Motorola® TMAP 1684
Circuit Description 1684
Conditions for Setting the DTC 1684
Diagnostic Aids 1684
DTC 115 – Oil Pressure Low 1685
Circuit Description 1685
Conditions for Setting the DTC 1685
DTC 121 – ECT Voltage High 1688
Circuit Description 1688
Conditions for Setting the DTC 1689
DTC 122 – ECT Voltage Low 1692
Circuit Description 1692
Conditions for Setting the DTC 1692
DTC 123 – ECT Higher Than Expected 1 1694
Circuit Description 1694
Conditions for Setting the DTC 1694
DTC 124 – ECT Higher Than Expected 2 1696
Circuit Description 1696
Conditions for Setting the DTC 1696
DTC 131 – MAP High Pressure Motorola® TMAP 1698
Circuit Description 1698
Conditions for Setting the DTC 1698
Diagnostic Aids 1698
DTC 132 – MAP Low Voltage Motorola® TMAP 1700
Circuit Description 1700
Conditions for Setting the DTC 1700
DTC 134 – BP High Pressure Motorola® TMAP 1704
Circuit Description 1704
Conditions for Setting the DTC 1704
DTC 135 – BP Low Pressure Motorola® TMAP 1706
Circuit Description 1706
Conditions for Setting the DTC 1706
DTC 142 – Crank Sync Noise 1710
Circuit Description 1710
Conditions for setting the DTC 1710
DTC 143 – Never Crank Synced At Start 1713
Circuit Description 1713
Conditions for Setting the DTC 1713
DTC 144 – Camshaft Sensor Loss 1716
Circuit Description 1716
Conditions for Setting the DTC 1716
DTC 145 – Camshaft Sensor Noise 1719
Circuit Description 1719
Conditions for Setting the DTC 1719
DTC 211 – Closed Loop Multiplier High (LPG) 1722
Circuit Description 1722
Conditions for Setting the DTC 1722
Diagnostic Aids 1722
DTC 212 – HO 2 S Open/Inactive 1724
Circuit Description 1724
Conditions for Setting the DTC 1724
DTC 221 – Closed Loop Multiplier High (Gasoline) 1728
Circuit Description 1728
Conditions for Setting the DTC 1728
Diagnostic Aids 1729
DTC 222 – Closed Loop Multiplier Low (Gasoline) 1730
Circuit Description 1730
Conditions for Setting the DTC 1730
Diagnostic Aids 1730
DTC 224 – Closed Loop Multiplier Low (LPG) 1732
Circuit Description 1732
Conditions for Setting the DTC 1732
Diagnostic Aids 1733
DTC 241 – Adaptive Lean Fault (High Limit-Gasoline) 1734
Circuit Description 1734
Conditions for Setting the DTC 1734
Diagnostic Aids 1735
DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline) 1738
Circuit Description 1738
Conditions for Setting the DTC 1738
Diagnostic Aids 1738
DTC 243 – Adaptive Learn High (LPG) 1740
Circuit Description 1740
Conditions for Setting the DTC 1740
Diagnostic Aids 1740
DTC 244 – Adaptive Learn Low (LPG) 1744
Circuit Description 1744
Conditions for Setting the DTC 1744
Diagnostic Aids 1744
DTC 261 – System Voltage High 1746
Circuit Description 1746
Conditions for Setting the DTC 1746
DTC 262 – System Voltage Low 1748
Circuit Description 1748
Conditions for Setting the DTC 1748
DTC 411 – Injector Driver 1 Open 1751
Circuit Description 1751
Conditions for Setting the DTC 1751
DTC 412 – Injector Driver 1 Shorted 1754
Circuit Description 1754
Conditions for Setting the DTC 1754
DTC 511 – COP Failure 1757
Circuit Description 1757
Conditions for Setting the DTC 1757
DTC 512 – Invalid Interrupt 1759
Circuit Description 1759
Conditions for Setting the DTC 1759
DTC 513 – A/D Loss 1761
Circuit Description 1761
Conditions for Setting the DTC 1761
DTC 514 – RTI 1 Loss 1763
Circuit Description 1763
Conditions for Setting the DTC 1763
DTC 515 – Flash Checksum Invalid 1765
Circuit Description 1765
Conditions for Setting the DTC 1765
DTC 516 – Ram Failure 1767
Circuit Description 1767
Conditions for Setting the DTC 1767
DTC 531 – External 5V Ref Lower Than Expected 1769
Circuit Description 1769
Conditions for Setting the DTC 1769
DTC 532 – External 5V Ref Higher Than Expected 1772
Circuit Description 1772
Conditions for Setting the DTC 1772
DTC 555 – RTI 2 Loss 1774
Circuit Description 1774
Conditions for Setting the DTC 1774
DTC 556 – RTI 3 Loss 1776
Circuit Description 1776
Conditions for Setting the DTC 1776
DTC 611 – FPP High Voltage 1778
Circuit Description 1778
Conditions for Setting the DTC 1778
DTC 612 – FPP Low Voltage 1781
Circuit Description 1781
Conditions for Setting the DTC 1781
DTC 631 – TPS1 Signal Voltage High 1785
Circuit Description 1785
Conditions for Setting the DTC 1785
DTC 632 – TPS1 Signal Voltage Low 1788
Circuit Description 1788
Conditions for Setting the DTC 1788
DTC 638 – Throttle Unable To Close 1790
Circuit Description 1790
Conditions for Setting the DTC 1790
Diagnostic Aids 1790
DTC 651 – Maximum Govern Speed Override 1794
Circuit Description 1794
Conditions for Setting the DTC 1794
Diagnostic Aids 1794
DTC 652 – Fuel Rev Limit 1796
Circuit Description 1796
Conditions for Setting the DTC 1796
Diagnostic Aids 1796
DTC 653 – Spark Rev Limit 1799
Circuit Description 1799
Conditions for Setting the DTC 1799
Diagnostic Aids 1799
GM 4 3L Wiring Schematics and Connectors 1802
GM 4 3L Diagnostic Trouble Codes 1819
DTC 111 – IAT High Voltage Bosch® TMAP 1819
Circuit Description 1819
Conditions for Setting the DTC 1819
DTC 111 – IAT High Voltage Motorola® TMAP 1822
Circuit Description 1822
Conditions for Setting the DTC 1822
DTC 112 – IAT Low Voltage Bosch® TMap 1824
Circuit Description 1824
Conditions for Setting the DTC 1824
DTC 112 – IAT Low Voltage Motorola® TMAP 1827
Circuit Description 1827
Conditions for Setting the DTC 1827
DTC 113 – IAT Higher Than Expected 1 Bosch® TMAP 1830
Circuit Description 1830
Conditions for Setting the DTC 1830
Diagnostic Aids 1830
DTC 113 – IAT Higher Than Expected 1 Motorola® TMAP 1831
Circuit Description 1831
Conditions for Setting the DTC 1831
Diagnostic Aids 1831
DTC 114 – IAT Higher Than Expected 2 Bosch® TMAP€ 1832
Circuit Description 1832
Conditions for Setting the DTC 1832
Diagnostic Aids 1832
DTC 114 – IAT Higher Than Expected 2 Motorola® TMAP 1833
Circuit Description 1833
Conditions for Setting the DTC 1833
Diagnostic Aids 1833
DTC 115 – Oil Pressure Low 1834
Circuit Description 1834
Conditions for Setting the DTC 1834
DTC 121 – ECT Voltage High 1837
Circuit Description 1837
Conditions for Setting the DTC 1838
DTC 122 – ECT Voltage Low 1840
Circuit Description 1840
Conditions for Setting the DTC 1840
DTC 123 – ECT Higher Than Expected 1 1843
Circuit Description 1843
Conditions for Setting the DTC 1843
DTC 124 – ECT Higher Than Expected 2 1845
Circuit Description 1845
Conditions for Setting the DTC 1845
DTC 131 – MAP High Pressure Bosch® TMAP 1846
Circuit Description 1846
Conditions for Setting the DTC 1846
Diagnostic Aids 1846
DTC 131 – MAP High Pressure Motorola® TMAP 1850
Circuit Description 1850
Conditions for Setting the DTC 1850
Diagnostic Aids 1850
DTC 132 – MAP Low Voltage Bosch® TMAP 1853
Circuit Description 1853
Conditions for Setting the DTC 1853
DTC 132 – MAP Low Voltage Motorola® TMAP 1856
Circuit Description 1856
Conditions for Setting the DTC 1856
DTC 134 – BP High Pressure Bosch® TMAP 1860
Circuit Description 1860
Conditions for Setting the DTC 1860
DTC 134 – BP High Pressure Motorola® TMAP 1862
Circuit Description 1862
Conditions for Setting the DTC 1862
DTC 135 – BP Low Pressure Bosch® TMAP 1864
Circuit Description 1864
Conditions for Setting the DTC 1864
DTC 135 – BP Low Pressure Motorola® TMAP 1868
Circuit Description 1868
Conditions for Setting the DTC 1868
DTC 142 – Crank Sync Noise 1872
Circuit Description 1872
Conditions for setting the DTC 1872
DTC 143 – Never Crank Synced At Start 1875
Circuit Description 1875
Conditions for Setting the DTC 1875
DTC 144 – Camshaft Sensor Loss 1878
Circuit Description 1878
Conditions for Setting the DTC 1878
DTC 145 – Camshaft Sensor Noise 1881
Circuit Description 1881
Conditions for Setting the DTC 1881
DTC 211 – Closed Loop Multiplier High (LPG) 1884
Circuit Description 1884
Conditions for Setting the DTC 1884
Diagnostic Aids 1884
DTC 212 – HO 2 S Open/Inactive 1886
Circuit Description 1886
Conditions for Setting the DTC 1886
DTC 221 – Closed Loop Multiplier High (Gasoline) 1890
Circuit Description 1890
Conditions for Setting the DTC 1890
Diagnostic Aids 1890
DTC 222 – Closed Loop Multiplier Low (Gasoline) 1892
Circuit Description 1892
Conditions for Setting the DTC 1892
Diagnostic Aids 1893
DTC 224 – Closed Loop Multiplier Low (LPG) 1894
Circuit Description 1894
Conditions for Setting the DTC 1894
Diagnostic Aids 1895
DTC 241 – Adaptive Lean Fault (High Limit-Gasoline) 1896
Circuit Description 1896
Conditions for Setting the DTC 1896
Diagnostic Aids 1897
DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline) 1900
Circuit Description 1900
Conditions for Setting the DTC 1900
Diagnostic Aids 1901
DTC 243 – Adaptive Learn High (LPG) 1903
Circuit Description 1903
Conditions for Setting the DTC 1903
Diagnostic Aids 1904
DTC 244 – Adaptive Learn Low (LPG) 1906
Circuit Description 1906
Conditions for Setting the DTC 1906
Diagnostic Aids 1907
DTC 261 – System Voltage High 1908
Circuit Description 1908
Conditions for Setting the DTC 1908
DTC 262 – System Voltage Low 1910
Circuit Description 1910
Conditions for Setting the DTC 1910
DTC 511 – COP Failure 1913
Circuit Description 1913
Conditions for Setting the DTC 1913
DTC 512 – Invalid Interrupt 1915
Circuit Description 1915
Conditions for Setting the DTC 1915
DTC 513 – A/D Loss 1917
Circuit Description 1917
Conditions for Setting the DTC 1917
DTC 514 – RTI 1 Loss 1919
Circuit Description 1919
Conditions for Setting the DTC 1919
DTC 515 – Flash Checksum Invalid 1921
Circuit Description 1921
Conditions for Setting the DTC 1921
DTC 516 – Ram Failure 1923
Circuit Description 1923
Conditions for Setting the DTC 1923
DTC 531 – External 5V Ref Lower Than Expected 1925
Circuit Description 1925
Conditions for Setting the DTC 1925
DTC 532 – External 5V Ref Higher Than Expected 1928
Circuit Description 1928
Conditions for Setting the DTC 1928
DTC 555 – RTI 2 Loss 1930
Circuit Description 1930
Conditions for Setting the DTC 1930
DTC 556 – RTI 3 Loss 1932
Circuit Description 1932
Conditions for Setting the DTC 1932
DTC 611 – FPP High Voltage 1934
Circuit Description 1934
Conditions for Setting the DTC 1934
DTC 612 – FPP Low Voltage 1938
Circuit Description 1938
Conditions for Setting the DTC 1938
DTC 631 – TPS1 Signal Voltage High 1942
Circuit Description 1942
Conditions for Setting the DTC 1942
DTC 632 – TPS1 Signal Voltage Low 1945
Circuit Description 1945
Conditions for Setting the DTC 1945
DTC 638 – Throttle Unable To Close 1948
Circuit Description 1948
Conditions for Setting the DTC 1948
Diagnostic Aids 1949
DTC 651 – Maximum Govern Speed Override 1951
Circuit Description 1951
Conditions for Setting the DTC 1951
Diagnostic Aids 1951
DTC 652 – Fuel Rev Limit 1954
Circuit Description 1954
Conditions for Setting the DTC 1954
Diagnostic Aids 1954
DTC 653 – Spark Rev Limit 1956
Circuit Description 1956
Conditions for Setting the DTC 1956
Diagnostic Aids 1956
Wire Harness Repair 1959
On Vehicle Service Wiring Harness Repair 1959
Connectors and Terminals 1959
Twisted/Shielded Cable Repair 1960
Twisted Leads Repair 1961
Micro-Pack 1962
Metri-Pack 1962
Remove 1962
Weather-Pack 1964
Weather-Pack Terminal Repair 1964
tables 1639
Table 1 OBD System Check 1659
Table 2 Preliminary Checks 1661
Table 3 Intermittent Checks 1662
Table 4 Communication Port C002 1663
Table 5 Coil Connector C003 1663
Table 6 Fuel System Interface C004 1663
Table 7 Oil Pressure Connector C005 1664
Table 8 Distributor Connector C006 1664
Table 9 Magnetic Pickup Connector C007 1664
Table 10 Heated Oxygen Sensor C008 1664
Table 11 Throttle Position Sensor Connector C009 1665
Table 12 Foot Pedal Position Connector C010 1665
Table 13 Governor Motor Connector C011 1665
Table 14 TMAP Connector C012 1665
Table 15 Starter Solenoid C013 1666
Table 16 Engine Coolant Temperature C014 1666
Table 17 Battery Connector C015 1666
Table 18 Alternator Connection C016 1666
Table 19 Battery Connector C017 1666
Table 20 Alternator Connector C018 1667
Table 21 Instrument Panel Connector C019 1667
Table 22 Instrument Panel Connector C020 1667
Table 23 Instrument Panel Connector C021 1668
Table 24 Fuel Trim Valve Connector C022 1668
Table 25 Fuel Lockoff Connector C023 1668
Table 26 Pressure Trim Valve Connector C024 1669
Table 27 Throttle Body Injector Connector C025 1669
Table 28 Relay and Fuse Center 1669
Table 29 DTC 111 – IAT Voltage High (Motorola® TMAP) 1678
Table 30 DTC 112 – IAT Low Voltage (Motorola® TMAP) 1681
Table 31 DTC 115 – Oil Pressure Low 1686
Table 32 Temperature Resistance 1688
Table 33 DTC 121 – ECT VOLTAGE HIGH 1689
Table 34 DTC 122 – ECT Voltage Low 1693
Table 35 DTC 123 – ECT Higher Than Expected 1 1695
Table 36 DTC 124 – ECT Higher Than Expected 2 1697
Table 37 DTC 131 – MAP HIGH PRESSURE (Motorola® TMAP) 1699
Table 38 DTC 132 – MAP Low Voltage (Motorola® TMAP) 1701
Table 39 DTC 134 – BP High Pressure (Motorola® TMAP) 1705
Table 40 DTC 135 – BP Low Pressure (Motorola® TMAP) 1706
Table 41 DTC 142 – Crank Sync Noise 1710
Table 42 DTC 143 – Never Crank Synced At Start 1713
Table 43 DTC 144 – Camshaft Sensor Loss 1716
Table 44 DTC 145 – Camshaft Sensor Noise 1719
Table 45 DTC 211 – Closed Loop Multiplier High (LPG) 1723
Table 46 DTC 212 – HO 2 S Open/Inactive 1725
Table 47 DTC 221 – Closed Loop Multiplier High (Gasoline) 1729
Table 48 DTC 222 – Closed Loop Multiplier Low (Gasoline) 1732
Table 49 DTC 224 – Closed Loop Multiplier Low (LPG) 1734
Table 50 DTC 241 – Adaptive Lean Fault (High Limit-Gasoline) 1736
Table 51 DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline) 1739
Table 52 DTC 243 – Adaptive Learn High (LPG) 1742
Table 53 DTC 244 – Adaptive Learn Low (LPG) 1745
Table 54 DTC 261 – System Voltage High 1747
Table 55 DTC 262 – System Voltage Low 1749
Table 56 DTC 411 – Injector Driver 1 Open 1752
Table 57 DTC 412 – Injector Driver 1 Shorted 1755
Table 58 DTC 511 – COP Failure 1758
Table 59 DTC 512 – Invalid Interrupt 1760
Table 60 DTC 513 – A/D Loss 1762
Table 61 DTC 514 – RTI 1 Loss 1764
Table 62 DTC 515 – Flash Checksum Invalid 1766
Table 63 DTC 516 – Ram Failure 1768
Table 64 DTC 531 – External 5V Ref Lower Than Expected 1770
Table 65 DTC 532 – External 5 V Ref Higher Than Expected 1772
Table 66 DTC 555 – RTI 2 Loss 1775
Table 67 DTC 556 – RTI 3 Loss 1777
Table 68 DTC 611 – FPP High Voltage 1778
Table 69 DTC 612 – FPP Low Voltage 1782
Table 70 DTC 631 – TPS1 Signal Voltage High 1786
Table 71 DTC 632 – TPS1 Signal Voltage Low 1789
Table 72 DTC 638 – Throttle Unable To Close 1791
Table 73 DTC 651 – Maximum Govern Speed Override 1795
Table 74 DTC 652 – Fuel Rev Limit 1797
Table 75 DTC 653 – Spark Rev Limit 1800
Table 76 Communication Port C002 1802
Table 77 Injector Connector C003 1802
Table 78 Injector Connector C004 1802
Table 79 Oil Pressure Connector C005 1803
Table 80 Throttle Position Sensor 1 Connector C006 1803
Table 81 Foot Pedal Position Connector C006A 1803
Table 82 Coil Connector C007 1803
Table 83 Module Connector C008 1804
Table 84 Crank Sensor Connector C009 1804
Table 85 EGO Sensor Connector C010 1804
Table 86 Cam Connector C011 1804
Table 87 Throttle Connector C012 1805
Table 88 Bosch TMAP Connector C013 (Gasoline Fuel System Only) 1805
Table 89 Motorola TMAP Connector C013 (LPG Fuel System Only) 1805
Table 90 Starter Solenoid Connector C014 1805
Table 91 ECT Connector C015 1806
Table 92 Starter Relay C016 1806
Table 93 Power Relay C017 1806
Table 94 Fuel Pump Relay C018 1806
Table 95 Battery Connector C019 1806
Table 96 Alternator Connector C020 1806
Table 97 Alternator Connector C021 1807
Table 98 Instrument Panel Connector C022 1807
Table 99 Instrument Panel Connector C023 1807
Table 100 Instrument Panel Connector C024 1808
Table 101 Fuel Trim Valve Connector C025 1808
Table 102 Fuel Lockoff Connector C026 1808
Table 103 Pressure Trim Valve Connector C027 1809
Table 104 Injector 1 Connector C028 1809
Table 105 Injector 2 Connector C029 1809
Table 106 Injector 3 Connector C030 1809
Table 107 Injector 4 Connector C031 1810
Table 108 Injector 5 Connector C032 1810
Table 109 Injector 6 Connector C033 1810
Table 110 Relay and Fuse Center 1811
Table 111 DTC 111 – IAT Voltage High (Bosch® TMAP) 1820
Table 112 DTC 111 – IAT Voltage High (Motorola® TMAP) 1823
Table 113 DTC 112 – IAT Low Voltage (Bosch® TMAP) 1825
Table 114 DTC 112 – IAT Low Voltage (Motorola® TMAP) 1828
Table 115 DTC 115 – Oil Pressure Low 1835
Table 116 Temperature Resistance 1837
Table 117 DTC 121 – ECT VOLTAGE HIGH 1838
Table 118 DTC 122 – ECT Voltage Low 1841
Table 119 DTC 123 – ECT Higher Than Expected 1 1844
Table 120 DTC 124 – ECT Higher Than Expected 2 1846
Table 121 DTC 131 – MAP High Pressure (Bosch® TMAP) 1847
Table 122 DTC 131 – MAP HIGH PRESSURE (Motorola® TMAP) 1851
Table 123 DTC 132 – MAP Low Voltage (Bosch® TMAP) 1854
Table 124 DTC 132 – MAP Low Voltage (Motorola® TMAP) 1857
Table 125 DTC 134 – BP High Pressure (Bosch® TMAP) 1861
Table 126 DTC 134 – BP High Pressure (Motorola® TMAP) 1863
Table 127 DTC 135 – BP Low Pressure (Bosch® TMAP) 1864
Table 128 DTC 135 – BP Low Pressure (Motorola® TMAP) 1868
Table 129 DTC 142 – Crank Sync Noise 1872
Table 130 DTC 143 – Never Crank Synced At Start 1875
Table 131 DTC 144 – Camshaft Sensor Loss 1878
Table 132 DTC 145 – Camshaft Sensor Noise 1881
Table 133 DTC 211 – Closed Loop Multiplier High (LPG) 1885
Table 134 DTC 212 – HO 2 S Open/Inactive 1887
Table 135 DTC 221 – Closed Loop Multiplier High (Gasoline) 1891
Table 136 DTC 222 – Closed Loop Multiplier Low (Gasoline) 1894
Table 137 DTC 224 – Closed Loop Multiplier Low (LPG) 1896
Table 138 DTC 241 – Adaptive Lean Fault (High Limit-Gasoline) 1898
Table 139 DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline) 1901
Table 140 DTC 243 – Adaptive Learn High (LPG) 1904
Table 141 DTC 244 – Adaptive Learn Low (LPG) 1907
Table 142 DTC 261 – System Voltage High 1909
Table 143 DTC 262 – System Voltage Low 1911
Table 144 DTC 511 – COP Failure 1914
Table 145 DTC 512 – Invalid Interrupt 1916
Table 146 DTC 513 – A/D Loss 1918
Table 147 DTC 514 – RTI 1 Loss 1920
Table 148 DTC 515 – Flash Checksum Invalid 1922
Table 149 DTC 516 – Ram Failure 1924
Table 150 DTC 531 – External 5V Ref Lower Than Expected 1926
Table 151 DTC 532 – External 5 V Ref Higher Than Expected 1928
Table 152 DTC 555 – RTI 2 Loss 1931
Table 153 DTC 556 – RTI 3 Loss 1933
Table 154 DTC 611 – FPP High Voltage 1935
Table 155 DTC 612 – FPP Low Voltage 1939
Table 156 DTC 631 – TPS1 Signal Voltage High 1943
Table 157 DTC 632 – TPS1 Signal Voltage Low 1946
Table 158 DTC 638 – Throttle Unable To Close 1949
Table 159 DTC 651 – Maximum Govern Speed Override 1952
Table 160 DTC 652 – Fuel Rev Limit 1955
Table 161 DTC 653 – Spark Rev Limit 1957
524214123 2200YRM1104 (03 2004) US EN 1969
toc 1969
Electrical System 1969
Safety Precautions Maintenance and Repair 1970
Ignition System 1973
General 1973
Ignition Timing Adjustment 1973
Spark Plugs Check 1973
Spark Plug Wires Check 1974
Distributor Repair 1974
Remove 1974
Disassemble 1974
Inspect 1975
Assemble 1975
Install 1976
Ignition Coil Check 1976
Primary Coil Winding 1976
Secondary Coil Winding 1976
Starter Repair 1977
General 1977
Remove 1977
No-Load Test 1978
Magnetic Switch Test 1979
Pull-Out Test 1979
Holding Coil Test 1979
Return Test 1979
Inspection of the Pinion Movement 1979
Disassemble 1980
Inspect 1981
Armature 1981
Brush and Brush Holder 1982
Magnetic Switch Check 1982
Assemble 1983
Alternator Repair 1984
General 1984
Charging System Inspection 1984
Output Current Check 1985
No-Load Adjusted Voltage Check 1985
Remove and Disassemble 1985
Inspection 1987
Stator Coil Check 1987
Rotor Check 1987
Rectifier Check 1988
Brushes and Springs 1988
Bearings Inspection 1988
Assemble and Install 1989
Troubleshooting 1989
Battery and Related Parts 1989
Magnetic Switch and Related Parts 1990
tables 1969
Table 1 Engine Specification Table 1973
Table 2 Spark Plug Wire Table 1974
Table 3 Starter Specifications 1977
Table 4 Problem Diagnosis Chart 1978
Table 5 Rectifier Check Table 1988
524214124 0900YRM1089 (04 2004) US EN 1995
toc 1995
Gasoline Fuel System 1995
Safety Precautions Maintenance and Repair 1996
General 2003
Description of Operation 2003
Intake-Air System 2004
Throttle Body 2005
Idle Air Control (IAC) Valve 2005
Electronic Governor 2005
Fuel System 2007
Fuel Injector 2008
Pressure Regulator 2009
Exhaust System 2009
Three Way Catalytic Converter (TWC) 2011
Control System 2011
Intake Air Temperature (IAT) Sensor 2013
Mass Air Flow (MAF) Sensor 2014
Throttle Position (TP) Sensor 2015
Camshaft Position (CMP) Sensor 2016
Engine Coolant Temperature (ECT) Sensor 2017
Boost Sensor 2018
Heated Oxygen Sensor (HO 2 S) 2019
Electronic Governor Sensor 2020
Engine Control Unit (ECU) 2021
Diagnosis System 2023
Service Code Check 2023
Procedure After the Failure Correction 2023
Service Code P0102 MAF Sensor Signals: Too Low Input Voltage to 2026
Failure Detection Condition 2026
Fail/Safe 2026
Possible Sources 2026
Service Code P0103 MAF Sensor Signals: Too High Input Voltage to 2027
Failure Detection Condition 2027
Fail/Safe 2027
Possible Sources 2027
Service Code P0112 IAT Sensor Signals: Too Low Input Voltage to 2028
Failure Detection Condition 2028
Fail/Safe 2028
Possible Sources 2028
Service Code P0113 IAT Sensor Signals: Too High Input Voltage to 2029
Failure Detection Condition 2029
Fail/Safe 2029
Possible Sources 2029
Service Code P0117 ECT Sensor Signals: Too Low Input Voltage to 2030
Failure Detection Condition 2030
Fail/Safe 2030
Possible Sources 2030
Service Code P0118 ECT Sensor Signals: Too High Input Voltage to 2031
Failure Detection Condition 2031
Fail/Safe 2031
Possible Sources 2031
Service Code P0122 TP Sensor Signals: Too Low Input Voltage to E 2032
Failure Detection Condition 2032
Fail/Safe 2032
Possible Sources 2032
Service Code P0123 TP Sensor Signals: Too High Input Voltage to 2033
Failure Detection Condition 2033
Fail/Safe 2033
Possible Sources 2033
Service Code P0131 HO 2 S Signals: Too Low Input Voltage to ECU 2034
Failure Detection Condition 2034
Fail/Safe 2034
Possible Sources 2034
Service Code P0132 HO 2 S Signals: Too High Input Voltage to ECU 2035
Failure Detection Conditions 2035
Fail/Safe 2035
Possible Sources 2035
Service Code P0134 HO 2 S Signals: Inactive 2036
Failure Detection Condition 2036
Fail/Safe 2036
Possible Sources 2036
Service Code P0171 Fuel Injection Control System: A/F Ratio Lean 2040
Failure Detection Condition 2040
Possible Sources 2040
Service Code P0172 Fuel Injection Control System: A/F Rich 2044
Failure Detection Condition 2044
Possible Sources 2044
Service Code P0340 CMP Sensor Signals 2046
Failure Detection Condition 2046
Fail/Safe 2046
Possible sources 2046
Service Code P1504 IAC System 2047
Failure Detection Condition 2047
Fail/Safe 2047
Possible Sources 2047
Service Code P1562 Battery Backup Power Supply 2048
Failure Detection Condition 2048
Possible Sources 2048
Service Code P1608 ECU Internal Circuit Breakage 2048
Failure Detection Condition 2048
Possible Sources 2048
Data Monitor 2049
Data Monitor Check 2049
Freeze Frame Data 2051
Simulation Check 2051
Drive Cycle 2052
Pending Code 2053
Engine Tune-up 2053
Engine Tune-Up Preparation 2053
Idle Speed Adjustment 2053
Idle-Up Speed Check 2053
Idle Mixture Check 2054
Intake-Air System 2054
Intake-Air System Manifold Vacuum Check 2054
Throttle Body 2054
Remove 2056
Install 2056
Electronic Governor 2056
Resistance Check 2056
Remove 2056
Install 2056
Intake-Air Control (IAC) Valve 2057
Resistance Check 2057
Remove 2057
Install 2057
Intake Manifold 2057
Remove 2057
Install 2058
Fuel System 2058
Before Repair Procedure 2058
Fuel Line Safety Procedure 2058
After Repair Procedure 2059
Fuel Hose, Install 2059
Fuel Leakage Check 2060
Fuel Line Pressure Check 2060
Fuel Injector 2061
Remove 2061
Install 2062
Resistance, Inspect 2062
Fuel Leakage Test 2062
Volume Test 2063
Pressure Regulator 2063
Remove 2063
Install 2064
Operation Check 2064
Exhaust System 2064
Exhaust System, Inspect 2064
Three Way Catalytic (TWC) Converter 2064
Remove and Install 2064
Exhaust Manifold 2064
Remove 2064
Install 2066
Positive Crankcase Ventilation (PCV) Valve 2066
Remove 2066
Inspect 2066
Install 2066
Control System 2066
Engine Control Unit (ECU) 2066
Remove 2066
Install 2067
ECU, Inspect 2067
Using a Voltmeter 2067
Using an Oscilloscope (Reference) 2070
Intake Air Temperature (IAT) Sensor 2073
Remove 2073
Inspect 2073
Install 2073
Mass Air Flow (MAF) Sensor 2073
Inspect 2073
Voltage Check 2073
Remove 2074
Install 2074
Throttle Position (TP) Sensor 2074
Resistance Check 2074
TP Sensor, Adjust 2074
Remove 2075
Install 2075
Engine Coolant Temperature (ECT) Sensor 2075
Resistance Check 2075
Remove 2076
Install 2076
Camshaft Position (CMP) Sensor 2076
Voltage Check 2076
Heated Oxygen Sensor (HO 2 S) 2077
Voltage Check 2077
Heater Resistance Check 2077
Boost Sensor 2077
Inspect 2077
Remove 2078
Install 2078
Electronic Governor Sensor Check 2078
Troubleshooting 2079
Intermittent Concern Troubleshooting 2079
Vibration Method 2079
Inspection Method for Switch Connectors or Wires 2079
Inspection Method for Sensor Connectors or Wires 2079
Inspection Method for Sensors 2080
Inspection Method for Actuators or Relays 2080
Water Sprinkling Method 2080
Symptom Diagnostics 2080
Engine Control System Operation Inspection 2084
Input Signal System Investigation Procedure 2084
Finding Unusual Signals 2084
Locating the Source of Unusual Signals 2084
Investigate the Input Signal System for Variable Resistance Type 2084
Investigate the Standard Power Supply System for Variable Resist 2085
Investigate the Ground (GND) System for Variable Resistance Type 2085
Investigate the Input Signal System for Variable Resistance Type 2085
Investigate the Electrical Supply System for Variable Resistance 2086
Investigate the Ground (GND) System for Variable Resistance Type 2086
Investigate the Input Signal System for Thermistor Type 2086
Investigate the Ground (GND) System for Thermistor Type 2086
Technical Data 2087
tables 1995
Table 1 Specifications 2004
Table 2 Specifications 2008
Table 3 Specifications 2009
Table 4 Specifications 2011
Table 5 Specifications 2011
Table 6 Engine Control Unit (ECU) Functions 2021
Table 7 Engine Control System Relation 2022
Table 8 Service Codes 2024
Table 9 Diagnosis Procedure 2037
Table 10 Diagnosis Procedure 2040
Table 11 Diagnosis Procedure 2044
Table 12 Monitor Item Chart 2049
Table 13 Freeze Frame Data Monitor Chart 2051
Table 14 Simulation Item Chart 2051
Table 15 Drive Cycle Chart 2053
Table 16 Specification 2053
Table 17 PCV Valve Specifications 2066
Table 18 ECU Terminal Voltage (Reference) 2068
Table 19 SGT Signal 2070
Table 20 HO 2 S Signal 2071
Table 21 IGT Signal 2071
Table 22 Fuel Injection Control Signal 2072
Table 23 IAC Signal 2072
Table 24 Specification 2073
Table 25 Closed Throttle Position Specifications 2075
Table 26 Specifications 2076
Table 27 Specifications 2077
Table 28 Specifications 2078
Table 29 Troubleshooting 2081
Table 30 List of Possible Causes 2083
Table 31 Gasoline Fuel Systems Technical Data 2087
524217573 2200YRM1092 (04 2005) US EN 2091
toc 2091
Governor Electronic Control Module (ECM) Diagnostic Troubleshoot 2091
Safety Precautions Maintenance and Repair 2092
General 2097
Description of ECM Based Diagnostics 2097
Definition of Terms 2097
Diagnostics Overview of the Spectrum System 2097
Malfunction Indicator Lamp (MIL) 2097
Spectrum Diagnostic Trouble Codes (DTC) 2098
Using a Laptop Computer to Diagnose the Spectrum System 2098
Installing the Spectrum Diagnostic Software 2098
Connecting a Laptop Computer to the Spectrum System 2098
Diagnostic Trouble Codes 2099
Checking Diagnostic Trouble Codes 2099
Clearing Diagnostic Trouble Codes 2099
DATA Stream 2100
Reading Sensor and Actuator Values 2100
Graphing and Data Logging 2101
Throttle Test 2102
Using a Diagnostic Jumper to Diagnose the ECM System 2102
On-Board Diagnostics System Check/Malfunction Indicator Lamp 2103
Circuit Description 2103
Preliminary and Intermittent Checks 2106
DTC 115 – Oil Pressure Low 2108
Circuit Description 2108
Conditions for Setting the DTC 2108
DTC 121 – ECT Voltage High 2111
Circuit Description 2111
Conditions for Setting the DTC 2111
DTC 122 – ECT Low Voltage 2114
Circuit Description 2114
Conditions for Setting the DTC 2114
DTC 123 – ECT Higher Than Expected 1 2117
Circuit Description 2117
Conditions for Setting the DTC 2117
DTC 131 – MAP High Pressure 2119
Circuit Description 2119
Conditions for Setting the DTC 2119
Diagnostic Aids 2119
DTC 132 – MAP Low Voltage 2122
Circuit Description 2122
Conditions for Setting the DTC 2122
DTC 134 – BP High Pressure 2126
Circuit Description 2126
Conditions for Setting the DTC 2126
DTC 135 – BP Low Pressure 2128
Circuit Description 2128
Conditions for Setting the DTC 2128
DTC 261 – System Voltage Low 2132
Circuit Description 2132
Conditions for Setting the DTC 2132
DTC 262 – System Voltage High 2134
Circuit Description 2134
Conditions for Setting the DTC 2134
DTC 511 – COP Failure 2136
Circuit Description 2136
Conditions for Setting the DTC 2136
DTC 512 – Invalid Interrupt 2138
Circuit Description 2138
Conditions for Setting the DTC 2138
DTC 513 – A/D Loss 2140
Circuit Description 2140
Conditions for Setting the DTC 2140
DTC 514 – RTI 1 Loss 2142
Circuit Description 2142
Conditions for Setting the DTC 2142
DTC 515 – Flash Checksum Invalid 2144
Circuit Description 2144
Conditions for Setting the DTC 2144
DTC 516 – Ram Failure 2146
Circuit Description 2146
Conditions for Setting the DTC 2146
DTC 531 – External 5V Ref Lower Than Expected 2148
Circuit Description 2148
Conditions for Setting the DTC 2148
DTC 532 – External 5V Ref Higher Than Expected 2150
Circuit Description 2150
Conditions for Setting the DTC 2150
DTC 555 – RTI 2 Loss 2152
Circuit Description 2152
Conditions for Setting the DTC 2152
DTC 556 – RTI 3 Loss 2154
Circuit Description 2154
Conditions for Setting the DTC 2154
DTC 611 – FPP High Voltage 2156
Circuit Description 2156
Conditions for Setting the DTC 2156
DTC 612 – FPP Low Voltage 2160
Circuit Description 2160
Conditions for Setting the DTC 2160
DTC 631 – TPS1 Signal Voltage High 2164
Circuit Description 2164
Conditions for Setting the DTC 2164
DTC 632 – TPS1 Signal Voltage Low 2167
Circuit Description 2167
Conditions for Setting the DTC 2167
DTC 633 – TPS2 Signal Voltage High 2170
Circuit Description 2170
Conditions for Setting the DTC 2170
DTC 634 – TPS2 Signal Voltage Low 2173
Circuit Description 2173
Conditions for Setting the DTC 2173
DTC 635 – TPS1 Higher Than TPS2 2176
Circuit Description 2176
Conditions for Setting the DTC 2176
DTC 636 – TPS1 Lower Than TPS2 2179
Circuit Description 2179
Conditions for Setting the DTC 2179
DTC 637 – Throttle Unable To Open 2182
Circuit Description 2182
Conditions for Setting the DTC 2182
DTC 638 – Throttle Unable To Close 2185
Circuit Description 2185
Conditions for Setting the DTC 2185
DTC 652 – Rev Limit 2188
Circuit Description 2188
Conditions for Setting the DTC 2188
DTC 653 – Rev Limit 2190
Circuit Description 2190
Conditions for Setting the DTC 2190
DTC 712 – External Fault Input Low 2193
Circuit Description 2193
Conditions for Setting the DTC 2193
Diagnostic Aids 2193
Wire Harness Repair 2194
On Vehicle Service Wiring Harness Repair 2194
Connectors and Terminals 2194
Twisted/Shielded Cable Repair 2195
Twisted Leads Repair 2196
Micro-Pack 2197
Metri-Pack 2197
Remove 2197
Weather-Pack 2199
Weather-Pack Terminal Repair 2199
tables 2091
Table 1 OBD System Check 2104
Table 2 Preliminary Checks 2106
Table 3 Intermittent Checks 2107
Table 4 DTC 115 – Oil Pressure Low 2109
Table 5 Temperature Resistance 2111
Table 6 DTC 121 – ECT Voltage High 2112
Table 7 DTC 122 – ECT Low Voltage 2115
Table 8 DTC 123 – ECT Higher Than Expected 1 2118
Table 9 DTC 131 – MAP High Pressure 2120
Table 10 DTC 132 – MAP Low Voltage 2122
Table 11 DTC 134 – BP High Pressure 2127
Table 12 DTC 135 – BP Low Pressure 2128
Table 13 DTC 261 – System Voltage Low 2132
Table 14 DTC 262 – System Voltage High 2135
Table 15 DTC 511 – COP Failure 2137
Table 16 DTC 512 – Invalid Interrupt 2139
Table 17 DTC 513 – A/D Loss 2141
Table 18 DTC 514 – RTI 1 Loss 2143
Table 19 DTC 515 – Flash Checksum Invalid 2145
Table 20 DTC 516 – Ram Failure 2147
Table 21 DTC 531 – External 5V Ref Lower Than Expected 2148
Table 22 DTC 532 – External 5 V Ref Higher Than Expected 2150
Table 23 DTC 555 – RTI 2 Loss 2153
Table 24 DTC 556 – RTI 3 Loss 2155
Table 25 DTC 611 – FPP High Voltage 2157
Table 26 DTC 612 – FPP Low Voltage 2161
Table 27 DTC 631 – TPS1 Signal Voltage High 2165
Table 28 DTC 632 – TPS1 Signal Voltage Low 2168
Table 29 DTC 633 – TPS2 Signal Voltage High 2171
Table 30 DTC 634 – TPS2 Signal Voltage Low 2174
Table 31 DTC 635 – TPS1 Higher Than TPS2 2177
Table 32 DTC 636 – TPS1 Lower Than TPS2 2180
Table 33 DTC 637 – Throttle Unable To Open 2183
Table 34 DTC 638 – Throttle Unable To Close 2186
Table 35 DTC 652 – Rev Limit 2189
Table 36 DTC 653 – Rev Limit 2191