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Hyster C024 Service Manual – PDF DOWNLOAD

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Description

Hyster C024 Service Manual – PDF DOWNLOAD

DESCRIPTION:

Hyster C024 Service Manual – PDF DOWNLOAD

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks.
• Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance
section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit whenmaking repairs,
or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.

TABLE OF CONTENTS:

Hyster C024 Service Manual – PDF DOWNLOAD

897106-1300SRM0324-(10-2003)-US-EN..................................................  1
	toc.............................................................................  1
		Two-Speed Powershift Transmission...........................................  1
		Safety Precautions Maintenance and Repair...................................  2
		General.....................................................................  5
		Mechanical Description......................................................  5
			Torque Converter........................................................  5
			Transmission Pump.......................................................  6
			Shaft Assemblies........................................................  6
			Input Shaft.............................................................  7
			Forward Clutch Shaft....................................................  7
			Clutch Assemblies.......................................................  7
			Countershaft............................................................ 14
			Output Shaft............................................................ 14
		Hydraulic Operation......................................................... 15
			Torque Converter........................................................ 15
			Seal Rings.............................................................. 16
		Control Valve............................................................... 16
			System Pressure Regulator............................................... 19
			Clutch Pressure Regulator............................................... 19
			Torque Converter Regulator.............................................. 20
			Inching Spool........................................................... 20
			Direction Spool, Direction Control Lever................................ 20
			Direction Spool, MONOTROL Pedal......................................... 21
			Range Spool............................................................. 21
			Drain Spool............................................................. 22
			Accumulator............................................................. 22
			Modulator Spool......................................................... 22
			Operation............................................................... 22
		Lubrication Circuit......................................................... 23
		MONOTROL Pedal.............................................................. 23
		Oil Flow Diagrams........................................................... 25
			Neutral................................................................. 25
			Forward-Low............................................................. 26
			Forward-Low-Inching..................................................... 27
			Reverse-Low............................................................. 28
897107-1300SRM0325-(10-2003)-US-EN.................................................. 31
	toc............................................................................. 31
		Two-Speed Powershift Transmission........................................... 31
		Safety Precautions Maintenance and Repair................................... 32
		General..................................................................... 35
		Transmission Repair......................................................... 35
			Transmission and Torque Converter, Remove............................... 35
			Transmission, Disassemble............................................... 37
			Reverse-Low Clutch, Disassemble......................................... 40
			Reverse-High Clutch, Disassemble........................................ 43
			Forward-Low Clutch, Disassemble......................................... 46
			Forward-High Clutch, Disassemble........................................ 49
			Clean and Inspect....................................................... 51
		Forward Low and High Clutches Assembly...................................... 52
			Forward Clutches, Assemble.............................................. 54
			Reverse-Low Clutch, Assemble............................................ 60
			Reverse Clutches, Assemble.............................................. 62
			Transmission, Assemble.................................................. 69
			Torque Converter, Install............................................... 76
		Control Valve Repair........................................................ 77
			Remove.................................................................. 77
			Disassemble............................................................. 78
			Assemble................................................................ 79
			Install................................................................. 81
		MONOTROL Pedal.............................................................. 81
			Remove and Disassemble.................................................. 81
			Assemble and Install.................................................... 81
		Stall Test.................................................................. 84
		Linkage Adjustments......................................................... 85
			Linkage for Inching Pedal H6.00-7.00XL (H135-155XL, H135-155XL 2........ 85
			Linkage for Inching Pedal S6.00-7.00XL (S135-155XL, S135-155XL 2........ 88
			Linkage for Range Lever - Early Model H6.00-7.00XL (H135-155XL) ........ 91
			Linkage for Direction Control Lever - Early Model H6.00-7.00XL (........ 91
			Linkage for Range Lever - Later Model H6.00-7.00XL (H135-155XL, ........ 93
			Linkage for Direction Control Lever - Later Model H6.00-7.00XL (........ 95
			Linkage for Range Lever S6.00-7.00XL (S135-155XL, S135-155XL 2 )........ 97
			Linkage for Direction Control Lever S6.00-7.00XL (S135-155XL, S1........ 97
		Oil Pressure Check.......................................................... 99
			System Pressure Check Port.............................................. 99
			Torque Converter Check Port............................................. 99
			Clutch Pressure Check Port.............................................. 99
			Inching Pressure........................................................100
			Solenoid Check Ports (MONOTROL Control Only)............................100
			Lubrication Pressure Check Ports........................................100
		Specifications..............................................................101
		Troubleshooting.............................................................101
			Correct System Pressure: 1300 ±124 kPa ( 189 ±18 psi)...................104
			Correct Clutch Pressure: 924 ±69 kPa ( 134 ±10 psi).....................105
			Correct Solenoid Pressure (MONOTROL Only): 965 ±138 kPa ( 140 ±2........106
			Torque Converter Pressure: 834 ±69 kPa ( 121 ±10 psi)...................106
			Lubrication Pressure: 83 ±21 kPa ( 12 ±3 psi)...........................106
	tables.......................................................................... 31
		Table 1. Stall Speed Specifications......................................... 84
897121-1900SRM0339-(10-2003)-US-EN..................................................109
	toc.............................................................................109
		Hydraulic Pump Drive Assembly...............................................109
		Safety Precautions Maintenance and Repair...................................110
		General.....................................................................113
		Description.................................................................113
		Hydraulic Pump Drive Assembly Repair........................................115
			Remove and Disassemble..................................................115
			Clean...................................................................116
			Inspect.................................................................116
			Assemble and Install....................................................116
		Troubleshooting.............................................................117
897304-8000SRM0393-(02-2007)-US-EN..................................................121
	toc.............................................................................121
		Periodic Maintenance........................................................121
		Safety Precautions Maintenance and Repair...................................122
		General.....................................................................127
			Serial Number Data......................................................127
			How to Move Disabled Lift Truck.........................................127
				How to Tow Lift Truck...............................................127
			How to Put Lift Truck on Blocks.........................................128
				How to Raise Drive Tires............................................128
				How to Raise Steering Tires.........................................128
		Maintenance Schedule........................................................129
		Safety Procedures When Working Near Mast....................................137
		Maintenance Procedures Every 8 Hours or Daily...............................140
			How to Make Checks With Engine Stopped..................................140
				Hydraulic System....................................................140
				Engine Oil..........................................................140
				Drive Belts.........................................................140
				Intake Manifold Rubber Cap..........................................140
				Cooling System......................................................140
				Air Filter..........................................................141
				Fuel System.........................................................143
				Primary Fuel Filter, Diesel Engine..................................143
				Battery.............................................................143
				Tires and Wheels....................................................143
				Forks...............................................................144
					Adjust..........................................................144
					Remove..........................................................144
					Install.........................................................146
				Forks, Mast, and Lift Chains, Inspect...............................146
				Operator Restraint System...........................................147
					Automatic Locking Retractor (ALR)...............................147
					Emergency Locking Retractor (ELR)...............................147
				Safety Labels.......................................................149
			How to Make Checks With Engine Running..................................149
				Gauges, Lights, Horn, and Fuses.....................................149
				Oil Level, Powershift Transmission..................................150
				Oil Level, Oil Clutch System, S6.00-7.00XL (S135-155XL).............150
				Control Levers and Pedals...........................................150
				Lift System Operation...............................................151
				Inching/Brake Pedal.................................................151
				Service Brakes......................................................152
				Parking Brake.......................................................152
				Steering System.....................................................152
		Maintenance Procedures Every 250 Hours or 6 Weeks...........................153
			Engine Oil and Filter, GM V-6...........................................153
			Mast, Lubrication.......................................................153
			Lift Chains, Lubrication................................................153
			Crankcase Breather, GM V-6 Engine.......................................153
			Drive Shafts, S6.00-7.00XL (S135-155XL).................................154
			Air Filter GM V-6 EPA Compliant Engine..................................154
		Maintenance Procedures Every 350 Hours or 2 Months..........................155
			Drive Belts.............................................................155
				Perkins Diesel Engine...............................................155
				GM V-6 Engine, Early Models.........................................155
				GM V-6 Engine, Late Models..........................................155
			Forks, Wear and Damage Check............................................157
			Lift Chains, Wear Check.................................................157
			Hydraulic Tank Breather, Clean and Check................................158
			Brake Fluid.............................................................158
			Fuel System, Checks and Adjustments.....................................158
				Diesel Fuel System..................................................158
				LPG Carburetor......................................................159
				Gasoline Carburetor (Early Models)..................................159
				Fuel Injection (Late Model GM V-6)..................................160
			Steering Axle, Lubrication..............................................160
			Cooling System, Clean Debris from Radiator Core.........................160
			Air Filter..............................................................160
		Maintenance Procedures Every 500 Hours or 3 Months..........................161
			Engine Oil and Filter, Perkins Diesel Engine............................161
			Crankcase Breather, Perkins Diesel Engine...............................161
			PCV Valve, GM V-6.......................................................161
		Maintenance Procedures Every 1000 Hours or 6 Months.........................161
			Manifold Heat Valve, GM V-6.............................................161
			Crankcase Breather, GM V-6..............................................161
			Ignition System, GM V-6.................................................161
			Valve Clearance, Check and Adjust.......................................162
			Fuel Filter, Diesel Engine, Replace.....................................162
			Fuel System Air Removal, Perkins (1004.42 Diesel Engine)................162
				Fuel Injection Pump With Vent Tube..................................162
				Fuel Injection Pump With Vent Screw.................................163
			Differential and Drive Axle, Oil Level Check............................165
				Differential S3.50-5.50XL (S70-120XL)...............................165
				Differential and Drive Axle for Powershift Transmission S6.00-7.....165
				Differential, Speed Reducer, and Drive Axle for Manual Transmiss....165
			Control Levers and Pedals, Lubrication..................................165
			Cooling System GM V-6 EPA Compliant Engine..............................165
			LPG Fuel Filter GM V-6 EPA Compliant Engine, Replace....................166
			Inspect Engine Electrical System, Connectors, and FCVS Connectio........166
			Spark Plug Replacement..................................................167
				Remove..............................................................167
				Install.............................................................167
		Maintenance Procedures Every 2000 Hours or Yearly...........................168
			Hydraulic System........................................................168
				Hydraulic Oil and Filter S3.50-5.50XL (S70-120XL), Replace..........168
				Hydraulic Oil and Filter S6.00-7.00XL (S135-155XL), Replace.........168
			Powershift Transmission (All Units), Oil Change and Oil Filter, ........168
				Manual Transmission and Differential S6.00-7.00XL (S135-155XL), ....169
			Oil Clutch System S6.00-7.00XL (S135-155XL), Oil and Filter Chan........169
			Differential and Drive Axle for Powershift Transmission (All Uni........169
			Cooling System..........................................................170
			PCV Valve, GM V-6.......................................................170
			Service Brakes..........................................................170
			LPG Filter, Replace (Pre-2004)..........................................170
			Oxygen Sensor GM V-6 EPA Compliant Engine...............................171
			Gasoline Fuel Filter, Replace...........................................171
			Air Filter Element, GM V-6 EPA Compliant Engine.........................171
			Test LPG/GAS Regulator Pressure.........................................171
			Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks..........171
			Check Throttle Shaft for Sticking.......................................172
			Inspect Exhaust Manifold and Piping for Leaks...........................172
		Hood Latch Check............................................................173
		Lift Chain Adjustments......................................................173
		Fuel Injectors Repair.......................................................175
		Lift and Tilt System Leak Check.............................................176
			Lift Cylinders, Leak Check..............................................176
			Tilt Cylinders, Leak Check..............................................176
		Welding Repairs.............................................................177
		Overhead Guard Changes......................................................177
		Wheel and Tire Replacement..................................................178
			Solid Rubber Tire, Change...............................................178
				Wheels, Install.....................................................179
		Adhesives and Sealants......................................................179
		Hydraulic Oil, Lubricant, and Coolant Specifications........................180
	tables..........................................................................121
		Table 1. Maintenance Schedule...............................................129
		Table 2. Hook-Type Carriage Chain Adjustment................................174
		Table 3. Pin-Type Carriage Chain Adjustment.................................174
897393-1800SRM0452-(02-2004)-US-EN..................................................183
	toc.............................................................................183
		Brake System................................................................183
		Safety Precautions Maintenance and Repair...................................184
		General.....................................................................187
		Description and Operation...................................................187
			Brake Booster and Master Cylinder.......................................187
			Service Brake Assembly..................................................189
			Parking Brake...........................................................189
		Brake Shoe Assemblies Repair................................................190
			Remove and Disassemble..................................................190
			Clean...................................................................191
			Inspect.................................................................191
			Assemble and Install....................................................191
		Master Cylinder Repair......................................................192
			Remove..................................................................192
			Disassemble.............................................................192
			Clean and Inspect.......................................................193
			Assemble................................................................193
			Install.................................................................194
		Brake Booster Repair........................................................194
			Remove..................................................................194
			Disassemble.............................................................194
			Clean and Inspect.......................................................194
			Assemble................................................................195
			Install.................................................................196
		Brake System Air Removal....................................................196
		Brake Pedal Adjustment......................................................196
		Brake Shoes Adjustment......................................................197
		Parking Brake Adjustment....................................................197
		Brake Booster Relief Valve Check............................................197
		Troubleshooting.............................................................198
897394-1900SRM0453-(09-2003)-US-EN..................................................203
	toc.............................................................................203
		Hydraulic System............................................................203
		Safety Precautions Maintenance and Repair...................................204
		General.....................................................................207
		Description and Operation...................................................207
			Main Hydraulic Pump.....................................................207
			Steering Pump...........................................................207
			Main Control Valve......................................................207
			Control Valve Lever.....................................................211
			Filter..................................................................211
			Steering Control Unit...................................................211
			Brake Booster...........................................................211
		Main Hydraulic Pump Repair..................................................212
			Remove..................................................................212
			Disassemble.............................................................212
			Clean and Inspect.......................................................212
			Assemble................................................................213
			Install.................................................................213
		Specifications..............................................................213
			Hydraulic System........................................................213
			Hydraulic Tank..........................................................213
			Hydraulic Oil...........................................................213
			Relief Pressures*.......................................................213
			Hydraulic Pump..........................................................213
			Steering Pump...........................................................213
		Troubleshooting.............................................................214
			Lift, Lower, and Tilt Circuit...........................................215
			Steering and Brake System...............................................216
897501-8000SRM0519-(06-2007)-US-EN..................................................221
	toc.............................................................................221
		Diagrams....................................................................221
		Safety Precautions Maintenance and Repair...................................222
897800-0600SRM0590-(08-2005)-US-EN..................................................309
	toc.............................................................................309
		GM Engines..................................................................309
		Safety Precautions Maintenance and Repair...................................310
		General.....................................................................313
		Description.................................................................313
		Engine Removal and Installation.............................................314
		Cylinder Head Repair........................................................314
			Remove and Disassemble..................................................314
			Clean and Inspect.......................................................314
			Valve Guides and Seats, Repairs.........................................315
			Valves, Repair..........................................................315
			Valve Seats, Repair.....................................................316
			Valve Springs...........................................................316
			Rocker Arm Studs (Early Models).........................................318
			Rocker Arm Studs (Late Models)..........................................318
			Assemble and Install....................................................319
		Cylinder Block Cleaning and Inspection......................................322
		Piston Bore Preparation.....................................................322
		Engine Mounts Installation..................................................323
		Lubrication System Repair...................................................323
			Oil Pump, Remove and Disassemble........................................323
			Clean and Inspect.......................................................323
			Oil Pump, Assemble and Install..........................................324
			Oil Sump, Install.......................................................324
		Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters.................325
			Timing Cover............................................................325
				Remove..............................................................325
				Install.............................................................327
			Timing Sprockets........................................................327
				Remove..............................................................327
				Install.............................................................327
			Camshaft................................................................328
				Remove..............................................................328
				Inspect.............................................................328
				Install.............................................................328
			Balance Shaft...........................................................329
				Remove..............................................................329
				Install.............................................................330
			Hydraulic Valve Lifters.................................................330
				Remove..............................................................330
				Disassemble.........................................................331
				Clean and Inspect...................................................331
				Assemble............................................................331
				Install.............................................................332
		Crankshaft Repair...........................................................333
			Remove..................................................................333
			Inspect and Repair......................................................333
			How to Check Clearance Between Main Bearings and Their Journals.........334
			Install.................................................................335
		Piston and Connecting Rod Assemblies Repair.................................336
			Connecting Rod Bearings, Replace........................................336
			Piston and Connecting Rod Assemblies, Remove............................337
			Disassemble.............................................................337
			Piston, Clean and Inspect...............................................338
			Cylinder Bores, Inspect and Repair......................................338
			Piston Rings............................................................339
			Assemble................................................................340
			Piston and Connecting Rod Assemblies, Install...........................340
		Flywheel and Flywheel Housing Repair........................................341
			Flywheel, Repair........................................................341
			Flywheel, Install.......................................................341
				H3.50-5.00XL (H70-110XL), S3.50-5.50XL (S70-120XL), S6.00-7.00XL....341
				H6.00-7.00XL (H135-155XL)...........................................341
			Flywheel Housing H3.50-5.00XL (H70-110XL), H3.50-5.50XM (H70-120........341
			Engine Adapter H6.00-7.00XL (H135-155XL)................................341
		Coolant Pump Repair.........................................................342
		Thermostat Replacement......................................................342
		Fan Mount Repair (Early Models).............................................342
		Fan Mount Assembly Repair (Late Models).....................................342
		Drive Belt Installation.....................................................344
		Valve Clearance Adjustment (Early Models)...................................345
		Valve Clearance Adjustment (New Models).....................................346
		Compression Check...........................................................346
		Engine Specifications.......................................................347
			Engine Data.............................................................347
			Cylinder Head...........................................................347
			Hydraulic Valve Lifter..................................................348
			Camshaft................................................................348
			Pistons.................................................................348
			Crankshaft..............................................................349
			Connecting Rods.........................................................349
			Balance Shaft...........................................................350
			Cooling System..........................................................350
			Lubrication System......................................................350
		Torque Specifications.......................................................350
		Troubleshooting.............................................................351
	tables..........................................................................309
		Table 1. Piston Rings Arrangement on Piston.................................340
897934-0700SRM0626-(11-2001)-US-EN..................................................357
	toc.............................................................................357
		Cooling System..............................................................357
		Safety Precautions Maintenance and Repair...................................358
		General.....................................................................361
		Description.................................................................362
			Radiator................................................................362
			Radiator Cap............................................................362
			Thermostat..............................................................362
			Water Pump..............................................................363
			Fan and Fan Shroud......................................................363
		Cooling System Checks.......................................................363
			Radiator................................................................363
			Thermostat..............................................................363
			Water Pump..............................................................364
			Exhaust Leaks...........................................................364
			Fan and Fan Shroud......................................................364
		Radiator Cleaning...........................................................364
			Drain...................................................................364
			Clean...................................................................364
			Fill....................................................................365
		Troubleshooting.............................................................366
899783-2000SRM0090-(10-2003)-US-EN..................................................369
	toc.............................................................................369
		Main Control Valve..........................................................369
		Safety Precautions Maintenance and Repair...................................370
		General.....................................................................373
		Description.................................................................373
		Operation...................................................................376
			Lift Spool..............................................................376
			Tilt Spool..............................................................377
				Tilt Backward.......................................................377
				Tilt Forward........................................................378
			Single-Stage Relief Valve...............................................380
			Two-Stage Relief Valve..................................................381
		Main Control Valve Repair...................................................382
			Remove and Disassemble..................................................382
			Clean and Inspect.......................................................382
			Assemble................................................................382
			Install.................................................................383
		Single-Stage Relief Valve Adjustment........................................383
		Two-Stage Relief Valve......................................................384
		Auxiliary Control Valve Relief Valve Adjustment (H60-110E Only).............384
		Troubleshooting.............................................................385
	tables..........................................................................369
		Table 1. Relief Pressures (Oil temperature at 55 to 66 C ( 131 t............383
1559545-2200SRM1090-(04-2005)-US-EN.................................................389
	toc.............................................................................389
		Electronic Control Module (ECM) Diagnostic Troubleshooting..................389
		Safety Precautions Maintenance and Repair...................................390
		General.....................................................................399
		Description of ECM Based Diagnostics........................................399
			Definition of Terms.....................................................399
			Diagnostics Overview of the Spectrum Fuel System........................399
			Malfunction Indicator Lamp (MIL)........................................400
			Spectrum Diagnostic Trouble Codes (DTC).................................400
			Using a Laptop Computer to Diagnose the Spectrum System.................400
				Installing the Spectrum Diagnostic Software.........................401
				Connecting a Laptop Computer to the Spectrum System.................401
				Diagnostic Communication Error......................................401
			Diagnostic Trouble Codes................................................402
				Checking Diagnostic Trouble Codes...................................402
				Clearing Diagnostic Trouble Codes...................................402
			DATA Stream.............................................................403
				Reading Sensor and Actuator Values..................................403
				Graphing and Data Logging...........................................404
			Ignition System Test....................................................405
				Disabling Ignition Outputs..........................................405
			Injector Test...........................................................406
				Disabling Injectors.................................................406
			Throttle Test...........................................................406
				Using a Diagnostic Jumper to Diagnose the ECI System................407
		On-Board Diagnostics System Check/Malfunction Indicator Lamp................408
			Circuit Description.....................................................408
		Preliminary and Intermittent Checks.........................................411
		GM 3.0L Wiring Schematics and Connectors....................................413
		GM 3.0L Diagnostic Trouble Codes............................................427
			DTC 111 - IAT High Voltage Motorola® TMAP...............................427
				Circuit Description.................................................427
				Conditions for Setting the DTC......................................427
			DTC 112 - IAT Low Voltage Motorola® TMAP................................430
				Circuit Description.................................................430
				Conditions for Setting the DTC......................................430
			DTC 113 - IAT Higher Than Expected 1 Motorola® TMAP.....................432
				Circuit Description.................................................432
				Conditions for Setting the DTC......................................432
				Diagnostic Aids.....................................................433
			DTC 114 - IAT Higher Than Expected 2 Motorola® TMAP.....................434
				Circuit Description.................................................434
				Conditions for Setting the DTC......................................434
				Diagnostic Aids.....................................................434
			DTC 115 - Oil Pressure Low..............................................435
				Circuit Description.................................................435
				Conditions for Setting the DTC......................................435
			DTC 121 - ECT Voltage High..............................................438
				Circuit Description.................................................438
				Conditions for Setting the DTC......................................439
			DTC 122 - ECT Voltage Low...............................................442
				Circuit Description.................................................442
				Conditions for Setting the DTC......................................442
			DTC 123 - ECT Higher Than Expected 1....................................444
				Circuit Description.................................................444
				Conditions for Setting the DTC......................................444
			DTC 124 - ECT Higher Than Expected 2....................................446
				Circuit Description.................................................446
				Conditions for Setting the DTC......................................446
			DTC 131 - MAP High Pressure Motorola® TMAP..............................448
				Circuit Description.................................................448
				Conditions for Setting the DTC......................................448
				Diagnostic Aids.....................................................448
			DTC 132 - MAP Low Voltage Motorola® TMAP................................451
				Circuit Description.................................................451
				Conditions for Setting the DTC......................................451
			DTC 134 - BP High Pressure Motorola® TMAP...............................455
				Circuit Description.................................................455
				Conditions for Setting the DTC......................................455
			DTC 135 - BP Low Pressure Motorola® TMAP................................456
				Circuit Description.................................................456
				Conditions for Setting the DTC......................................456
			DTC 142 - Crank Sync Noise..............................................460
				Circuit Description.................................................460
				Conditions for setting the DTC......................................460
			DTC 143 - Never Crank Synced At Start...................................464
				Circuit Description.................................................464
				Conditions for Setting the DTC......................................464
			DTC 144 - Camshaft Sensor Loss..........................................467
				Circuit Description.................................................467
				Conditions for Setting the DTC......................................467
			DTC 145 - Camshaft Sensor Noise.........................................470
				Circuit Description.................................................470
				Conditions for Setting the DTC......................................470
			DTC 211 - Closed Loop Multiplier High (LPG).............................473
				Circuit Description.................................................473
				Conditions for Setting the DTC......................................473
				Diagnostic Aids.....................................................473
			DTC 212 - HO 2 S Open/Inactive..........................................476
				Circuit Description.................................................476
				Conditions for Setting the DTC......................................476
			DTC 221 - Closed Loop Multiplier High (Gasoline)........................478
				Circuit Description.................................................478
				Conditions for Setting the DTC......................................478
				Diagnostic Aids.....................................................479
			DTC 222 - Closed Loop Multiplier Low (Gasoline).........................482
				Circuit Description.................................................482
				Conditions for Setting the DTC......................................482
				Diagnostic Aids.....................................................482
			DTC 224 - Closed Loop Multiplier Low (LPG)..............................484
				Circuit Description.................................................484
				Conditions for Setting the DTC......................................484
				Diagnostic Aids.....................................................484
			DTC 241 - Adaptive Lean Fault (High Limit-Gasoline).....................486
				Circuit Description.................................................486
				Conditions for Setting the DTC......................................486
				Diagnostic Aids.....................................................486
			DTC 242 - Adaptive Rich Fault (Low Limit-Gasoline)......................489
				Circuit Description.................................................489
				Conditions for Setting the DTC......................................489
				Diagnostic Aids.....................................................489
			DTC 243 - Adaptive Learn High (LPG).....................................492
				Circuit Description.................................................492
				Conditions for Setting the DTC......................................492
				Diagnostic Aids.....................................................492
			DTC 244 - Adaptive Learn Low (LPG)......................................495
				Circuit Description.................................................495
				Conditions for Setting the DTC......................................495
				Diagnostic Aids.....................................................495
			DTC 261 - System Voltage High...........................................498
				Circuit Description.................................................498
				Conditions for Setting the DTC......................................498
			DTC 262 - System Voltage Low............................................500
				Circuit Description.................................................500
				Conditions for Setting the DTC......................................500
			DTC 411 - Injector Driver 1 Open........................................502
				Circuit Description.................................................502
				Conditions for Setting the DTC......................................502
			DTC 412 - Injector Driver 1 Shorted.....................................505
				Circuit Description.................................................505
				Conditions for Setting the DTC......................................505
			DTC 511 - COP Failure...................................................508
				Circuit Description.................................................508
				Conditions for Setting the DTC......................................508
			DTC 512 - Invalid Interrupt.............................................510
				Circuit Description.................................................510
				Conditions for Setting the DTC......................................510
			DTC 513 - A/D Loss......................................................512
				Circuit Description.................................................512
				Conditions for Setting the DTC......................................512
			DTC 514 - RTI 1 Loss....................................................514
				Circuit Description.................................................514
				Conditions for Setting the DTC......................................514
			DTC 515 - Flash Checksum Invalid........................................516
				Circuit Description.................................................516
				Conditions for Setting the DTC......................................516
			DTC 516 - Ram Failure...................................................518
				Circuit Description.................................................518
				Conditions for Setting the DTC......................................518
			DTC 531 - External 5V Ref Lower Than Expected...........................520
				Circuit Description.................................................520
				Conditions for Setting the DTC......................................520
			DTC 532 - External 5V Ref Higher Than Expected..........................522
				Circuit Description.................................................522
				Conditions for Setting the DTC......................................522
			DTC 555 - RTI 2 Loss....................................................524
				Circuit Description.................................................524
				Conditions for Setting the DTC......................................524
			DTC 556 - RTI 3 Loss....................................................526
				Circuit Description.................................................526
				Conditions for Setting the DTC......................................526
			DTC 611 - FPP High Voltage..............................................528
				Circuit Description.................................................528
				Conditions for Setting the DTC......................................528
			DTC 612 - FPP Low Voltage...............................................532
				Circuit Description.................................................532
				Conditions for Setting the DTC......................................532
			DTC 631 - TPS1 Signal Voltage High......................................536
				Circuit Description.................................................536
				Conditions for Setting the DTC......................................536
			DTC 632 - TPS1 Signal Voltage Low.......................................539
				Circuit Description.................................................539
				Conditions for Setting the DTC......................................539
			DTC 638 - Throttle Unable To Close......................................542
				Circuit Description.................................................542
				Conditions for Setting the DTC......................................542
				Diagnostic Aids.....................................................543
			DTC 651 - Maximum Govern Speed Override.................................545
				Circuit Description.................................................545
				Conditions for Setting the DTC......................................545
				Diagnostic Aids.....................................................545
			DTC 652 - Fuel Rev Limit................................................548
				Circuit Description.................................................548
				Conditions for Setting the DTC......................................548
				Diagnostic Aids.....................................................548
			DTC 653 - Spark Rev Limit...............................................550
				Circuit Description.................................................550
				Conditions for Setting the DTC......................................550
				Diagnostic Aids.....................................................550
		GM 4.3L Wiring Schematics and Connectors....................................554
		GM 4.3L Diagnostic Trouble Codes............................................571
			DTC 111 - IAT High Voltage Bosch® TMAP..................................571
				Circuit Description.................................................571
				Conditions for Setting the DTC......................................571
			DTC 111 - IAT High Voltage Motorola® TMAP...............................574
				Circuit Description.................................................574
				Conditions for Setting the DTC......................................574
			DTC 112 - IAT Low Voltage Bosch® TMap...................................576
				Circuit Description.................................................576
				Conditions for Setting the DTC......................................577
			DTC 112 - IAT Low Voltage Motorola® TMAP................................579
				Circuit Description.................................................579
				Conditions for Setting the DTC......................................579
			DTC 113 - IAT Higher Than Expected 1 Bosch® TMAP........................582
				Circuit Description.................................................582
				Conditions for Setting the DTC......................................582
				Diagnostic Aids.....................................................582
			DTC 113 - IAT Higher Than Expected 1 Motorola® TMAP.....................583
				Circuit Description.................................................583
				Conditions for Setting the DTC......................................583
				Diagnostic Aids.....................................................583
			DTC 114 - IAT Higher Than Expected 2 Bosch® TMAP€.......................584
				Circuit Description.................................................584
				Conditions for Setting the DTC......................................584
				Diagnostic Aids.....................................................584
			DTC 114 - IAT Higher Than Expected 2 Motorola® TMAP.....................585
				Circuit Description.................................................585
				Conditions for Setting the DTC......................................585
				Diagnostic Aids.....................................................585
			DTC 115 - Oil Pressure Low..............................................586
				Circuit Description.................................................586
				Conditions for Setting the DTC......................................586
			DTC 121 - ECT Voltage High..............................................588
				Circuit Description.................................................588
				Conditions for Setting the DTC......................................589
			DTC 122 - ECT Voltage Low...............................................592
				Circuit Description.................................................592
				Conditions for Setting the DTC......................................592
			DTC 123 - ECT Higher Than Expected 1....................................595
				Circuit Description.................................................595
				Conditions for Setting the DTC......................................595
			DTC 124 - ECT Higher Than Expected 2....................................597
				Circuit Description.................................................597
				Conditions for Setting the DTC......................................597
			DTC 131 - MAP High Pressure Bosch® TMAP.................................598
				Circuit Description.................................................598
				Conditions for Setting the DTC......................................598
				Diagnostic Aids.....................................................598
			DTC 131 - MAP High Pressure Motorola® TMAP..............................602
				Circuit Description.................................................602
				Conditions for Setting the DTC......................................602
				Diagnostic Aids.....................................................602
			DTC 132 - MAP Low Voltage Bosch® TMAP...................................605
				Circuit Description.................................................605
				Conditions for Setting the DTC......................................605
			DTC 132 - MAP Low Voltage Motorola® TMAP................................608
				Circuit Description.................................................608
				Conditions for Setting the DTC......................................608
			DTC 134 - BP High Pressure Bosch® TMAP..................................613
				Circuit Description.................................................613
				Conditions for Setting the DTC......................................613
			DTC 134 - BP High Pressure Motorola® TMAP...............................615
				Circuit Description.................................................615
				Conditions for Setting the DTC......................................615
			DTC 135 - BP Low Pressure Bosch® TMAP...................................617
				Circuit Description.................................................617
				Conditions for Setting the DTC......................................617
			DTC 135 - BP Low Pressure Motorola® TMAP................................621
				Circuit Description.................................................621
				Conditions for Setting the DTC......................................621
			DTC 142 - Crank Sync Noise..............................................624
				Circuit Description.................................................624
				Conditions for setting the DTC......................................624
			DTC 143 - Never Crank Synced At Start...................................628
				Circuit Description.................................................628
				Conditions for Setting the DTC......................................628
			DTC 144 - Camshaft Sensor Loss..........................................631
				Circuit Description.................................................631
				Conditions for Setting the DTC......................................631
			DTC 145 - Camshaft Sensor Noise.........................................634
				Circuit Description.................................................634
				Conditions for Setting the DTC......................................634
			DTC 211 - Closed Loop Multiplier High (LPG).............................637
				Circuit Description.................................................637
				Conditions for Setting the DTC......................................637
				Diagnostic Aids.....................................................638
			DTC 212 - HO 2 S Open/Inactive..........................................640
				Circuit Description.................................................640
				Conditions for Setting the DTC......................................640
			DTC 221 - Closed Loop Multiplier High (Gasoline)........................643
				Circuit Description.................................................643
				Conditions for Setting the DTC......................................643
				Diagnostic Aids.....................................................643
			DTC 222 - Closed Loop Multiplier Low (Gasoline).........................646
				Circuit Description.................................................646
				Conditions for Setting the DTC......................................646
				Diagnostic Aids.....................................................646
			DTC 224 - Closed Loop Multiplier Low (LPG)..............................648
				Circuit Description.................................................648
				Conditions for Setting the DTC......................................648
				Diagnostic Aids.....................................................649
			DTC 241 - Adaptive Lean Fault (High Limit-Gasoline).....................650
				Circuit Description.................................................650
				Conditions for Setting the DTC......................................650
				Diagnostic Aids.....................................................650
			DTC 242 - Adaptive Rich Fault (Low Limit-Gasoline)......................653
				Circuit Description.................................................653
				Conditions for Setting the DTC......................................653
				Diagnostic Aids.....................................................653
			DTC 243 - Adaptive Learn High (LPG).....................................656
				Circuit Description.................................................656
				Conditions for Setting the DTC......................................656
				Diagnostic Aids.....................................................656
			DTC 244 - Adaptive Learn Low (LPG)......................................659
				Circuit Description.................................................659
				Conditions for Setting the DTC......................................659
				Diagnostic Aids.....................................................659
			DTC 261 - System Voltage High...........................................662
				Circuit Description.................................................662
				Conditions for Setting the DTC......................................662
			DTC 262 - System Voltage Low............................................664
				Circuit Description.................................................664
				Conditions for Setting the DTC......................................664
			DTC 511 - COP Failure...................................................666
				Circuit Description.................................................666
				Conditions for Setting the DTC......................................666
			DTC 512 - Invalid Interrupt.............................................668
				Circuit Description.................................................668
				Conditions for Setting the DTC......................................668
			DTC 513 - A/D Loss......................................................670
				Circuit Description.................................................670
				Conditions for Setting the DTC......................................670
			DTC 514 - RTI 1 Loss....................................................672
				Circuit Description.................................................672
				Conditions for Setting the DTC......................................672
			DTC 515 - Flash Checksum Invalid........................................674
				Circuit Description.................................................674
				Conditions for Setting the DTC......................................674
			DTC 516 - Ram Failure...................................................676
				Circuit Description.................................................676
				Conditions for Setting the DTC......................................676
			DTC 531 - External 5V Ref Lower Than Expected...........................678
				Circuit Description.................................................678
				Conditions for Setting the DTC......................................678
			DTC 532 - External 5V Ref Higher Than Expected..........................680
				Circuit Description.................................................680
				Conditions for Setting the DTC......................................680
			DTC 555 - RTI 2 Loss....................................................682
				Circuit Description.................................................682
				Conditions for Setting the DTC......................................682
			DTC 556 - RTI 3 Loss....................................................684
				Circuit Description.................................................684
				Conditions for Setting the DTC......................................684
			DTC 611 - FPP High Voltage..............................................686
				Circuit Description.................................................686
				Conditions for Setting the DTC......................................686
			DTC 612 - FPP Low Voltage...............................................690
				Circuit Description.................................................690
				Conditions for Setting the DTC......................................690
			DTC 631 - TPS1 Signal Voltage High......................................694
				Circuit Description.................................................694
				Conditions for Setting the DTC......................................694
			DTC 632 - TPS1 Signal Voltage Low.......................................697
				Circuit Description.................................................697
				Conditions for Setting the DTC......................................697
			DTC 638 - Throttle Unable To Close......................................700
				Circuit Description.................................................700
				Conditions for Setting the DTC......................................700
				Diagnostic Aids.....................................................701
			DTC 651 - Maximum Govern Speed Override.................................703
				Circuit Description.................................................703
				Conditions for Setting the DTC......................................703
				Diagnostic Aids.....................................................703
			DTC 652 - Fuel Rev Limit................................................706
				Circuit Description.................................................706
				Conditions for Setting the DTC......................................706
				Diagnostic Aids.....................................................706
			DTC 653 - Spark Rev Limit...............................................708
				Circuit Description.................................................708
				Conditions for Setting the DTC......................................708
				Diagnostic Aids.....................................................708
		Wire Harness Repair.........................................................711
			On Vehicle Service Wiring Harness Repair................................711
			Connectors and Terminals................................................712
				Twisted/Shielded Cable Repair.......................................712
				Twisted Leads Repair................................................713
				Micro-Pack..........................................................714
				Metri-Pack..........................................................714
					Remove..........................................................714
				Weather-Pack........................................................716
					Weather-Pack Terminal Repair....................................717
	tables..........................................................................389
		Table 1. OBD System Check...................................................409
		Table 2. Preliminary Checks.................................................411
		Table 3. Intermittent Checks................................................412
		Table 4. Communication Port C002............................................413
		Table 5. Coil Connector C003................................................413
		Table 6. Fuel System Interface C004.........................................413
		Table 7. Oil Pressure Connector C005........................................414
		Table 8. Distributor Connector C006.........................................414
		Table 9. Magnetic Pickup Connector C007.....................................414
		Table 10. Heated Oxygen Sensor C008.........................................414
		Table 11. Throttle Position Sensor Connector C009...........................415
		Table 12. Foot Pedal Position Connector C010................................415
		Table 13. Governor Motor Connector C011.....................................415
		Table 14. TMAP Connector C012...............................................415
		Table 15. Starter Solenoid C013.............................................416
		Table 16. Engine Coolant Temperature C014...................................416
		Table 17. Battery Connector C015............................................416
		Table 18. Alternator Connection C016........................................416
		Table 19. Battery Connector C017............................................416
		Table 20. Alternator Connector C018.........................................417
		Table 21. Instrument Panel Connector C019...................................417
		Table 22. Instrument Panel Connector C020...................................417
		Table 23. Instrument Panel Connector C021...................................418
		Table 24. Fuel Trim Valve Connector C022....................................418
		Table 25. Fuel Lockoff Connector C023.......................................418
		Table 26. Pressure Trim Valve Connector C024................................419
		Table 27. Throttle Body Injector Connector C025.............................419
		Table 28. Relay and Fuse Center.............................................419
		Table 29. DTC 111 - IAT Voltage High (Motorola® TMAP).......................428
		Table 30. DTC 112 - IAT Low Voltage (Motorola® TMAP)........................431
		Table 31. DTC 115 - Oil Pressure Low........................................436
		Table 32. Temperature Resistance............................................438
		Table 33. DTC 121 - ECT VOLTAGE HIGH........................................439
		Table 34. DTC 122 - ECT Voltage Low.........................................443
		Table 35. DTC 123 - ECT Higher Than Expected 1..............................445
		Table 36. DTC 124 - ECT Higher Than Expected 2..............................447
		Table 37. DTC 131 - MAP HIGH PRESSURE (Motorola® TMAP)......................449
		Table 38. DTC 132 - MAP Low Voltage (Motorola® TMAP)........................452
		Table 39. DTC 134 - BP High Pressure (Motorola® TMAP).......................455
		Table 40. DTC 135 - BP Low Pressure (Motorola® TMAP)........................457
		Table 41. DTC 142 - Crank Sync Noise........................................461
		Table 42. DTC 143 - Never Crank Synced At Start.............................464
		Table 43. DTC 144 - Camshaft Sensor Loss....................................467
		Table 44. DTC 145 - Camshaft Sensor Noise...................................470
		Table 45. DTC 211 - Closed Loop Multiplier High (LPG).......................474
		Table 46. DTC 212 - HO 2 S Open/Inactive....................................477
		Table 47. DTC 221 - Closed Loop Multiplier High (Gasoline)..................480
		Table 48. DTC 222 - Closed Loop Multiplier Low (Gasoline)...................483
		Table 49. DTC 224 - Closed Loop Multiplier Low (LPG)........................485
		Table 50. DTC 241 - Adaptive Lean Fault (High Limit-Gasoline)...............487
		Table 51. DTC 242 - Adaptive Rich Fault (Low Limit-Gasoline)................490
		Table 52. DTC 243 - Adaptive Learn High (LPG)...............................493
		Table 53. DTC 244 - Adaptive Learn Low (LPG)................................496
		Table 54. DTC 261 - System Voltage High.....................................499
		Table 55. DTC 262 - System Voltage Low......................................500
		Table 56. DTC 411 - Injector Driver 1 Open..................................503
		Table 57. DTC 412 - Injector Driver 1 Shorted...............................506
		Table 58. DTC 511 - COP Failure.............................................509
		Table 59. DTC 512 - Invalid Interrupt.......................................511
		Table 60. DTC 513 - A/D Loss................................................513
		Table 61. DTC 514 - RTI 1 Loss..............................................515
		Table 62. DTC 515 - Flash Checksum Invalid..................................517
		Table 63. DTC 516 - Ram Failure.............................................519
		Table 64. DTC 531 - External 5V Ref Lower Than Expected.....................521
		Table 65. DTC 532 - External 5 V Ref Higher Than Expected...................523
		Table 66. DTC 555 - RTI 2 Loss..............................................525
		Table 67. DTC 556 - RTI 3 Loss..............................................527
		Table 68. DTC 611 - FPP High Voltage........................................529
		Table 69. DTC 612 - FPP Low Voltage.........................................533
		Table 70. DTC 631 - TPS1 Signal Voltage High................................537
		Table 71. DTC 632 - TPS1 Signal Voltage Low.................................540
		Table 72. DTC 638 - Throttle Unable To Close................................543
		Table 73. DTC 651 - Maximum Govern Speed Override...........................546
		Table 74. DTC 652 - Fuel Rev Limit..........................................549
		Table 75. DTC 653 - Spark Rev Limit.........................................551
		Table 76. Communication Port C002...........................................554
		Table 77. Injector Connector C003...........................................554
		Table 78. Injector Connector C004...........................................554
		Table 79. Oil Pressure Connector C005.......................................555
		Table 80. Throttle Position Sensor 1 Connector C006.........................555
		Table 81. Foot Pedal Position Connector C006A...............................555
		Table 82. Coil Connector C007...............................................555
		Table 83. Module Connector C008.............................................556
		Table 84. Crank Sensor Connector C009.......................................556
		Table 85. EGO Sensor Connector C010.........................................556
		Table 86. Cam Connector C011................................................557
		Table 87. Throttle Connector C012...........................................557
		Table 88. Bosch TMAP Connector C013 (Gasoline Fuel System Only).............557
		Table 89. Motorola TMAP Connector C013 (LPG Fuel System Only)...............558
		Table 90. Starter Solenoid Connector C014...................................558
		Table 91. ECT Connector C015................................................558
		Table 92. Starter Relay C016................................................558
		Table 93. Power Relay C017..................................................558
		Table 94. Fuel Pump Relay C018..............................................558
		Table 95. Battery Connector C019............................................559
		Table 96. Alternator Connector C020.........................................559
		Table 97. Alternator Connector C021.........................................559
		Table 98. Instrument Panel Connector C022...................................559
		Table 99. Instrument Panel Connector C023...................................560
		Table 100. Instrument Panel Connector C024..................................560
		Table 101. Fuel Trim Valve Connector C025...................................560
		Table 102. Fuel Lockoff Connector C026......................................561
		Table 103. Pressure Trim Valve Connector C027...............................561
		Table 104. Injector 1 Connector C028........................................561
		Table 105. Injector 2 Connector C029........................................562
		Table 106. Injector 3 Connector C030........................................562
		Table 107. Injector 4 Connector C031........................................562
		Table 108. Injector 5 Connector C032........................................563
		Table 109. Injector 6 Connector C033........................................563
		Table 110. Relay and Fuse Center............................................563
		Table 111. DTC 111 - IAT Voltage High (Bosch® TMAP).........................572
		Table 112. DTC 111 - IAT Voltage High (Motorola® TMAP)......................575
		Table 113. DTC 112 - IAT Low Voltage (Bosch® TMAP)..........................577
		Table 114. DTC 112 - IAT Low Voltage (Motorola® TMAP).......................580
		Table 115. DTC 115 - Oil Pressure Low.......................................586
		Table 116. Temperature Resistance...........................................589
		Table 117. DTC 121 - ECT VOLTAGE HIGH.......................................590
		Table 118. DTC 122 - ECT Voltage Low........................................593
		Table 119. DTC 123 - ECT Higher Than Expected 1.............................596
		Table 120. DTC 124 - ECT Higher Than Expected 2.............................598
		Table 121. DTC 131 - MAP High Pressure (Bosch® TMAP)........................599
		Table 122. DTC 131 - MAP HIGH PRESSURE (Motorola® TMAP).....................603
		Table 123. DTC 132 - MAP Low Voltage (Bosch® TMAP)..........................606
		Table 124. DTC 132 - MAP Low Voltage (Motorola® TMAP).......................609
		Table 125. DTC 134 - BP High Pressure (Bosch® TMAP).........................614
		Table 126. DTC 134 - BP High Pressure (Motorola® TMAP)......................616
		Table 127. DTC 135 - BP Low Pressure (Bosch® TMAP)..........................617
		Table 128. DTC 135 - BP Low Pressure (Motorola® TMAP).......................621
		Table 129. DTC 142 - Crank Sync Noise.......................................625
		Table 130. DTC 143 - Never Crank Synced At Start............................628
		Table 131. DTC 144 - Camshaft Sensor Loss...................................631
		Table 132. DTC 145 - Camshaft Sensor Noise..................................634
		Table 133. DTC 211 - Closed Loop Multiplier High (LPG)......................638
		Table 134. DTC 212 - HO 2 S Open/Inactive...................................641
		Table 135. DTC 221 - Closed Loop Multiplier High (Gasoline).................644
		Table 136. DTC 222 - Closed Loop Multiplier Low (Gasoline)..................647
		Table 137. DTC 224 - Closed Loop Multiplier Low (LPG).......................649
		Table 138. DTC 241 - Adaptive Lean Fault (High Limit-Gasoline)..............651
		Table 139. DTC 242 - Adaptive Rich Fault (Low Limit-Gasoline)...............654
		Table 140. DTC 243 - Adaptive Learn High (LPG)..............................657
		Table 141. DTC 244 - Adaptive Learn Low (LPG)...............................660
		Table 142. DTC 261 - System Voltage High....................................663
		Table 143. DTC 262 - System Voltage Low.....................................664
		Table 144. DTC 511 - COP Failure............................................667
		Table 145. DTC 512 - Invalid Interrupt......................................669
		Table 146. DTC 513 - A/D Loss...............................................671
		Table 147. DTC 514 - RTI 1 Loss.............................................673
		Table 148. DTC 515 - Flash Checksum Invalid.................................675
		Table 149. DTC 516 - Ram Failure............................................677
		Table 150. DTC 531 - External 5V Ref Lower Than Expected....................679
		Table 151. DTC 532 - External 5 V Ref Higher Than Expected..................681
		Table 152. DTC 555 - RTI 2 Loss.............................................683
		Table 153. DTC 556 - RTI 3 Loss.............................................685
		Table 154. DTC 611 - FPP High Voltage.......................................687
		Table 155. DTC 612 - FPP Low Voltage........................................690
		Table 156. DTC 631 - TPS1 Signal Voltage High...............................695
		Table 157. DTC 632 - TPS1 Signal Voltage Low................................698
		Table 158. DTC 638 - Throttle Unable To Close...............................701
		Table 159. DTC 651 - Maximum Govern Speed Override..........................704
		Table 160. DTC 652 - Fuel Rev Limit.........................................707
		Table 161. DTC 653 - Spark Rev Limit........................................710
1559550-2200SRM1097-(03-2007)-US-EN.................................................721
	toc.............................................................................721
		High Voltage Switch (HVS) Ignition..........................................721
		Safety Precautions Maintenance and Repair...................................722
		Description.................................................................725
			Distributor Ignition (DI) System........................................725
			Crankshaft Position (CKP) Sensor........................................725
			Camshaft Position (CMP) Sensor..........................................725
			Ignition Coil and Ignition Control Module (ICM).........................725
			Secondary Ignition Components...........................................725
		Spark Plugs and Wires.......................................................725
			Spark Plug Wire Inspection..............................................725
			Spark Plug Wire Replacement.............................................725
				Remove..............................................................725
				Install.............................................................726
			Spark Plug Inspection...................................................726
				Usage...............................................................726
				Inspection..........................................................726
				Visual Inspection...................................................728
			Spark Plug Replacement..................................................728
				Remove..............................................................728
				Install.............................................................729
		Distributor Repair..........................................................729
			Inspect.................................................................729
			Overhaul................................................................730
				Disassemble.........................................................730
				Assemble............................................................732
			Replace.................................................................733
				Remove..............................................................733
				Install Procedure 1.................................................735
				Install Procedure 2.................................................735
		Ignition Coil Replacement...................................................737
			Remove..................................................................737
			Install.................................................................737
		Ignition Control Module Replacement.........................................738
			Remove..................................................................738
			Install.................................................................738
		Camshaft Position (CMP) Sensor Replacement..................................739
			Remove..................................................................739
			Install.................................................................740
		Crankshaft Position (CKP) Sensor Replacement................................741
			Remove..................................................................741
			Install.................................................................741
		Wire Harness Repair.........................................................742
			On Vehicle Service Wiring Harness Repair................................742
			Connectors and Terminals................................................742
				Twisted/Shielded Cable Repair.......................................743
				Twisted Leads Repair................................................744
				Micro-Pack..........................................................745
				Metri-Pack..........................................................745
					Remove..........................................................745
				Weather-Pack........................................................747
					Weather-Pack Terminal Repair....................................747
		Specifications and Special Tools............................................749
		System Diagnosis............................................................750
	tables..........................................................................721
		Table 1. Ignition System Specifications.....................................749
		Table 2. Fastener Tightening Specifications.................................749
		Table 3. Special Tools......................................................750
		Table 4. Distributor Ignition (DI)..........................................750

HYSTER C024 SERVICE MANUAL – PDF DOWNLOAD:

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PLEASE NOTE:

  • This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
  • The manual can be all yours – Once payment is complete, you will be taken to the download page from where you can download the manual. All in 2-5 minutes time!!
  • Need any other service / repair / parts manual, please feel free to contact us at heydownloadss @gmail.com . We may surprise you with a nice offer

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