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Hyster G006 Service Manual – PDF DOWNLOAD
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Description
Hyster G006 Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster G006 Service Manual – PDF DOWNLOAD
SAFETY PRECAUTIONS MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance
section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit whenmaking repairs,
or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
TABLE OF CONTENTS:
Hyster G006 Service Manual – PDF DOWNLOAD
0100SRM0322-(02-2007)-US-EN............................................................. 1 toc................................................................................. 1 Frame........................................................................... 1 Safety Precautions Maintenance and Repair....................................... 2 General......................................................................... 5 Description..................................................................... 5 Counterweight Repair............................................................ 6 Remove...................................................................... 6 Install..................................................................... 6 Hood Repair..................................................................... 7 Remove...................................................................... 7 Install..................................................................... 7 Overhead Guard Repair........................................................... 7 Remove...................................................................... 7 Install..................................................................... 7 Operator Restraint System Repair................................................ 8 Automatic Locking Retractor (ALR)........................................... 8 Emergency Locking Retractor (ELR)........................................... 8 Hydraulic Tank Repair........................................................... 10 Remove...................................................................... 10 Inspect..................................................................... 10 Small Leaks Repair.......................................................... 10 Large Leaks Repair.......................................................... 10 Clean....................................................................... 10 Steam Method............................................................ 11 Chemical Solution Method................................................ 11 Other Methods of Preparation for Repair..................................... 11 Install..................................................................... 11 Fuel Tank Repair................................................................ 12 Remove...................................................................... 12 Repair...................................................................... 12 Install..................................................................... 12 Radiator Repair................................................................. 12 Remove...................................................................... 12 Install..................................................................... 12 Engine Repair................................................................... 13 Remove...................................................................... 13 Install..................................................................... 13 Throttle Pedal Adjustment....................................................... 15 Perkins 1104C-44(RE) Diesel Engine.......................................... 15 Safety Labels................................................................... 16 Cab Repair...................................................................... 18 Cab, Replace................................................................ 18 Window, Replace............................................................. 18 Windshield Wipers and Heater................................................ 18 tables.............................................................................. 1 Table 1. Material Specifications for Cab Windows................................ 20 0600SRM0590-(08-2005)-US-EN............................................................. 23 toc................................................................................. 23 GM Engines...................................................................... 23 Safety Precautions Maintenance and Repair....................................... 24 General......................................................................... 27 Description..................................................................... 27 Engine Removal and Installation................................................. 28 Cylinder Head Repair............................................................ 28 Remove and Disassemble...................................................... 28 Clean and Inspect........................................................... 28 Valve Guides and Seats, Repairs............................................. 29 Valves, Repair.............................................................. 29 Valve Seats, Repair......................................................... 30 Valve Springs............................................................... 30 Rocker Arm Studs (Early Models)............................................. 32 Rocker Arm Studs (Late Models).............................................. 32 Assemble and Install........................................................ 33 Cylinder Block Cleaning and Inspection.......................................... 36 Piston Bore Preparation......................................................... 36 Engine Mounts Installation...................................................... 37 Lubrication System Repair....................................................... 37 Oil Pump, Remove and Disassemble............................................ 37 Clean and Inspect........................................................... 37 Oil Pump, Assemble and Install.............................................. 38 Oil Sump, Install........................................................... 38 Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters..................... 39 Timing Cover................................................................ 39 Remove.................................................................. 39 Install................................................................. 41 Timing Sprockets............................................................ 41 Remove.................................................................. 41 Install................................................................. 41 Camshaft.................................................................... 42 Remove.................................................................. 42 Inspect................................................................. 42 Install................................................................. 42 Balance Shaft............................................................... 43 Remove.................................................................. 43 Install................................................................. 44 Hydraulic Valve Lifters..................................................... 44 Remove.................................................................. 44 Disassemble............................................................. 45 Clean and Inspect....................................................... 45 Assemble................................................................ 45 Install................................................................. 46 Crankshaft Repair............................................................... 47 Remove...................................................................... 47 Inspect and Repair.......................................................... 47 How to Check Clearance Between Main Bearings and Their Journals............. 48 Install..................................................................... 49 Piston and Connecting Rod Assemblies Repair..................................... 50 Connecting Rod Bearings, Replace............................................ 50 Piston and Connecting Rod Assemblies, Remove................................ 51 Disassemble................................................................. 51 Piston, Clean and Inspect................................................... 52 Cylinder Bores, Inspect and Repair.......................................... 52 Piston Rings................................................................ 53 Assemble.................................................................... 54 Piston and Connecting Rod Assemblies, Install............................... 54 Flywheel and Flywheel Housing Repair............................................ 55 Flywheel, Repair............................................................ 55 Flywheel, Install........................................................... 55 H3.50-5.00XL (H70-110XL), S3.50-5.50XL (S70-120XL), S6.00-7.00XL........ 55 H6.00-7.00XL (H135-155XL)............................................... 55 Flywheel Housing H3.50-5.00XL (H70-110XL), H3.50-5.50XM (H70-120............ 55 Engine Adapter H6.00-7.00XL (H135-155XL).................................... 55 Coolant Pump Repair............................................................. 56 Thermostat Replacement.......................................................... 56 Fan Mount Repair (Early Models)................................................. 56 Fan Mount Assembly Repair (Late Models)......................................... 56 Drive Belt Installation......................................................... 58 Valve Clearance Adjustment (Early Models)....................................... 59 Valve Clearance Adjustment (New Models)......................................... 60 Compression Check............................................................... 60 Engine Specifications........................................................... 61 Engine Data................................................................. 61 Cylinder Head............................................................... 61 Hydraulic Valve Lifter...................................................... 62 Camshaft.................................................................... 62 Pistons..................................................................... 62 Crankshaft.................................................................. 63 Connecting Rods............................................................. 63 Balance Shaft............................................................... 64 Cooling System.............................................................. 64 Lubrication System.......................................................... 64 Torque Specifications........................................................... 64 Troubleshooting................................................................. 65 tables.............................................................................. 23 Table 1. Piston Rings Arrangement on Piston..................................... 54 0600SRM1070-(06-2007)-US-EN............................................................. 71 toc................................................................................. 71 Perkins Diesel Engines.......................................................... 71 Safety Precautions Maintenance and Repair....................................... 72 General......................................................................... 79 General Safety Rules........................................................ 79 Description..................................................................... 80 Engine Serial Number Codes.................................................. 82 Engine Data................................................................. 82 Engine Removal and Installation................................................. 83 Cylinder Head Assembly Repair................................................... 84 Engine Breather............................................................. 84 Remove.................................................................. 84 Install................................................................. 84 Valve Cover................................................................. 85 Remove.................................................................. 85 Install................................................................. 85 Rocker Arm Assembly......................................................... 86 Remove.................................................................. 86 Disassemble............................................................. 86 Inspect................................................................. 86 Assemble................................................................ 87 Install................................................................. 87 Valve Clearance Adjustments................................................. 88 Valve Springs............................................................... 88 Cylinder Head Assembly...................................................... 90 Remove.................................................................. 90 Inspect................................................................. 91 Install................................................................. 91 Valves and Valve Springs.................................................... 93 Remove.................................................................. 93 Inspect................................................................. 93 Install................................................................. 94 Valve Guides................................................................ 94 Inspect................................................................. 94 Remove.................................................................. 95 Install................................................................. 95 Valve Seats................................................................. 96 Inspect................................................................. 96 Repair.................................................................. 96 New Valve Seats, Install................................................ 97 Piston and Connecting Rod Assemblies Repair..................................... 98 General..................................................................... 98 Rod Bearings................................................................ 98 Remove.................................................................. 98 Install................................................................. 99 Piston and Connecting Rod Assembly.......................................... 100 Service Note............................................................ 100 Remove.................................................................. 100 Disassemble............................................................. 100 Inspect................................................................. 100 How to Select Correct Replacements...................................... 102 Assemble................................................................ 102 Install................................................................. 103 Piston Cooling Jets......................................................... 105 Remove.................................................................. 105 Install................................................................. 105 Crankshaft Assembly Repair...................................................... 106 General..................................................................... 106 Crankshaft Pulley........................................................... 106 Remove.................................................................. 106 Inspect................................................................. 106 Install................................................................. 106 Rear Oil Seal............................................................... 107 Remove.................................................................. 107 Install................................................................. 107 Crankshaft Flange Wear Sleeve............................................... 109 Remove.................................................................. 109 Install................................................................. 109 Main Bearings............................................................... 110 Remove.................................................................. 110 Inspect................................................................. 110 Install................................................................. 110 Thrust Washers.............................................................. 111 Crankshaft Axle Movement, Check......................................... 111 Remove.................................................................. 112 Install................................................................. 112 Crankshaft.................................................................. 113 Remove.................................................................. 113 Inspect................................................................. 113 Install................................................................. 114 Crankshaft Timing Ring...................................................... 115 Remove.................................................................. 115 Install................................................................. 116 Flywheel.................................................................... 116 Remove.................................................................. 116 Ring Gear, Replace...................................................... 116 Install................................................................. 116 Flywheel Housing............................................................ 117 Remove.................................................................. 117 Install................................................................. 117 Timing Case and Timing Gears Repair............................................. 118 General..................................................................... 118 Timing Case Cover........................................................... 118 Remove.................................................................. 118 Install................................................................. 118 Front Oil Seal.............................................................. 119 Remove, With Timing Case Installed...................................... 119 Install, With Timing Case Installed..................................... 120 Remove, With Timing Case Removed........................................ 121 Install, With Timing Case Removed....................................... 121 Crankshaft Pulley Wear Sleeve, Install...................................... 121 Fuel Pump Gear.............................................................. 122 Remove.................................................................. 122 Install................................................................. 123 Idler Gear and Hub.......................................................... 124 Remove.................................................................. 124 Disassemble............................................................. 125 Standard Idler Gear and Hub Assembly................................ 125 Heavy Duty Idler Gear and Hub Assembly.............................. 125 Assemble................................................................ 126 Standard Idler Gear and Hub Assembly................................ 126 Heavy Duty Idler Gear and Hub Assembly.............................. 126 Install................................................................. 127 Camshaft Gear............................................................... 127 Remove.................................................................. 127 Install................................................................. 128 Crankshaft Gear............................................................. 128 Remove.................................................................. 128 Install................................................................. 128 Timing Case................................................................. 129 Remove.................................................................. 129 Install................................................................. 130 Power Take-Off (PTO) Adaptor................................................ 131 Remove.................................................................. 131 Disassemble............................................................. 131 Assemble................................................................ 132 Install................................................................. 132 Camshaft and Tappets........................................................ 132 Remove.................................................................. 132 Install................................................................. 132 Cylinder Block Assembly Repair.................................................. 133 General..................................................................... 133 Cylinder Block.............................................................. 133 Disassemble............................................................. 133 Inspect................................................................. 134 Assemble................................................................ 134 Cylinder Bore............................................................... 134 Inspect................................................................. 134 Cylinder Liner Condition Check.......................................... 134 Engine Timing................................................................... 135 General..................................................................... 135 How to Set Number One Piston to TDC on Compression Stroke................... 135 Fuel Injection Pump Timing, Check........................................... 136 Fuel Injection Pump Timing, Adjust.......................................... 137 Lubrication System Repair....................................................... 139 General..................................................................... 139 Oil Filter, Replace......................................................... 139 Oil Filter Head............................................................. 140 Remove.................................................................. 140 Install................................................................. 140 Oil Sump.................................................................... 140 Remove.................................................................. 140 Install................................................................. 141 Oil Pump.................................................................... 142 Remove.................................................................. 142 Inspect................................................................. 142 Install................................................................. 142 Oil Strainer and Suction Pipe............................................... 143 Remove.................................................................. 143 Install................................................................. 143 Relief Valve................................................................ 144 Remove.................................................................. 144 Install................................................................. 144 Dipstick Tube............................................................... 144 Remove and Install...................................................... 144 Fuel System Repair.............................................................. 145 General..................................................................... 145 Cold Start Advance Unit (KSB)............................................... 145 Typical Fuel System......................................................... 146 Fuel Filter................................................................. 148 Remove.................................................................. 148 Install................................................................. 148 Fuel Injectors.............................................................. 149 Remove.................................................................. 149 Install................................................................. 150 Fuel System Air Removal..................................................... 151 Bosch EVPE Fuel Injection Pump.............................................. 151 General................................................................. 151 Remove.................................................................. 152 Install................................................................. 153 Cooling System Repair........................................................... 153 General..................................................................... 153 Thermostat.................................................................. 155 Remove.................................................................. 155 Install................................................................. 155 Test.................................................................... 155 Coolant Pump................................................................ 156 Remove.................................................................. 156 Disassemble............................................................. 156 Assemble................................................................ 157 Install................................................................. 158 Fan......................................................................... 159 Remove and Install...................................................... 159 Fan Drive................................................................... 159 Remove.................................................................. 159 Install................................................................. 159 Oil Cooler.................................................................. 159 Remove.................................................................. 159 Disassemble and Assemble................................................ 160 Install................................................................. 160 Coolant Bypass Hose......................................................... 160 Removal................................................................. 160 Install................................................................. 160 Electrical Equipment Repair..................................................... 161 Drive Belt.................................................................. 161 Check................................................................... 161 Adjust.................................................................. 161 Remove.................................................................. 161 Install................................................................. 161 Alternator.................................................................. 162 Remove.................................................................. 162 Install................................................................. 162 Fault Diagnosis......................................................... 162 Normal Operation:................................................... 162 If the Warning Lamp is Not Illuminated When the Ignition Switch .... 163 If the Warning Light Continues to be Illuminated When the Altern.... 163 Starter Motor............................................................... 164 Remove.................................................................. 164 Install................................................................. 164 Test.................................................................... 164 Starting Aid................................................................ 164 Remove.................................................................. 164 Install................................................................. 165 Check................................................................... 165 Power Supply Continuity............................................. 165 Operation........................................................... 165 Pressure Sensor............................................................. 166 Remove.................................................................. 166 Install................................................................. 167 Temperature Sensor.......................................................... 167 Remove.................................................................. 167 Install................................................................. 168 Engine Specifications........................................................... 168 Cylinder Head Assembly...................................................... 168 Piston and Connecting Rods.................................................. 171 Crankshaft Assembly......................................................... 173 Crankshaft Overhaul..................................................... 173 Timing Case and Drive Assembly.............................................. 175 Engine Block Assembly....................................................... 176 Lubrication System.......................................................... 176 Fuel System................................................................. 177 Cooling System.............................................................. 178 Flywheel and Housing........................................................ 179 Electrical Equipment........................................................ 179 Torque Specifications........................................................... 179 Special Torque Specifications................................................... 180 Cylinder Head Assembly...................................................... 180 Piston and Connecting Rod Assemblies........................................ 180 Crankshaft Assembly......................................................... 180 Timing Case and Drive Assembly.............................................. 180 Cylinder block.............................................................. 180 Fuel System................................................................. 180 Lubrication System.......................................................... 180 Cooling System.............................................................. 181 Flywheel and Housing........................................................ 181 Electrical Equipment........................................................ 181 Special Tools................................................................... 182 Troubleshooting................................................................. 186 tables.............................................................................. 71 Table 1. Cylinder Head.......................................................... 168 Table 2. Valve Guides........................................................... 169 Table 3. Inlet Valves........................................................... 169 Table 4. Exhaust Valves......................................................... 170 Table 5. Valve Springs.......................................................... 171 Table 6. Tappets................................................................ 171 Table 7. Rocker Arm Shaft....................................................... 171 Table 8. Rocker Arms and Bushings............................................... 171 Table 9. Pistons................................................................ 171 Table 10. Piston Rings.......................................................... 171 Table 11. Piston Pins........................................................... 172 Table 12. Connecting Rods....................................................... 172 Table 13. Small End Bushings.................................................... 172 Table 14. Connecting Rod Bearings............................................... 172 Table 15. Piston Cooling Jets................................................... 173 Table 16. Crankshaft Overhaul Specifications.................................... 173 Table 17. Maximum Variation (Run-out)........................................... 174 Table 18. Camshaft.............................................................. 175 Table 19. Camshaft Thrust Washer................................................ 175 Table 20. Camshaft Gear......................................................... 175 Table 21. Gear for Fuel Pump.................................................... 175 Table 22. Crankshaft Gear....................................................... 175 Table 23. Idler Gear and Hub.................................................... 175 Table 24. Timing Gear Backlash Values........................................... 176 Table 25. Cylinder Block........................................................ 176 Table 26. Oil Pump.............................................................. 176 Table 27. Idler Gear for Oil Pump............................................... 176 Table 28. Relief Valve.......................................................... 177 Table 29. Oil Filter............................................................ 177 Table 30. Bosch Fuel Injection Pump............................................. 177 Table 31. Fuel Injector Settings................................................ 177 Table 32. Fuel Pump............................................................. 178 Table 33. Fuel Filter........................................................... 178 Table 34. Coolant Pump.......................................................... 178 Table 35. Thermostat............................................................ 178 Table 36. Fan Drive Housing..................................................... 178 Table 37. Limits for Flywheel Run Out and Alignment (Total Indic................ 179 Table 38. Alternator............................................................ 179 Table 39. Starter Motor......................................................... 179 Table 40. Starting Aids......................................................... 179 Table 41. List of Possible Causes............................................... 187 0700SRM0626-(11-2001)-US-EN............................................................. 191 toc................................................................................. 191 Cooling System.................................................................. 191 Safety Precautions Maintenance and Repair....................................... 192 General......................................................................... 195 Description..................................................................... 196 Radiator.................................................................... 196 Radiator Cap................................................................ 196 Thermostat.................................................................. 196 Water Pump.................................................................. 197 Fan and Fan Shroud.......................................................... 197 Cooling System Checks........................................................... 197 Radiator.................................................................... 197 Thermostat.................................................................. 197 Water Pump.................................................................. 198 Exhaust Leaks............................................................... 198 Fan and Fan Shroud.......................................................... 198 Radiator Cleaning............................................................... 198 Drain....................................................................... 198 Clean....................................................................... 198 Fill........................................................................ 199 Troubleshooting................................................................. 200 0900SRM1088-(05-2006)-US-EN............................................................. 203 toc................................................................................. 203 Electronic Controlled LPG/Gasoline Fuel System.................................. 203 Safety Precautions Maintenance and Repair....................................... 204 General......................................................................... 209 Fuel System Warnings and Cautions........................................... 209 Glossary........................................................................ 210 Description and Operation of LPG Fuel System.................................... 214 Propane Fuel System......................................................... 214 LPG Fuel Tank............................................................... 216 Service Line................................................................ 216 Fuel Filter................................................................. 216 Low Pressure Lock-Off (LPL)................................................. 217 Low Pressure Regulator (LPR)................................................ 217 Air Fuel Mixer.............................................................. 217 Throttle Control Device..................................................... 218 Drive By Cable.......................................................... 218 Three-Way Catalytic (TWC) Muffler........................................... 219 Electronic Control Module (ECM)............................................. 219 Heated Exhaust Gas Oxygen (HEGO) Sensor..................................... 222 Description and Operation of Gasoline Fuel System............................... 222 Gasoline Fuel System Throttle Body Injection (TBI), 3.0L Engine ............ 222 Gasoline Multi-Point Fuel Injection (MPFI) System, 4.3L Only................ 224 Gasoline Fuel Storage Tank.................................................. 224 Gasoline Fuel Pump.......................................................... 224 Fuel Filter................................................................. 224 Fuel Pressure Regulator, 3.0L Only.......................................... 226 Fuel Rail and Pressure Regulator, 4.3L Only................................. 226 Fuel Injector............................................................... 226 Throttle Control Device..................................................... 226 Drive By Cable.......................................................... 226 Three-Way Catalytic Muffler................................................. 227 Electronic Control Module (ECM)............................................. 228 Heated Exhaust Gas Oxygen (HEGO) Sensor..................................... 229 LPG Fuel System Repair.......................................................... 230 Propane Fuel System Pressure Relief......................................... 230 Propane Fuel System Leak Test............................................... 230 Propane Fuel Filter Replacement............................................. 230 Remove.................................................................. 230 Install................................................................. 231 Low Pressure Lock-Off (LPL) Replacement..................................... 231 Remove.................................................................. 231 Install................................................................. 231 Pressure Trim Valve (PTV) Replacement....................................... 233 Remove.................................................................. 233 Install................................................................. 233 Low Pressure Regulator...................................................... 233 Remove.................................................................. 233 Install................................................................. 233 Fuel Trim Valve (FTV) Solenoid Replacement.................................. 234 Remove.................................................................. 234 Install................................................................. 234 Temperature Manifold Absolute Pressure (TMAP)............................... 237 Remove.................................................................. 237 Install................................................................. 237 Throttle Body Replacement................................................... 237 Remove.................................................................. 237 Install................................................................. 238 Mixer Replacement........................................................... 238 Remove.................................................................. 238 Install................................................................. 238 Coolant Hose Replacement.................................................... 238 Remove.................................................................. 238 Install................................................................. 239 Vapor Hose Replacement...................................................... 239 Remove.................................................................. 239 Install................................................................. 239 Balance Line Hose Replacement............................................... 239 Remove.................................................................. 239 Install................................................................. 239 PTV Hose Replacement........................................................ 239 Remove.................................................................. 239 Install................................................................. 239 FTV Hose Replacement........................................................ 240 Remove.................................................................. 240 Install................................................................. 240 Throttle Position Sensor (TPS) Replacement.................................. 240 Foot Pedal Position (FPP) Sensor Replacement................................ 242 Electronic Control Module (ECM) Replacement................................. 245 Remove.................................................................. 245 Install................................................................. 245 Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement......................... 246 Remove.................................................................. 246 Install................................................................. 246 Three-Way Catalytic Muffler (TWC) Replacement............................... 246 Remove.................................................................. 246 Install................................................................. 246 Restricted Exhaust System Diagnosis......................................... 246 Exhaust System Description.............................................. 246 Tools Required...................................................... 246 Diagnostic Tool..................................................... 246 Check at Heated Exhaust Gas Oxygen Sensor (HEGO)........................ 247 Gasoline Fuel System Repair..................................................... 247 Gasoline MPFI and TBI Fuel System Pressure Relief........................... 247 Gasoline Fuel System Leak Test.............................................. 248 Throttle Body Injector (TBI) Assembly Replacement, 3.0L Only................ 248 Remove.................................................................. 248 Install................................................................. 248 Throttle Body Assembly Replacement, 3.0L Only............................... 250 Remove.................................................................. 250 Install................................................................. 250 Throttle Body Assembly Replacement, 4.3L Only............................... 250 Remove.................................................................. 250 Install................................................................. 251 Fuel Rail Replacement, Gasoline 4.3L Only................................... 253 Remove.................................................................. 253 Install................................................................. 253 Injector Replacement, Gasoline 4.3L Only.................................... 253 Remove.................................................................. 253 Install................................................................. 253 Injector Replacement, Gasoline 3.0L Only.................................... 254 Remove.................................................................. 254 Install................................................................. 254 Temperature Manifold Absolute Pressure (TMAP) Replacement................... 254 Remove.................................................................. 254 Install................................................................. 254 Throttle Position Sensor (TPS) Replacement.................................. 254 Foot Pedal Position (FPP) Sensor Replacement................................ 257 Electronic Control Module (ECM) Replacement................................. 260 Remove.................................................................. 260 Install................................................................. 260 Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement......................... 260 Remove.................................................................. 260 Install................................................................. 261 Three-Way Catalytic Muffler (TWC) Replacement............................... 261 Remove.................................................................. 261 Install................................................................. 261 Restricted Exhaust System Diagnosis......................................... 261 Exhaust System Description.............................................. 261 Tools Required...................................................... 261 Diagnostic Tool..................................................... 261 Check at Heated Exhaust Gas Oxygen Sensor (HEGO)........................ 261 LPG System Diagnosis............................................................ 262 Fuel System Description..................................................... 262 Diagnostic Aids............................................................. 263 Tools Required.......................................................... 263 Duty Cycle Monitoring Tool.............................................. 263 Diagnostic Tool......................................................... 263 Pressure Gauges......................................................... 263 Test Description........................................................ 263 Gasoline System Diagnosis....................................................... 271 Fuel System Description, 3.0L Only.......................................... 271 Fuel System Description, 4.3L Only.......................................... 271 Diagnostic Aids............................................................. 272 Tools Required.......................................................... 272 Diagnostic Tool......................................................... 272 Test Description........................................................ 272 LPG Symptom Diagnosis........................................................... 279 Gasoline Symptom Diagnosis...................................................... 293 Wire Harness Repair............................................................. 303 On Vehicle Service Wiring Harness Repair.................................... 303 Connectors and Terminals.................................................... 304 Twisted/Shielded Cable Repair........................................... 304 Twisted Leads Repair.................................................... 305 Micro-Pack.............................................................. 306 Metri-Pack.............................................................. 307 Remove.............................................................. 307 Weather-Pack............................................................ 308 Weather-Pack Terminal Repair........................................ 309 tables.............................................................................. 203 Table 1. TPS Replacement Procedure.............................................. 240 Table 2. FPP Replacement Procedure.............................................. 243 Table 3. TPS Replacement Procedure.............................................. 255 Table 4. FPP Replacement Procedure.............................................. 258 Table 5. LPG Fuel System Diagnosis.............................................. 263 Table 6. Fuel Control Diagnosis................................................. 267 Table 7. Gasoline Fuel System Diagnosis, 3.0L Only.............................. 273 Table 8. Gasoline Fuel System Diagnosis, 4.3L Only.............................. 276 Table 9. Preliminary Checks..................................................... 279 Table 10. Intermittent ......................................................... 281 Table 11. No Start.............................................................. 282 Table 12. Hard Start............................................................ 284 Table 13. Cuts Out or Misses.................................................... 285 Table 14. Hesitation, Sag, or Stumble........................................... 286 Table 15. Backfire.............................................................. 287 Table 16. Lack of Power, Sluggishness, or Sponginess............................ 288 Table 17. Poor Fuel Economy..................................................... 289 Table 18. Rough, Unstable, Incorrect Idle, or Stalling.......................... 290 Table 19. Surges or Chuggles.................................................... 292 Table 20. Preliminary Checks.................................................... 293 Table 21. Intermittent.......................................................... 294 Table 22. No Start.............................................................. 295 Table 23. Hard Start............................................................ 296 Table 24. Cuts Out or Misses.................................................... 297 Table 25. Hesitation, Sag, or Stumble........................................... 298 Table 26. Backfire.............................................................. 299 Table 27. Lack of Power, Sluggishness, or Sponginess............................ 300 Table 28. Poor Fuel Economy..................................................... 301 Table 29. Rough, Unstable, Incorrect Idle, or Stalling.......................... 302 Table 30. Surges or Chuggles.................................................... 303 1300SRM0324-(10-2003)-US-EN............................................................. 313 toc................................................................................. 313 Two-Speed Powershift Transmission............................................... 313 Safety Precautions Maintenance and Repair....................................... 314 General......................................................................... 317 Mechanical Description.......................................................... 317 Torque Converter............................................................ 317 Transmission Pump........................................................... 318 Shaft Assemblies............................................................ 318 Input Shaft................................................................. 319 Forward Clutch Shaft........................................................ 319 Clutch Assemblies........................................................... 319 Countershaft................................................................ 326 Output Shaft................................................................ 326 Hydraulic Operation............................................................. 327 Torque Converter............................................................ 327 Seal Rings.................................................................. 328 Control Valve................................................................... 328 System Pressure Regulator................................................... 331 Clutch Pressure Regulator................................................... 331 Torque Converter Regulator.................................................. 332 Inching Spool............................................................... 332 Direction Spool, Direction Control Lever.................................... 332 Direction Spool, MONOTROL Pedal............................................. 333 Range Spool................................................................. 333 Drain Spool................................................................. 334 Accumulator................................................................. 334 Modulator Spool............................................................. 334 Operation................................................................... 334 Lubrication Circuit............................................................. 335 MONOTROL Pedal.................................................................. 335 Oil Flow Diagrams............................................................... 337 Neutral..................................................................... 337 Forward-Low................................................................. 338 Forward-Low-Inching......................................................... 339 Reverse-Low................................................................. 340 1300SRM0325-(10-2003)-US-EN............................................................. 343 toc................................................................................. 343 Two-Speed Powershift Transmission............................................... 343 Safety Precautions Maintenance and Repair....................................... 344 General......................................................................... 347 Transmission Repair............................................................. 347 Transmission and Torque Converter, Remove................................... 347 Transmission, Disassemble................................................... 349 Reverse-Low Clutch, Disassemble............................................. 352 Reverse-High Clutch, Disassemble............................................ 355 Forward-Low Clutch, Disassemble............................................. 358 Forward-High Clutch, Disassemble............................................ 361 Clean and Inspect........................................................... 363 Forward Low and High Clutches Assembly.......................................... 364 Forward Clutches, Assemble.................................................. 366 Reverse-Low Clutch, Assemble................................................ 372 Reverse Clutches, Assemble.................................................. 374 Transmission, Assemble...................................................... 381 Torque Converter, Install................................................... 388 Control Valve Repair............................................................ 389 Remove...................................................................... 389 Disassemble................................................................. 390 Assemble.................................................................... 391 Install..................................................................... 393 MONOTROL Pedal.................................................................. 393 Remove and Disassemble...................................................... 393 Assemble and Install........................................................ 393 Stall Test...................................................................... 396 Linkage Adjustments............................................................. 397 Linkage for Inching Pedal H6.00-7.00XL (H135-155XL, H135-155XL 2............ 397 Linkage for Inching Pedal S6.00-7.00XL (S135-155XL, S135-155XL 2............ 400 Linkage for Range Lever - Early Model H6.00-7.00XL (H135-155XL) ............ 403 Linkage for Direction Control Lever - Early Model H6.00-7.00XL (............ 403 Linkage for Range Lever - Later Model H6.00-7.00XL (H135-155XL, ............ 405 Linkage for Direction Control Lever - Later Model H6.00-7.00XL (............ 407 Linkage for Range Lever S6.00-7.00XL (S135-155XL, S135-155XL 2 )............ 409 Linkage for Direction Control Lever S6.00-7.00XL (S135-155XL, S1............ 409 Oil Pressure Check.............................................................. 411 System Pressure Check Port.................................................. 411 Torque Converter Check Port................................................. 411 Clutch Pressure Check Port.................................................. 411 Inching Pressure............................................................ 412 Solenoid Check Ports (MONOTROL Control Only)................................ 412 Lubrication Pressure Check Ports............................................ 412 Specifications.................................................................. 413 Troubleshooting................................................................. 413 Correct System Pressure: 1300 ±124 kPa ( 189 ±18 psi)....................... 416 Correct Clutch Pressure: 924 ±69 kPa ( 134 ±10 psi)......................... 417 Correct Solenoid Pressure (MONOTROL Only): 965 ±138 kPa ( 140 ±2............ 418 Torque Converter Pressure: 834 ±69 kPa ( 121 ±10 psi)....................... 418 Lubrication Pressure: 83 ±21 kPa ( 12 ±3 psi)............................... 418 tables.............................................................................. 343 Table 1. Stall Speed Specifications............................................. 396 1400SRM0046-(07-2007)-US-EN............................................................. 421 toc................................................................................. 421 Differential.................................................................... 421 Safety Precautions Maintenance and Repair....................................... 422 General......................................................................... 425 Description..................................................................... 425 Differential Repair............................................................. 426 Remove...................................................................... 426 Differential Carrier From Axle Housing, Remove.......................... 426 Differential and Ring Gear From Differential Carrier, Remove............ 428 Drive Pinion and Pinion Carrier From Differential Carrier, Remov........ 430 Disassemble................................................................. 431 Differential and Ring Gear Assembly, Disassemble........................ 431 Drive Pinion and Pinion Carrier, Disassemble............................ 433 Clean and Inspect........................................................... 436 Assemble.................................................................... 437 Pinion, Bearings, and Pinion Carrier, Assemble.......................... 437 Pinion Bearings, Adjust Preload......................................... 437 Press Method........................................................ 437 Yoke or Flange Method............................................... 438 Triple-Lip Seal, Install................................................ 439 Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)............. 440 Differential and Ring Gear, Assemble.................................... 442 Differential Gears Rotating Torque, Check............................... 444 Differential and Ring Gear Assembly, Install............................ 445 Differential Bearings, Preload Adjust................................... 447 Ring Gear, Runout Check................................................. 448 Ring Gear Backlash, Adjust.............................................. 448 Gear Set, Tooth Contact Pattern Check................................... 450 Thrust Screw, Install and Adjust........................................ 453 Install..................................................................... 453 Differential Assembly Into Axle Housing, Install........................ 453 Specifications.................................................................. 455 Troubleshooting................................................................. 460 tables.............................................................................. 421 Table 1. Ring Gear Backlash Adjustment Specifications........................... 450 Table 2. Ring and Pinion Tooth Contact Adjustment............................... 451 Table 3. General Specifications................................................. 455 Table 4. Rivet Installation Pressure............................................ 455 Table 5. Pinion Adjustment...................................................... 456 Table 6. Pinion Preload Pressure................................................ 456 Table 7. Torque Specifications.................................................. 457 Table 8. Torque Specifications for Metric Hardware.............................. 458 Table 9. Torque Specifications for Metric (Fine) Hardware....................... 459 1400SRM0049-(09-2003)-US-EN............................................................. 463 toc................................................................................. 463 Drive Axle...................................................................... 463 Safety Precautions Maintenance and Repair....................................... 464 General......................................................................... 467 Description..................................................................... 467 Drive Axle Repair............................................................... 468 Disassemble (Type 1 Shown).................................................. 468 Clean....................................................................... 471 Inspect..................................................................... 471 Assemble (Type 1 Shown)..................................................... 472 Torque Specifications........................................................... 475 Troubleshooting................................................................. 476 1600SRM0054-(10-2003)-US-EN............................................................. 479 toc................................................................................. 479 Steering Control Unit........................................................... 479 Safety Precautions Maintenance and Repair....................................... 480 General......................................................................... 483 Description..................................................................... 483 Operation....................................................................... 483 Steering Wheel and Column Assembly Repair....................................... 485 Steering Column Assembly Repair................................................. 485 Type A Steering Column Assembly............................................. 485 Remove and Disassemble.................................................. 485 Assemble and Install.................................................... 487 Type B Steering Column Assembly............................................. 489 Remove and Disassemble.................................................. 489 Assemble and Install.................................................... 489 Steering Control Unit................................................... 492 Disassemble......................................................... 492 Clean............................................................... 495 Assemble............................................................ 496 System Air Removal.............................................................. 501 Troubleshooting................................................................. 501 1600SRM0326-(03-2007)-US-EN............................................................. 505 toc................................................................................. 505 Steering Axle................................................................... 505 Safety Precautions Maintenance and Repair....................................... 506 General......................................................................... 509 Description..................................................................... 509 Steering Axle Assembly Repair................................................... 514 Steering Axle H3.50-5.00XL (H70-110XL) (G005), S3.50-5.50XL (S70............ 514 Remove.................................................................. 514 Install................................................................. 514 Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL 2 ) (F006, G0............ 515 Remove.................................................................. 515 Install................................................................. 515 Wheels and Hubs Repair (All Units).............................................. 516 Remove and Disassemble...................................................... 516 Clean....................................................................... 516 Inspect..................................................................... 516 Assemble and Install........................................................ 516 Spindles and Bearings Repair (All Units)........................................ 518 Remove...................................................................... 518 Clean....................................................................... 518 Assemble and Install........................................................ 519 Tie Rods Repair (All Units)..................................................... 520 Remove...................................................................... 520 Clean....................................................................... 520 Install..................................................................... 520 Steering Cylinder Repair........................................................ 523 Remove and Disassemble...................................................... 523 Clean and Inspect........................................................... 523 Assemble and Install........................................................ 523 Troubleshooting................................................................. 524 1800SRM0327-(09-2003)-US-EN............................................................. 529 toc................................................................................. 529 Brake System.................................................................... 529 Safety Precautions Maintenance and Repair....................................... 530 General......................................................................... 533 Description..................................................................... 533 Operation....................................................................... 534 Brake Booster and Master Cylinder........................................... 534 Brake Booster........................................................... 534 Master Cylinder......................................................... 535 Service Brake Assembly...................................................... 536 Parking Brake............................................................... 537 Brake Shoe Assemblies Repair.................................................... 538 Remove and Disassemble...................................................... 538 Clean and Inspect........................................................... 539 Cleaning Procedures..................................................... 539 Inspect................................................................. 539 Assemble and Install........................................................ 540 Master Cylinder Repair.......................................................... 541 Remove...................................................................... 541 Disassemble................................................................. 541 Assemble.................................................................... 543 Install..................................................................... 543 Brake Booster Repair............................................................ 543 Remove...................................................................... 543 Disassemble................................................................. 543 Clean and Inspect........................................................... 545 Assemble.................................................................... 545 Install..................................................................... 545 Brake System Air Removal........................................................ 545 Brake Pedal Adjustment.......................................................... 546 Brake Shoes Adjustment.......................................................... 547 Parking Brake Adjustment........................................................ 547 Parking Brake Switch Adjustment................................................. 547 Brake Booster Relief Valve Check................................................ 547 Troubleshooting................................................................. 548 1900SRM0097-(07-2006)-US-EN............................................................. 553 toc................................................................................. 553 Hydraulic Gear Pumps............................................................ 553 Safety Precautions Maintenance and Repair....................................... 554 Description..................................................................... 557 Operation....................................................................... 558 Flow Control Valve.......................................................... 558 Relief Valve................................................................ 559 Hydraulic Gear Pump Repair...................................................... 559 Remove...................................................................... 559 Disassemble................................................................. 560 Clean....................................................................... 560 Inspect..................................................................... 561 Assemble.................................................................... 564 Install..................................................................... 566 Pump Output Check............................................................... 566 Method No. 1................................................................ 566 Method No. 2................................................................ 567 Hydraulic System Air Check...................................................... 568 Troubleshooting................................................................. 569 2000SRM0090-(10-2003)-US-EN............................................................. 575 toc................................................................................. 575 Main Control Valve.............................................................. 575 Safety Precautions Maintenance and Repair....................................... 576 General......................................................................... 579 Description..................................................................... 579 Operation....................................................................... 582 Lift Spool.................................................................. 582 Tilt Spool.................................................................. 583 Tilt Backward........................................................... 583 Tilt Forward............................................................ 584 Single-Stage Relief Valve................................................... 586 Two-Stage Relief Valve...................................................... 587 Main Control Valve Repair....................................................... 588 Remove and Disassemble...................................................... 588 Clean and Inspect........................................................... 588 Assemble.................................................................... 588 Install..................................................................... 589 Single-Stage Relief Valve Adjustment............................................ 589 Two-Stage Relief Valve.......................................................... 590 Auxiliary Control Valve Relief Valve Adjustment (H60-110E Only)................. 590 Troubleshooting................................................................. 591 tables.............................................................................. 575 Table 1. Relief Pressures (Oil temperature at 55 to 66 C ( 131 t................ 589 2100SRM0103-(03-2007)-US-EN............................................................. 595 toc................................................................................. 595 Tilt Cylinders.................................................................. 595 Safety Precautions Maintenance and Repair....................................... 596 General......................................................................... 599 Description..................................................................... 599 Tilt Cylinder Repair............................................................ 599 Remove...................................................................... 599 Disassemble................................................................. 599 Clean....................................................................... 599 Assemble.................................................................... 599 Tilt Cylinders With O-Ring or Single-Lip Seals.......................... 599 Tilt Cylinders for XM and XMS Models.................................... 601 Tilt Cylinders for XL, XLS, and XL 3 Models............................. 602 Tilt Cylinders for H700-800A and Early Model H700-920B.................. 604 Install..................................................................... 605 Tilt Cylinders Using Chevron Packing.................................... 605 Install............................................................. 606 Tilt Cylinder Leak Check........................................................ 608 Tilt Cylinder Stroke and Mast Tilt Angle Adjustment............................. 610 Torque Specifications........................................................... 610 Piston Rod Nut.............................................................. 610 Retainer.................................................................... 611 Troubleshooting................................................................. 613 tables.............................................................................. 595 Table 1. Movement Rates (Maximum) for Tilt Cylinders............................ 609 2200SRM0002-(12-2004)-US-EN............................................................. 617 toc................................................................................. 617 Alternator with Regulator....................................................... 617 Safety Precautions Maintenance and Repair....................................... 618 General......................................................................... 621 Description..................................................................... 621 Alternator Repair............................................................... 623 Alternator Type A........................................................... 623 Remove and Disassemble.................................................. 623 Clean................................................................... 624 Assemble................................................................ 625 Install................................................................. 625 Alternator Type B........................................................... 628 Remove and Disassemble.................................................. 628 Clean................................................................... 628 Assemble................................................................ 629 Install................................................................. 630 General Check and Adjustment.................................................... 631 Low Output Check (Type A or Type B)............................................. 631 High Output Check (Type A or Type B)............................................ 633 Brushes Circuit Check........................................................... 634 Delco Alternators........................................................... 634 Motorola Alternators........................................................ 635 Diodes Check.................................................................... 636 Diode Bridge Check.............................................................. 636 Delco and Leece-Neville Alternators......................................... 636 Motorola Alternators........................................................ 636 Rotor Field Winding Check....................................................... 637 Stator Windings Check........................................................... 638 Voltage Regulator Check......................................................... 638 Troubleshooting................................................................. 638 2200SRM0106-(12-2004)-US-EN............................................................. 643 toc................................................................................. 643 Starter......................................................................... 643 Safety Precautions Maintenance and Repair....................................... 644 General......................................................................... 647 Description and Operation....................................................... 647 Starter Repair.................................................................. 649 Remove...................................................................... 649 Disassemble................................................................. 649 Clean....................................................................... 650 Assemble.................................................................... 650 Install..................................................................... 651 General Checks and Adjustments.................................................. 651 Troubleshooting................................................................. 654 2200SRM0143-(02-2007)-US-EN............................................................. 659 toc................................................................................. 659 Instrument Panel Indicators and Senders......................................... 659 Safety Precautions Maintenance and Repair....................................... 660 General......................................................................... 663 Description..................................................................... 664 Steering Column Gauges, Meters, and Indicators.............................. 664 LED Display Panel........................................................... 664 Battery Discharge Indicators............................................ 664 Brush Wear Indicators................................................... 670 Motor Temperature Indicators............................................ 670 LX Series Display Panel..................................................... 672 Hourmeter Functions..................................................... 673 Battery Indicator Function.............................................. 673 Status Code Function.................................................... 673 ZX Series Display Panels.................................................... 675 Display Panel........................................................... 675 Basic Display Panels.................................................... 675 Performance Display..................................................... 677 Brush Wear Indicators................................................... 681 Adjustments - General........................................................... 681 Replacement - General Information............................................... 681 Meter Replacement............................................................... 682 Sender Replacement.............................................................. 683 Fuel Level Sender........................................................... 683 Pressure and Temperature Sender............................................. 683 Seat Sensor, Operator Presence System (OPS)................................. 684 Remove.................................................................. 684 Install................................................................. 684 Operator Presence System Module Replacement................................. 684 Remove.................................................................. 685 Install................................................................. 686 ITW Display Panel Replacement................................................... 687 Remove...................................................................... 687 Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl................ 687 Remove...................................................................... 687 Display Panel Assembly, Replace............................................. 687 Indicator LEDs.............................................................. 688 Battery Indicators.......................................................... 688 Digital Display (Performance Display Panel Only)............................ 688 Status Code or Performance Level Switches and Indicator LEDs (Pe............ 689 Basic Display Panel, Replace Parts.......................................... 689 Performance Display Panel, Replace Parts.................................... 691 Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace................ 691 Remove and Replace.......................................................... 691 Specifications.................................................................. 692 Meter Specifications........................................................ 692 Sender Specifications....................................................... 692 Troubleshooting................................................................. 693 Meter....................................................................... 693 Troubleshooting for Operator Presence System.................................... 694 tables.............................................................................. 659 Table 1. Troubleshooting Procedure for Operator Presence Module................. 694 2200SRM1090-(04-2005)-US-EN............................................................. 699 toc................................................................................. 699 Electronic Control Module (ECM) Diagnostic Troubleshooting...................... 699 Safety Precautions Maintenance and Repair....................................... 700 General......................................................................... 709 Description of ECM Based Diagnostics............................................ 709 Definition of Terms......................................................... 709 Diagnostics Overview of the Spectrum Fuel System............................ 709 Malfunction Indicator Lamp (MIL)............................................ 710 Spectrum Diagnostic Trouble Codes (DTC)..................................... 710 Using a Laptop Computer to Diagnose the Spectrum System..................... 710 Installing the Spectrum Diagnostic Software............................. 711 Connecting a Laptop Computer to the Spectrum System..................... 711 Diagnostic Communication Error.......................................... 711 Diagnostic Trouble Codes.................................................... 712 Checking Diagnostic Trouble Codes....................................... 712 Clearing Diagnostic Trouble Codes....................................... 712 DATA Stream................................................................. 713 Reading Sensor and Actuator Values...................................... 713 Graphing and Data Logging............................................... 714 Ignition System Test........................................................ 715 Disabling Ignition Outputs.............................................. 715 Injector Test............................................................... 716 Disabling Injectors..................................................... 716 Throttle Test............................................................... 716 Using a Diagnostic Jumper to Diagnose the ECI System.................... 717 On-Board Diagnostics System Check/Malfunction Indicator Lamp.................... 718 Circuit Description......................................................... 718 Preliminary and Intermittent Checks............................................. 721 GM 3.0L Wiring Schematics and Connectors........................................ 723 GM 3.0L Diagnostic Trouble Codes................................................ 737 DTC 111 - IAT High Voltage Motorola® TMAP................................... 737 Circuit Description..................................................... 737 Conditions for Setting the DTC.......................................... 737 DTC 112 - IAT Low Voltage Motorola® TMAP.................................... 740 Circuit Description..................................................... 740 Conditions for Setting the DTC.......................................... 740 DTC 113 - IAT Higher Than Expected 1 Motorola® TMAP......................... 742 Circuit Description..................................................... 742 Conditions for Setting the DTC.......................................... 742 Diagnostic Aids......................................................... 743 DTC 114 - IAT Higher Than Expected 2 Motorola® TMAP......................... 744 Circuit Description..................................................... 744 Conditions for Setting the DTC.......................................... 744 Diagnostic Aids......................................................... 744 DTC 115 - Oil Pressure Low.................................................. 745 Circuit Description..................................................... 745 Conditions for Setting the DTC.......................................... 745 DTC 121 - ECT Voltage High.................................................. 748 Circuit Description..................................................... 748 Conditions for Setting the DTC.......................................... 749 DTC 122 - ECT Voltage Low................................................... 752 Circuit Description..................................................... 752 Conditions for Setting the DTC.......................................... 752 DTC 123 - ECT Higher Than Expected 1........................................ 754 Circuit Description..................................................... 754 Conditions for Setting the DTC.......................................... 754 DTC 124 - ECT Higher Than Expected 2........................................ 756 Circuit Description..................................................... 756 Conditions for Setting the DTC.......................................... 756 DTC 131 - MAP High Pressure Motorola® TMAP.................................. 758 Circuit Description..................................................... 758 Conditions for Setting the DTC.......................................... 758 Diagnostic Aids......................................................... 758 DTC 132 - MAP Low Voltage Motorola® TMAP.................................... 761 Circuit Description..................................................... 761 Conditions for Setting the DTC.......................................... 761 DTC 134 - BP High Pressure Motorola® TMAP................................... 765 Circuit Description..................................................... 765 Conditions for Setting the DTC.......................................... 765 DTC 135 - BP Low Pressure Motorola® TMAP.................................... 766 Circuit Description..................................................... 766 Conditions for Setting the DTC.......................................... 766 DTC 142 - Crank Sync Noise.................................................. 770 Circuit Description..................................................... 770 Conditions for setting the DTC.......................................... 770 DTC 143 - Never Crank Synced At Start....................................... 774 Circuit Description..................................................... 774 Conditions for Setting the DTC.......................................... 774 DTC 144 - Camshaft Sensor Loss.............................................. 777 Circuit Description..................................................... 777 Conditions for Setting the DTC.......................................... 777 DTC 145 - Camshaft Sensor Noise............................................. 780 Circuit Description..................................................... 780 Conditions for Setting the DTC.......................................... 780 DTC 211 - Closed Loop Multiplier High (LPG)................................. 783 Circuit Description..................................................... 783 Conditions for Setting the DTC.......................................... 783 Diagnostic Aids......................................................... 783 DTC 212 - HO 2 S Open/Inactive.............................................. 786 Circuit Description..................................................... 786 Conditions for Setting the DTC.......................................... 786 DTC 221 - Closed Loop Multiplier High (Gasoline)............................ 788 Circuit Description..................................................... 788 Conditions for Setting the DTC.......................................... 788 Diagnostic Aids......................................................... 789 DTC 222 - Closed Loop Multiplier Low (Gasoline)............................. 792 Circuit Description..................................................... 792 Conditions for Setting the DTC.......................................... 792 Diagnostic Aids......................................................... 792 DTC 224 - Closed Loop Multiplier Low (LPG).................................. 794 Circuit Description..................................................... 794 Conditions for Setting the DTC.......................................... 794 Diagnostic Aids......................................................... 794 DTC 241 - Adaptive Lean Fault (High Limit-Gasoline)......................... 796 Circuit Description..................................................... 796 Conditions for Setting the DTC.......................................... 796 Diagnostic Aids......................................................... 796 DTC 242 - Adaptive Rich Fault (Low Limit-Gasoline).......................... 799 Circuit Description..................................................... 799 Conditions for Setting the DTC.......................................... 799 Diagnostic Aids......................................................... 799 DTC 243 - Adaptive Learn High (LPG)......................................... 802 Circuit Description..................................................... 802 Conditions for Setting the DTC.......................................... 802 Diagnostic Aids......................................................... 802 DTC 244 - Adaptive Learn Low (LPG).......................................... 805 Circuit Description..................................................... 805 Conditions for Setting the DTC.......................................... 805 Diagnostic Aids......................................................... 805 DTC 261 - System Voltage High............................................... 808 Circuit Description..................................................... 808 Conditions for Setting the DTC.......................................... 808 DTC 262 - System Voltage Low................................................ 810 Circuit Description..................................................... 810 Conditions for Setting the DTC.......................................... 810 DTC 411 - Injector Driver 1 Open............................................ 812 Circuit Description..................................................... 812 Conditions for Setting the DTC.......................................... 812 DTC 412 - Injector Driver 1 Shorted......................................... 815 Circuit Description..................................................... 815 Conditions for Setting the DTC.......................................... 815 DTC 511 - COP Failure....................................................... 818 Circuit Description..................................................... 818 Conditions for Setting the DTC.......................................... 818 DTC 512 - Invalid Interrupt................................................. 820 Circuit Description..................................................... 820 Conditions for Setting the DTC.......................................... 820 DTC 513 - A/D Loss.......................................................... 822 Circuit Description..................................................... 822 Conditions for Setting the DTC.......................................... 822 DTC 514 - RTI 1 Loss........................................................ 824 Circuit Description..................................................... 824 Conditions for Setting the DTC.......................................... 824 DTC 515 - Flash Checksum Invalid............................................ 826 Circuit Description..................................................... 826 Conditions for Setting the DTC.......................................... 826 DTC 516 - Ram Failure....................................................... 828 Circuit Description..................................................... 828 Conditions for Setting the DTC.......................................... 828 DTC 531 - External 5V Ref Lower Than Expected............................... 830 Circuit Description..................................................... 830 Conditions for Setting the DTC.......................................... 830 DTC 532 - External 5V Ref Higher Than Expected.............................. 832 Circuit Description..................................................... 832 Conditions for Setting the DTC.......................................... 832 DTC 555 - RTI 2 Loss........................................................ 834 Circuit Description..................................................... 834 Conditions for Setting the DTC.......................................... 834 DTC 556 - RTI 3 Loss........................................................ 836 Circuit Description..................................................... 836 Conditions for Setting the DTC.......................................... 836 DTC 611 - FPP High Voltage.................................................. 838 Circuit Description..................................................... 838 Conditions for Setting the DTC.......................................... 838 DTC 612 - FPP Low Voltage................................................... 842 Circuit Description..................................................... 842 Conditions for Setting the DTC.......................................... 842 DTC 631 - TPS1 Signal Voltage High.......................................... 846 Circuit Description..................................................... 846 Conditions for Setting the DTC.......................................... 846 DTC 632 - TPS1 Signal Voltage Low........................................... 849 Circuit Description..................................................... 849 Conditions for Setting the DTC.......................................... 849 DTC 638 - Throttle Unable To Close.......................................... 852 Circuit Description..................................................... 852 Conditions for Setting the DTC.......................................... 852 Diagnostic Aids......................................................... 853 DTC 651 - Maximum Govern Speed Override..................................... 855 Circuit Description..................................................... 855 Conditions for Setting the DTC.......................................... 855 Diagnostic Aids......................................................... 855 DTC 652 - Fuel Rev Limit.................................................... 858 Circuit Description..................................................... 858 Conditions for Setting the DTC.......................................... 858 Diagnostic Aids......................................................... 858 DTC 653 - Spark Rev Limit................................................... 860 Circuit Description..................................................... 860 Conditions for Setting the DTC.......................................... 860 Diagnostic Aids......................................................... 860 GM 4.3L Wiring Schematics and Connectors........................................ 864 GM 4.3L Diagnostic Trouble Codes................................................ 881 DTC 111 - IAT High Voltage Bosch® TMAP...................................... 881 Circuit Description..................................................... 881 Conditions for Setting the DTC.......................................... 881 DTC 111 - IAT High Voltage Motorola® TMAP................................... 884 Circuit Description..................................................... 884 Conditions for Setting the DTC.......................................... 884 DTC 112 - IAT Low Voltage Bosch® TMap....................................... 886 Circuit Description..................................................... 886 Conditions for Setting the DTC.......................................... 887 DTC 112 - IAT Low Voltage Motorola® TMAP.................................... 889 Circuit Description..................................................... 889 Conditions for Setting the DTC.......................................... 889 DTC 113 - IAT Higher Than Expected 1 Bosch® TMAP............................ 892 Circuit Description..................................................... 892 Conditions for Setting the DTC.......................................... 892 Diagnostic Aids......................................................... 892 DTC 113 - IAT Higher Than Expected 1 Motorola® TMAP......................... 893 Circuit Description..................................................... 893 Conditions for Setting the DTC.......................................... 893 Diagnostic Aids......................................................... 893 DTC 114 - IAT Higher Than Expected 2 Bosch® TMAP€........................... 894 Circuit Description..................................................... 894 Conditions for Setting the DTC.......................................... 894 Diagnostic Aids......................................................... 894 DTC 114 - IAT Higher Than Expected 2 Motorola® TMAP......................... 895 Circuit Description..................................................... 895 Conditions for Setting the DTC.......................................... 895 Diagnostic Aids......................................................... 895 DTC 115 - Oil Pressure Low.................................................. 896 Circuit Description..................................................... 896 Conditions for Setting the DTC.......................................... 896 DTC 121 - ECT Voltage High.................................................. 898 Circuit Description..................................................... 898 Conditions for Setting the DTC.......................................... 899 DTC 122 - ECT Voltage Low................................................... 902 Circuit Description..................................................... 902 Conditions for Setting the DTC.......................................... 902 DTC 123 - ECT Higher Than Expected 1........................................ 905 Circuit Description..................................................... 905 Conditions for Setting the DTC.......................................... 905 DTC 124 - ECT Higher Than Expected 2........................................ 907 Circuit Description..................................................... 907 Conditions for Setting the DTC.......................................... 907 DTC 131 - MAP High Pressure Bosch® TMAP..................................... 908 Circuit Description..................................................... 908 Conditions for Setting the DTC.......................................... 908 Diagnostic Aids......................................................... 908 DTC 131 - MAP High Pressure Motorola® TMAP.................................. 912 Circuit Description..................................................... 912 Conditions for Setting the DTC.......................................... 912 Diagnostic Aids......................................................... 912 DTC 132 - MAP Low Voltage Bosch® TMAP....................................... 915 Circuit Description..................................................... 915 Conditions for Setting the DTC.......................................... 915 DTC 132 - MAP Low Voltage Motorola® TMAP.................................... 918 Circuit Description..................................................... 918 Conditions for Setting the DTC.......................................... 918 DTC 134 - BP High Pressure Bosch® TMAP...................................... 923 Circuit Description..................................................... 923 Conditions for Setting the DTC.......................................... 923 DTC 134 - BP High Pressure Motorola® TMAP................................... 925 Circuit Description..................................................... 925 Conditions for Setting the DTC.......................................... 925 DTC 135 - BP Low Pressure Bosch® TMAP....................................... 927 Circuit Description..................................................... 927 Conditions for Setting the DTC.......................................... 927 DTC 135 - BP Low Pressure Motorola® TMAP.................................... 931 Circuit Description..................................................... 931 Conditions for Setting the DTC.......................................... 931 DTC 142 - Crank Sync Noise.................................................. 934 Circuit Description..................................................... 934 Conditions for setting the DTC.......................................... 934 DTC 143 - Never Crank Synced At Start....................................... 938 Circuit Description..................................................... 938 Conditions for Setting the DTC.......................................... 938 DTC 144 - Camshaft Sensor Loss.............................................. 941 Circuit Description..................................................... 941 Conditions for Setting the DTC.......................................... 941 DTC 145 - Camshaft Sensor Noise............................................. 944 Circuit Description..................................................... 944 Conditions for Setting the DTC.......................................... 944 DTC 211 - Closed Loop Multiplier High (LPG)................................. 947 Circuit Description..................................................... 947 Conditions for Setting the DTC.......................................... 947 Diagnostic Aids......................................................... 948 DTC 212 - HO 2 S Open/Inactive.............................................. 950 Circuit Description..................................................... 950 Conditions for Setting the DTC.......................................... 950 DTC 221 - Closed Loop Multiplier High (Gasoline)............................ 953 Circuit Description..................................................... 953 Conditions for Setting the DTC.......................................... 953 Diagnostic Aids......................................................... 953 DTC 222 - Closed Loop Multiplier Low (Gasoline)............................. 956 Circuit Description..................................................... 956 Conditions for Setting the DTC.......................................... 956 Diagnostic Aids......................................................... 956 DTC 224 - Closed Loop Multiplier Low (LPG).................................. 958 Circuit Description..................................................... 958 Conditions for Setting the DTC.......................................... 958 Diagnostic Aids......................................................... 959 DTC 241 - Adaptive Lean Fault (High Limit-Gasoline)......................... 960 Circuit Description..................................................... 960 Conditions for Setting the DTC.......................................... 960 Diagnostic Aids......................................................... 960 DTC 242 - Adaptive Rich Fault (Low Limit-Gasoline).......................... 963 Circuit Description..................................................... 963 Conditions for Setting the DTC.......................................... 963 Diagnostic Aids......................................................... 963 DTC 243 - Adaptive Learn High (LPG)......................................... 966 Circuit Description..................................................... 966 Conditions for Setting the DTC.......................................... 966 Diagnostic Aids......................................................... 966 DTC 244 - Adaptive Learn Low (LPG).......................................... 969 Circuit Description..................................................... 969 Conditions for Setting the DTC.......................................... 969 Diagnostic Aids......................................................... 969 DTC 261 - System Voltage High............................................... 972 Circuit Description..................................................... 972 Conditions for Setting the DTC.......................................... 972 DTC 262 - System Voltage Low................................................ 974 Circuit Description..................................................... 974 Conditions for Setting the DTC.......................................... 974 DTC 511 - COP Failure....................................................... 976 Circuit Description..................................................... 976 Conditions for Setting the DTC.......................................... 976 DTC 512 - Invalid Interrupt................................................. 978 Circuit Description..................................................... 978 Conditions for Setting the DTC.......................................... 978 DTC 513 - A/D Loss.......................................................... 980 Circuit Description..................................................... 980 Conditions for Setting the DTC.......................................... 980 DTC 514 - RTI 1 Loss........................................................ 982 Circuit Description..................................................... 982 Conditions for Setting the DTC.......................................... 982 DTC 515 - Flash Checksum Invalid............................................ 984 Circuit Description..................................................... 984 Conditions for Setting the DTC.......................................... 984 DTC 516 - Ram Failure....................................................... 986 Circuit Description..................................................... 986 Conditions for Setting the DTC.......................................... 986 DTC 531 - External 5V Ref Lower Than Expected............................... 988 Circuit Description..................................................... 988 Conditions for Setting the DTC.......................................... 988 DTC 532 - External 5V Ref Higher Than Expected.............................. 990 Circuit Description..................................................... 990 Conditions for Setting the DTC.......................................... 990 DTC 555 - RTI 2 Loss........................................................ 992 Circuit Description..................................................... 992 Conditions for Setting the DTC.......................................... 992 DTC 556 - RTI 3 Loss........................................................ 994 Circuit Description..................................................... 994 Conditions for Setting the DTC.......................................... 994 DTC 611 - FPP High Voltage.................................................. 996 Circuit Description..................................................... 996 Conditions for Setting the DTC.......................................... 996 DTC 612 - FPP Low Voltage...................................................1000 Circuit Description.....................................................1000 Conditions for Setting the DTC..........................................1000 DTC 631 - TPS1 Signal Voltage High..........................................1004 Circuit Description.....................................................1004 Conditions for Setting the DTC..........................................1004 DTC 632 - TPS1 Signal Voltage Low...........................................1007 Circuit Description.....................................................1007 Conditions for Setting the DTC..........................................1007 DTC 638 - Throttle Unable To Close..........................................1010 Circuit Description.....................................................1010 Conditions for Setting the DTC..........................................1010 Diagnostic Aids.........................................................1011 DTC 651 - Maximum Govern Speed Override.....................................1013 Circuit Description.....................................................1013 Conditions for Setting the DTC..........................................1013 Diagnostic Aids.........................................................1013 DTC 652 - Fuel Rev Limit....................................................1016 Circuit Description.....................................................1016 Conditions for Setting the DTC..........................................1016 Diagnostic Aids.........................................................1016 DTC 653 - Spark Rev Limit...................................................1018 Circuit Description.....................................................1018 Conditions for Setting the DTC..........................................1018 Diagnostic Aids.........................................................1018 Wire Harness Repair.............................................................1021 On Vehicle Service Wiring Harness Repair....................................1021 Connectors and Terminals....................................................1022 Twisted/Shielded Cable Repair...........................................1022 Twisted Leads Repair....................................................1023 Micro-Pack..............................................................1024 Metri-Pack..............................................................1024 Remove..............................................................1024 Weather-Pack............................................................1026 Weather-Pack Terminal Repair........................................1027 tables.............................................................................. 699 Table 1. OBD System Check....................................................... 719 Table 2. Preliminary Checks..................................................... 721 Table 3. Intermittent Checks.................................................... 722 Table 4. Communication Port C002................................................ 723 Table 5. Coil Connector C003.................................................... 723 Table 6. Fuel System Interface C004............................................. 723 Table 7. Oil Pressure Connector C005............................................ 724 Table 8. Distributor Connector C006............................................. 724 Table 9. Magnetic Pickup Connector C007......................................... 724 Table 10. Heated Oxygen Sensor C008............................................. 724 Table 11. Throttle Position Sensor Connector C009............................... 725 Table 12. Foot Pedal Position Connector C010.................................... 725 Table 13. Governor Motor Connector C011......................................... 725 Table 14. TMAP Connector C012................................................... 725 Table 15. Starter Solenoid C013................................................. 726 Table 16. Engine Coolant Temperature C014....................................... 726 Table 17. Battery Connector C015................................................ 726 Table 18. Alternator Connection C016............................................ 726 Table 19. Battery Connector C017................................................ 726 Table 20. Alternator Connector C018............................................. 727 Table 21. Instrument Panel Connector C019....................................... 727 Table 22. Instrument Panel Connector C020....................................... 727 Table 23. Instrument Panel Connector C021....................................... 728 Table 24. Fuel Trim Valve Connector C022........................................ 728 Table 25. Fuel Lockoff Connector C023........................................... 728 Table 26. Pressure Trim Valve Connector C024.................................... 729 Table 27. Throttle Body Injector Connector C025................................. 729 Table 28. Relay and Fuse Center................................................. 729 Table 29. DTC 111 - IAT Voltage High (Motorola® TMAP)........................... 738 Table 30. DTC 112 - IAT Low Voltage (Motorola® TMAP)............................ 741 Table 31. DTC 115 - Oil Pressure Low............................................ 746 Table 32. Temperature Resistance................................................ 748 Table 33. DTC 121 - ECT VOLTAGE HIGH............................................ 749 Table 34. DTC 122 - ECT Voltage Low............................................. 753 Table 35. DTC 123 - ECT Higher Than Expected 1.................................. 755 Table 36. DTC 124 - ECT Higher Than Expected 2.................................. 757 Table 37. DTC 131 - MAP HIGH PRESSURE (Motorola® TMAP).......................... 759 Table 38. DTC 132 - MAP Low Voltage (Motorola® TMAP)............................ 762 Table 39. DTC 134 - BP High Pressure (Motorola® TMAP)........................... 765 Table 40. DTC 135 - BP Low Pressure (Motorola® TMAP)............................ 767 Table 41. DTC 142 - Crank Sync Noise............................................ 771 Table 42. DTC 143 - Never Crank Synced At Start................................. 774 Table 43. DTC 144 - Camshaft Sensor Loss........................................ 777 Table 44. DTC 145 - Camshaft Sensor Noise....................................... 780 Table 45. DTC 211 - Closed Loop Multiplier High (LPG)........................... 784 Table 46. DTC 212 - HO 2 S Open/Inactive........................................ 787 Table 47. DTC 221 - Closed Loop Multiplier High (Gasoline)...................... 790 Table 48. DTC 222 - Closed Loop Multiplier Low (Gasoline)....................... 793 Table 49. DTC 224 - Closed Loop Multiplier Low (LPG)............................ 795 Table 50. DTC 241 - Adaptive Lean Fault (High Limit-Gasoline)................... 797 Table 51. DTC 242 - Adaptive Rich Fault (Low Limit-Gasoline).................... 800 Table 52. DTC 243 - Adaptive Learn High (LPG)................................... 803 Table 53. DTC 244 - Adaptive Learn Low (LPG).................................... 806 Table 54. DTC 261 - System Voltage High......................................... 809 Table 55. DTC 262 - System Voltage Low.......................................... 810 Table 56. DTC 411 - Injector Driver 1 Open...................................... 813 Table 57. DTC 412 - Injector Driver 1 Shorted................................... 816 Table 58. DTC 511 - COP Failure................................................. 819 Table 59. DTC 512 - Invalid Interrupt........................................... 821 Table 60. DTC 513 - A/D Loss.................................................... 823 Table 61. DTC 514 - RTI 1 Loss.................................................. 825 Table 62. DTC 515 - Flash Checksum Invalid...................................... 827 Table 63. DTC 516 - Ram Failure................................................. 829 Table 64. DTC 531 - External 5V Ref Lower Than Expected......................... 831 Table 65. DTC 532 - External 5 V Ref Higher Than Expected....................... 833 Table 66. DTC 555 - RTI 2 Loss.................................................. 835 Table 67. DTC 556 - RTI 3 Loss.................................................. 837 Table 68. DTC 611 - FPP High Voltage............................................ 839 Table 69. DTC 612 - FPP Low Voltage............................................. 843 Table 70. DTC 631 - TPS1 Signal Voltage High.................................... 847 Table 71. DTC 632 - TPS1 Signal Voltage Low..................................... 850 Table 72. DTC 638 - Throttle Unable To Close.................................... 853 Table 73. DTC 651 - Maximum Govern Speed Override............................... 856 Table 74. DTC 652 - Fuel Rev Limit.............................................. 859 Table 75. DTC 653 - Spark Rev Limit............................................. 861 Table 76. Communication Port C002............................................... 864 Table 77. Injector Connector C003............................................... 864 Table 78. Injector Connector C004............................................... 864 Table 79. Oil Pressure Connector C005........................................... 865 Table 80. Throttle Position Sensor 1 Connector C006............................. 865 Table 81. Foot Pedal Position Connector C006A................................... 865 Table 82. Coil Connector C007................................................... 865 Table 83. Module Connector C008................................................. 866 Table 84. Crank Sensor Connector C009........................................... 866 Table 85. EGO Sensor Connector C010............................................. 866 Table 86. Cam Connector C011.................................................... 867 Table 87. Throttle Connector C012............................................... 867 Table 88. Bosch TMAP Connector C013 (Gasoline Fuel System Only)................. 867 Table 89. Motorola TMAP Connector C013 (LPG Fuel System Only)................... 868 Table 90. Starter Solenoid Connector C014....................................... 868 Table 91. ECT Connector C015.................................................... 868 Table 92. Starter Relay C016.................................................... 868 Table 93. Power Relay C017...................................................... 868 Table 94. Fuel Pump Relay C018.................................................. 868 Table 95. Battery Connector C019................................................ 869 Table 96. Alternator Connector C020............................................. 869 Table 97. Alternator Connector C021............................................. 869 Table 98. Instrument Panel Connector C022....................................... 869 Table 99. Instrument Panel Connector C023....................................... 870 Table 100. Instrument Panel Connector C024...................................... 870 Table 101. Fuel Trim Valve Connector C025....................................... 870 Table 102. Fuel Lockoff Connector C026.......................................... 871 Table 103. Pressure Trim Valve Connector C027................................... 871 Table 104. Injector 1 Connector C028............................................ 871 Table 105. Injector 2 Connector C029............................................ 872 Table 106. Injector 3 Connector C030............................................ 872 Table 107. Injector 4 Connector C031............................................ 872 Table 108. Injector 5 Connector C032............................................ 873 Table 109. Injector 6 Connector C033............................................ 873 Table 110. Relay and Fuse Center................................................ 873 Table 111. DTC 111 - IAT Voltage High (Bosch® TMAP)............................. 882 Table 112. DTC 111 - IAT Voltage High (Motorola® TMAP).......................... 885 Table 113. DTC 112 - IAT Low Voltage (Bosch® TMAP).............................. 887 Table 114. DTC 112 - IAT Low Voltage (Motorola® TMAP)........................... 890 Table 115. DTC 115 - Oil Pressure Low........................................... 896 Table 116. Temperature Resistance............................................... 899 Table 117. DTC 121 - ECT VOLTAGE HIGH........................................... 900 Table 118. DTC 122 - ECT Voltage Low............................................ 903 Table 119. DTC 123 - ECT Higher Than Expected 1................................. 906 Table 120. DTC 124 - ECT Higher Than Expected 2................................. 908 Table 121. DTC 131 - MAP High Pressure (Bosch® TMAP)............................ 909 Table 122. DTC 131 - MAP HIGH PRESSURE (Motorola® TMAP)......................... 913 Table 123. DTC 132 - MAP Low Voltage (Bosch® TMAP).............................. 916 Table 124. DTC 132 - MAP Low Voltage (Motorola® TMAP)........................... 919 Table 125. DTC 134 - BP High Pressure (Bosch® TMAP)............................. 924 Table 126. DTC 134 - BP High Pressure (Motorola® TMAP).......................... 926 Table 127. DTC 135 - BP Low Pressure (Bosch® TMAP).............................. 927 Table 128. DTC 135 - BP Low Pressure (Motorola® TMAP)........................... 931 Table 129. DTC 142 - Crank Sync Noise........................................... 935 Table 130. DTC 143 - Never Crank Synced At Start................................ 938 Table 131. DTC 144 - Camshaft Sensor Loss....................................... 941 Table 132. DTC 145 - Camshaft Sensor Noise...................................... 944 Table 133. DTC 211 - Closed Loop Multiplier High (LPG).......................... 948 Table 134. DTC 212 - HO 2 S Open/Inactive....................................... 951 Table 135. DTC 221 - Closed Loop Multiplier High (Gasoline)..................... 954 Table 136. DTC 222 - Closed Loop Multiplier Low (Gasoline)...................... 957 Table 137. DTC 224 - Closed Loop Multiplier Low (LPG)........................... 959 Table 138. DTC 241 - Adaptive Lean Fault (High Limit-Gasoline).................. 961 Table 139. DTC 242 - Adaptive Rich Fault (Low Limit-Gasoline)................... 964 Table 140. DTC 243 - Adaptive Learn High (LPG).................................. 967 Table 141. DTC 244 - Adaptive Learn Low (LPG)................................... 970 Table 142. DTC 261 - System Voltage High........................................ 973 Table 143. DTC 262 - System Voltage Low......................................... 974 Table 144. DTC 511 - COP Failure................................................ 977 Table 145. DTC 512 - Invalid Interrupt.......................................... 979 Table 146. DTC 513 - A/D Loss................................................... 981 Table 147. DTC 514 - RTI 1 Loss................................................. 983 Table 148. DTC 515 - Flash Checksum Invalid..................................... 985 Table 149. DTC 516 - Ram Failure................................................ 987 Table 150. DTC 531 - External 5V Ref Lower Than Expected........................ 989 Table 151. DTC 532 - External 5 V Ref Higher Than Expected...................... 991 Table 152. DTC 555 - RTI 2 Loss................................................. 993 Table 153. DTC 556 - RTI 3 Loss................................................. 995 Table 154. DTC 611 - FPP High Voltage........................................... 997 Table 155. DTC 612 - FPP Low Voltage............................................1000 Table 156. DTC 631 - TPS1 Signal Voltage High...................................1005 Table 157. DTC 632 - TPS1 Signal Voltage Low....................................1008 Table 158. DTC 638 - Throttle Unable To Close...................................1011 Table 159. DTC 651 - Maximum Govern Speed Override..............................1014 Table 160. DTC 652 - Fuel Rev Limit.............................................1017 Table 161. DTC 653 - Spark Rev Limit............................................1020 2200SRM1097-(03-2007)-US-EN.............................................................1031 toc.................................................................................1031 High Voltage Switch (HVS) Ignition..............................................1031 Safety Precautions Maintenance and Repair.......................................1032 Description.....................................................................1035 Distributor Ignition (DI) System............................................1035 Crankshaft Position (CKP) Sensor............................................1035 Camshaft Position (CMP) Sensor..............................................1035 Ignition Coil and Ignition Control Module (ICM).............................1035 Secondary Ignition Components...............................................1035 Spark Plugs and Wires...........................................................1035 Spark Plug Wire Inspection..................................................1035 Spark Plug Wire Replacement.................................................1035 Remove..................................................................1035 Install.................................................................1036 Spark Plug Inspection.......................................................1036 Usage...................................................................1036 Inspection..............................................................1036 Visual Inspection.......................................................1038 Spark Plug Replacement......................................................1038 Remove..................................................................1038 Install.................................................................1039 Distributor Repair..............................................................1039 Inspect.....................................................................1039 Overhaul....................................................................1040 Disassemble.............................................................1040 Assemble................................................................1042 Replace.....................................................................1043 Remove..................................................................1043 Install Procedure 1.....................................................1045 Install Procedure 2.....................................................1045 Ignition Coil Replacement.......................................................1047 Remove......................................................................1047 Install.....................................................................1047 Ignition Control Module Replacement.............................................1048 Remove......................................................................1048 Install.....................................................................1048 Camshaft Position (CMP) Sensor Replacement......................................1049 Remove......................................................................1049 Install.....................................................................1050 Crankshaft Position (CKP) Sensor Replacement....................................1051 Remove......................................................................1051 Install.....................................................................1051 Wire Harness Repair.............................................................1052 On Vehicle Service Wiring Harness Repair....................................1052 Connectors and Terminals....................................................1052 Twisted/Shielded Cable Repair...........................................1053 Twisted Leads Repair....................................................1054 Micro-Pack..............................................................1055 Metri-Pack..............................................................1055 Remove..............................................................1055 Weather-Pack............................................................1057 Weather-Pack Terminal Repair........................................1057 Specifications and Special Tools................................................1059 System Diagnosis................................................................1060 tables..............................................................................1031 Table 1. Ignition System Specifications.........................................1059 Table 2. Fastener Tightening Specifications.....................................1059 Table 3. Special Tools..........................................................1060 Table 4. Distributor Ignition (DI)..............................................1060 4000SRM0135-(10-2003)-US-EN.............................................................1069 toc.................................................................................1069 Lift Cylinders..................................................................1069 Safety Precautions Maintenance and Repair.......................................1070 Safety Procedures When Working Near Mast........................................1073 General.........................................................................1077 Description.....................................................................1077 Lowering Control Valve......................................................1077 Cylinders (General).........................................................1080 Cylinders (H520-620B, H700-800A)............................................1080 Retainer, Install.......................................................1080 Cylinders (H360-460B).......................................................1082 Cylinders (Two-Speed).......................................................1084 Lift Cylinder Repair............................................................1086 Lift Cylinder Removal Without Removing Mast.................................1086 Standard Masts With Main Lift Cylinder Fastened to Crossmember o........1086 Standard and Full Free-Lift Masts With Lift Cylinder Fastened to........1086 Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift ........1086 Disassemble.................................................................1088 Assemble....................................................................1088 Lift Cylinder Installation in Mast..........................................1090 Standard Masts With Main Lift Cylinder Fastened to Crossmember o........1090 Standard and Full Free-Lift Masts With Lift Cylinder Fastened to........1090 Chevron-Style Packing.......................................................1090 Chevron-Style Packing Installation on Piston............................1091 Chevron-Style Packing Installation in Packing Gland.....................1093 Lift Cylinders for VISTA® Masts.................................................1094 Description.................................................................1094 Lowering Control Valve..................................................1094 Remove......................................................................1096 Disassemble.................................................................1097 Assemble....................................................................1098 Install.....................................................................1099 Main Lift Cylinders.....................................................1099 Free-Lift Cylinder......................................................1099 Lift System Leak Check..........................................................1100 Specifications..................................................................1101 Troubleshooting.................................................................1102 tables..............................................................................1069 Table 1. Lift Trucks with Two-Speed Lift Cylinders..............................1085 Table 2. Cylinder Retainer Torque Specifications and Weight Guid................1101 4000SRM0329-(10-2003)-US-EN.............................................................1105 toc.................................................................................1105 Masts...........................................................................1105 Safety Precautions Maintenance and Repair.......................................1106 General.........................................................................1109 Description and Operation.......................................................1109 General.....................................................................1109 Safety Procedures When Working Near Mast....................................1110 Two-Stage Mast..............................................................1110 Three-Stage Mast............................................................1112 Carriage Repair.................................................................1114 Remove......................................................................1114 Sideshift Carriage, Disassemble.............................................1114 Sideshift Carriage, Assemble................................................1115 Install.....................................................................1115 Two-Stage Mast Repair...........................................................1117 Remove......................................................................1117 Disassemble.................................................................1118 Clean and Inspect...........................................................1119 Assemble....................................................................1120 Install.....................................................................1120 Three-Stage Mast Repair.........................................................1122 Remove......................................................................1122 Disassemble.................................................................1122 Clean and Inspect...........................................................1122 Assemble....................................................................1122 Install.....................................................................1124 Mast Operation Check............................................................1124 Lift and Tilt System Leaks Check................................................1125 Lift System.................................................................1125 Tilt System.................................................................1125 Tilt Cylinder Stroke and Backward Tilt Angle Adjustment.........................1126 Lift Chain Adjustments..........................................................1126 Mast Adjustments................................................................1129 Carriage Adjustment.............................................................1129 Troubleshooting.................................................................1131 tables..............................................................................1105 Table 1. Mast Parts Weight......................................................1118 Table 2. Hook-Type Carriage Chain Adjustment....................................1127 Table 3. Pin-Type Carriage Chain Adjustment.....................................1127 8000SRM0231-(12-2004)-US-EN.............................................................1135 toc.................................................................................1135 Metric and Inch (SAE) Fasteners.................................................1135 Safety Precautions Maintenance and Repair.......................................1136 General.........................................................................1139 Threaded Fasteners..........................................................1139 Nomenclature, Threads.......................................................1139 Strength Identification.....................................................1140 Cotter (Split) Pins.........................................................1140 Fastener Torque Tables......................................................1145 Conversion Table............................................................1147 tables..............................................................................1135 Table 1. Bolts and Screws.......................................................1141 Table 2. Studs and Nuts.........................................................1142 Table 3. Torque Nuts............................................................1143 Table 4. Torque Nuts With Nylon Insert..........................................1144 Table 5. Torque Values for Metric Fasteners*....................................1145 Table 6. Torque Values for Inch Fasteners*......................................1146 Table 7. Conversion Table for Metric and English Units..........................1147 Table 8. Cotter Pin Dimensional Data............................................1148 Table 9. Cotter Pin Dimensional Data............................................1149 Table 10. Cotter Pin Dimensional Data...........................................1150 Table 11. Cotter Pin Dimensional Data...........................................1152 8000SRM0331-(09-2003)-US-EN.............................................................1157 toc.................................................................................1157 Capacities and Specifications...................................................1157 Safety Precautions Maintenance and Repair.......................................1158 Lift Truck Weights..............................................................1161 Capacities......................................................................1161 Tire Sizes......................................................................1162 Tire Pressure...................................................................1162 Electrical System...............................................................1162 Wheel Nut Torque................................................................1162 Engine Specifications...........................................................1163 Hydraulic System................................................................1163 Mast Speeds.....................................................................1164 Transmission Oil Pressures......................................................1164 Torque Specifications...........................................................1165 Engine - GM 4.3L V-6........................................................1165 Engine - Perkins 4.2482.....................................................1165 Engine - Perkins 1004.4.....................................................1165 Clutch......................................................................1165 Manual Transmission.........................................................1166 Powershift Transmission.....................................................1166 Speed Reducer...............................................................1166 Drive Axle..................................................................1166 Steering System.............................................................1166 Brake System................................................................1166 Hydraulic System............................................................1167 Tilt Cylinder...............................................................1167 Mast........................................................................1167 8000SRM0341-(06-2007)-US-EN.............................................................1171 toc.................................................................................1171 Periodic Maintenance............................................................1171 Safety Precautions Maintenance and Repair.......................................1172 General.........................................................................1177 Serial Number Data..........................................................1177 How to Move Disabled Truck..................................................1177 How to Tow Lift Truck...................................................1177 How to Put Lift Truck on Blocks.............................................1178 How to Raise Drive Tires................................................1178 How to Raise Steering Tires.............................................1178 Maintenance Schedule............................................................1179 Maintenance Procedures Every 8 Hours or Daily...................................1192 How to Make Checks With Engine Stopped......................................1192 Hydraulic System Oil....................................................1192 Engine Oil..............................................................1194 Drive Belts.............................................................1194 Intake Manifold Rubber Cap..............................................1195 Cooling System..........................................................1195 Air Filter..............................................................1195 Fuel System.............................................................1196 Primary Fuel Filter, Diesel Engine......................................1196 Battery.................................................................1196 Tires and Wheels........................................................1196 Forks...................................................................1197 Adjust..............................................................1197 Remove and Install..................................................1199 Forks, Mast, and Lift Chains, Inspect...................................1200 Operator Restraint System...............................................1201 Automatic Locking Retractor (ALR)...................................1201 Emergency Locking Retractor (ELR)...................................1201 Safety Labels...........................................................1202 How to Make Checks With Engine Running......................................1203 Gauges, Lights, Horn, and Fuses.........................................1203 Oil Level, Powershift Transmission......................................1204 Oil Level, Oil Clutch System, H3.50-5.00XL (H70-110XL)..................1205 Control Levers and Pedals...............................................1205 Lift System Operation...................................................1205 Inching/Brake Pedal.....................................................1205 Service Brakes..........................................................1205 Parking Brake...........................................................1206 Steering System.........................................................1206 Maintenance Procedures Every 250 Hours or 6 Weeks...............................1206 Engine Oil and Filter, GM V-6 Engine........................................1206 Lift Chains, Lubrication....................................................1206 Drive Shafts................................................................1206 Mast Lubrication............................................................1207 Crankcase Breather, GM V-6..................................................1208 Air Filter, GM V-6 EPA Compliant Engine ....................................1208 Maintenance Procedures Every 350 Hours or 2 Months..............................1209 Engine Oil and Filter, Perkins 4.2482 Diesel Engine.........................1209 Drive Belts.................................................................1209 Perkins Diesel Engine...................................................1209 GM V-6 Engine (Early Models)............................................1209 GM V-6 Engine (Late Models).............................................1210 Brake Fluid.................................................................1212 Lift Chains Wear Check......................................................1212 Forks Wear and Damage Check.................................................1212 Steering Axle Lubrication...................................................1212 Fuel System, Checks and Adjustments.........................................1213 Diesel Fuel System......................................................1213 LPG Carburetor (Early Models)...........................................1213 Gasoline Carburetor (Early Models)......................................1214 Fuel Injection (Late Models)............................................1214 Crankcase Breather, Perkins 4.2482 Diesel Engine............................1214 Hydraulic Tank Breather.....................................................1214 Cooling System, Clean Debris from Radiator Core.............................1214 Maintenance Procedures Every 500 Hours or 3 Months..............................1215 Engine Oil and Filter, Perkins Diesel Engine................................1215 Crankcase Breather, Perkins Diesel Engine...................................1215 PCV Valve, GM V-6...........................................................1215 Maintenance Procedures Every 1000 Hours or 6 Months.............................1215 Manifold Heat Valve, GM V-6 (Early Models)..................................1215 Ignition System, GM V-6.....................................................1215 Valve Clearance Adjustment..................................................1215 Fuel Filter, Replace (Diesel Engine)........................................1216 Fuel System Air Removal (Perkins 1004-4 Diesel Engine)......................1216 Fuel Injection Pump With Vent Tube......................................1216 Fuel Injection Pump With Vent Screw.....................................1217 Fuel System Air Removal (Perkins 4.2482 Diesel Engine)......................1219 Oil Level Check in Transmission.............................................1219 Manual Transmission, H3.50-5.00XL (H70-110XL)...........................1219 Speed Reducer for Powershift Transmission, H3.50-5.00XL (H70-110........1219 Manual Transmission, H6.00-7.00XL (H135-155XL)..........................1219 Differential and Drive Axle for Powershift Transmission, H6.00-7........1219 Differential, Speed Reducer, and Drive Axle for Manual Transmiss........1220 Control Levers and Pedals, Lubricate........................................1220 Crankcase Breather, Replace.................................................1220 Cooling System, GM V-6 EPA Compliant Engine.................................1220 Spark Plug Replacement......................................................1220 Remove..................................................................1220 Install.................................................................1221 LPG Fuel Filter GM V-6 EPA Compliant Engine, Replace........................1221 Inspect Engine Electrical System, Connectors, and FCVS Connectio............1222 Maintenance Procedures Every 2000 Hours or Yearly...............................1222 Hydraulic System............................................................1222 Hydraulic Oil and Filter, H3.50-5.00XL (H70-110XL), Replace.............1222 Hydraulic Oil and Filter, H6.00-7.00XL (H135-155XL, H135-155XL 2........1223 Oil Change and Oil Filter Replacement, Powershift Transmission, ............1223 Oil Change, Manual Transmission, H3.50-5.00XL (H70-110XL)...................1223 Oil Change, Manual Transmission, H6.00-7.00XL (H135-155XL)..................1223 Oil Change, Speed Reducer, Powershift Transmission, H3.50-5.00XL............1223 Oil and Filter Change, Oil Clutch System, H3.50-5.00XL (H70-110X............1224 Oil Change, Differential and Drive Axle, Powershift Transmission............1224 Oil Change, Differential, Speed Reducer, and Drive Axle, Manual ............1224 Cooling System..............................................................1224 PCV Valve, GM V-6...........................................................1224 Service Brakes..............................................................1225 LPG Filter, Replace.........................................................1225 Gasoline Fuel Filter, Replace...............................................1226 Hood Latch Check, H3.50-5.00XL (H70-110XL)..................................1226 Air Filter Element, GM V-6 EPA Compliant Engine.............................1226 Oxygen Sensor GM V-6 EPA Compliant Engine...................................1226 Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks..............1227 Check Throttle Shaft for Sticking...........................................1228 Inspect Exhaust Manifold and Piping for Leaks...............................1228 Test LPG/GAS Regulator Pressure.............................................1228 Safety Procedures When Working Near Mast........................................1228 Lift Chain Adjustments..........................................................1230 Fuel Injectors Repair...........................................................1232 Lift and Tilt System Leak Check.................................................1233 Lift Cylinders, Leak Check..................................................1233 Tilt Cylinders, Leak Check..................................................1233 Welding Repairs.................................................................1234 Overhead Guard Changes..........................................................1234 Wheel and Tire Replacement......................................................1235 Remove Wheels From Lift Truck...............................................1235 Remove Wheels From Tire.....................................................1235 Remove Tire From Two-Piece Wheel........................................1237 Remove Tire From Three- and Four-Piece Wheels...........................1239 Install Wheel in Tire.......................................................1240 Install Three- or Four-Piece Wheel in Tire..............................1241 Install Two-Piece Wheel in Tire.........................................1242 Add Air to Pneumatic Tires..................................................1243 Wheels, Install.............................................................1243 Solid Rubber Tires Repair.......................................................1244 Wheel, Tire Remove..........................................................1244 Wheel, Tire Install.........................................................1246 SIT Tire, Change for H3.50-5.00XL (G005), and H6.00-7.00XL (F006............1248 Remove SIT Solid Tire From Wheel........................................1248 Install SIT Solid Tire on Wheel.........................................1249 Adhesives and Sealants..........................................................1250 Hydraulic Oil, Lubricant, and Coolant Specifications............................1251 tables..............................................................................1171 Table 1. Maintenance Schedule...................................................1181 Table 2. Hook-Type Carriage Chain Adjustment....................................1231 Table 3. Pin-Type Carriage Chain Adjustment.....................................1231 8000SRM0519-(06-2007)-US-EN.............................................................1255 toc.................................................................................1255 Diagrams........................................................................1255 Safety Precautions Maintenance and Repair.......................................1256
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