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Hyster D187 (H2.00-3.20XM H40-65XM) Service Manual – PDF DOWNLOAD
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Hyster D187 (H2.00-3.20XM H40-65XM) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Hyster D187 (H2.00-3.20XM H40-65XM) Service Manual – PDF DOWNLOAD
Language : English
Pages : 1583
Downloadable : Yes
File Type : PDF
Size: 54.5 MB
TABLE OF CONTENTS:
Hyster D187 (H2.00-3.20XM H40-65XM) Service Manual – PDF DOWNLOAD
Alternator with Regulator........................................................... 1 toc............................................................................. 1 Alternator with Regulator................................................... 1 General..................................................................... 3 Description................................................................. 3 Alternator Repair........................................................... 5 Alternator Type A....................................................... 5 Remove and Disassemble.............................................. 5 Clean............................................................... 6 Assemble............................................................ 7 Install............................................................. 7 Alternator Type B....................................................... 10 Remove and Disassemble.............................................. 10 Clean............................................................... 10 Assemble............................................................ 11 Install............................................................. 12 General Check and Adjustment................................................ 13 Low Output Check (Type A or Type B)......................................... 13 High Output Check (Type A or Type B)........................................ 15 Brushes Circuit Check....................................................... 16 Delco Alternators....................................................... 16 Motorola Alternators.................................................... 17 Diodes Check................................................................ 18 Diode Bridge Check.......................................................... 18 Delco and Leece-Neville Alternators..................................... 18 Motorola Alternators.................................................... 18 Rotor Field Winding Check................................................... 19 Stator Windings Check....................................................... 20 Voltage Regulator Check..................................................... 20 Troubleshooting............................................................. 20 Brake System........................................................................ 24 toc............................................................................. 24 Brake System................................................................ 24 General..................................................................... 26 Description and Operation................................................... 26 Service Brakes.......................................................... 26 Master Cylinder......................................................... 26 Parking Brake........................................................... 28 Service Brakes Repair....................................................... 28 Remove and Disassemble.................................................. 28 Clean................................................................... 30 Inspect................................................................. 30 Assemble and Install.................................................... 32 Adjust.................................................................. 36 Parking Brake Repair........................................................ 36 Remove and Disassemble.................................................. 36 Assemble and Install.................................................... 36 Adjust.................................................................. 36 Master Cylinder Repair...................................................... 38 Remove.................................................................. 38 Clean and Inspect....................................................... 38 Repair.................................................................. 39 Install................................................................. 41 Service Brakes Adjustment................................................... 41 Brake System Air Removal.................................................... 42 Parking Brake Not Applied Switch Test....................................... 42 Parking Brake Switch Test (MONOTROL® Pedal Only)............................ 42 Inching/Brake Pedal Adjustment.............................................. 43 Neutral Start Switch Adjustment, MONOTROL Pedal H2.00-3.20XM (H4............ 47 Neutral Start Switch Adjustment, MONOTROL Pedal S2.00-3.20XM (S4............ 48 Neutral Start Switch Test (MONOTROL Pedal).................................. 49 Torque Specifications....................................................... 49 H2.00-3.20XM (H40-65XM)................................................. 49 S2.00-3.20XM (S40-65XM)................................................. 49 Troubleshooting............................................................. 49 Capacities and Specifications....................................................... 55 toc............................................................................. 55 Capacities and Specifications............................................... 55 Lift Truck Weights.......................................................... 57 Tire Pressure............................................................... 57 Capacities.................................................................. 58 Tire Sizes.................................................................. 59 Electrical System........................................................... 59 Gasoline/LPG............................................................ 59 Diesel.................................................................. 59 Transmission Oil Pressures.................................................. 60 Hydraulic System............................................................ 60 Stall Speeds................................................................ 61 H2.00-3.20XM (H45-65XM)................................................. 61 S2.00-3.20XM (S40-65XM)................................................. 61 Engine Specifications....................................................... 62 Gasoline/LPG............................................................ 62 Diesel.................................................................. 63 Mast Speeds................................................................. 64 H40-65XM Mast Speeds (US Models) - Mazda M4-2.0G Engine................. 64 H40-65XM Mast Speeds (US Models) - Mazda M4-2.2G Engine................. 65 H40-65XM Mast Speeds (US Models) - GM 3.0L Engine....................... 66 H45-65XM Mast Speeds (US Models) - Perkins 704-26 (UB) Diesel En........ 68 S45-65XM Mast Speeds (US Models) - Mazda M4-2.0G Engine................. 69 S40-65XM Mast Speeds (US Models) - Mazda M4-2.2G Engine................. 71 S40-65XM Mast Speeds (US Models) - GM 3.0L Engine....................... 72 H2.00-3.20XM Mast Speeds (European Models) - Mazda M4-2.0G Engin........ 76 H2.00-3.20XM Mast Speeds (European Models) - Mazda M4-2.2G Engin........ 77 H2.00-3.20XM Mast Speeds (European Models) - GM 3.0L Engine............. 78 H2.00-3.20XM Mast Speeds (European Models) - Perkins 704-26 (UB)........ 80 S2.00-3.20XM Mast Speeds (European Models) - Mazda M4-2.0G Engin........ 81 S2.00-3.20XM Mast Speeds (European Models) - Mazda M4-2.2G Engin........ 83 S2.00-3.20XM Mast Speeds (European Models) - GM 3.0L Engine............. 84 Torque Specifications....................................................... 88 Frame................................................................... 88 Brake System............................................................ 88 Mast.................................................................... 88 Steering System......................................................... 88 Drive Axle.............................................................. 88 Transmission and Differential........................................... 89 Engine - Mazda M4-2.0G and M4-2.2G...................................... 89 Engine - GM 3.0L........................................................ 90 Engine - Perkins 704-26 (UB)............................................ 90 Cooling System...................................................................... 94 toc............................................................................. 94 Cooling System.............................................................. 94 General..................................................................... 96 Description................................................................. 97 Radiator................................................................ 97 Radiator Cap............................................................ 97 Thermostat.............................................................. 97 Water Pump.............................................................. 98 Fan and Fan Shroud...................................................... 98 Cooling System Checks....................................................... 98 Radiator................................................................ 98 Thermostat.............................................................. 98 Water Pump.............................................................. 99 Exhaust Leaks........................................................... 99 Fan and Fan Shroud...................................................... 99 Radiator Cleaning........................................................... 99 Drain................................................................... 99 Clean................................................................... 99 Fill.................................................................... 100 Troubleshooting............................................................. 101 Diagrams............................................................................ 103 toc............................................................................. 103 Diagrams.................................................................... 103 Drive Axle.......................................................................... 196 toc............................................................................. 196 Drive Axle.................................................................. 196 General..................................................................... 198 Description................................................................. 198 Drive Axle Repair........................................................... 198 Remove and Disassemble.................................................. 198 Clean and Inspect....................................................... 200 Assemble and Install.................................................... 200 Torque Specifications....................................................... 202 H2.00-3.20XM (H40-65XM)................................................. 202 S2.00-3.20XM (S40-65XM)................................................. 202 Troubleshooting............................................................. 203 Dual Fuel System.................................................................... 205 ................................................................................ 205 ................................................................................ 206 ................................................................................ 207 ................................................................................ 208 ................................................................................ 209 ................................................................................ 210 Dual Fuel System-2.................................................................. 211 ................................................................................ 211 ................................................................................ 212 ................................................................................ 213 ................................................................................ 214 ................................................................................ 215 ................................................................................ 216 Electrical System................................................................... 217 toc............................................................................. 217 Electrical System........................................................... 217 General..................................................................... 219 Description................................................................. 219 Starting System......................................................... 219 Ignition System......................................................... 219 Charging System......................................................... 220 Starter Repair.............................................................. 221 Remove and Disassemble.................................................. 221 Assemble and Install.................................................... 221 Coil Replacement............................................................ 223 Distributor Repair H1.50-1.75XM, H2.00XMS (S/H25-35XM, S/H40XMS)............ 224 Remove and Disassemble.................................................. 224 Assemble and Install.................................................... 224 Distributor Repair S/H2.00-3.20XM (S/H40-65XM).............................. 226 Remove and Disassemble.................................................. 226 Assemble and Install.................................................... 228 Alternator Repair........................................................... 228 Remove and Disassemble.................................................. 228 Assemble and Install.................................................... 230 General Checks and Adjustments.............................................. 230 Starter Checks.............................................................. 230 Operation, Check........................................................ 230 Brush Holder, Check..................................................... 231 Armature, Check......................................................... 231 Field Windings, Check................................................... 231 Clutch and Bearing, Check............................................... 232 Ignition System Check and Adjustment........................................ 232 Engine Timing, Adjust................................................... 232 Spark Plugs, Check...................................................... 233 Charging Circuit Checks..................................................... 233 Low Output, Check....................................................... 233 High Output, Check...................................................... 234 Diodes, Check........................................................... 234 Rotor Field Winding, Check.............................................. 235 Stator Windings, Check.................................................. 235 Brushes and Bearings, Check............................................. 236 Voltage Regulator, Check................................................ 236 Troubleshooting............................................................. 236 Electronic Control Module (ECM) Diagnostic Troubleshooting.......................... 240 toc............................................................................. 240 Electronic Control Module (ECM) Diagnostic Troubleshooting.................. 240 General..................................................................... 249 Description of ECM Based Diagnostics........................................ 249 Definition of Terms..................................................... 249 Diagnostics Overview of the Spectrum Fuel System........................ 249 Malfunction Indicator Lamp (MIL)........................................ 250 Spectrum Diagnostic Trouble Codes (DTC)................................. 250 Using a Laptop Computer to Diagnose the Spectrum System................. 250 Installing the Spectrum Diagnostic Software......................... 251 Connecting a Laptop Computer to the Spectrum System................. 251 Diagnostic Communication Error...................................... 251 Diagnostic Trouble Codes................................................ 252 Checking Diagnostic Trouble Codes................................... 252 Clearing Diagnostic Trouble Codes................................... 252 DATA Stream............................................................. 253 Reading Sensor and Actuator Values.................................. 253 Graphing and Data Logging........................................... 254 Ignition System Test.................................................... 255 Disabling Ignition Outputs.......................................... 255 Injector Test........................................................... 256 Disabling Injectors................................................. 256 Throttle Test........................................................... 256 Using a Diagnostic Jumper to Diagnose the ECI System................ 257 On-Board Diagnostics System Check/Malfunction Indicator Lamp................ 258 Circuit Description..................................................... 258 Preliminary and Intermittent Checks......................................... 261 GM 3.0L Wiring Schematics and Connectors.................................... 263 GM 3.0L Diagnostic Trouble Codes............................................ 277 DTC 111 - IAT High Voltage Motorola® TMAP............................... 277 Circuit Description................................................. 277 Conditions for Setting the DTC...................................... 277 DTC 112 - IAT Low Voltage Motorola® TMAP................................ 280 Circuit Description................................................. 280 Conditions for Setting the DTC...................................... 280 DTC 113 - IAT Higher Than Expected 1 Motorola® TMAP..................... 282 Circuit Description................................................. 282 Conditions for Setting the DTC...................................... 282 Diagnostic Aids..................................................... 283 DTC 114 - IAT Higher Than Expected 2 Motorola® TMAP..................... 284 Circuit Description................................................. 284 Conditions for Setting the DTC...................................... 284 Diagnostic Aids..................................................... 284 DTC 115 - Oil Pressure Low.............................................. 285 Circuit Description................................................. 285 Conditions for Setting the DTC...................................... 285 DTC 121 - ECT Voltage High.............................................. 288 Circuit Description................................................. 288 Conditions for Setting the DTC...................................... 289 DTC 122 - ECT Voltage Low............................................... 292 Circuit Description................................................. 292 Conditions for Setting the DTC...................................... 292 DTC 123 - ECT Higher Than Expected 1.................................... 294 Circuit Description................................................. 294 Conditions for Setting the DTC...................................... 294 DTC 124 - ECT Higher Than Expected 2.................................... 296 Circuit Description................................................. 296 Conditions for Setting the DTC...................................... 296 DTC 131 - MAP High Pressure Motorola® TMAP.............................. 298 Circuit Description................................................. 298 Conditions for Setting the DTC...................................... 298 Diagnostic Aids..................................................... 298 DTC 132 - MAP Low Voltage Motorola® TMAP................................ 301 Circuit Description................................................. 301 Conditions for Setting the DTC...................................... 301 DTC 134 - BP High Pressure Motorola® TMAP............................... 305 Circuit Description................................................. 305 Conditions for Setting the DTC...................................... 305 DTC 135 - BP Low Pressure Motorola® TMAP................................ 306 Circuit Description................................................. 306 Conditions for Setting the DTC...................................... 306 DTC 142 - Crank Sync Noise.............................................. 310 Circuit Description................................................. 310 Conditions for setting the DTC...................................... 310 DTC 143 - Never Crank Synced At Start................................... 314 Circuit Description................................................. 314 Conditions for Setting the DTC...................................... 314 DTC 144 - Camshaft Sensor Loss.......................................... 317 Circuit Description................................................. 317 Conditions for Setting the DTC...................................... 317 DTC 145 - Camshaft Sensor Noise......................................... 320 Circuit Description................................................. 320 Conditions for Setting the DTC...................................... 320 DTC 211 - Closed Loop Multiplier High (LPG)............................. 323 Circuit Description................................................. 323 Conditions for Setting the DTC...................................... 323 Diagnostic Aids..................................................... 323 DTC 212 - HO 2 S Open/Inactive.......................................... 326 Circuit Description................................................. 326 Conditions for Setting the DTC...................................... 326 DTC 221 - Closed Loop Multiplier High (Gasoline)........................ 328 Circuit Description................................................. 328 Conditions for Setting the DTC...................................... 328 Diagnostic Aids..................................................... 329 DTC 222 - Closed Loop Multiplier Low (Gasoline)......................... 332 Circuit Description................................................. 332 Conditions for Setting the DTC...................................... 332 Diagnostic Aids..................................................... 332 DTC 224 - Closed Loop Multiplier Low (LPG).............................. 334 Circuit Description................................................. 334 Conditions for Setting the DTC...................................... 334 Diagnostic Aids..................................................... 334 DTC 241 - Adaptive Lean Fault (High Limit-Gasoline)..................... 336 Circuit Description................................................. 336 Conditions for Setting the DTC...................................... 336 Diagnostic Aids..................................................... 336 DTC 242 - Adaptive Rich Fault (Low Limit-Gasoline)...................... 339 Circuit Description................................................. 339 Conditions for Setting the DTC...................................... 339 Diagnostic Aids..................................................... 339 DTC 243 - Adaptive Learn High (LPG)..................................... 342 Circuit Description................................................. 342 Conditions for Setting the DTC...................................... 342 Diagnostic Aids..................................................... 342 DTC 244 - Adaptive Learn Low (LPG)...................................... 345 Circuit Description................................................. 345 Conditions for Setting the DTC...................................... 345 Diagnostic Aids..................................................... 345 DTC 261 - System Voltage High........................................... 348 Circuit Description................................................. 348 Conditions for Setting the DTC...................................... 348 DTC 262 - System Voltage Low............................................ 350 Circuit Description................................................. 350 Conditions for Setting the DTC...................................... 350 DTC 411 - Injector Driver 1 Open........................................ 352 Circuit Description................................................. 352 Conditions for Setting the DTC...................................... 352 DTC 412 - Injector Driver 1 Shorted..................................... 355 Circuit Description................................................. 355 Conditions for Setting the DTC...................................... 355 DTC 511 - COP Failure................................................... 358 Circuit Description................................................. 358 Conditions for Setting the DTC...................................... 358 DTC 512 - Invalid Interrupt............................................. 360 Circuit Description................................................. 360 Conditions for Setting the DTC...................................... 360 DTC 513 - A/D Loss...................................................... 362 Circuit Description................................................. 362 Conditions for Setting the DTC...................................... 362 DTC 514 - RTI 1 Loss.................................................... 364 Circuit Description................................................. 364 Conditions for Setting the DTC...................................... 364 DTC 515 - Flash Checksum Invalid........................................ 366 Circuit Description................................................. 366 Conditions for Setting the DTC...................................... 366 DTC 516 - Ram Failure................................................... 368 Circuit Description................................................. 368 Conditions for Setting the DTC...................................... 368 DTC 531 - External 5V Ref Lower Than Expected........................... 370 Circuit Description................................................. 370 Conditions for Setting the DTC...................................... 370 DTC 532 - External 5V Ref Higher Than Expected.......................... 372 Circuit Description................................................. 372 Conditions for Setting the DTC...................................... 372 DTC 555 - RTI 2 Loss.................................................... 374 Circuit Description................................................. 374 Conditions for Setting the DTC...................................... 374 DTC 556 - RTI 3 Loss.................................................... 376 Circuit Description................................................. 376 Conditions for Setting the DTC...................................... 376 DTC 611 - FPP High Voltage.............................................. 378 Circuit Description................................................. 378 Conditions for Setting the DTC...................................... 378 DTC 612 - FPP Low Voltage............................................... 382 Circuit Description................................................. 382 Conditions for Setting the DTC...................................... 382 DTC 631 - TPS1 Signal Voltage High...................................... 386 Circuit Description................................................. 386 Conditions for Setting the DTC...................................... 386 DTC 632 - TPS1 Signal Voltage Low....................................... 389 Circuit Description................................................. 389 Conditions for Setting the DTC...................................... 389 DTC 638 - Throttle Unable To Close...................................... 392 Circuit Description................................................. 392 Conditions for Setting the DTC...................................... 392 Diagnostic Aids..................................................... 393 DTC 651 - Maximum Govern Speed Override................................. 395 Circuit Description................................................. 395 Conditions for Setting the DTC...................................... 395 Diagnostic Aids..................................................... 395 DTC 652 - Fuel Rev Limit................................................ 398 Circuit Description................................................. 398 Conditions for Setting the DTC...................................... 398 Diagnostic Aids..................................................... 398 DTC 653 - Spark Rev Limit............................................... 400 Circuit Description................................................. 400 Conditions for Setting the DTC...................................... 400 Diagnostic Aids..................................................... 400 GM 4.3L Wiring Schematics and Connectors.................................... 404 GM 4.3L Diagnostic Trouble Codes............................................ 421 DTC 111 - IAT High Voltage Bosch® TMAP.................................. 421 Circuit Description................................................. 421 Conditions for Setting the DTC...................................... 421 DTC 111 - IAT High Voltage Motorola® TMAP............................... 424 Circuit Description................................................. 424 Conditions for Setting the DTC...................................... 424 DTC 112 - IAT Low Voltage Bosch® TMap................................... 426 Circuit Description................................................. 426 Conditions for Setting the DTC...................................... 427 DTC 112 - IAT Low Voltage Motorola® TMAP................................ 429 Circuit Description................................................. 429 Conditions for Setting the DTC...................................... 429 DTC 113 - IAT Higher Than Expected 1 Bosch® TMAP........................ 432 Circuit Description................................................. 432 Conditions for Setting the DTC...................................... 432 Diagnostic Aids..................................................... 432 DTC 113 - IAT Higher Than Expected 1 Motorola® TMAP..................... 433 Circuit Description................................................. 433 Conditions for Setting the DTC...................................... 433 Diagnostic Aids..................................................... 433 DTC 114 - IAT Higher Than Expected 2 Bosch® TMAP€....................... 434 Circuit Description................................................. 434 Conditions for Setting the DTC...................................... 434 Diagnostic Aids..................................................... 434 DTC 114 - IAT Higher Than Expected 2 Motorola® TMAP..................... 435 Circuit Description................................................. 435 Conditions for Setting the DTC...................................... 435 Diagnostic Aids..................................................... 435 DTC 115 - Oil Pressure Low.............................................. 436 Circuit Description................................................. 436 Conditions for Setting the DTC...................................... 436 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.................................... 445 Circuit Description................................................. 445 Conditions for Setting the DTC...................................... 445 DTC 124 - ECT Higher Than Expected 2.................................... 447 Circuit Description................................................. 447 Conditions for Setting the DTC...................................... 447 DTC 131 - MAP High Pressure Bosch® TMAP................................. 448 Circuit Description................................................. 448 Conditions for Setting the DTC...................................... 448 Diagnostic Aids..................................................... 448 DTC 131 - MAP High Pressure Motorola® TMAP.............................. 452 Circuit Description................................................. 452 Conditions for Setting the DTC...................................... 452 Diagnostic Aids..................................................... 452 DTC 132 - MAP Low Voltage Bosch® TMAP................................... 455 Circuit Description................................................. 455 Conditions for Setting the DTC...................................... 455 DTC 132 - MAP Low Voltage Motorola® TMAP................................ 458 Circuit Description................................................. 458 Conditions for Setting the DTC...................................... 458 DTC 134 - BP High Pressure Bosch® TMAP.................................. 463 Circuit Description................................................. 463 Conditions for Setting the DTC...................................... 463 DTC 134 - BP High Pressure Motorola® TMAP............................... 465 Circuit Description................................................. 465 Conditions for Setting the DTC...................................... 465 DTC 135 - BP Low Pressure Bosch® TMAP................................... 467 Circuit Description................................................. 467 Conditions for Setting the DTC...................................... 467 DTC 135 - BP Low Pressure Motorola® TMAP................................ 471 Circuit Description................................................. 471 Conditions for Setting the DTC...................................... 471 DTC 142 - Crank Sync Noise.............................................. 474 Circuit Description................................................. 474 Conditions for setting the DTC...................................... 474 DTC 143 - Never Crank Synced At Start................................... 478 Circuit Description................................................. 478 Conditions for Setting the DTC...................................... 478 DTC 144 - Camshaft Sensor Loss.......................................... 481 Circuit Description................................................. 481 Conditions for Setting the DTC...................................... 481 DTC 145 - Camshaft Sensor Noise......................................... 484 Circuit Description................................................. 484 Conditions for Setting the DTC...................................... 484 DTC 211 - Closed Loop Multiplier High (LPG)............................. 487 Circuit Description................................................. 487 Conditions for Setting the DTC...................................... 487 Diagnostic Aids..................................................... 488 DTC 212 - HO 2 S Open/Inactive.......................................... 490 Circuit Description................................................. 490 Conditions for Setting the DTC...................................... 490 DTC 221 - Closed Loop Multiplier High (Gasoline)........................ 493 Circuit Description................................................. 493 Conditions for Setting the DTC...................................... 493 Diagnostic Aids..................................................... 493 DTC 222 - Closed Loop Multiplier Low (Gasoline)......................... 496 Circuit Description................................................. 496 Conditions for Setting the DTC...................................... 496 Diagnostic Aids..................................................... 496 DTC 224 - Closed Loop Multiplier Low (LPG).............................. 498 Circuit Description................................................. 498 Conditions for Setting the DTC...................................... 498 Diagnostic Aids..................................................... 499 DTC 241 - Adaptive Lean Fault (High Limit-Gasoline)..................... 500 Circuit Description................................................. 500 Conditions for Setting the DTC...................................... 500 Diagnostic Aids..................................................... 500 DTC 242 - Adaptive Rich Fault (Low Limit-Gasoline)...................... 503 Circuit Description................................................. 503 Conditions for Setting the DTC...................................... 503 Diagnostic Aids..................................................... 503 DTC 243 - Adaptive Learn High (LPG)..................................... 506 Circuit Description................................................. 506 Conditions for Setting the DTC...................................... 506 Diagnostic Aids..................................................... 506 DTC 244 - Adaptive Learn Low (LPG)...................................... 509 Circuit Description................................................. 509 Conditions for Setting the DTC...................................... 509 Diagnostic Aids..................................................... 509 DTC 261 - System Voltage High........................................... 512 Circuit Description................................................. 512 Conditions for Setting the DTC...................................... 512 DTC 262 - System Voltage Low............................................ 514 Circuit Description................................................. 514 Conditions for Setting the DTC...................................... 514 DTC 511 - COP Failure................................................... 516 Circuit Description................................................. 516 Conditions for Setting the DTC...................................... 516 DTC 512 - Invalid Interrupt............................................. 518 Circuit Description................................................. 518 Conditions for Setting the DTC...................................... 518 DTC 513 - A/D Loss...................................................... 520 Circuit Description................................................. 520 Conditions for Setting the DTC...................................... 520 DTC 514 - RTI 1 Loss.................................................... 522 Circuit Description................................................. 522 Conditions for Setting the DTC...................................... 522 DTC 515 - Flash Checksum Invalid........................................ 524 Circuit Description................................................. 524 Conditions for Setting the DTC...................................... 524 DTC 516 - Ram Failure................................................... 526 Circuit Description................................................. 526 Conditions for Setting the DTC...................................... 526 DTC 531 - External 5V Ref Lower Than Expected........................... 528 Circuit Description................................................. 528 Conditions for Setting the DTC...................................... 528 DTC 532 - External 5V Ref Higher Than Expected.......................... 530 Circuit Description................................................. 530 Conditions for Setting the DTC...................................... 530 DTC 555 - RTI 2 Loss.................................................... 532 Circuit Description................................................. 532 Conditions for Setting the DTC...................................... 532 DTC 556 - RTI 3 Loss.................................................... 534 Circuit Description................................................. 534 Conditions for Setting the DTC...................................... 534 DTC 611 - FPP High Voltage.............................................. 536 Circuit Description................................................. 536 Conditions for Setting the DTC...................................... 536 DTC 612 - FPP Low Voltage............................................... 540 Circuit Description................................................. 540 Conditions for Setting the DTC...................................... 540 DTC 631 - TPS1 Signal Voltage High...................................... 544 Circuit Description................................................. 544 Conditions for Setting the DTC...................................... 544 DTC 632 - TPS1 Signal Voltage Low....................................... 547 Circuit Description................................................. 547 Conditions for Setting the DTC...................................... 547 DTC 638 - Throttle Unable To Close...................................... 550 Circuit Description................................................. 550 Conditions for Setting the DTC...................................... 550 Diagnostic Aids..................................................... 551 DTC 651 - Maximum Govern Speed Override................................. 553 Circuit Description................................................. 553 Conditions for Setting the DTC...................................... 553 Diagnostic Aids..................................................... 553 DTC 652 - Fuel Rev Limit................................................ 556 Circuit Description................................................. 556 Conditions for Setting the DTC...................................... 556 Diagnostic Aids..................................................... 556 DTC 653 - Spark Rev Limit............................................... 558 Circuit Description................................................. 558 Conditions for Setting the DTC...................................... 558 Diagnostic Aids..................................................... 558 Wire Harness Repair......................................................... 561 On Vehicle Service Wiring Harness Repair................................ 561 Connectors and Terminals................................................ 562 Twisted/Shielded Cable Repair....................................... 562 Twisted Leads Repair................................................ 563 Micro-Pack.......................................................... 564 Metri-Pack.......................................................... 564 Remove.......................................................... 564 Weather-Pack........................................................ 566 Weather-Pack Terminal Repair.................................... 567 tables.......................................................................... 240 Table 1. OBD System Check................................................... 259 Table 2. Preliminary Checks................................................. 261 Table 3. Intermittent Checks................................................ 262 Table 4. Communication Port C002............................................ 263 Table 5. Coil Connector C003................................................ 263 Table 6. Fuel System Interface C004......................................... 263 Table 7. Oil Pressure Connector C005........................................ 264 Table 8. Distributor Connector C006......................................... 264 Table 9. Magnetic Pickup Connector C007..................................... 264 Table 10. Heated Oxygen Sensor C008......................................... 264 Table 11. Throttle Position Sensor Connector C009........................... 265 Table 12. Foot Pedal Position Connector C010................................ 265 Table 13. Governor Motor Connector C011..................................... 265 Table 14. TMAP Connector C012............................................... 265 Table 15. Starter Solenoid C013............................................. 266 Table 16. Engine Coolant Temperature C014................................... 266 Table 17. Battery Connector C015............................................ 266 Table 18. Alternator Connection C016........................................ 266 Table 19. Battery Connector C017............................................ 266 Table 20. Alternator Connector C018......................................... 267 Table 21. Instrument Panel Connector C019................................... 267 Table 22. Instrument Panel Connector C020................................... 267 Table 23. Instrument Panel Connector C021................................... 268 Table 24. Fuel Trim Valve Connector C022.................................... 268 Table 25. Fuel Lockoff Connector C023....................................... 268 Table 26. Pressure Trim Valve Connector C024................................ 269 Table 27. Throttle Body Injector Connector C025............................. 269 Table 28. Relay and Fuse Center............................................. 269 Table 29. DTC 111 - IAT Voltage High (Motorola® TMAP)....................... 278 Table 30. DTC 112 - IAT Low Voltage (Motorola® TMAP)........................ 281 Table 31. DTC 115 - Oil Pressure Low........................................ 286 Table 32. Temperature Resistance............................................ 288 Table 33. DTC 121 - ECT VOLTAGE HIGH........................................ 289 Table 34. DTC 122 - ECT Voltage Low......................................... 293 Table 35. DTC 123 - ECT Higher Than Expected 1.............................. 295 Table 36. DTC 124 - ECT Higher Than Expected 2.............................. 297 Table 37. DTC 131 - MAP HIGH PRESSURE (Motorola® TMAP)...................... 299 Table 38. DTC 132 - MAP Low Voltage (Motorola® TMAP)........................ 302 Table 39. DTC 134 - BP High Pressure (Motorola® TMAP)....................... 305 Table 40. DTC 135 - BP Low Pressure (Motorola® TMAP)........................ 307 Table 41. DTC 142 - Crank Sync Noise........................................ 311 Table 42. DTC 143 - Never Crank Synced At Start............................. 314 Table 43. DTC 144 - Camshaft Sensor Loss.................................... 317 Table 44. DTC 145 - Camshaft Sensor Noise................................... 320 Table 45. DTC 211 - Closed Loop Multiplier High (LPG)....................... 324 Table 46. DTC 212 - HO 2 S Open/Inactive.................................... 327 Table 47. DTC 221 - Closed Loop Multiplier High (Gasoline).................. 330 Table 48. DTC 222 - Closed Loop Multiplier Low (Gasoline)................... 333 Table 49. DTC 224 - Closed Loop Multiplier Low (LPG)........................ 335 Table 50. DTC 241 - Adaptive Lean Fault (High Limit-Gasoline)............... 337 Table 51. DTC 242 - Adaptive Rich Fault (Low Limit-Gasoline)................ 340 Table 52. DTC 243 - Adaptive Learn High (LPG)............................... 343 Table 53. DTC 244 - Adaptive Learn Low (LPG)................................ 346 Table 54. DTC 261 - System Voltage High..................................... 349 Table 55. DTC 262 - System Voltage Low...................................... 350 Table 56. DTC 411 - Injector Driver 1 Open.................................. 353 Table 57. DTC 412 - Injector Driver 1 Shorted............................... 356 Table 58. DTC 511 - COP Failure............................................. 359 Table 59. DTC 512 - Invalid Interrupt....................................... 361 Table 60. DTC 513 - A/D Loss................................................ 363 Table 61. DTC 514 - RTI 1 Loss.............................................. 365 Table 62. DTC 515 - Flash Checksum Invalid.................................. 367 Table 63. DTC 516 - Ram Failure............................................. 369 Table 64. DTC 531 - External 5V Ref Lower Than Expected..................... 371 Table 65. DTC 532 - External 5 V Ref Higher Than Expected................... 373 Table 66. DTC 555 - RTI 2 Loss.............................................. 375 Table 67. DTC 556 - RTI 3 Loss.............................................. 377 Table 68. DTC 611 - FPP High Voltage........................................ 379 Table 69. DTC 612 - FPP Low Voltage......................................... 383 Table 70. DTC 631 - TPS1 Signal Voltage High................................ 387 Table 71. DTC 632 - TPS1 Signal Voltage Low................................. 390 Table 72. DTC 638 - Throttle Unable To Close................................ 393 Table 73. DTC 651 - Maximum Govern Speed Override........................... 396 Table 74. DTC 652 - Fuel Rev Limit.......................................... 399 Table 75. DTC 653 - Spark Rev Limit......................................... 401 Table 76. Communication Port C002........................................... 404 Table 77. Injector Connector C003........................................... 404 Table 78. Injector Connector C004........................................... 404 Table 79. Oil Pressure Connector C005....................................... 405 Table 80. Throttle Position Sensor 1 Connector C006......................... 405 Table 81. Foot Pedal Position Connector C006A............................... 405 Table 82. Coil Connector C007............................................... 405 Table 83. Module Connector C008............................................. 406 Table 84. Crank Sensor Connector C009....................................... 406 Table 85. EGO Sensor Connector C010......................................... 406 Table 86. Cam Connector C011................................................ 407 Table 87. Throttle Connector C012........................................... 407 Table 88. Bosch TMAP Connector C013 (Gasoline Fuel System Only)............. 407 Table 89. Motorola TMAP Connector C013 (LPG Fuel System Only)............... 408 Table 90. Starter Solenoid Connector C014................................... 408 Table 91. ECT Connector C015................................................ 408 Table 92. Starter Relay C016................................................ 408 Table 93. Power Relay C017.................................................. 408 Table 94. Fuel Pump Relay C018.............................................. 408 Table 95. Battery Connector C019............................................ 409 Table 96. Alternator Connector C020......................................... 409 Table 97. Alternator Connector C021......................................... 409 Table 98. Instrument Panel Connector C022................................... 409 Table 99. Instrument Panel Connector C023................................... 410 Table 100. Instrument Panel Connector C024.................................. 410 Table 101. Fuel Trim Valve Connector C025................................... 410 Table 102. Fuel Lockoff Connector C026...................................... 411 Table 103. Pressure Trim Valve Connector C027............................... 411 Table 104. Injector 1 Connector C028........................................ 411 Table 105. Injector 2 Connector C029........................................ 412 Table 106. Injector 3 Connector C030........................................ 412 Table 107. Injector 4 Connector C031........................................ 412 Table 108. Injector 5 Connector C032........................................ 413 Table 109. Injector 6 Connector C033........................................ 413 Table 110. Relay and Fuse Center............................................ 413 Table 111. DTC 111 - IAT Voltage High (Bosch® TMAP)......................... 422 Table 112. DTC 111 - IAT Voltage High (Motorola® TMAP)...................... 425 Table 113. DTC 112 - IAT Low Voltage (Bosch® TMAP).......................... 427 Table 114. DTC 112 - IAT Low Voltage (Motorola® TMAP)....................... 430 Table 115. DTC 115 - Oil Pressure Low....................................... 436 Table 116. Temperature Resistance........................................... 439 Table 117. DTC 121 - ECT VOLTAGE HIGH....................................... 440 Table 118. DTC 122 - ECT Voltage Low........................................ 443 Table 119. DTC 123 - ECT Higher Than Expected 1............................. 446 Table 120. DTC 124 - ECT Higher Than Expected 2............................. 448 Table 121. DTC 131 - MAP High Pressure (Bosch® TMAP)........................ 449 Table 122. DTC 131 - MAP HIGH PRESSURE (Motorola® TMAP)..................... 453 Table 123. DTC 132 - MAP Low Voltage (Bosch® TMAP).......................... 456 Table 124. DTC 132 - MAP Low Voltage (Motorola® TMAP)....................... 459 Table 125. DTC 134 - BP High Pressure (Bosch® TMAP)......................... 464 Table 126. DTC 134 - BP High Pressure (Motorola® TMAP)...................... 466 Table 127. DTC 135 - BP Low Pressure (Bosch® TMAP).......................... 467 Table 128. DTC 135 - BP Low Pressure (Motorola® TMAP)....................... 471 Table 129. DTC 142 - Crank Sync Noise....................................... 475 Table 130. DTC 143 - Never Crank Synced At Start............................ 478 Table 131. DTC 144 - Camshaft Sensor Loss................................... 481 Table 132. DTC 145 - Camshaft Sensor Noise.................................. 484 Table 133. DTC 211 - Closed Loop Multiplier High (LPG)...................... 488 Table 134. DTC 212 - HO 2 S Open/Inactive................................... 491 Table 135. DTC 221 - Closed Loop Multiplier High (Gasoline)................. 494 Table 136. DTC 222 - Closed Loop Multiplier Low (Gasoline).................. 497 Table 137. DTC 224 - Closed Loop Multiplier Low (LPG)....................... 499 Table 138. DTC 241 - Adaptive Lean Fault (High Limit-Gasoline).............. 501 Table 139. DTC 242 - Adaptive Rich Fault (Low Limit-Gasoline)............... 504 Table 140. DTC 243 - Adaptive Learn High (LPG).............................. 507 Table 141. DTC 244 - Adaptive Learn Low (LPG)............................... 510 Table 142. DTC 261 - System Voltage High.................................... 513 Table 143. DTC 262 - System Voltage Low..................................... 514 Table 144. DTC 511 - COP Failure............................................ 517 Table 145. DTC 512 - Invalid Interrupt...................................... 519 Table 146. DTC 513 - A/D Loss............................................... 521 Table 147. DTC 514 - RTI 1 Loss............................................. 523 Table 148. DTC 515 - Flash Checksum Invalid................................. 525 Table 149. DTC 516 - Ram Failure............................................ 527 Table 150. DTC 531 - External 5V Ref Lower Than Expected.................... 529 Table 151. DTC 532 - External 5 V Ref Higher Than Expected.................. 531 Table 152. DTC 555 - RTI 2 Loss............................................. 533 Table 153. DTC 556 - RTI 3 Loss............................................. 535 Table 154. DTC 611 - FPP High Voltage....................................... 537 Table 155. DTC 612 - FPP Low Voltage........................................ 540 Table 156. DTC 631 - TPS1 Signal Voltage High............................... 545 Table 157. DTC 632 - TPS1 Signal Voltage Low................................ 548 Table 158. DTC 638 - Throttle Unable To Close............................... 551 Table 159. DTC 651 - Maximum Govern Speed Override.......................... 554 Table 160. DTC 652 - Fuel Rev Limit......................................... 557 Table 161. DTC 653 - Spark Rev Limit........................................ 560 Electronic Controlled LPGGasoline Fuel System....................................... 570 toc............................................................................. 570 Electronic Controlled LPG/Gasoline Fuel System.............................. 570 General..................................................................... 575 Fuel System Warnings and Cautions....................................... 575 Glossary.................................................................... 576 Description and Operation of LPG Fuel System................................ 580 Propane Fuel System..................................................... 580 LPG Fuel Tank........................................................... 582 Service Line............................................................ 582 Fuel Filter............................................................. 582 Low Pressure Lock-Off (LPL)............................................. 583 Low Pressure Regulator (LPR)............................................ 583 Air Fuel Mixer.......................................................... 583 Throttle Control Device................................................. 584 Drive By Cable...................................................... 584 Three-Way Catalytic (TWC) Muffler....................................... 585 Electronic Control Module (ECM)......................................... 585 Heated Exhaust Gas Oxygen (HEGO) Sensor................................. 588 Description and Operation of Gasoline Fuel System........................... 588 Gasoline Fuel System Throttle Body Injection (TBI), 3.0L Engine ........ 588 Gasoline Multi-Point Fuel Injection (MPFI) System, 4.3L Only............ 590 Gasoline Fuel Storage Tank.............................................. 590 Gasoline Fuel Pump...................................................... 590 Fuel Filter............................................................. 590 Fuel Pressure Regulator, 3.0L Only...................................... 592 Fuel Rail and Pressure Regulator, 4.3L Only............................. 592 Fuel Injector........................................................... 592 Throttle Control Device................................................. 592 Drive By Cable...................................................... 592 Three-Way Catalytic Muffler............................................. 593 Electronic Control Module (ECM)......................................... 594 Heated Exhaust Gas Oxygen (HEGO) Sensor................................. 595 LPG Fuel System Repair...................................................... 596 Propane Fuel System Pressure Relief..................................... 596 Propane Fuel System Leak Test........................................... 596 Propane Fuel Filter Replacement......................................... 596 Remove.............................................................. 596 Install............................................................. 597 Low Pressure Lock-Off (LPL) Replacement................................. 597 Remove.............................................................. 597 Install............................................................. 597 Pressure Trim Valve (PTV) Replacement................................... 599 Remove.............................................................. 599 Install............................................................. 599 Low Pressure Regulator.................................................. 599 Remove.............................................................. 599 Install............................................................. 599 Fuel Trim Valve (FTV) Solenoid Replacement.............................. 600 Remove.............................................................. 600 Install............................................................. 600 Temperature Manifold Absolute Pressure (TMAP)........................... 603 Remove.............................................................. 603 Install............................................................. 603 Throttle Body Replacement............................................... 603 Remove.............................................................. 603 Install............................................................. 604 Mixer Replacement....................................................... 604 Remove.............................................................. 604 Install............................................................. 604 Coolant Hose Replacement................................................ 604 Remove.............................................................. 604 Install............................................................. 605 Vapor Hose Replacement.................................................. 605 Remove.............................................................. 605 Install............................................................. 605 Balance Line Hose Replacement........................................... 605 Remove.............................................................. 605 Install............................................................. 605 PTV Hose Replacement.................................................... 605 Remove.............................................................. 605 Install............................................................. 605 FTV Hose Replacement.................................................... 606 Remove.............................................................. 606 Install............................................................. 606 Throttle Position Sensor (TPS) Replacement.............................. 606 Foot Pedal Position (FPP) Sensor Replacement............................ 608 Electronic Control Module (ECM) Replacement............................. 611 Remove.............................................................. 611 Install............................................................. 611 Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement..................... 612 Remove.............................................................. 612 Install............................................................. 612 Three-Way Catalytic Muffler (TWC) Replacement........................... 612 Remove.............................................................. 612 Install............................................................. 612 Restricted Exhaust System Diagnosis..................................... 612 Exhaust System Description.......................................... 612 Tools Required.................................................. 612 Diagnostic Tool................................................. 612 Check at Heated Exhaust Gas Oxygen Sensor (HEGO).................... 613 Gasoline Fuel System Repair................................................. 613 Gasoline MPFI and TBI Fuel System Pressure Relief....................... 613 Gasoline Fuel System Leak Test.......................................... 614 Throttle Body Injector (TBI) Assembly Replacement, 3.0L Only............ 614 Remove.............................................................. 614 Install............................................................. 614 Throttle Body Assembly Replacement, 3.0L Only........................... 616 Remove.............................................................. 616 Install............................................................. 616 Throttle Body Assembly Replacement, 4.3L Only........................... 616 Remove.............................................................. 616 Install............................................................. 617 Fuel Rail Replacement, Gasoline 4.3L Only............................... 619 Remove.............................................................. 619 Install............................................................. 619 Injector Replacement, Gasoline 4.3L Only................................ 619 Remove.............................................................. 619 Install............................................................. 619 Injector Replacement, Gasoline 3.0L Only................................ 620 Remove.............................................................. 620 Install............................................................. 620 Temperature Manifold Absolute Pressure (TMAP) Replacement............... 620 Remove.............................................................. 620 Install............................................................. 620 Throttle Position Sensor (TPS) Replacement.............................. 620 Foot Pedal Position (FPP) Sensor Replacement............................ 623 Electronic Control Module (ECM) Replacement............................. 626 Remove.............................................................. 626 Install............................................................. 626 Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement..................... 626 Remove.............................................................. 626 Install............................................................. 627 Three-Way Catalytic Muffler (TWC) Replacement........................... 627 Remove.............................................................. 627 Install............................................................. 627 Restricted Exhaust System Diagnosis..................................... 627 Exhaust System Description.......................................... 627 Tools Required.................................................. 627 Diagnostic Tool................................................. 627 Check at Heated Exhaust Gas Oxygen Sensor (HEGO).................... 627 LPG System Diagnosis........................................................ 628 Fuel System Description................................................. 628 Diagnostic Aids......................................................... 629 Tools Required...................................................... 629 Duty Cycle Monitoring Tool.......................................... 629 Diagnostic Tool..................................................... 629 Pressure Gauges..................................................... 629 Test Description.................................................... 629 Gasoline System Diagnosis................................................... 637 Fuel System Description, 3.0L Only...................................... 637 Fuel System Description, 4.3L Only...................................... 637 Diagnostic Aids......................................................... 638 Tools Required...................................................... 638 Diagnostic Tool..................................................... 638 Test Description.................................................... 638 LPG Symptom Diagnosis....................................................... 645 Gasoline Symptom Diagnosis.................................................. 659 Wire Harness Repair......................................................... 669 On Vehicle Service Wiring Harness Repair................................ 669 Connectors and Terminals................................................ 670 Twisted/Shielded Cable Repair....................................... 670 Twisted Leads Repair................................................ 671 Micro-Pack.......................................................... 672 Metri-Pack.......................................................... 673 Remove.......................................................... 673 Weather-Pack........................................................ 674 Weather-Pack Terminal Repair.................................... 675 tables.......................................................................... 570 Table 1. TPS Replacement Procedure.......................................... 606 Table 2. FPP Replacement Procedure.......................................... 609 Table 3. TPS Replacement Procedure.......................................... 621 Table 4. FPP Replacement Procedure.......................................... 624 Table 5. LPG Fuel System Diagnosis.......................................... 629 Table 6. Fuel Control Diagnosis............................................. 633 Table 7. Gasoline Fuel System Diagnosis, 3.0L Only.......................... 639 Table 8. Gasoline Fuel System Diagnosis, 4.3L Only.......................... 642 Table 9. Preliminary Checks................................................. 645 Table 10. Intermittent ..................................................... 647 Table 11. No Start.......................................................... 648 Table 12. Hard Start........................................................ 650 Table 13. Cuts Out or Misses................................................ 651 Table 14. Hesitation, Sag, or Stumble....................................... 652 Table 15. Backfire.......................................................... 653 Table 16. Lack of Power, Sluggishness, or Sponginess........................ 654 Table 17. Poor Fuel Economy................................................. 655 Table 18. Rough, Unstable, Incorrect Idle, or Stalling...................... 656 Table 19. Surges or Chuggles................................................ 658 Table 20. Preliminary Checks................................................ 659 Table 21. Intermittent...................................................... 660 Table 22. No Start.......................................................... 661 Table 23. Hard Start........................................................ 662 Table 24. Cuts Out or Misses................................................ 663 Table 25. Hesitation, Sag, or Stumble....................................... 664 Table 26. Backfire.......................................................... 665 Table 27. Lack of Power, Sluggishness, or Sponginess........................ 666 Table 28. Poor Fuel Economy................................................. 667 Table 29. Rough, Unstable, Incorrect Idle, or Stalling...................... 668 Table 30. Surges or Chuggles................................................ 669 Electronic Engine Control........................................................... 678 ................................................................................ 678 ................................................................................ 679 ................................................................................ 680 ................................................................................ 681 ................................................................................ 682 ................................................................................ 683 ................................................................................ 684 ................................................................................ 685 ................................................................................ 686 ................................................................................ 687 ................................................................................ 688 ................................................................................ 689 ................................................................................ 690 ................................................................................ 691 ................................................................................ 692 ................................................................................ 693 ................................................................................ 694 ................................................................................ 695 ................................................................................ 696 ................................................................................ 697 ................................................................................ 698 ................................................................................ 699 ................................................................................ 700 ................................................................................ 701 ................................................................................ 702 ................................................................................ 703 ................................................................................ 704 ................................................................................ 705 ................................................................................ 706 ................................................................................ 707 ................................................................................ 708 ................................................................................ 709 ................................................................................ 710 ................................................................................ 711 ................................................................................ 712 ................................................................................ 713 ................................................................................ 714 ................................................................................ 715 ................................................................................ 716 ................................................................................ 717 ................................................................................ 718 ................................................................................ 719 ................................................................................ 720 ................................................................................ 721 ................................................................................ 722 ................................................................................ 723 ................................................................................ 724 ................................................................................ 725 ................................................................................ 726 ................................................................................ 727 ................................................................................ 728 ................................................................................ 729 ................................................................................ 730 ................................................................................ 731 ................................................................................ 732 ................................................................................ 733 ................................................................................ 734 ................................................................................ 735 ................................................................................ 736 ................................................................................ 737 ................................................................................ 738 ................................................................................ 739 ................................................................................ 740 ................................................................................ 741 ................................................................................ 742 ................................................................................ 743 ................................................................................ 744 ................................................................................ 745 ................................................................................ 746 ................................................................................ 747 ................................................................................ 748 ................................................................................ 749 ................................................................................ 750 ................................................................................ 751 ................................................................................ 752 ................................................................................ 753 ................................................................................ 754 ................................................................................ 755 ................................................................................ 756 ................................................................................ 757 ................................................................................ 758 ................................................................................ 759 ................................................................................ 760 ................................................................................ 761 ................................................................................ 762 ................................................................................ 763 ................................................................................ 764 ................................................................................ 765 ................................................................................ 766 ................................................................................ 767 ................................................................................ 768 ................................................................................ 769 ................................................................................ 770 ................................................................................ 771 Electronic Engine Control-2......................................................... 772 ................................................................................ 772 ................................................................................ 773 ................................................................................ 774 ................................................................................ 775 ................................................................................ 776 ................................................................................ 777 ................................................................................ 778 ................................................................................ 779 ................................................................................ 780 ................................................................................ 781 ................................................................................ 782 ................................................................................ 783 ................................................................................ 784 ................................................................................ 785 ................................................................................ 786 ................................................................................ 787 ................................................................................ 788 Four-Stage Mast..................................................................... 789 toc............................................................................. 789 Four-Stage Mast............................................................. 789 General..................................................................... 791 Description................................................................. 791 Carriages............................................................... 791 Mast Mounts............................................................. 792 Mast.................................................................... 792 Description......................................................... 792 Operation........................................................... 793 Forks Repair................................................................ 796 Remove.................................................................. 796 Install................................................................. 796 Safety Procedures When Working Near Mast.................................... 798 Carriage Repair............................................................. 801 Remove.................................................................. 801 Standard Carriage................................................... 801 Sideshift Carriage.................................................. 801 Repairs................................................................. 802 Install................................................................. 803 Standard Carriage................................................... 803 Sideshift Carriage.................................................. 803 Mast Repair................................................................. 804 Remove.................................................................. 804 Disassemble............................................................. 804 Clean and Inspect....................................................... 805 Assemble................................................................ 806 Install................................................................. 809 Lift Cylinders Repair....................................................... 812 Remove.................................................................. 812 Main Lift Cylinders................................................. 812 Free-Lift Cylinders................................................. 812 Disassemble............................................................. 814 Assemble................................................................ 814 Install................................................................. 816 Main Lift Cylinder.................................................. 816 Free-Lift Cylinder.................................................. 817 Header Hose Arrangements.................................................... 818 Header Hoses, Install................................................... 818 Lift and Tilt System Leaks Check............................................ 825 Lift Cylinders Leaks Check.............................................. 825 Tilt Cylinders Leaks Check.............................................. 825 Tilt Cylinders Adjustment................................................... 826 Lift Chain Adjustments...................................................... 826 Mast Adjustments............................................................ 828 Carriage Adjustments........................................................ 830 Troubleshooting............................................................. 831 tables.......................................................................... 789 Table 1. Standard Four-Stage Hose Dimensions................................ 824 Table 2. Hook type Carriage Chain Adjustment................................ 827 Table 3. Pin-Type Carriage Chain Adjustment................................. 827 Frame............................................................................... 834 toc............................................................................. 834 Frame....................................................................... 834 General..................................................................... 836 Description................................................................. 836 Operator Module Repair...................................................... 836 Remove.................................................................. 836 Install................................................................. 836 Hood and Side Covers Repair................................................. 838 Remove.................................................................. 838 Install................................................................. 839 Overhead Guard Repair....................................................... 839 Remove and Install...................................................... 839 LED Backup and Brake Lights, Replace.................................... 840 Remove.............................................................. 840 Install............................................................. 840 Counterweight Repair........................................................ 840 Remove.................................................................. 841 Install................................................................. 842 Exhaust System Repair....................................................... 843 Muffler, Replace........................................................ 843 Radiator and Cooling System Repair.......................................... 848 Remove.................................................................. 848 Install................................................................. 848 Operator Restraint System Repair............................................ 850 Engine Repair............................................................... 851 Remove Engine Only...................................................... 851 Remove Engine and Transmission.......................................... 851 Install Engine Only..................................................... 852 Install Engine and Transmission......................................... 853 Fuel and Hydraulic Tanks Repair............................................. 853 Inspect................................................................. 853 Small Leaks, Repair..................................................... 853 Large Leaks, Repair..................................................... 853 Clean................................................................... 854 Steam Method of Cleaning............................................ 854 Chemical Solution Method of Cleaning................................ 854 Additional Preparations for Repair...................................... 854 Safety Labels............................................................... 855 tables.......................................................................... 834 Table 1. Weight of Counterweights........................................... 842 Gasonline........................................................................... 859 ................................................................................ 859 ................................................................................ 860 ................................................................................ 861 ................................................................................ 862 ................................................................................ 863 ................................................................................ 864 ................................................................................ 865 ................................................................................ 866 ................................................................................ 867 ................................................................................ 868 ................................................................................ 869 ................................................................................ 870 ................................................................................ 871 ................................................................................ 872 ................................................................................ 873 ................................................................................ 874 ................................................................................ 875 ................................................................................ 876 ................................................................................ 877 ................................................................................ 878 ................................................................................ 879 GM Engine Repair.................................................................... 880 toc............................................................................. 880 GM Engine Repair............................................................ 880 General..................................................................... 883 Description................................................................. 883 Engine Removal and Installation............................................. 891 Cylinder Head and Valve Mechanism Repair.................................... 892 Cylinder Head, Remove................................................... 892 Cylinder Head, Disassemble.............................................. 893 Clean and Inspect....................................................... 894 Valves and Valve Seats.................................................. 896 Studs for Rocker Arms................................................... 897 Hydraulic Valve Lifters................................................. 898 Replace............................................................. 898 Clean and Inspect................................................... 898 Cylinder Head, Assemble................................................. 898 Cylinder Head, Install.................................................. 898 Valve Clearance, Adjust................................................. 899 Rocker Arm Cover, Install............................................... 900 Timing Gear Cover Repair.................................................... 900 Remove.................................................................. 900 Install................................................................. 901 Timing Wheel Repair......................................................... 902 Timing Wheel, Removal................................................... 902 Timing Wheel, Install................................................... 902 Air Gap Adjustment...................................................... 903 Camshaft Repair............................................................. 904 Camshaft, Remove........................................................ 904 Camshaft, Clean and Inspect............................................. 905 Camshaft Bearings, Remove............................................... 907 Camshaft Bearings, Clean and Inspect.................................... 907 Camshaft Bearings, Install.............................................. 907 Camshaft, Install....................................................... 908 Distributor Repair.......................................................... 908 Remove.................................................................. 908 Install................................................................. 909 Lubrication System Repair................................................... 910 Oil Pan................................................................. 910 Remove.............................................................. 910 Install............................................................. 910 Oil Pump................................................................ 910 Remove.............................................................. 910 Disassemble......................................................... 911 Clean and Inspect................................................... 911 Assemble............................................................ 912 Install............................................................. 912 Piston and Piston Rod Assemblies Repair..................................... 913 Piston Rod Bearings, Replace............................................ 913 Piston and Piston Rod Assemblies, Remove................................ 914 Piston and Piston Rod Assemblies, Disassemble........................... 915 Pistons, Clean and Inspect.............................................. 915 Cylinder Bores, Inspect and Repair...................................... 915 Piston Rings, Inspect................................................... 916 Piston and Piston Rod Assemblies, Assemble.............................. 917 Piston and Piston Rod Assemblies, Install............................... 918 Crankshaft Repair........................................................... 918 Main Bearings, Replace.................................................. 918 Oil Seal for Rear Main Bearing, Replace................................. 919 Crankshaft, Remove...................................................... 920 Inspect and Repair...................................................... 920 Main Bearing and Journal Clearance, Check............................... 921 Crankshaft, Install..................................................... 922 Flywheel and Flywheel Housing Repair........................................ 923 Flywheel, Remove........................................................ 924 Ring Gear, Replace...................................................... 924 Flywheel, Install....................................................... 925 Cooling System Repair....................................................... 925 Water Pump.............................................................. 925 Remove.............................................................. 925 Inspect............................................................. 925 Install............................................................. 926 Thermostat.............................................................. 926 Remove and Install.................................................. 926 Alternator Repair........................................................... 926 Starter Repair.............................................................. 926 Checks and Adjustments...................................................... 928 Engine Compression Test................................................. 928 Test Procedure...................................................... 928 Test Results........................................................ 928 Engine Noise Diagnostic Test............................................ 928 Description......................................................... 928 Test Procedure...................................................... 928 Engine Specifications....................................................... 930 Engine Data............................................................. 930 Cylinder Bore........................................................... 930 Piston.................................................................. 930 Piston Rings............................................................ 930 Wrist Pin............................................................... 931 Crankshaft.............................................................. 931 Piston Rod.............................................................. 932 Camshaft................................................................ 932 Hydraulic Valve System.................................................. 932 Cylinder Head Warpage................................................... 933 Lubrication System...................................................... 933 Cooling System.......................................................... 933 Torque Specifications....................................................... 934 Troubleshooting............................................................. 935 High Energy Ignition (HEI) System................................................... 940 toc............................................................................. 940 High Energy Ignition (HEI) System........................................... 940 Description................................................................. 942 Distributor Repair.......................................................... 944 Remove.................................................................. 944 Disassemble............................................................. 944 Assemble................................................................ 949 Install, If Crankshaft WAS NOT Rotated when Distributor was Remo........ 950 Install, If Crankshaft WAS Rotated when Distributor was Removed......... 950 Ignition Coil Replacement................................................... 951 Some Four- and Six-Cylinder Models...................................... 951 Remove.............................................................. 951 Install............................................................. 952 V8, Some Four- and Six-Cylinder Models.................................. 952 Remove.............................................................. 952 Install............................................................. 953 Electronic Module Replacement............................................... 954 Remove.................................................................. 954 Install................................................................. 954 Sensing Coil Replacement.................................................... 955 Remove.................................................................. 955 Install................................................................. 955 Spark Plugs Replacement..................................................... 955 Remove.................................................................. 955 Install................................................................. 956 Visual Check................................................................ 956 High Voltage Wires Check.................................................... 956 Ignition Coil Check......................................................... 957 Coil in Distributor Cap Design.......................................... 957 Separate Coil Design.................................................... 957 Sensing Coil, Check..................................................... 958 Electronic Module Check..................................................... 958 Ignition Timing Adjustment.................................................. 958 GM V8-366 (6-liter) Ignition System Check................................... 960 GM V6-LPG (4.3 liter) GM V6-LPG (4.3 liter) Ignition Timing and ............ 960 Specifications.............................................................. 960 Troubleshooting............................................................. 961 Hydraulic System.................................................................... 965 toc............................................................................. 965 Hydraulic System............................................................ 965 General..................................................................... 967 Description................................................................. 967 Hydraulic System........................................................ 967 Gear Pump Assembly...................................................... 967 Flow Control Valve...................................................... 967 Relief Valve............................................................ 967 Operation................................................................... 974 Hydraulic System........................................................ 974 Gear Pump............................................................... 974 Flow Control Valve...................................................... 974 Relief Valve............................................................ 974 Gear Pump Assembly Repair................................................... 976 Remove and Disassemble.................................................. 976 Assemble and Install.................................................... 977 Steering Relief Pressure Check and Adjustment............................... 977 Gear Pump Flow Check........................................................ 978 Troubleshooting............................................................. 978 Instrument Cluster.................................................................. 982 toc............................................................................. 982 Instrument Cluster.......................................................... 982 General..................................................................... 984 Description................................................................. 984 Display Panels on Steering Column, Internal Combustion.................. 984 Display Panels on Steering Column, Electric Lift Trucks................. 989 Standard Display Panel.............................................. 989 Enhanced Display Panel.............................................. 990 Curtis 1215 Display Panel............................................... 994 Description and Features............................................ 994 Operation........................................................... 994 Cluster-Type Display Panel (Internal Combustion) Replacement................ 995 Remove and Disassemble.................................................. 995 Assemble and Install.................................................... 998 Cluster Display Panel (Electric Lift Truck) Replacement.....................1000 Display Panel Assembly, Replace.........................................1000 LED Indicators..........................................................1000 Battery Indicators......................................................1001 Digital Display (Enhanced Display Panel Only)...........................1001 Status Code or Performance Level Switches and LED indicators (En........1001 Standard Display Panel Parts, Replace...................................1001 Enhanced Display Panel Parts, Replace...................................1002 Curtis 1215 Display Panel Replacement.......................................1002 Remove..................................................................1002 Install.................................................................1002 tables.......................................................................... 982 Table 1. Instrument Cluster, Internal Combustion............................ 984 LPG Fuel System.....................................................................1005 ................................................................................1005 ................................................................................1006 ................................................................................1007 ................................................................................1008 ................................................................................1009 ................................................................................1010 ................................................................................1011 ................................................................................1012 ................................................................................1013 ................................................................................1014 ................................................................................1015 ................................................................................1016 ................................................................................1017 ................................................................................1018 ................................................................................1019 ................................................................................1020 ................................................................................1021 ................................................................................1022 ................................................................................1023 ................................................................................1024 ................................................................................1025 ................................................................................1026 ................................................................................1027 ................................................................................1028 ................................................................................1029 LPG Fuel System-2...................................................................1030 ................................................................................1030 ................................................................................1031 ................................................................................1032 ................................................................................1033 ................................................................................1034 ................................................................................1035 ................................................................................1036 ................................................................................1037 ................................................................................1038 ................................................................................1039 ................................................................................1040 ................................................................................1041 ................................................................................1042 ................................................................................1043 ................................................................................1044 ................................................................................1045 ................................................................................1046 ................................................................................1047 ................................................................................1048 ................................................................................1049 ................................................................................1050 ................................................................................1051 ................................................................................1052 ................................................................................1053 ................................................................................1054 ................................................................................1055 LPG Fuel System-3...................................................................1056 toc.............................................................................1056 LPG Fuel System.............................................................1056 General.....................................................................1059 Description and Operation...................................................1059 Fuel Tank...............................................................1060 Regulator...............................................................1060 Start Mode..........................................................1062 Idle Mode...........................................................1062 Run Mode............................................................1062 Resonator...............................................................1062 Carburetor..............................................................1063 Start Mode..........................................................1063 Idle Mode...........................................................1063 Run Mode............................................................1063 Governor............................................................1064 Hoses Replacement...........................................................1065 LPG Tank Repair.............................................................1065 Remove..................................................................1065 Install.................................................................1066 Relief Valve Repair.........................................................1066 Remove and Install......................................................1066 Carburetor Repair...........................................................1066 Remove..................................................................1066 Disassemble.............................................................1066 Clean...................................................................1067 Assemble................................................................1068 Install.................................................................1068 Governor Repair.............................................................1068 Remove..................................................................1068 Inspect.................................................................1068 Install.................................................................1068 Regulator Repair............................................................1069 Remove..................................................................1069 Disassemble.............................................................1069 Clean...................................................................1069 Inspect.................................................................1069 Assemble................................................................1071 Install.................................................................1072 Regulator Adjustment........................................................1072 Regulator Height Adjustment.............................................1072 Regulator Assembly Air Tightness Test...................................1073 Carburetor Adjustment.......................................................1074 Idle Speed and Fuel Mixture.............................................1074 Idle Control Adjustment.................................................1074 Governor Adjustment.........................................................1075 Checks..................................................................1075 Adjustments.............................................................1075 Throttle Linkage Adjustment S/H2.00-3.20XM (S/H40-65XM).....................1076 MONOTROL® Pedal Check.......................................................1077 Throttle Linkage Adjustment S/H1.50-2.00XMS (S/H25-40XMS)...................1078 Troubleshooting.............................................................1079 tables..........................................................................1056 Table 1. Power Adjusting Screw..............................................1068 Table 2. Air Adjusting Screw................................................1068 Table 3. Idle Mixture Adjusting Screw.......................................1071 Table 4. Idle Mixture Adjusting Screw.......................................1074 LPG Fuel System-4...................................................................1086 toc.............................................................................1086 LPG Fuel System.............................................................1086 General.....................................................................1089 Description and Operation...................................................1089 Fuel Tank...............................................................1089 Oxygen Sensor...........................................................1089 Regulator...............................................................1089 Start Mode..........................................................1092 Idle Mode...........................................................1095 Run Mode............................................................1095 Resonator...............................................................1095 Carburetor..............................................................1095 Start Mode..........................................................1095 Idle Mode...........................................................1096 Run Mode............................................................1096 Governor............................................................1097 Hoses Replacement...........................................................1097 LPG Tank Repair.............................................................1098 Remove..................................................................1098 Install.................................................................1098 Relief Valve Repair.........................................................1099 Remove and Install......................................................1099 Carburetor Repair...........................................................1099 Remove..................................................................1099 Disassemble.............................................................1099 Clean...................................................................1100 Assemble................................................................1100 Install.................................................................1101 Fuel Injector Repair........................................................1101 Remove..................................................................1101 Clean and Inspect.......................................................1101 Install.................................................................1101 Governor Repair.............................................................1102 Remove..................................................................1102 Inspect.................................................................1102 Install.................................................................1102 Regulator Repair............................................................1102 Remove..................................................................1102 Install.................................................................1102 Oxygen Sensor Repair........................................................1103 Remove and Install......................................................1103 Vacuum Switches Repair......................................................1103 Remove and Install......................................................1103 Inspect.................................................................1103 Resistor Repair.............................................................1103 Remove and Install......................................................1103 Inspect.................................................................1103 Carburetor and New Regulator Adjustment.....................................1104 Idle Speed and Fuel Mixture.............................................1104 Idle Control Adjustment.................................................1104 Governor Checks and Adjustments.............................................1105 Checks..................................................................1105 Adjustments.............................................................1106 Throttle Linkage Adjustment.................................................1106 MONOTROL Pedal Check........................................................1108 Check Engine Light..........................................................1108 Inspect Warning Lamp....................................................1108 Check Feedback Operation................................................1108 Check VAC1 and VAC2 Signals.............................................1108 Check Resistor..........................................................1108 Check Fuel Injector.....................................................1109 Check Oxygen Sensor.....................................................1109 Check Vacuum Switch 1...................................................1109 Check Vacuum Switch 2...................................................1109 After Completing Checks.................................................1109 Troubleshooting.............................................................1110 tables..........................................................................1086 Table 1. Adjusting Screw....................................................1101 Main Control Valve..................................................................1118 ................................................................................1118 ................................................................................1119 ................................................................................1120 ................................................................................1121 ................................................................................1122 ................................................................................1123 ................................................................................1124 ................................................................................1125 ................................................................................1126 ................................................................................1127 ................................................................................1128 ................................................................................1129 ................................................................................1130 Mast................................................................................1131 toc.............................................................................1131 Mast........................................................................1131 General.....................................................................1133 Description and Operation...................................................1133 Carriages...............................................................1133 Mast Mounts.............................................................1135 Two-Stage Mast, Limited Free-Lift (LFL).....................................1137 Description and Operation...............................................1137 Two-Stage Mast, Full Free-Lift (FFL)........................................1139 Description and Operation...............................................1139 Three-Stage Mast, Full Free-Lift (FFL)......................................1141 Description and Operation...............................................1141 Four-Stage Mast.............................................................1144 Description and Operation...............................................1144 Cylinder Cushion During Lifting Sequence....................................1147 Cylinder Cushion During Lowering Sequence...................................1148 Mast-2..............................................................................1150 toc.............................................................................1150 Mast........................................................................1150 General.....................................................................1153 Safety Procedures When Working Near Mast....................................1153 Forks Repair................................................................1155 Remove..................................................................1155 Install.................................................................1156 Carriages Repair............................................................1156 Standard Carriage, Remove...............................................1156 Hang-On Sideshift Carriage, Remove......................................1157 Standard Carriage and Hang-On Sideshift Carriage, Repair................1158 Standard Carriage, Install..............................................1158 Hang-On Sideshift Carriage, Install.....................................1159 Integral Sideshift Carriage.............................................1159 Remove..............................................................1159 Clean and Inspect...................................................1161 Repair..............................................................1161 Install.............................................................1162 Mast Repair.................................................................1162 Remove..................................................................1162 Two-Stage LFL and Two-Stage FFL Masts, Disassemble......................1164 Three-Stage FFL Mast....................................................1171 Disassemble.........................................................1171 Mast and Chains, Clean and Inspect..................................1174 Two-Stage LFL and Two-Stage FFL Mast, Assemble..........................1175 Three-Stage FFL Mast, Assemble..........................................1176 Install.................................................................1178 Lift Cylinders Repair.......................................................1179 Main Lift Cylinders, Remove.............................................1179 Free-Lift Cylinder, Remove..............................................1179 Lift Cylinders, Disassemble.............................................1180 Lift Cylinders, Assemble................................................1180 Main Lift Cylinders, Install............................................1183 Free-Lift Cylinder, Install.............................................1184 Header Hose Arrangements....................................................1184 Two-Stage LFL Mast, New Hose Install....................................1184 Two-Stage LFL Mast, Adjust Hoses After Installation.....................1190 Two-Stage FFL Mast, New Hose Install....................................1190 Two-Stage FFL Mast, Adjust Hoses After Installation.....................1195 Three-Stage FFL Mast, New Hose Install..................................1197 Three-Stage FFL Mast, Adjust Hoses After Installation...................1207 Header Hose Arrangement.....................................................1208 Two-Stage LFL Mast, New Hose Install....................................1208 Two-Stage LFL Mast, Adjust Hoses After Installation.....................1208 Two-Stage FFL Mast, New Hose Install....................................1212 Two-Stage FFL Mast, Adjust Hoses After Installation.....................1217 Three-Stage FFL Mast, New Hose Install..................................1219 Three-Stage FFL Mast, Adjust Hoses After Install........................1224 Lift and Tilt System Leak Check.............................................1228 Lift Cylinders Leak Check...............................................1228 Tilt Cylinders Leak Check...............................................1228 Tilt Cylinders Adjustment...................................................1229 Lift Chains Adjustment......................................................1230 Mast Adjustment.............................................................1232 Carriage Adjustment.........................................................1234 Troubleshooting.............................................................1234 tables..........................................................................1150 Table 1. Hook-Type Carriage Chain Adjustment................................1231 Table 2. Pin-Type Carriage Chain Adjustment.................................1231 Mazda Engine........................................................................1238 toc.............................................................................1238 Mazda Engine................................................................1238 General.....................................................................1241 Description.................................................................1241 Engine Removal and Installation.............................................1241 Cylinder Head, Camshaft, and Valve Mechanism Repair.........................1242 Remove..................................................................1242 Clean...................................................................1243 Inspect and Repair......................................................1244 Cylinder Head.......................................................1244 Rocker Shaft Assembly...............................................1244 Camshaft............................................................1244 Valve Guides........................................................1245 Valve Seats.........................................................1246 Valves..............................................................1246 Valve Springs.......................................................1247 Install.................................................................1247 Crankshaft and Main Bearings Repair.........................................1250 Remove..................................................................1250 Inspect and Repair......................................................1250 Crankshaft..........................................................1250 Main Bearings.......................................................1250 Install.................................................................1251 Pistons and Connecting Rods Repair..........................................1252 Remove and Disassemble..................................................1252 Clean...................................................................1252 Inspect and Repair......................................................1252 Pistons.............................................................1252 Piston Rings........................................................1252 Connecting Rods and Bearings........................................1253 Assemble and Install....................................................1253 Cylinder Block Repair.......................................................1255 Oil Pump Repair.............................................................1255 Remove..................................................................1255 Disassemble.............................................................1256 Clean...................................................................1256 Inspect.................................................................1257 Assemble................................................................1257 Install.................................................................1258 Cooling System Repair.......................................................1258 Thermostat..............................................................1258 Replace.............................................................1258 Fan Assembly............................................................1258 Remove and Disassemble..............................................1258 Assemble and Install................................................1259 Water Pump..............................................................1259 Remove and Disassemble..............................................1259 Assemble and Install................................................1260 Distributor Repair..........................................................1261 Remove..................................................................1261 Install.................................................................1261 Flywheel and Ring Gear Repair S/H2.00-3.20XM (S/H40-65XM)...................1262 Remove..................................................................1262 Ring Gear, Replace......................................................1262 Install.................................................................1262 Flywheel Repair H1.50-175XM, H2.00XMS (S/H25-35XM, S/H40XMS)................1263 Remove..................................................................1263 Install.................................................................1263 Valve Adjustment............................................................1264 Compression Pressure Check..................................................1265 Engine Timing Adjustment....................................................1265 Throttle Linkage Adjustment.................................................1266 Gasoline Engines........................................................1266 LPG Engines (IMPCO).....................................................1266 LPG Engines (AISAN).....................................................1266 Engine Specifications.......................................................1266 Engine Data.............................................................1266 Thermostat..............................................................1266 Cylinder Head...........................................................1266 Valve Mechanism.........................................................1267 Camshaft................................................................1267 Crankshaft..............................................................1267 Connecting Rods.........................................................1268 Cylinder Block..........................................................1268 Pistons.................................................................1268 Oil Pump................................................................1268 Torque Specifications.......................................................1269 Troubleshooting.............................................................1270 Metric and Inch (SAE) Fasteners.....................................................1274 toc.............................................................................1274 Metric and Inch (SAE) Fasteners.............................................1274 General.....................................................................1276 Threaded Fasteners......................................................1276 Nomenclature, Threads...................................................1276 Strength Identification.................................................1277 Cotter (Split) Pins.....................................................1277 Fastener Torque Tables..................................................1282 Conversion Table........................................................1284 tables..........................................................................1274 Table 1. Bolts and Screws...................................................1278 Table 2. Studs and Nuts.....................................................1279 Table 3. Torque Nuts........................................................1280 Table 4. Torque Nuts With Nylon Insert......................................1281 Table 5. Torque Values for Metric Fasteners*................................1282 Table 6. Torque Values for Inch Fasteners*..................................1283 Table 7. Conversion Table for Metric and English Units......................1284 Table 8. Cotter Pin Dimensional Data........................................1285 Table 9. Cotter Pin Dimensional Data........................................1286 Table 10. Cotter Pin Dimensional Data.......................................1287 Table 11. Cotter Pin Dimensional Data.......................................1289 Microprocessor Spark Timing System (MSTS)...........................................1293 ................................................................................1293 ................................................................................1294 ................................................................................1295 ................................................................................1296 ................................................................................1297 ................................................................................1298 ................................................................................1299 ................................................................................1300 ................................................................................1301 ................................................................................1302 ................................................................................1303 ................................................................................1304 ................................................................................1305 ................................................................................1306 ................................................................................1307 ................................................................................1308 ................................................................................1309 ................................................................................1310 ................................................................................1311 ................................................................................1312 ................................................................................1313 ................................................................................1314 ................................................................................1315 ................................................................................1316 ................................................................................1317 ................................................................................1318 ................................................................................1319 ................................................................................1320 ................................................................................1321 ................................................................................1322 ................................................................................1323 ................................................................................1324 ................................................................................1325 ................................................................................1326 Microprocessor Spark Timing System (MSTS)-2.........................................1327 toc.............................................................................1327 Microprocessor Spark Timing System (MSTS)...................................1327 General.....................................................................1330 Description.................................................................1331 What MSTS Does..........................................................1331 How MSTS Begins Operation...............................................1331 Operation...................................................................1332 Distributor.............................................................1332 Ignition Coil...........................................................1332 Ignition Module.........................................................1332 When Engine Is Being Started............................................1333 When Engine Is Running..................................................1334 Manifold Absolute Pressure (MAP) Sensor.................................1335 Engine Coolant Temperature (ECT) Sensor.................................1335 MSTS Module Corrections.................................................1336 Troubleshooting.............................................................1337 General.................................................................1337 Tools and Test Equipment................................................1339 MSTS....................................................................1340 Troubleshooting Procedure...............................................1340 Where to Start......................................................1340 Visual/Physical Inspection..........................................1340 Knowledge/Tools Required............................................1340 Damage from Static Discharge (Static Electricity)...................1340 Troubleshooting Information.............................................1341 Malfunction Indicator Lamp (MIL)....................................1341 Connecting CodeMate Tester..........................................1341 Reading Diagnostic Trouble Codes (DTC)..............................1342 Clearing Diagnostic Trouble Codes (DTC's)...........................1343 On-Board Diagnostic (OBD) System Check..................................1343 Test Description....................................................1343 No Malfunction Indicator Lamp...............................................1345 Circuit Description.....................................................1345 Test Description........................................................1345 No DTC-12, Malfunction Indicator Lamp ON....................................1347 Circuit Description.....................................................1347 Test Description........................................................1347 Starter Rotates Engine, Engine Does Not Run.................................1348 Test Description........................................................1348 DTC-14 Engine Coolant Temperature (ECT) (Low Temperature Indicat............1352 Circuit Description.....................................................1352 Test Description........................................................1352 DTC-15 Engine Coolant Temperature Sensor (ECT) (High Temperature............1354 Circuit Description.....................................................1354 Test Description........................................................1354 DTC-34 Manifold Absolute Pressure (MAP) Sensor..............................1356 Circuit Description.....................................................1356 Test Description........................................................1356 DTC-41 Electronic Spark Timing (EST) Open Circuit...........................1359 Circuit Description.....................................................1359 Test Description........................................................1359 DTC-42 Electronic Spark Timing (EST) Grounded Circuit.......................1361 Circuit Description.....................................................1361 Test Description........................................................1361 DTC-51 MSTS Failure.........................................................1363 Circuit Description.....................................................1363 Distributor Repair..........................................................1363 Remove..................................................................1363 Disassemble.............................................................1364 Inspect.................................................................1364 Assemble................................................................1364 Install.................................................................1365 Ignition Timing.........................................................1365 Ignition Module Repair......................................................1366 Test For Fault..........................................................1366 Replace.................................................................1367 Sensing Coil Repair.........................................................1367 Test For Fault..........................................................1367 Replace.................................................................1367 Ignition Coil Repair........................................................1368 Test For Fault..........................................................1368 Remove..................................................................1368 Install.................................................................1368 MSTS Module Repair..........................................................1369 Remove..................................................................1369 Install.................................................................1369 ECT Sensor Replacement......................................................1369 MAP Sensor Replacement......................................................1370 tables..........................................................................1327 Table 1. MSTS Module Connections............................................1338 Table 2. Pressure Conversion Chart..........................................1339 Table 3. MSTS Diagnostic Codes..............................................1341 Periodic Maintenance................................................................1373 toc.............................................................................1373 Periodic Maintenance........................................................1373 General.....................................................................1377 Serial Number...........................................................1377 How to Move Disabled Lift Truck.........................................1377 How to Tow Lift Truck...............................................1377 How to Put Lift Truck on Blocks.........................................1378 How to Raise Drive Tires............................................1378 How to Raise Steering Tires.........................................1378 Maintenance Schedule........................................................1379 Maintenance Procedures Every 8 Hours or Daily...............................1388 How to Make Checks With Engine Stopped..................................1388 Tires and Wheels....................................................1389 Forks...............................................................1390 Adjust..........................................................1390 Remove..........................................................1391 Install.........................................................1391 Forks, Mast, and Lift Chains, Inspect...............................1391 Safety Labels.......................................................1392 Operator Restraint System...........................................1392 Steering Column Latch...............................................1393 Fuel, Oil, or Coolant Leaks, Check..................................1393 Drive Belt..........................................................1394 Intake Manifold Rubber Cap..........................................1394 Powershift Transmission Oil Temperature.............................1394 Powershift Transmission Oil Level...................................1394 Engine Oil..........................................................1394 Hydraulic System....................................................1394 Air Filter..........................................................1396 How to Make Checks With Engine Running..................................1396 Gauges, Indicator Lights, Horn, Fuses, and Relays...................1396 Check Engine Light (Mazda and GM LPG Closed Loop with Low-Emissi....1396 Malfunction Indicator Lamp (GM 3.0L Gasoline Engine)................1397 Engine Oil Pressure.................................................1398 Cooling System......................................................1398 Steering System.....................................................1399 Service Brakes......................................................1399 Brake Fluid Level...............................................1399 Operation, Check................................................1399 Parking Brake.......................................................1399 Water Separator, Diesel Engine......................................1399 Drain Water from Water Separator................................1399 Fuel Filter, Diesel Engine..........................................1400 Diesel Fuel System, Remove Air......................................1400 Control Levers and Pedals...........................................1400 Lift System, Operate................................................1400 Cooling System......................................................1400 Maintenance Procedures Every 250 Hours or 6 Weeks...........................1401 Air Filter..............................................................1401 Drive Belt..............................................................1401 Mazda M4-2.0G and M4-2.2G Engines...................................1401 Fan and Alternator Drive Belt...................................1401 Timing Belt.....................................................1402 GM 3.0L.............................................................1402 Perkins 704-26 (UB).................................................1403 Engine Oil Filter.......................................................1403 Brake Fluid.............................................................1404 Hydraulic Tank Breather.................................................1404 Battery.................................................................1404 Forks...................................................................1404 Lift Chains.............................................................1404 Lubrication.........................................................1404 Wear, Check.........................................................1404 Mast....................................................................1405 Steering Axle...........................................................1405 Fuel System.............................................................1405 Engine Speed, Diesel, Perkins 704-26 (UB)...........................1406 Engine Speed, LPG Carburetor, Mazda and GM (Aisan Open-Loop and ....1406 Engine Speed, LPG Carburetor, Mazda (Impco).........................1406 Engine Speed, LPG Carburetor, GM 3.0L (Impco).......................1407 Engine Speed, Mazda Gasoline Carburetor.............................1408 Hydraulic System........................................................1409 Cooling System, Clean Debris From Radiator Core.........................1409 Maintenance Procedures Every 500 Hours or 3 Months..........................1410 Drain Tar From Aisan LPG Regulator......................................1410 PCV Valve...............................................................1410 Maintenance Procedures Every 1000 Hours or 6 Months.........................1410 Diesel Fuel System......................................................1410 Fuel Filter, Replace................................................1410 Water Separator, Remove Water.......................................1411 Water Separator, Replace............................................1411 Diesel Fuel System Air Removal......................................1412 Differential and Drive Axle, Powershift Transmission....................1413 Valve Clearance, Check and Adjust.......................................1413 Ignition System.........................................................1413 GM 3.0L LPG (IMPCO).................................................1413 GM 3.0L LPG (Aisan).................................................1413 Mazda M4-2.0G and M4-2.2G ..........................................1413 Aisan Regulator Pressure/Diaphragm and O-Ring Checks....................1414 PCV Valve...............................................................1414 Integral Sideshift Carriage, Check Bearings.............................1414 Control Levers and Pedals...............................................1414 Cooling System, GM 3.0L EPA Compliant Engine............................1414 LPG Fuel Filter (IMPCO), GM 3.0L EPA Compliant Engine, Replace..........1415 Inspect Engine Electrical System, Connectors, and FCVS Connectio........1416 Maintenance Procedures Every 2000 Hours or Yearly...........................1416 Hydraulic System........................................................1416 Hydraulic Oil and Filter, Replace...................................1416 Powershift Transmission Oil and Filter..................................1416 Replace.............................................................1416 Cooling System..........................................................1417 Service Brakes..........................................................1417 Differential............................................................1418 LPG Fuel Filter, Replace (Pre-2004).....................................1418 Gasoline Fuel Filter....................................................1418 Fuel Filter, Replace (Aisan LPG System).................................1418 LPG Fuel Injector (Aisan Closed-Loop Low Emission System)...............1419 Integral Sideshift Carriage, Replace Bearings...........................1419 Oxygen Sensor, GM 3.0L EPA Compliant Engine.............................1419 Air Filter Element, GM 3.0L EPA Compliant Engine........................1419 Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks..........1419 Check Throttle Shaft for Sticking.......................................1420 Inspect Exhaust Manifold and Piping for Leaks...........................1420 Test LPG/GAS Regulator Pressure.........................................1420 Safety Procedures When Working Near Mast....................................1421 Hood Latch Check............................................................1423 Lift Chain Adjustments......................................................1423 Lift and Tilt System Leak Check.............................................1425 Lift Cylinder, Leak Check...............................................1425 Tilt Cylinder, Leak Check...............................................1426 Charging Battery............................................................1426 Diesel Engine Fuel Injector Check...........................................1426 Welding Repairs.............................................................1427 Overhead Guard Changes......................................................1427 Wheel and Tire Replacement..................................................1427 Solid Rubber Tire, Change S40-65XM Models...............................1427 Remove and Install Tire on Wheel....................................1427 Pneumatic Tire, Repair H45-65XM Models..................................1428 Remove Wheels From Lift Truck.......................................1428 Remove Wheel From Tire..............................................1429 Remove Tire From Two-Piece Wheel................................1429 Remove Tire From Three- and Four-Piece Wheels...................1430 Install Wheel on Tire...............................................1431 Install Tire on Three- or Four-Piece Wheels.....................1431 Install Three-Piece or Four-Piece Wheel in Tire.................1432 Install Tire on Two-Piece Wheel.................................1433 Install Two-Piece Wheel in Tire.................................1433 Add Air to Pneumatic Tires..............................................1434 Wheels, Install.....................................................1434 Dual Drive Wheels, Install..........................................1434 Solid Rubber Tire, Change H45-65XM Models...............................1435 Remove Wheel From Tire..............................................1435 Install Wheel in Tire...............................................1437 Adhesives and Sealants......................................................1439 tables..........................................................................1373 Table 1. Maintenance Schedule...............................................1380 Table 2. Hook-Type Carriage Chain Adjustment................................1424 Table 3. Pin-Type Carriage Chain Adjustment.................................1424 Single-Speed Powershift Transmission................................................1442 toc.............................................................................1442 Single-Speed Powershift Transmission........................................1442 General.....................................................................1444 Description and Operation...................................................1444 General.................................................................1444 Torque Converter........................................................1445 Description.........................................................1445 Operation...........................................................1445 Clutch Assemblies.......................................................1447 Description.........................................................1447 Operation...........................................................1448 Hydraulic System........................................................1451 General.............................................................1451 Control Valve...........................................................1452 General.............................................................1452 Clutch Pressure Regulator...........................................1453 Inching Spool Assembly..............................................1454 Direction Spool.....................................................1454 Modulator Circuit...................................................1454 Torque Converter Regulator..........................................1454 MONOTROL® Pedal.........................................................1454 MONOTROL Pedal Start Circuit........................................1455 Direction Control Lever.................................................1455 Differential............................................................1455 Oil Flow Diagrams...........................................................1457 Neutral.................................................................1457 Modulator Operation.....................................................1457 Forward.................................................................1461 Forward-Inching.........................................................1461 Single-Speed Powershift Transmission-2..............................................1467 toc.............................................................................1467 Single-Speed Powershift Transmission........................................1467 General.....................................................................1469 Transmission Removal........................................................1473 Torque Converter and Housing Repair.........................................1473 Remove..................................................................1473 Install.................................................................1473 Transmission Pump Repair....................................................1475 Remove..................................................................1475 Repair..................................................................1475 Install.................................................................1475 Front Cover and Pump Drive Repair...........................................1475 Remove and Disassemble..................................................1475 Assemble and Install....................................................1475 Clutch Assemblies Repair....................................................1478 Remove and Disassemble..................................................1481 Inspect.................................................................1483 Assemble................................................................1484 Install.................................................................1490 Differential Repair.........................................................1490 Remove and Disassemble..................................................1490 Inspect.................................................................1490 Assemble and Install....................................................1492 Control Valve Repair........................................................1500 Remove and Disassemble..................................................1500 Inspect.................................................................1502 Assemble and Install....................................................1502 MONOTROL® Pedal Repair......................................................1503 Remove and Disassemble..................................................1503 Assemble and Install....................................................1503 Direction Control Lever Repair..............................................1507 Remove and Disassemble..................................................1507 Assemble and Install....................................................1507 Stall Test..................................................................1508 Inching/Brake Pedal Adjustment..............................................1509 Neutral Start Switch, MONOTROL Pedal Adjustment H2.00-3.20XM (H4............1513 Neutral Start Switch, MONOTROL Pedal Adjustment S2.00-3.20XM (S4............1514 Neutral Start Switch Test, MONOTROL® Pedal..................................1515 Oil Pressure Checks.........................................................1516 Relief Valve for Transmission Pump Check, TEST PORT 1...................1516 Clutch Pressure Check, TEST PORTS 2 and 3...............................1516 Torque Converter Regulator Check, TEST PORT 4...........................1516 Lubrication Circuit Oil Pressure Check, TEST PORT 5.....................1517 Modulator Pressure Check, TEST PORT 6...................................1517 Troubleshooting.............................................................1518 Troubleshooting - Pressure Tests............................................1521 tables..........................................................................1467 Table 1. Adjustment of Shims for Pinion Assembly............................1493 Table 2. Ring and Pinion Tooth Contact Adjustment...........................1494 Table 3. Stall Speeds.......................................................1509 Table 4. Transmission Oil Pressures Test Ports..............................1517 Starter.............................................................................1524 toc.............................................................................1524 Starter.....................................................................1524 General.....................................................................1526 Description and Operation...................................................1526 Starter Repair..............................................................1528 Remove..................................................................1528 Disassemble.............................................................1528 Clean...................................................................1529 Assemble................................................................1529 Install.................................................................1530 General Checks and Adjustments..............................................1530 Troubleshooting.............................................................1533 Steering Axle.......................................................................1536 toc.............................................................................1536 Steering Axle...............................................................1536 General.....................................................................1538 Description.................................................................1538 Steering Axle Assembly Replacement..........................................1540 Remove..................................................................1540 Install.................................................................1540 Wheels Repair...............................................................1541 Remove and Disassemble..................................................1541 Clean...................................................................1541 Inspect.................................................................1541 Assemble and Install....................................................1541 Spindles, Bearings, and Tie Rods Repair.....................................1543 Remove and Disassemble..................................................1543 Assemble and Install....................................................1544 Steering Cylinder Repair....................................................1545 Remove and Disassemble..................................................1545 Clean and Inspect.......................................................1545 Assemble and Install....................................................1546 Torque Specifications.......................................................1546 Troubleshooting.............................................................1547 Steering Housing and Control Unit...................................................1548 toc.............................................................................1548 Steering Housing and Control Unit...........................................1548 General.....................................................................1550 Description.................................................................1550 Operation...................................................................1551 Steering Wheel and Column Assembly Repair...................................1553 Assembly Components, Remove.............................................1553 Steering Control Unit, Disassemble......................................1556 Steering Control Unit, Clean............................................1558 Steering Control Unit, Assemble.........................................1558 Assembly Components, Install............................................1560 System Air Removal..........................................................1561 Troubleshooting.............................................................1562 Tilt Cylinders......................................................................1565 toc.............................................................................1565 Tilt Cylinders..............................................................1565 General.....................................................................1567 Description.................................................................1567 Tilt Cylinder Repair........................................................1567 Remove..................................................................1567 Disassemble.............................................................1567 Clean...................................................................1567 Assemble................................................................1567 Tilt Cylinders With O-Ring or Single-Lip Seals......................1567 Tilt Cylinders for XM and XMS Models................................1569 Tilt Cylinders for XL, XLS, and XL 3 Models.........................1570 Tilt Cylinders for H700-800A and Early Model H700-920B..............1572 Install.................................................................1573 Tilt Cylinders Using Chevron Packing................................1573 Install.........................................................1574 Tilt Cylinder Leak Check....................................................1576 Tilt Cylinder Stroke and Mast Tilt Angle Adjustment.........................1578 Torque Specifications.......................................................1578 Piston Rod Nut..........................................................1578 Retainer................................................................1579 Troubleshooting.............................................................1581 tables..........................................................................1565 Table 1. Movement Rates (Maximum) for Tilt Cylinders........................1577
HYSTER D187 (H2.00-3.20XM H40-65XM) SERVICE MANUAL – PDF DOWNLOAD:
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