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Yale Forklift E813 (GPGLPGDP070-090LJMJ; GPGLPGDP100-120MJ) Service Manual – PDF DOWNLOAD
Language : English
Pages : 1394
Downloadable : Yes
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TABLE OF CONTENTS:
Yale Forklift E813 (GPGLPGDP070-090LJMJ; GPGLPGDP100-120MJ) Service Manual – PDF DOWNLOAD
524150791 2200YRM0002 (01 2016) US EN 1
General 5
Description 6
Alternator Repair 8
Alternator Type A 8
Remove and Disassemble 8
Clean 10
Assemble 10
Install 11
Alternator Type B 14
Remove and Disassemble 14
Clean 14
Assemble 15
Install 16
General Check and Adjustment 16
Low Output Check (Type A or Type B) 17
High Output Check (Type A or Type B) 20
Brushes Circuit Check 21
Delco Alternators 21
Motorola Alternators 21
Diodes Check 22
Diode Bridge Check 22
Delco and Leece-Neville Alternators 22
Motorola Alternators 22
Rotor Field Winding Check 23
Stator Windings Check 24
Voltage Regulator Check 24
Troubleshooting 24
524150797 8000YRM0231 (02 2023) US EN 29
General 35
Threaded Fasteners 35
Nomenclature, Threads 35
Strength Identification 36
Cotter (Split) Pins 37
Fastener Torque Tables 42
Conversion Table 44
524150797 8000YRM0231 (03 2020) US EN 51
General 55
Threaded Fasteners 55
Nomenclature, Threads 55
Strength Identification 56
Cotter (Split) Pins 57
Fastener Torque Tables 62
Conversion Table 64
524153606 1300YRM0801 (08 2001) US EN 71
toc 71
Hydrostatic Transmission 71
Safety Precautions Maintenance and Repair 72
General 75
TransLink—42 User Interface Software 75
Connecting PC to TCM 75
Transmission Fluid 76
Startup and Calibration 78
Startup Procedure Following Service or Repairs 78
Throttle System Calibration 79
Hydrostatic Pump Repair 80
Remove 80
Install 81
Charge Pump Repair 83
Remove 83
Inspect 84
Install 84
Pump Control Valve Repair 84
Remove 84
Inspect 84
Install 84
Replace Pilot Solenoid 85
Replace Directional Solenoid Pair 85
Clean or Replace Pilot Supply Filter Disk 86
Replace Loop Relief Cartridges 86
Replace Filter Cartridge 86
Replace Filter Head 86
Drive Axle Repair 86
Remove and Disassemble 86
Inspect 87
Assemble and Install 87
Axle Valve Repair 89
Remove 89
Inspect 89
Install 90
Replace Pressure Reducing Valve 90
Replace Shuttle Valve 90
Replace Charge Supply Regulator 90
Replace Retard Valve 90
Replace Temperature Sensor 90
Transmission Control Module (TCM) Replacement 91
Throttle Pedal/ Foot Directional Control Pedal Repair 92
Remove Standard Throttle Pedal 92
Install Standard Throttle Pedal 92
Remove and Disassemble Foot Directional Control Pedal 92
Assemble and Install Foot Directional Control Pedal 93
Replace Throttle Pedal Position Sensor 95
Replace Throttle Pedal Switch 95
Throttle-Up Assembly Repair 96
Remove 96
Inspect 96
Install 96
Replace Throttle Motor 97
Replace Engine Throttle Position Sensor 97
Throttle-Up Switch Assembly Repair 97
Remove 97
Install 97
Replace Lift Lever Position Sensor 97
Replace Throttle-Up Switches 98
Hydrostatic Drive Checks and Adjustments 98
Swashplate Positioning Cylinder 98
Truck Travel Speed Limit Adjustment 99
Charge Pressure 99
Pilot Supply Pressure 99
Pilot Pressure 100
POR Pressure 100
Loop Pressure 100
Throttle Pedal/ Foot Directional Control Pedal Checks and Adjust 101
Throttle Cable 101
Pedal Stop 101
Standard Throttle Pedal 101
Foot Directional Control Pedal 101
Foot Directional Control Pedal Operation 101
Throttle Pedal Position Sensor 101
Throttle Pedal Switch 102
Foot Directional Control Pedal Switch 103
Throttle-Up Assembly Checks and Adjustments 104
Engine Throttle Position Sensor 104
Throttle-Up Motor 104
Throttle-Up Switch Assembly Checks and Adjustments 105
Throttle-Up Switches 105
Lift Lever Position Sensor 105
Sensor Checks 106
Charge Pressure Sensor 106
Brake Pressure Sensor 106
Oil Temperature Sensor 107
Speed Sensor 107
Event Codes 108
Troubleshooting 114
tables 71
Table 1 Charge and Brake Sensor Outputs 106
Table 2 Oil Temperature Sensor Outputs 107
Table 3 Speed Sensor Outputs 107
524153897 0600YRM0590 (04 2014) US EN 123
524153904 1600YRM0732 (10 2003) US EN 175
toc 175
Steering Control Unit 175
Safety Precautions Maintenance and Repair 176
General 179
Description 179
Operation 179
Steering Wheel and Column Assembly Repair 181
Remove and Disassemble 181
Assemble and Install 181
Steering Control Unit 184
Disassemble 184
Clean 186
Assemble 187
System Air Removal 190
Troubleshooting 190
524153909 1900YRM0743 (06 2005) US EN 195
toc 195
Hydraulic System 195
Safety Precautions Maintenance and Repair 196
General 199
Description 199
Operation 201
Hydraulic Pump GLP/GDP 3 5-5 5LJ/MJ (GP/GLP/GDP70-120LJ/MJ) 201
Hydraulic Pump GC070-120LJ/MJ 201
Main Control Valve 201
Steering Control Unit 202
Specifications 202
Hydraulic System Capacity (Powershift) 202
Hydraulic System Capacity (Hydrostatic) 202
Hydraulic Tank Capacity (Powershift and Hydrostatic) 203
Hydraulic Tank Capacity 203
Relief Pressures @ 2200 RPM, 50 to 80 C ( 120 to 180 F) 203
Hydraulic Pump Flow to Valve 203
Steering Priority Flow 203
Troubleshooting 203
Lift, Lower and Tilt Circuit 204
Steering Circuit 205
524153910 2000YRM0754 (12 2003) US EN 209
toc 209
Main Control Valve 209
Safety Precautions Maintenance and Repair 210
General 213
Description 213
Operation 213
Lift Section 213
Tilt and Auxiliary Sections 217
Reattaching the Clevis End of the Tilt Spool 218
Relief Valve 218
Main Control Valve Repair 218
Remove and Disassemble 218
Clean and Inspect 220
Assemble 222
Install 222
Pressure Relief Valve Check and Adjustment 223
Main Relief Valve (Lift) 223
Steering Relief Valve 223
Secondary Relief Valve (Tilt and Auxiliary) 226
Specifications 227
Troubleshooting 227
524153913 2200YRM0755 (10 2003) US EN 233
toc 233
Starter 233
Safety Precautions Maintenance and Repair 234
General 237
Description 237
Yoke Assembly 238
Armature Assembly 238
Clutch Assembly 238
Magnetic Switch Assembly 238
Operation 238
Starter Repair 239
Remove 239
Disassemble 240
Clean 243
Assemble 244
Install 247
General Checks and Adjustments 247
Armature Tests 248
Armature Short Circuit Test 248
Armature Winding Ground Test 248
Commutator Run-Out Test 248
Yoke Test 249
Brush and Brush Holder Check 249
Brush Holder Insulation Test 249
Clutch Test 249
Magnetic Switch Test 250
Pull-In Test 250
Hold-In Test 250
Return Test 250
Performance Tests 251
No-Load Test 251
Troubleshooting 251
524153915 2200YRM0756 (02 2007) US EN 257
toc 257
Instrument Panel Indicators and Senders 257
Safety Precautions Maintenance and Repair 258
General 261
Description 261
Instruments and Senders 261
Password Function 267
Supervisor Password Function 267
Entering Operator Passwords 267
Deleting Operator Passwords 268
Retrieve the Most Recent Operator Password Used to Enable the Tr 268
Display All Operator Passwords Programmed Into the System 268
Enable and Disable Operator Passwords Function 268
Allow Supervisor Password to Enable the Truck to Start 268
Operator Passwords Function 268
Component Replacement – General Information 269
Sender Replacement 269
Fuel Level Sender 269
Pressure and Temperature Sender 270
Seat Sensor, Operator Presence System (OPS) 271
Remove 271
Install 271
Operator Presence System Module Replacement 271
Remove 271
Install 273
Display Panel Replacement 274
Specifications 276
Troubleshooting 277
Troubleshooting For Operator Presence System GP/GLP/GDP70-120LJ/ 278
Troubleshooting For Operator Presence System GC70-120LJ/MJ (C818 280
tables 257
Table 1 Instrument Panel Description 262
Table 2 Sender Description 266
Table 3 Meter and Sender Specifications 276
Table 4 Troubleshooting Procedure for the Operator Presence Mod 278
Table 5 Troubleshooting Procedure for the Operator Presence Mod 280
524153919 4000YRM0741 (03 2005) US EN 285
toc 285
Lift Cylinders 285
Safety Precautions Maintenance and Repair 286
Safety Procedures When Working Near Mast 289
General 291
Description 291
Lowering Control Valve (Velocity Fuse) 291
Lift Cylinder Repair 294
Remove 294
Disassemble 295
Assemble 295
Install 295
Lift System Leak Check 296
Troubleshooting 297
524153920 4000YRM0736 (07 2010) US EN 301
toc 301
Masts 301
Safety Precautions Maintenance and Repair 302
General 305
Description and Operation 305
Carriages 305
Two-Stage Mast With Limited Free-Lift 305
Two-Stage Mast With Full Free-Lift 306
Three-Stage Mast With Full Free-Lift 307
Safety Procedures When Working Near Mast 309
Fork Replacement 311
Remove 312
Install 312
Carriage Repair 313
Remove 313
Sideshift Carriage Repair 315
Remove 315
Disassemble 315
Assemble 315
Install 315
Two-Stage Mast With Limited Free-Lift Repair 317
Remove, GLP/GDP3 5-5 5LJ/MJ (GP/GLP/GDP070-120LJ/MJ) Model Lift 317
Remove, GC070-120LJ/MJ, ERC070-120HG (A839), and ERC35-55HG (ERC 319
Disassemble 322
Clean and Inspect 322
Assemble 323
Install, GLP/GDP3 5-5 5LJ/MJ (GP/GLP/GDP070-120LJ/MJ) Lift Truck 324
Install, GC070-120LJ/MJ, ERC070-120HG (A839), and ERC35-55HG (ER 326
Two-Stage Mast With Full Free-Lift Repair 328
Remove 328
Disassemble 328
Clean and Inspect 330
Assemble 330
Install 330
Three-Stage Mast With Full Free-Lift Repair 332
Remove 332
Disassemble 332
Clean and Inspect 336
Assemble 336
Install 337
Mast Operation Check 343
Lift and Tilt System Leak Check 344
Lift System 344
Tilt System 345
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment 346
Lift Chain Adjustments 348
Mast Adjustments 350
Carriage Adjustment 352
Troubleshooting 353
tables 301
Table 1 Tilt Cylinder Leak Check Specifications, GC070-120LJ/MJ 345
Table 2 Hook-Type Carriage Chain Adjustment 348
Table 3 Pin-Type Carriage Chain Adjustment 349
524173800 0100YRM0726 (02 2007) US EN 359
toc 359
Frame 359
Safety Precautions Maintenance and Repair 360
General 363
Description 363
Counterweight Repair 363
Remove 363
Install 364
Hood Repair 364
Remove 364
Install 364
Overhead Guard Repair 366
Remove 366
Inspect 366
Install 366
LED Backup and Brake Lights, Replace 366
Remove 366
Install 366
Operator Restraint System Repair 367
Automatic Locking Retractor (ALR) 367
Emergency Locking Retractor (ELR) 368
Radiator Repair 369
Remove 369
Install 369
Exhaust System Repair 371
Muffler 371
Remove 371
Install 371
LPG/Gas Engine Exhaust Pipe – Lift Trucks Without Low Emissions 374
Remove 374
Install 374
EPA Compliant LPG/Gas Engine Exhaust System 374
Remove 374
Install 376
Diesel Engine Exhaust Pipe 376
Remove 376
Install 378
Engine Repair 378
Remove 378
Install 380
Throttle Pedal Adjustment 382
Perkins 1104C-44(RE) Diesel Engine 382
Lift Trucks With an Accelerator Pedal 382
Lift Trucks With a Foot Directional Control Pedal 383
Fuel and Hydraulic Tanks Repair 385
Inspect 385
Small Leaks, Repair 385
Large Leaks, Repair 385
Clean 385
Steam Method 385
Chemical Solution Method 385
Other Preparation Methods for Repair 386
Safety Labels 386
tables 359
Table 1 Weight of Counterweights 363
524173801 0100YRM0778 (06 2004) US EN 391
toc 391
Operators Cab 391
Safety Precautions Maintenance and Repair 392
General 395
Cab Repair 396
Remove 396
Install 397
Switch Panel 397
Window Wipers Replacement 398
Front Wiper Assembly 398
Rear Wiper Assembly 398
Door Handle Assembly 400
Fuse Panel 401
Heater Assembly 401
Remove 401
Install 401
Window Replacement 403
Options 405
Rear Strobe Lights 405
Heavy-Duty Air Cleaner 405
Label Replacement 406
Electrical Schematics 406
tables 391
Table 1 Material Specifications for Cab Windows 403
524173802 0700YRM0740 (02 2004) US EN 411
toc 411
Cooling System 411
Safety Precautions Maintenance and Repair 412
General 415
Description 415
Radiator 415
Radiator Cap 415
Thermostat 415
Water Pump 416
Fan and Fan Shroud 416
Drive Shaft 416
Cooling System Checks 416
Exhaust Leaks into Cooling System 416
Radiator Repair 416
Checks 416
Clean 416
Cooling System 418
Drain 418
Fill 418
Water Pump Repair 418
Checks 418
Thermostat Repair 419
Checks 419
Fan Assembly Repair 419
Remove 419
Inspect 419
Install 419
Fan Belt Repair 422
Remove 422
Install 422
Drive Shaft Repair 422
Remove 422
Install 422
Troubleshooting 422
524173804 1300YRM0727 (06 2004) US EN 427
toc 427
Two-Speed Powershift Transmission 427
Safety Precautions Maintenance and Repair 428
General 431
Mechanical Description 431
Torque Converter 432
Transmission Pump 432
Shaft Assemblies 432
Input (Reverse) Shaft 432
Counter (Forward) Clutch Shafts 432
Clutch Assemblies 432
Output Gear and Pinion 433
Electronic Control Unit 433
Hydraulic Operation 434
Torque Converter 434
Seal Rings 435
Control Valve 435
Clutch Pressure Regulator 435
Inching Spool Assembly 435
Direction Spool 437
Modulator Circuit 437
Torque Converter Regulator 437
Foot Directional Control Pedal 438
Foot Directional Control Pedal Start Circuit 438
Direction Control Lever 439
Oil Flow Diagrams 439
Neutral 440
Modulator Operation 441
Forward-Low 443
Forward-Low-Inching 443
Reverse 449
524173805 1300YRM0728 (08 2006) US EN 457
toc 457
Two-Speed Powershift Transmission 457
Safety Precautions Maintenance and Repair 458
General 461
Transmission Repair 461
Remove 461
Install 461
Clutch Packs Repair 464
Remove and Disassemble 464
Clutch Assemblies, Disassemble 467
Inspect 469
Assemble and Install 470
Clutch Assemblies, Assemble and Install 470
Differential Repair 478
Remove and Disassemble 478
Inspect 479
Original Parts, Assemble and Install 479
New Parts, Assemble and Install 479
Adjustments With Original Shim Pack 480
Adjustments Without Original Shim Pack 481
Differential and Ring Gear Assembly, Assemble 483
Control Valve Repair 488
Remove and Disassemble 488
Inspect 490
Assemble and Install 490
Foot Directional Control Pedal Repair 491
Remove and Disassemble 491
Assemble and Install 491
Direction Control Lever 494
Remove and Disassemble 494
Assemble and Install 494
Stall Test 495
Inching/Brake Pedal Adjustment 496
Foot Directional Control Pedal Neutral Start Switch Adjustment 498
Foot Directional Control Pedal Neutral Start Switch Test 499
Test 1 499
Test 2 499
Electronic Control Unit Check 500
Oil Pressure Check 501
Transmission Pump Relief Valve, Test Port 1, Check 502
Input (Reverse) Clutch Pressure, Test Port 2, Check 502
Counter (Forward) Clutch Pressure, Test Ports 3 and 4, Check 502
Torque Converter Regulator, Test Port 5, Check 502
Lubrication Circuit Oil Pressure, Test Port 6, Check 502
Modulator Pressure, Test Port 7, Check 502
2-Speed Transmission Will Not Shift 503
Troubleshooting 504
Troubleshooting – Pressure Tests 507
tables 457
Table 1 Pinion Variation Numbers Examples 480
Table 2 Ring and Pinion Tooth Contact Adjustment 486
Table 3 Stall Speeds (New Engines) 495
Table 4 Electronic Control Unit Connector 500
Table 5 Transmission Pressure Port Check 501
524173806 1400YRM0731 (09 2003) US EN 511
toc 511
Drive Axle 511
Safety Precautions Maintenance and Repair 512
General 515
Description 515
Drive Axle Repair 515
Remove and Disassemble 515
Clean and Inspect 517
Assemble and Install 517
Troubleshooting 519
524173807 1600YRM0733 (09 2003) US EN 523
toc 523
Steering Axle 523
Safety Precautions Maintenance and Repair 524
General 527
Description 527
Steering Axle Assembly Repair 528
Remove 528
Install 528
Wheels and Hub Repair 529
Remove and Disassemble 529
Clean 529
Inspect 529
Assemble and Install 529
Spindles and Bearings Repair 530
Remove 530
Clean 530
Inspect 530
Assemble and Install 530
Tie Rods Repair 531
Remove 531
Clean 531
Inspect 531
Install 531
Steering Cylinder Repair 531
Remove and Disassemble 531
Clean and Inspect 531
Assemble and Install 532
Troubleshooting 533
524173808 1800YRM0734 (05 2005) US EN 537
toc 537
Brake System 537
Safety Precautions Maintenance and Repair 538
General 541
Description and Operation 541
Brake Booster and Master Cylinder 541
Service Brake Assembly 541
Parking Brake 541
Brake Shoe Assemblies Repair 542
Remove and Disassemble 542
Clean 544
Inspect 544
Assemble and Install 545
Brake Booster and Master Cylinder Repair 548
Remove 548
Disassemble 548
Clean and Inspect 548
Assemble 548
Install 548
Brake Booster Filter, Replace 548
Parking Brake Repair 551
Remove and Disassemble 551
Assemble and Install 551
Brake System Air Removal 551
Brake Pedal Adjustment 551
Parking Brake Adjustment 552
Parking Brake Not Applied Switch Test 552
Parking Brake Switch Test ( Foot Directional Control Pedal Only) 553
Brake Shoes Adjustment 553
Troubleshooting 554
524173809 1900YRM0753 (09 2003) US EN 559
toc 559
Hydraulic Gear Pump 559
Safety Precautions Maintenance and Repair 560
General 563
Description 563
Operation 563
Hydraulic Gear Pump Repair 564
Remove 564
Disassemble 564
Clean 566
Inspect 566
Assemble 567
Install 567
Pump Output Check 568
Method No 1 568
Method No 2 569
Hydraulic System Air Check 570
Troubleshooting 570
524173810 2100YRM0735 (11 2004) US EN 575
toc 575
Tilt Cylinders 575
Safety Precautions Maintenance and Repair 576
General 579
Description 579
Tilt Cylinder Repair 579
Remove 579
Disassemble 580
Clean 581
Inspect 581
Assemble 581
Install 581
Tilt Cylinder Leak Check 582
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment 582
Troubleshooting 582
524173814 8000YRM0737 (03 2011) US EN 587
toc 587
Periodic Maintenance 587
Safety Precautions Maintenance and Repair 588
General 593
Serial Number Data 593
How to Move Disabled Lift Truck 593
How to Tow Lift Truck 593
How to Put Lift Truck on Blocks 594
How to Raise Drive Tires 594
How to Raise Steering Tires 594
Maintenance Schedule 595
Maintenance Procedures Every 8 Hours or Daily 607
How to Make Checks With Engine Stopped 607
Engine Oil 608
Hydraulic System Oil 608
Cooling System 609
Heavy Duty Precleaner 609
Fuel System 609
Battery 610
Tires and Wheels 610
Forks 611
Adjust 611
Hook Fork, Remove 612
Hook Fork, Install 612
Forks, Mast, and Lift Chains, Inspect 613
Operator Restraint System 613
Automatic Locking Retractor (ALR) 613
Emergency Locking Retractor (ELR) 613
Safety Labels 615
How to Make Checks With Engine Running 615
Gauges, Lights, Horn, and Fuses 615
Engine Oil Pressure 616
Cooling System 618
Powershift Transmission Oil Level Check 618
Hydrostatic Transmission Oil Level Check 619
Control Levers and Pedals 619
Lift System Operation 619
Inching/Brake Pedal 619
Service Brakes 620
Parking Brake 620
Steering System 620
Maintenance Procedures Every 250 Hours or 6 Weeks 621
Engine Oil and Filter, GM V-6 EPA Compliant Engine (Americas Onl 621
Air Filter, GM V-6 EPA Compliant Engine 621
Maintenance Procedures Every 500 Hours or 2 Months 622
Lift Chains Lubrication 622
Air Filter 622
Hydraulic Pump Drive Shaft 622
Engine Oil and Filter, Diesel and GM V-6 (European Only) 622
Drive Belts 623
Fan Drive Belts 623
Perkins Diesel Engine 623
Alternator Drive Belt 623
GM 4 3L Engine 624
Serpentine Drive Belt 624
Hydraulic Tank Breather, Clean and Check 625
Hydrostatic Transmission Filter 625
Filter Cartridge, Replace 625
Filter Head, Replace 625
Brake Fluid 626
Lift Chains Wear Check 626
Forks, Wear and Damage Check 627
Mast, Lubrication 627
Control Levers and Pedals, Lubrication 628
Steering Axle, Lubrication 628
Fuel System, Checks and Adjustments 628
LPG Carburetor 628
Fuel Injection (Perkins Engine) 628
GM V-6 Engine 628
Cooling System, Clean Debris from Radiator Core 628
Maintenance Procedures Every 1000 Hours or 6 Months 628
PCV Valve, GM V-6 628
Crankcase Breather, GM-V6 628
Spark Plug Replacement 628
Remove 628
Install 629
Valve Clearance, Check and Adjust 629
Water Separator, Diesel Engine 629
Fuel Filter, Replace (Diesel Engine) 630
Fuel System Air Removal, Perkins (1004 42 Diesel Engine) 630
Differential and Drive Axle 632
Cooling System, GM V-6 EPA Compliant Engine 632
LPG Fuel Filter GM V-6 EPA Compliant Engine, Replace 632
Inspect Engine Electrical System, Connectors, and FCVS Connectio 633
Maintenance Procedures Every 2000 Hours or Yearly 633
Differential Thrust Screw 633
Hydraulic System 634
Hydraulic Oil and Filter, Replace 634
Powershift Transmission Oil and Filter, Replace 634
Hydrostatic Transmission Oil and Filter, Replace 635
Cooling System 635
Wheel Bearings 635
Steering Wheels, Lubrication 635
Drive Wheels, Lubrication 636
PCV Valve, GM V-6 636
Service Brakes 636
Brake Booster Filter, Replace 636
LPG Filter, Replace (Pre-2004) 637
Gasoline Fuel Filter, Replace 637
Operator Restraint System 637
Oxygen Sensor (Pre 2004) 638
Oxygen Sensor GM V-6 EPA Compliant Engine 638
Air Filter Element, GM V-6 EPA Compliant Engine 638
Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks 638
Check Throttle Shaft for Sticking 639
Inspect Exhaust Manifold and Piping for Leaks 639
Test LPG/GAS Regulator Pressure 639
Safety Procedures When Working Near Mast 640
Lift Chain Adjustments 642
Fuel Injectors Repair 643
Lift and Tilt System Leak Check 644
Lift Cylinders, Leak Check 644
Tilt Cylinders, Leak Check 644
Welding Repairs 645
Overhead Guard Changes 645
Wheel and Tire Replacement 646
Remove Wheels From Lift Truck 646
Remove Wheel From Tire 647
Remove Tire From Two-Piece Wheel 648
Remove Tire From Three- and Four-Piece Wheel 650
Install Wheel in Tire 651
Install Tire on Three- or Four-Piece Wheel 652
Install Tire in Two-Piece Wheel 653
Add Air to Tires 654
Wheels, Install 654
Dual Drive Wheels Installation 655
Solid Rubber Tire Repair 655
Wheel, Tire Remove 656
Wheel, Tire Install 657
SIT Tire, Change for H3 50-5 50XM (European Trucks Only) 659
Remove SIT Solid Tire From Wheel 660
Install SIT Solid Tire on Wheel 661
Adhesives and Sealants 662
Hydraulic Oil, Lubricant, and Coolant Specifications 662
tables 587
Table 1 Maintenance Schedule 598
Table 2 Hook-Type Carriage Chain Adjustment 642
Table 3 Pin-Type Carriage Chain Adjustment 643
524173815 8000YRM0738 (05 2004) US EN 665
toc 665
Capacities and Specifications 665
Safety Precautions Maintenance and Repair 666
Lift Truck Weights 669
Electrical System 669
Stall Speeds 669
Capacities 670
Tire Pressure 670
Engine Specifications 671
Transmission Oil Pressures 672
Hydraulic System 673
Mast Speeds 674
Torque Specifications 674
Brake System 674
Differential 674
Drive Axle 675
Engine, GM V-6 4 3 Liter 675
Engine, Perkins 1004-42 676
Frame 676
Lift Cylinders 676
Main Control Valve 676
Masts 676
Powershift Transmission 677
Steering System 677
Tilt Cylinders 677
Hydrostatic Components 677
tables 665
Table 1 Single-Speed 672
Table 2 Two-Speed 672
Table 3 Hydrostatic Transmission 673
524173816 8000YRM0757 (11 2008) US EN 681
toc 681
Diagrams 681
Safety Precautions Maintenance and Repair 682
524174201 1300YRM0751 (06 2004) US EN 723
toc 723
Single-Speed Powershift Transmission 723
Safety Precautions Maintenance and Repair 724
General 727
Mechanical Description 727
Torque Converter 727
Transmission Pump 728
Shaft Assemblies 728
Input (Reverse) Shaft 728
Counter (Forward) Clutch Shaft 728
Clutch Assemblies 728
Output Gear and Pinion 728
Hydraulic Operation 729
Torque Converter 729
Seal Rings 730
Control Valve 731
Clutch Pressure Regulator 732
Inching Spool Assembly 732
Direction Spool 732
Modulator Circuit 732
Torque Converter Regulator 732
Foot Directional Control Pedal 733
Foot Directional Control Pedal Start Circuit 733
Creep Speed Switch (Optional) 733
Direction Control Lever 734
Oil Flow Diagrams 734
Neutral 734
Modulator Operation 737
Forward 737
Forward-Inching 741
Reverse 741
524174202 1300YRM0752 (06 2004) US EN 749
toc 749
Single-Speed Powershift Transmission 749
Safety Precautions Maintenance and Repair 750
General 753
Transmission Repair 753
Remove 753
Install 753
Clutch Assemblies Repair 756
Remove and Disassemble 756
Clutch Assemblies, Disassemble 759
Inspect 761
Assemble and Install 762
Clutch Assemblies, Assemble and Install 762
Differential Repair 769
Remove and Disassemble 769
Inspect 770
Original Parts, Assemble and Install 770
New Parts, Assemble and Install 770
Adjustments With Original Shim Pack 771
Adjustments Without Original Shim Pack 772
Assemble Differential and Ring Gear Assembly 774
Control Valve Repair 779
Remove and Disassemble 779
Inspect 781
Assemble and Install 781
Foot Directional Control Pedal Repair 782
Remove and Disassemble 782
Assemble and Install 782
Direction Control Lever Repair 785
Remove and Disassemble 785
Assemble and Install 785
Stall Test 785
Inching/Brake Pedal Adjustment 786
Neutral Start Switch Adjustment, Foot Directional Control pEDAL 788
Neutral Start Switch Test, Foot Directional Control Pedal 789
Oil Pressures Check 790
Check Relief Valve for Transmission Pump, TEST PORT 1 790
Check Input (Reverse) Clutch Pressure, TEST PORT 2 791
Check Counter (Forward) Clutch Pressure, TEST PORT 3 791
Check Torque Converter Regulator, TEST PORT 4 791
Check Lubrication Circuit Oil Pressure, TEST PORT 5 791
Check Modulator Pressure, TEST PORT 6 791
Troubleshooting 792
Troubleshooting – Pressure Tests 795
tables 749
Table 1 Pinion Variation Numbers Examples 771
Table 2 Ring and Pinion Tooth Contact Adjustment 777
Table 3 Stall Speeds 786
Table 4 Check Ports for Transmission Pressure 790
524201517 0600YRM1070 (06 2007) US EN 799
toc 799
Perkins Diesel Engines 799
Safety Precautions Maintenance and Repair 800
General 807
General Safety Rules 807
Description 808
Engine Serial Number Codes 810
Engine Data 810
Engine Removal and Installation 811
Cylinder Head Assembly Repair 812
Engine Breather 812
Remove 812
Install 812
Valve Cover 813
Remove 813
Install 813
Rocker Arm Assembly 814
Remove 814
Disassemble 814
Inspect 815
Assemble 815
Install 815
Valve Clearance Adjustments 816
Valve Springs 816
Cylinder Head Assembly 817
Remove 817
Inspect 818
Install 819
Valves and Valve Springs 821
Remove 821
Inspect 822
Install 822
Valve Guides 822
Inspect 822
Remove 823
Install 823
Valve Seats 824
Inspect 824
Repair 824
New Valve Seats, Install 825
Piston and Connecting Rod Assemblies Repair 826
General 826
Rod Bearings 826
Remove 826
Install 827
Piston and Connecting Rod Assembly 828
Service Note 828
Remove 828
Disassemble 828
Inspect 828
How to Select Correct Replacements 830
Assemble 830
Install 831
Piston Cooling Jets 833
Remove 833
Install 833
Crankshaft Assembly Repair 834
General 834
Crankshaft Pulley 834
Remove 834
Inspect 834
Install 834
Rear Oil Seal 835
Remove 835
Install 835
Crankshaft Flange Wear Sleeve 837
Remove 837
Install 837
Main Bearings 838
Remove 838
Inspect 838
Install 838
Thrust Washers 839
Crankshaft Axle Movement, Check 839
Remove 840
Install 840
Crankshaft 841
Remove 841
Inspect 841
Install 841
Crankshaft Timing Ring 843
Remove 843
Install 843
Flywheel 844
Remove 844
Ring Gear, Replace 844
Install 844
Flywheel Housing 845
Remove 845
Install 845
Timing Case and Timing Gears Repair 846
General 846
Timing Case Cover 846
Remove 846
Install 846
Front Oil Seal 847
Remove, With Timing Case Installed 847
Install, With Timing Case Installed 847
Remove, With Timing Case Removed 848
Install, With Timing Case Removed 848
Crankshaft Pulley Wear Sleeve, Install 849
Fuel Pump Gear 849
Remove 849
Install 851
Idler Gear and Hub 852
Remove 852
Disassemble 852
Standard Idler Gear and Hub Assembly 852
Heavy Duty Idler Gear and Hub Assembly 853
Assemble 853
Standard Idler Gear and Hub Assembly 853
Heavy Duty Idler Gear and Hub Assembly 853
Install 854
Camshaft Gear 855
Remove 855
Install 855
Crankshaft Gear 855
Remove 855
Install 855
Timing Case 856
Remove 856
Install 857
Power Take-Off (PTO) Adaptor 858
Remove 858
Disassemble 858
Assemble 859
Install 859
Camshaft and Tappets 859
Remove 859
Install 860
Cylinder Block Assembly Repair 860
General 860
Cylinder Block 860
Disassemble 860
Inspect 861
Assemble 861
Cylinder Bore 861
Inspect 861
Cylinder Liner Condition Check 861
Engine Timing 862
General 862
How to Set Number One Piston to TDC on Compression Stroke 862
Fuel Injection Pump Timing, Check 863
Fuel Injection Pump Timing, Adjust 864
Lubrication System Repair 866
General 866
Oil Filter, Replace 866
Oil Filter Head 867
Remove 867
Install 867
Oil Sump 867
Remove 867
Install 868
Oil Pump 869
Remove 869
Inspect 869
Install 870
Oil Strainer and Suction Pipe 870
Remove 870
Install 870
Relief Valve 871
Remove 871
Install 871
Dipstick Tube 871
Remove and Install 871
Fuel System Repair 872
General 872
Cold Start Advance Unit (KSB) 872
Typical Fuel System 874
Fuel Filter 875
Remove 875
Install 875
Fuel Injectors 876
Remove 876
Install 877
Fuel System Air Removal 878
Bosch EVPE Fuel Injection Pump 878
General 878
Remove 879
Install 880
Cooling System Repair 880
General 880
Thermostat 882
Remove 882
Install 882
Test 882
Coolant Pump 882
Remove 882
Disassemble 883
Assemble 884
Install 885
Fan 886
Remove and Install 886
Fan Drive 886
Remove 886
Install 886
Oil Cooler 886
Remove 886
Disassemble and Assemble 887
Install 887
Coolant Bypass Hose 887
Removal 887
Install 887
Electrical Equipment Repair 888
Drive Belt 888
Check 888
Adjust 888
Remove 888
Install 888
Alternator 889
Remove 889
Install 889
Fault Diagnosis 889
Normal Operation: 889
If the Warning Lamp is Not Illuminated When the Ignition Switch 890
If the Warning Light Continues to be Illuminated When the Altern 890
Starter Motor 891
Remove 891
Install 891
Test 891
Starting Aid 891
Remove 891
Install 892
Check 892
Power Supply Continuity 892
Operation 892
Pressure Sensor 893
Remove 893
Install 894
Temperature Sensor 894
Remove 894
Install 895
Engine Specifications 895
Cylinder Head Assembly 895
Piston and Connecting Rods 898
Crankshaft Assembly 900
Crankshaft Overhaul 900
Timing Case and Drive Assembly 902
Engine Block Assembly 903
Lubrication System 904
Fuel System 904
Cooling System 905
Flywheel and Housing 906
Electrical Equipment 906
Torque Specifications 906
Special Torque Specifications 907
Cylinder Head Assembly 907
Piston and Connecting Rod Assemblies 907
Crankshaft Assembly 907
Timing Case and Drive Assembly 907
Cylinder block 907
Fuel System 907
Lubrication System 907
Cooling System 908
Flywheel and Housing 908
Electrical Equipment 908
Special Tools 908
Troubleshooting 912
tables 799
Table 1 Cylinder Head 895
Table 2 Valve Guides 896
Table 3 Inlet Valves 896
Table 4 Exhaust Valves 897
Table 5 Valve Springs 898
Table 6 Tappets 898
Table 7 Rocker Arm Shaft 898
Table 8 Rocker Arms and Bushings 898
Table 9 Pistons 898
Table 10 Piston Rings 898
Table 11 Piston Pins 899
Table 12 Connecting Rods 899
Table 13 Small End Bushings 899
Table 14 Connecting Rod Bearings 900
Table 15 Piston Cooling Jets 900
Table 16 Crankshaft Overhaul Specifications 901
Table 17 Maximum Variation (Run-out) 902
Table 18 Camshaft 902
Table 19 Camshaft Thrust Washer 902
Table 20 Camshaft Gear 902
Table 21 Gear for Fuel Pump 902
Table 22 Crankshaft Gear 902
Table 23 Idler Gear and Hub 903
Table 24 Timing Gear Backlash Values 903
Table 25 Cylinder Block 903
Table 26 Oil Pump 904
Table 27 Idler Gear for Oil Pump 904
Table 28 Relief Valve 904
Table 29 Oil Filter 904
Table 30 Bosch Fuel Injection Pump 904
Table 31 Fuel Injector Settings 904
Table 32 Fuel Pump 905
Table 33 Fuel Filter 905
Table 34 Coolant Pump 905
Table 35 Thermostat 905
Table 36 Fan Drive Housing 905
Table 37 Limits for Flywheel Run Out and Alignment (Total Indic 906
Table 38 Alternator 906
Table 39 Starter Motor 906
Table 40 Starting Aids 906
Table 41 List of Possible Causes 913
524208004 0900YRM1088 (05 2006) US EN 917
toc 917
Electronic Controlled LPG/Gasoline Fuel System 917
Safety Precautions Maintenance and Repair 918
General 923
Fuel System Warnings and Cautions 923
Glossary 924
Description and Operation of LPG Fuel System 928
Propane Fuel System 928
LPG Fuel Tank 930
Service Line 930
Fuel Filter 930
Low Pressure Lock-Off (LPL) 930
Low Pressure Regulator (LPR) 931
Air Fuel Mixer 931
Throttle Control Device 932
Drive By Cable 932
Three-Way Catalytic (TWC) Muffler 933
Electronic Control Module (ECM) 933
Heated Exhaust Gas Oxygen (HEGO) Sensor 934
Description and Operation of Gasoline Fuel System 936
Gasoline Fuel System Throttle Body Injection (TBI), 3 0L Engine 936
Gasoline Multi-Point Fuel Injection (MPFI) System, 4 3L Only 936
Gasoline Fuel Storage Tank 936
Gasoline Fuel Pump 936
Fuel Filter 936
Fuel Pressure Regulator, 3 0L Only 939
Fuel Rail and Pressure Regulator, 4 3L Only 940
Fuel Injector 940
Throttle Control Device 940
Drive By Cable 940
Three-Way Catalytic Muffler 941
Electronic Control Module (ECM) 941
Heated Exhaust Gas Oxygen (HEGO) Sensor 943
LPG Fuel System Repair 943
Propane Fuel System Pressure Relief 943
Propane Fuel System Leak Test 943
Propane Fuel Filter Replacement 944
Remove 944
Install 944
Low Pressure Lock-Off (LPL) Replacement 944
Remove 944
Install 944
Pressure Trim Valve (PTV) Replacement 946
Remove 946
Install 946
Low Pressure Regulator 946
Remove 946
Install 946
Fuel Trim Valve (FTV) Solenoid Replacement 947
Remove 947
Install 947
Temperature Manifold Absolute Pressure (TMAP) 947
Remove 947
Install 947
Throttle Body Replacement 949
Remove 949
Install 949
Mixer Replacement 951
Remove 951
Install 951
Coolant Hose Replacement 951
Remove 951
Install 952
Vapor Hose Replacement 952
Remove 952
Install 952
Balance Line Hose Replacement 952
Remove 952
Install 952
PTV Hose Replacement 952
Remove 952
Install 952
FTV Hose Replacement 953
Remove 953
Install 953
Throttle Position Sensor (TPS) Replacement 953
Foot Pedal Position (FPP) Sensor Replacement 955
Electronic Control Module (ECM) Replacement 958
Remove 958
Install 958
Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement 958
Remove 958
Install 959
Three-Way Catalytic Muffler (TWC) Replacement 959
Remove 959
Install 959
Restricted Exhaust System Diagnosis 959
Exhaust System Description 959
Tools Required 959
Diagnostic Tool 959
Check at Heated Exhaust Gas Oxygen Sensor (HEGO) 959
Gasoline Fuel System Repair 960
Gasoline MPFI and TBI Fuel System Pressure Relief 960
Gasoline Fuel System Leak Test 961
Throttle Body Injector (TBI) Assembly Replacement, 3 0L Only 961
Remove 961
Install 961
Throttle Body Assembly Replacement, 3 0L Only 963
Remove 963
Install 963
Throttle Body Assembly Replacement, 4 3L Only 964
Remove 964
Install 964
Fuel Rail Replacement, Gasoline 4 3L Only 965
Remove 965
Install 965
Injector Replacement, Gasoline 4 3L Only 965
Remove 965
Install 965
Injector Replacement, Gasoline 3 0L Only 967
Remove 967
Install 967
Temperature Manifold Absolute Pressure (TMAP) Replacement 967
Remove 967
Install 967
Throttle Position Sensor (TPS) Replacement 967
Foot Pedal Position (FPP) Sensor Replacement 970
Electronic Control Module (ECM) Replacement 973
Remove 973
Install 973
Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement 974
Remove 974
Install 974
Three-Way Catalytic Muffler (TWC) Replacement 974
Remove 974
Install 974
Restricted Exhaust System Diagnosis 974
Exhaust System Description 974
Tools Required 974
Diagnostic Tool 974
Check at Heated Exhaust Gas Oxygen Sensor (HEGO) 975
LPG System Diagnosis 975
Fuel System Description 975
Diagnostic Aids 976
Tools Required 976
Duty Cycle Monitoring Tool 976
Diagnostic Tool 976
Pressure Gauges 976
Test Description 976
Gasoline System Diagnosis 984
Fuel System Description, 3 0L Only 984
Fuel System Description, 4 3L Only 984
Diagnostic Aids 985
Tools Required 985
Diagnostic Tool 985
Test Description 985
LPG Symptom Diagnosis 992
Gasoline Symptom Diagnosis 1006
Wire Harness Repair 1017
On Vehicle Service Wiring Harness Repair 1017
Connectors and Terminals 1017
Twisted/Shielded Cable Repair 1018
Twisted Leads Repair 1019
Micro-Pack 1020
Metri-Pack 1020
Remove 1020
Weather-Pack 1022
Weather-Pack Terminal Repair 1023
tables 917
Table 1 TPS Replacement Procedure 953
Table 2 FPP Replacement Procedure 956
Table 3 TPS Replacement Procedure 968
Table 4 FPP Replacement Procedure 971
Table 5 LPG Fuel System Diagnosis 976
Table 6 Fuel Control Diagnosis 980
Table 7 Gasoline Fuel System Diagnosis, 3 0L Only 986
Table 8 Gasoline Fuel System Diagnosis, 4 3L Only 989
Table 9 Preliminary Checks 992
Table 10 Intermittent 993
Table 11 No Start 994
Table 12 Hard Start 996
Table 13 Cuts Out or Misses 997
Table 14 Hesitation, Sag, or Stumble 998
Table 15 Backfire 999
Table 16 Lack of Power, Sluggishness, or Sponginess 1000
Table 17 Poor Fuel Economy 1001
Table 18 Rough, Unstable, Incorrect Idle, or Stalling 1003
Table 19 Surges or Chuggles 1005
Table 20 Preliminary Checks 1006
Table 21 Intermittent 1007
Table 22 No Start 1008
Table 23 Hard Start 1009
Table 24 Cuts Out or Misses 1010
Table 25 Hesitation, Sag, or Stumble 1011
Table 26 Backfire 1012
Table 27 Lack of Power, Sluggishness, or Sponginess 1013
Table 28 Poor Fuel Economy 1014
Table 29 Rough, Unstable, Incorrect Idle, or Stalling 1015
Table 30 Surges or Chuggles 1016
524208009 2200YRM1090 (04 2005) US EN 1027
toc 1027
Electronic Control Module (ECM) Diagnostic Troubleshooting 1027
Safety Precautions Maintenance and Repair 1028
General 1037
Description of ECM Based Diagnostics 1037
Definition of Terms 1037
Diagnostics Overview of the Spectrum Fuel System 1037
Malfunction Indicator Lamp (MIL) 1037
Spectrum Diagnostic Trouble Codes (DTC) 1038
Using a Laptop Computer to Diagnose the Spectrum System 1038
Installing the Spectrum Diagnostic Software 1038
Connecting a Laptop Computer to the Spectrum System 1038
Diagnostic Communication Error 1039
Diagnostic Trouble Codes 1039
Checking Diagnostic Trouble Codes 1040
Clearing Diagnostic Trouble Codes 1040
DATA Stream 1040
Reading Sensor and Actuator Values 1040
Graphing and Data Logging 1041
Ignition System Test 1042
Disabling Ignition Outputs 1042
Injector Test 1043
Disabling Injectors 1043
Throttle Test 1044
Using a Diagnostic Jumper to Diagnose the ECI System 1045
On-Board Diagnostics System Check/Malfunction Indicator Lamp 1046
Circuit Description 1046
Preliminary and Intermittent Checks 1049
GM 3 0L Wiring Schematics and Connectors 1051
GM 3 0L Diagnostic Trouble Codes 1065
DTC 111 – IAT High Voltage Motorola® TMAP 1065
Circuit Description 1065
Conditions for Setting the DTC 1065
DTC 112 – IAT Low Voltage Motorola® TMAP 1068
Circuit Description 1068
Conditions for Setting the DTC 1068
DTC 113 – IAT Higher Than Expected 1 Motorola® TMAP 1071
Circuit Description 1071
Conditions for Setting the DTC 1071
Diagnostic Aids 1071
DTC 114 – IAT Higher Than Expected 2 Motorola® TMAP 1072
Circuit Description 1072
Conditions for Setting the DTC 1072
Diagnostic Aids 1072
DTC 115 – Oil Pressure Low 1073
Circuit Description 1073
Conditions for Setting the DTC 1073
DTC 121 – ECT Voltage High 1076
Circuit Description 1076
Conditions for Setting the DTC 1077
DTC 122 – ECT Voltage Low 1080
Circuit Description 1080
Conditions for Setting the DTC 1080
DTC 123 – ECT Higher Than Expected 1 1082
Circuit Description 1082
Conditions for Setting the DTC 1082
DTC 124 – ECT Higher Than Expected 2 1084
Circuit Description 1084
Conditions for Setting the DTC 1084
DTC 131 – MAP High Pressure Motorola® TMAP 1086
Circuit Description 1086
Conditions for Setting the DTC 1086
Diagnostic Aids 1086
DTC 132 – MAP Low Voltage Motorola® TMAP 1088
Circuit Description 1088
Conditions for Setting the DTC 1088
DTC 134 – BP High Pressure Motorola® TMAP 1092
Circuit Description 1092
Conditions for Setting the DTC 1092
DTC 135 – BP Low Pressure Motorola® TMAP 1094
Circuit Description 1094
Conditions for Setting the DTC 1094
DTC 142 – Crank Sync Noise 1098
Circuit Description 1098
Conditions for setting the DTC 1098
DTC 143 – Never Crank Synced At Start 1101
Circuit Description 1101
Conditions for Setting the DTC 1101
DTC 144 – Camshaft Sensor Loss 1104
Circuit Description 1104
Conditions for Setting the DTC 1104
DTC 145 – Camshaft Sensor Noise 1107
Circuit Description 1107
Conditions for Setting the DTC 1107
DTC 211 – Closed Loop Multiplier High (LPG) 1110
Circuit Description 1110
Conditions for Setting the DTC 1110
Diagnostic Aids 1110
DTC 212 – HO 2 S Open/Inactive 1112
Circuit Description 1112
Conditions for Setting the DTC 1112
DTC 221 – Closed Loop Multiplier High (Gasoline) 1116
Circuit Description 1116
Conditions for Setting the DTC 1116
Diagnostic Aids 1117
DTC 222 – Closed Loop Multiplier Low (Gasoline) 1118
Circuit Description 1118
Conditions for Setting the DTC 1118
Diagnostic Aids 1118
DTC 224 – Closed Loop Multiplier Low (LPG) 1120
Circuit Description 1120
Conditions for Setting the DTC 1120
Diagnostic Aids 1121
DTC 241 – Adaptive Lean Fault (High Limit-Gasoline) 1122
Circuit Description 1122
Conditions for Setting the DTC 1122
Diagnostic Aids 1123
DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline) 1126
Circuit Description 1126
Conditions for Setting the DTC 1126
Diagnostic Aids 1126
DTC 243 – Adaptive Learn High (LPG) 1128
Circuit Description 1128
Conditions for Setting the DTC 1128
Diagnostic Aids 1128
DTC 244 – Adaptive Learn Low (LPG) 1132
Circuit Description 1132
Conditions for Setting the DTC 1132
Diagnostic Aids 1132
DTC 261 – System Voltage High 1134
Circuit Description 1134
Conditions for Setting the DTC 1134
DTC 262 – System Voltage Low 1136
Circuit Description 1136
Conditions for Setting the DTC 1136
DTC 411 – Injector Driver 1 Open 1139
Circuit Description 1139
Conditions for Setting the DTC 1139
DTC 412 – Injector Driver 1 Shorted 1142
Circuit Description 1142
Conditions for Setting the DTC 1142
DTC 511 – COP Failure 1145
Circuit Description 1145
Conditions for Setting the DTC 1145
DTC 512 – Invalid Interrupt 1147
Circuit Description 1147
Conditions for Setting the DTC 1147
DTC 513 – A/D Loss 1149
Circuit Description 1149
Conditions for Setting the DTC 1149
DTC 514 – RTI 1 Loss 1151
Circuit Description 1151
Conditions for Setting the DTC 1151
DTC 515 – Flash Checksum Invalid 1153
Circuit Description 1153
Conditions for Setting the DTC 1153
DTC 516 – Ram Failure 1155
Circuit Description 1155
Conditions for Setting the DTC 1155
DTC 531 – External 5V Ref Lower Than Expected 1157
Circuit Description 1157
Conditions for Setting the DTC 1157
DTC 532 – External 5V Ref Higher Than Expected 1160
Circuit Description 1160
Conditions for Setting the DTC 1160
DTC 555 – RTI 2 Loss 1162
Circuit Description 1162
Conditions for Setting the DTC 1162
DTC 556 – RTI 3 Loss 1164
Circuit Description 1164
Conditions for Setting the DTC 1164
DTC 611 – FPP High Voltage 1166
Circuit Description 1166
Conditions for Setting the DTC 1166
DTC 612 – FPP Low Voltage 1169
Circuit Description 1169
Conditions for Setting the DTC 1169
DTC 631 – TPS1 Signal Voltage High 1173
Circuit Description 1173
Conditions for Setting the DTC 1173
DTC 632 – TPS1 Signal Voltage Low 1176
Circuit Description 1176
Conditions for Setting the DTC 1176
DTC 638 – Throttle Unable To Close 1178
Circuit Description 1178
Conditions for Setting the DTC 1178
Diagnostic Aids 1178
DTC 651 – Maximum Govern Speed Override 1182
Circuit Description 1182
Conditions for Setting the DTC 1182
Diagnostic Aids 1182
DTC 652 – Fuel Rev Limit 1184
Circuit Description 1184
Conditions for Setting the DTC 1184
Diagnostic Aids 1184
DTC 653 – Spark Rev Limit 1187
Circuit Description 1187
Conditions for Setting the DTC 1187
Diagnostic Aids 1187
GM 4 3L Wiring Schematics and Connectors 1190
GM 4 3L Diagnostic Trouble Codes 1207
DTC 111 – IAT High Voltage Bosch® TMAP 1207
Circuit Description 1207
Conditions for Setting the DTC 1207
DTC 111 – IAT High Voltage Motorola® TMAP 1210
Circuit Description 1210
Conditions for Setting the DTC 1210
DTC 112 – IAT Low Voltage Bosch® TMap 1212
Circuit Description 1212
Conditions for Setting the DTC 1212
DTC 112 – IAT Low Voltage Motorola® TMAP 1215
Circuit Description 1215
Conditions for Setting the DTC 1215
DTC 113 – IAT Higher Than Expected 1 Bosch® TMAP 1218
Circuit Description 1218
Conditions for Setting the DTC 1218
Diagnostic Aids 1218
DTC 113 – IAT Higher Than Expected 1 Motorola® TMAP 1219
Circuit Description 1219
Conditions for Setting the DTC 1219
Diagnostic Aids 1219
DTC 114 – IAT Higher Than Expected 2 Bosch® TMAP€ 1220
Circuit Description 1220
Conditions for Setting the DTC 1220
Diagnostic Aids 1220
DTC 114 – IAT Higher Than Expected 2 Motorola® TMAP 1221
Circuit Description 1221
Conditions for Setting the DTC 1221
Diagnostic Aids 1221
DTC 115 – Oil Pressure Low 1222
Circuit Description 1222
Conditions for Setting the DTC 1222
DTC 121 – ECT Voltage High 1225
Circuit Description 1225
Conditions for Setting the DTC 1226
DTC 122 – ECT Voltage Low 1228
Circuit Description 1228
Conditions for Setting the DTC 1228
DTC 123 – ECT Higher Than Expected 1 1231
Circuit Description 1231
Conditions for Setting the DTC 1231
DTC 124 – ECT Higher Than Expected 2 1233
Circuit Description 1233
Conditions for Setting the DTC 1233
DTC 131 – MAP High Pressure Bosch® TMAP 1234
Circuit Description 1234
Conditions for Setting the DTC 1234
Diagnostic Aids 1234
DTC 131 – MAP High Pressure Motorola® TMAP 1238
Circuit Description 1238
Conditions for Setting the DTC 1238
Diagnostic Aids 1238
DTC 132 – MAP Low Voltage Bosch® TMAP 1241
Circuit Description 1241
Conditions for Setting the DTC 1241
DTC 132 – MAP Low Voltage Motorola® TMAP 1244
Circuit Description 1244
Conditions for Setting the DTC 1244
DTC 134 – BP High Pressure Bosch® TMAP 1248
Circuit Description 1248
Conditions for Setting the DTC 1248
DTC 134 – BP High Pressure Motorola® TMAP 1250
Circuit Description 1250
Conditions for Setting the DTC 1250
DTC 135 – BP Low Pressure Bosch® TMAP 1252
Circuit Description 1252
Conditions for Setting the DTC 1252
DTC 135 – BP Low Pressure Motorola® TMAP 1256
Circuit Description 1256
Conditions for Setting the DTC 1256
DTC 142 – Crank Sync Noise 1260
Circuit Description 1260
Conditions for setting the DTC 1260
DTC 143 – Never Crank Synced At Start 1263
Circuit Description 1263
Conditions for Setting the DTC 1263
DTC 144 – Camshaft Sensor Loss 1266
Circuit Description 1266
Conditions for Setting the DTC 1266
DTC 145 – Camshaft Sensor Noise 1269
Circuit Description 1269
Conditions for Setting the DTC 1269
DTC 211 – Closed Loop Multiplier High (LPG) 1272
Circuit Description 1272
Conditions for Setting the DTC 1272
Diagnostic Aids 1272
DTC 212 – HO 2 S Open/Inactive 1274
Circuit Description 1274
Conditions for Setting the DTC 1274
DTC 221 – Closed Loop Multiplier High (Gasoline) 1278
Circuit Description 1278
Conditions for Setting the DTC 1278
Diagnostic Aids 1278
DTC 222 – Closed Loop Multiplier Low (Gasoline) 1280
Circuit Description 1280
Conditions for Setting the DTC 1280
Diagnostic Aids 1281
DTC 224 – Closed Loop Multiplier Low (LPG) 1282
Circuit Description 1282
Conditions for Setting the DTC 1282
Diagnostic Aids 1283
DTC 241 – Adaptive Lean Fault (High Limit-Gasoline) 1284
Circuit Description 1284
Conditions for Setting the DTC 1284
Diagnostic Aids 1285
DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline) 1288
Circuit Description 1288
Conditions for Setting the DTC 1288
Diagnostic Aids 1289
DTC 243 – Adaptive Learn High (LPG) 1291
Circuit Description 1291
Conditions for Setting the DTC 1291
Diagnostic Aids 1292
DTC 244 – Adaptive Learn Low (LPG) 1294
Circuit Description 1294
Conditions for Setting the DTC 1294
Diagnostic Aids 1295
DTC 261 – System Voltage High 1296
Circuit Description 1296
Conditions for Setting the DTC 1296
DTC 262 – System Voltage Low 1298
Circuit Description 1298
Conditions for Setting the DTC 1298
DTC 511 – COP Failure 1301
Circuit Description 1301
Conditions for Setting the DTC 1301
DTC 512 – Invalid Interrupt 1303
Circuit Description 1303
Conditions for Setting the DTC 1303
DTC 513 – A/D Loss 1305
Circuit Description 1305
Conditions for Setting the DTC 1305
DTC 514 – RTI 1 Loss 1307
Circuit Description 1307
Conditions for Setting the DTC 1307
DTC 515 – Flash Checksum Invalid 1309
Circuit Description 1309
Conditions for Setting the DTC 1309
DTC 516 – Ram Failure 1311
Circuit Description 1311
Conditions for Setting the DTC 1311
DTC 531 – External 5V Ref Lower Than Expected 1313
Circuit Description 1313
Conditions for Setting the DTC 1313
DTC 532 – External 5V Ref Higher Than Expected 1316
Circuit Description 1316
Conditions for Setting the DTC 1316
DTC 555 – RTI 2 Loss 1318
Circuit Description 1318
Conditions for Setting the DTC 1318
DTC 556 – RTI 3 Loss 1320
Circuit Description 1320
Conditions for Setting the DTC 1320
DTC 611 – FPP High Voltage 1322
Circuit Description 1322
Conditions for Setting the DTC 1322
DTC 612 – FPP Low Voltage 1326
Circuit Description 1326
Conditions for Setting the DTC 1326
DTC 631 – TPS1 Signal Voltage High 1330
Circuit Description 1330
Conditions for Setting the DTC 1330
DTC 632 – TPS1 Signal Voltage Low 1333
Circuit Description 1333
Conditions for Setting the DTC 1333
DTC 638 – Throttle Unable To Close 1336
Circuit Description 1336
Conditions for Setting the DTC 1336
Diagnostic Aids 1337
DTC 651 – Maximum Govern Speed Override 1339
Circuit Description 1339
Conditions for Setting the DTC 1339
Diagnostic Aids 1339
DTC 652 – Fuel Rev Limit 1342
Circuit Description 1342
Conditions for Setting the DTC 1342
Diagnostic Aids 1342
DTC 653 – Spark Rev Limit 1344
Circuit Description 1344
Conditions for Setting the DTC 1344
Diagnostic Aids 1344
Wire Harness Repair 1347
On Vehicle Service Wiring Harness Repair 1347
Connectors and Terminals 1347
Twisted/Shielded Cable Repair 1348
Twisted Leads Repair 1349
Micro-Pack 1350
Metri-Pack 1350
Remove 1350
Weather-Pack 1352
Weather-Pack Terminal Repair 1352
tables 1027
Table 1 OBD System Check 1047
Table 2 Preliminary Checks 1049
Table 3 Intermittent Checks 1050
Table 4 Communication Port C002 1051
Table 5 Coil Connector C003 1051
Table 6 Fuel System Interface C004 1051
Table 7 Oil Pressure Connector C005 1052
Table 8 Distributor Connector C006 1052
Table 9 Magnetic Pickup Connector C007 1052
Table 10 Heated Oxygen Sensor C008 1052
Table 11 Throttle Position Sensor Connector C009 1053
Table 12 Foot Pedal Position Connector C010 1053
Table 13 Governor Motor Connector C011 1053
Table 14 TMAP Connector C012 1053
Table 15 Starter Solenoid C013 1054
Table 16 Engine Coolant Temperature C014 1054
Table 17 Battery Connector C015 1054
Table 18 Alternator Connection C016 1054
Table 19 Battery Connector C017 1054
Table 20 Alternator Connector C018 1055
Table 21 Instrument Panel Connector C019 1055
Table 22 Instrument Panel Connector C020 1055
Table 23 Instrument Panel Connector C021 1056
Table 24 Fuel Trim Valve Connector C022 1056
Table 25 Fuel Lockoff Connector C023 1056
Table 26 Pressure Trim Valve Connector C024 1057
Table 27 Throttle Body Injector Connector C025 1057
Table 28 Relay and Fuse Center 1057
Table 29 DTC 111 – IAT Voltage High (Motorola® TMAP) 1066
Table 30 DTC 112 – IAT Low Voltage (Motorola® TMAP) 1069
Table 31 DTC 115 – Oil Pressure Low 1074
Table 32 Temperature Resistance 1076
Table 33 DTC 121 – ECT VOLTAGE HIGH 1077
Table 34 DTC 122 – ECT Voltage Low 1081
Table 35 DTC 123 – ECT Higher Than Expected 1 1083
Table 36 DTC 124 – ECT Higher Than Expected 2 1085
Table 37 DTC 131 – MAP HIGH PRESSURE (Motorola® TMAP) 1087
Table 38 DTC 132 – MAP Low Voltage (Motorola® TMAP) 1089
Table 39 DTC 134 – BP High Pressure (Motorola® TMAP) 1093
Table 40 DTC 135 – BP Low Pressure (Motorola® TMAP) 1094
Table 41 DTC 142 – Crank Sync Noise 1098
Table 42 DTC 143 – Never Crank Synced At Start 1101
Table 43 DTC 144 – Camshaft Sensor Loss 1104
Table 44 DTC 145 – Camshaft Sensor Noise 1107
Table 45 DTC 211 – Closed Loop Multiplier High (LPG) 1111
Table 46 DTC 212 – HO 2 S Open/Inactive 1113
Table 47 DTC 221 – Closed Loop Multiplier High (Gasoline) 1117
Table 48 DTC 222 – Closed Loop Multiplier Low (Gasoline) 1120
Table 49 DTC 224 – Closed Loop Multiplier Low (LPG) 1122
Table 50 DTC 241 – Adaptive Lean Fault (High Limit-Gasoline) 1124
Table 51 DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline) 1127
Table 52 DTC 243 – Adaptive Learn High (LPG) 1130
Table 53 DTC 244 – Adaptive Learn Low (LPG) 1133
Table 54 DTC 261 – System Voltage High 1135
Table 55 DTC 262 – System Voltage Low 1137
Table 56 DTC 411 – Injector Driver 1 Open 1140
Table 57 DTC 412 – Injector Driver 1 Shorted 1143
Table 58 DTC 511 – COP Failure 1146
Table 59 DTC 512 – Invalid Interrupt 1148
Table 60 DTC 513 – A/D Loss 1150
Table 61 DTC 514 – RTI 1 Loss 1152
Table 62 DTC 515 – Flash Checksum Invalid 1154
Table 63 DTC 516 – Ram Failure 1156
Table 64 DTC 531 – External 5V Ref Lower Than Expected 1158
Table 65 DTC 532 – External 5 V Ref Higher Than Expected 1160
Table 66 DTC 555 – RTI 2 Loss 1163
Table 67 DTC 556 – RTI 3 Loss 1165
Table 68 DTC 611 – FPP High Voltage 1166
Table 69 DTC 612 – FPP Low Voltage 1170
Table 70 DTC 631 – TPS1 Signal Voltage High 1174
Table 71 DTC 632 – TPS1 Signal Voltage Low 1177
Table 72 DTC 638 – Throttle Unable To Close 1179
Table 73 DTC 651 – Maximum Govern Speed Override 1183
Table 74 DTC 652 – Fuel Rev Limit 1185
Table 75 DTC 653 – Spark Rev Limit 1188
Table 76 Communication Port C002 1190
Table 77 Injector Connector C003 1190
Table 78 Injector Connector C004 1190
Table 79 Oil Pressure Connector C005 1191
Table 80 Throttle Position Sensor 1 Connector C006 1191
Table 81 Foot Pedal Position Connector C006A 1191
Table 82 Coil Connector C007 1191
Table 83 Module Connector C008 1192
Table 84 Crank Sensor Connector C009 1192
Table 85 EGO Sensor Connector C010 1192
Table 86 Cam Connector C011 1192
Table 87 Throttle Connector C012 1193
Table 88 Bosch TMAP Connector C013 (Gasoline Fuel System Only) 1193
Table 89 Motorola TMAP Connector C013 (LPG Fuel System Only) 1193
Table 90 Starter Solenoid Connector C014 1193
Table 91 ECT Connector C015 1194
Table 92 Starter Relay C016 1194
Table 93 Power Relay C017 1194
Table 94 Fuel Pump Relay C018 1194
Table 95 Battery Connector C019 1194
Table 96 Alternator Connector C020 1194
Table 97 Alternator Connector C021 1195
Table 98 Instrument Panel Connector C022 1195
Table 99 Instrument Panel Connector C023 1195
Table 100 Instrument Panel Connector C024 1196
Table 101 Fuel Trim Valve Connector C025 1196
Table 102 Fuel Lockoff Connector C026 1196
Table 103 Pressure Trim Valve Connector C027 1197
Table 104 Injector 1 Connector C028 1197
Table 105 Injector 2 Connector C029 1197
Table 106 Injector 3 Connector C030 1197
Table 107 Injector 4 Connector C031 1198
Table 108 Injector 5 Connector C032 1198
Table 109 Injector 6 Connector C033 1198
Table 110 Relay and Fuse Center 1199
Table 111 DTC 111 – IAT Voltage High (Bosch® TMAP) 1208
Table 112 DTC 111 – IAT Voltage High (Motorola® TMAP) 1211
Table 113 DTC 112 – IAT Low Voltage (Bosch® TMAP) 1213
Table 114 DTC 112 – IAT Low Voltage (Motorola® TMAP) 1216
Table 115 DTC 115 – Oil Pressure Low 1223
Table 116 Temperature Resistance 1225
Table 117 DTC 121 – ECT VOLTAGE HIGH 1226
Table 118 DTC 122 – ECT Voltage Low 1229
Table 119 DTC 123 – ECT Higher Than Expected 1 1232
Table 120 DTC 124 – ECT Higher Than Expected 2 1234
Table 121 DTC 131 – MAP High Pressure (Bosch® TMAP) 1235
Table 122 DTC 131 – MAP HIGH PRESSURE (Motorola® TMAP) 1239
Table 123 DTC 132 – MAP Low Voltage (Bosch® TMAP) 1242
Table 124 DTC 132 – MAP Low Voltage (Motorola® TMAP) 1245
Table 125 DTC 134 – BP High Pressure (Bosch® TMAP) 1249
Table 126 DTC 134 – BP High Pressure (Motorola® TMAP) 1251
Table 127 DTC 135 – BP Low Pressure (Bosch® TMAP) 1252
Table 128 DTC 135 – BP Low Pressure (Motorola® TMAP) 1256
Table 129 DTC 142 – Crank Sync Noise 1260
Table 130 DTC 143 – Never Crank Synced At Start 1263
Table 131 DTC 144 – Camshaft Sensor Loss 1266
Table 132 DTC 145 – Camshaft Sensor Noise 1269
Table 133 DTC 211 – Closed Loop Multiplier High (LPG) 1273
Table 134 DTC 212 – HO 2 S Open/Inactive 1275
Table 135 DTC 221 – Closed Loop Multiplier High (Gasoline) 1279
Table 136 DTC 222 – Closed Loop Multiplier Low (Gasoline) 1282
Table 137 DTC 224 – Closed Loop Multiplier Low (LPG) 1284
Table 138 DTC 241 – Adaptive Lean Fault (High Limit-Gasoline) 1286
Table 139 DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline) 1289
Table 140 DTC 243 – Adaptive Learn High (LPG) 1292
Table 141 DTC 244 – Adaptive Learn Low (LPG) 1295
Table 142 DTC 261 – System Voltage High 1297
Table 143 DTC 262 – System Voltage Low 1299
Table 144 DTC 511 – COP Failure 1302
Table 145 DTC 512 – Invalid Interrupt 1304
Table 146 DTC 513 – A/D Loss 1306
Table 147 DTC 514 – RTI 1 Loss 1308
Table 148 DTC 515 – Flash Checksum Invalid 1310
Table 149 DTC 516 – Ram Failure 1312
Table 150 DTC 531 – External 5V Ref Lower Than Expected 1314
Table 151 DTC 532 – External 5 V Ref Higher Than Expected 1316
Table 152 DTC 555 – RTI 2 Loss 1319
Table 153 DTC 556 – RTI 3 Loss 1321
Table 154 DTC 611 – FPP High Voltage 1323
Table 155 DTC 612 – FPP Low Voltage 1327
Table 156 DTC 631 – TPS1 Signal Voltage High 1331
Table 157 DTC 632 – TPS1 Signal Voltage Low 1334
Table 158 DTC 638 – Throttle Unable To Close 1337
Table 159 DTC 651 – Maximum Govern Speed Override 1340
Table 160 DTC 652 – Fuel Rev Limit 1343
Table 161 DTC 653 – Spark Rev Limit 1345
524208014 2200YRM1097 (03 2020) US EN 1357
Series Code / Model Designation Reference Table 1361
Description 1362
Distributor Ignition (DI) System 1362
Crankshaft Position (CKP) Sensor 1362
Camshaft Position (CMP) Sensor 1362
Ignition Coil and Ignition Control Module (ICM) 1362
Secondary Ignition Components 1362
Spark Plugs and Wires 1363
Spark Plug Wire Inspection 1363
Spark Plug Wire Replacement 1363
Remove 1363
Install 1364
Spark Plug Inspection 1364
Usage 1364
Inspection 1364
Visual Inspection 1366
Spark Plug Replacement 1366
Remove 1366
Install 1366
Distributor Repair 1367
Inspect 1367
Overhaul 1367
Disassemble 1367
Assemble 1370
Replace 1371
Remove 1371
Install Procedure 1 1373
Install Procedure 2 1374
Ignition Coil Replacement 1375
Remove 1375
Install 1375
Ignition Control Module Replacement 1376
Remove 1376
Install 1376
Starter Replacement 1377
Remove 1377
Install 1380
Sensors and Switches 1381
Gas and LPG Trucks 1381
Crankshaft Position (CKP) Sensor 1381
Remove 1381
Install 1381
Camshaft Position (CMP) Sensor 1382
Remove 1382
Install 1384
Oil Pressure Sensor 1384
Remove 1384
Install 1385
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 1386
Remove 1386
Install 1386
Engine Coolant Temperature (ECT) Sensor 1387
Remove 1387
Install 1388
Air Flow Restriction Switch 1388
Remove 1388
Install 1389
Specifications and Special Tools 1390