Yale Forklift D818 (GC_GDC_GLC070_080LJ_LJ-BCS GC_GDC_GLC100_120MJ_MJ-BCS) Service Manual PDF

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Yale Forklift D818 (GC_GDC_GLC070_080LJ_LJ-BCS GC_GDC_GLC100_120MJ_MJ-BCS) Service Manual – PDF DOWNLOAD

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Yale Forklift D818 (GC_GDC_GLC070_080LJ_LJ-BCS GC_GDC_GLC100_120MJ_MJ-BCS) Service Manual – PDF DOWNLOAD

Language : English
Pages : 1410
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift D818 (GC_GDC_GLC070_080LJ_LJ-BCS GC_GDC_GLC100_120MJ_MJ-BCS) Service Manual – PDF DOWNLOAD

524150774-0600YRM0705-(03-2006)-US-EN 1
toc 1
Perkins Diesel Engines 1
Safety Precautions Maintenance and Repair 2
General 9
General Safety Rules 9
Description 10
Engine Serial Number Codes 13
Engine Data 13
Engine Removal and Installation 15
Lift Engine 15
Cylinder Head Assembly Repair 15
Valve Cover 15
Remove 15
Install 16
Rocker Arm Assembly 16
Remove 16
Install 16
Disassemble 16
Inspect 17
Assemble 17
Valve Clearance Adjustments 17
Four-Cylinder Engines 18
Six-Cylinder Engines 18
Valve Springs 18
Cylinder Head Assembly 20
Remove 20
Install 22
Valves and Valve Springs 26
Remove 26
Inspect 26
Install 27
Valve Guides 27
Inspect 27
Remove 28
Install 28
Cylinder Head and Valve Seats 28
Inspect 28
Repair 28
New Valve Seats, Install 28
Piston and Connecting Rod Assemblies Repair 30
Rod Bearings 30
Remove 31
Install 31
Piston and Connecting Rod Assembly 32
Service Note 32
Remove 32
Install 33
Piston Rings 34
Remove 34
Inspect 34
Install 34
Piston and Connecting Rod 35
Disassemble 35
Inspect 36
How to Select Correct Replacements 36
Install 37
Piston Cooling Jets 37
Remove 37
Install 38
Crankshaft Assembly Repair 38
General 38
Crankshaft Pulley 39
Engine AR, Remove 39
Engines YG and YH, Remove 39
Inspect 40
Engine AR, Install 40
Engines YG and YH, Install 40
Rear Oil Seal 41
Replace 41
Main Bearings 42
Remove 42
Inspect 43
Install 43
Thrust Washers 43
Crankshaft Axial Movement, Check 43
Remove 44
Install 44
Crankshaft 45
Remove 45
Inspect 45
Install 45
Flywheel 47
Remove 47
Ring Gear, Replace 47
Install 47
Flywheel Housing 48
Remove 48
Install 48
Timing Case and Timing Gears Repair 49
General 49
Timing Case Cover 49
Remove 49
Install 50
Front Oil Seal 50
Remove 50
Install 50
Crankshaft Pulley Wear Sleeve 51
Install 51
Idler Gear and Hub 51
Remove 51
Install 52
Air Compressor Drive, Bendix 53
Disassemble 53
Assemble 54
Fuel Injection Pump Gear 54
Remove 55
Install 55
Camshaft Gear 56
Remove 56
Install 56
Crankshaft Gear 57
Remove 57
Install 57
Timing Case 57
Remove 57
Install 58
Camshaft and Tappets 59
Remove 59
Install 59
Cylinder Block Assembly Repair 60
Description 60
Cylinder Block 60
Disassemble 60
Inspect 61
Assemble 61
Cylinder Bore (Four-Cylinder Engines) 61
Cylinder Liner (Six-Cylinder Engines) 62
Inspect 62
Cylinder Liner Condition, Check 62
Remove 63
Service Liner, Install 63
Partially Finished Liner, Install 65
Engine Timing 65
Description 65
How to Set Number One Piston to TDC on Compression Stroke 67
How to Set Number One Piston to TDC on Compression Stroke (Alter 67
Valve Timing, Check 68
Fuel Injection Pump Timing, Check 69
Turbocharger – Engine YH Repair 70
General 70
Remove 70
Install 70
Impeller and Compressor Housing, Clean 71
Lubrication System Repair 72
General 72
Oil Filter, Replace 72
Filter Head 72
Remove and Install 72
Oil Sump 73
Remove 73
Install 73
Oil Pump 73
Remove 73
Inspect 74
Install 75
Relief Valve 75
Remove 75
Disassemble 76
Inspect 76
Assemble 76
Install 76
Idler Gear Shaft, Replace 77
Remove 77
Remove (Alternative) 77
Install 78
Install (Alternative) 78
Install (Alternative for Four-Cylinder Engines Only) 79
Fuel System Repair 79
Description 79
Fuel Injection Pump 80
Remove 80
Install 81
Check and Adjust 81
Fuel System Air Removal 82
Fuel Filter, Replace 83
Canister Type 83
Quick Release Canister Type 84
Fuel Injectors 85
Remove 85
Inspect 85
Install 85
Fuel Pump 86
Remove 86
Disassemble 86
Assemble 87
Install 88
Test 88
Cooling System Repair 88
General 88
Thermostat 88
Remove 88
Install 89
Test 89
Coolant Pump 89
Remove 89
Disassemble 90
Assemble 91
Install 94
Fan and Fan Drive 94
Remove 94
Install 95
Oil Cooler (Six-Cylinder Engines) 95
Remove 95
Disassemble and Assemble 95
Install 96
Oil Cooler Bypass Valve 96
Electrical Equipment Repair 96
Drive Belts 96
Adjustment 96
Remove 97
Install 97
Alternator 97
Remove 97
Install 97
Starter Motor 98
Remove 98
Install 98
Cold Start Aid 98
Air Compressor – Engines YG and YH 98
General 98
Repair 98
Remove 98
Install 99
Rotary Exhauster Replacement 100
Remove 100
Clean 100
Install 100
Engine Specifications 101
Cylinder Head Assembly 101
Piston and Connecting Rods 104
Crankshaft Assembly 107
Crankshaft Overhaul 108
Timing Case and Drive Assembly 110
Engine Block Assembly 111
Turbocharger 114
Lubrication System 114
Fuel System 115
Cooling System 117
Flywheel and Housing 117
Electrical Equipment 118
Torque Specifications 118
Cylinder Head Assembly 118
Piston and Connecting Rod Assemblies 118
Crankshaft Assembly 118
Timing Case and Drive Assembly 119
Turbocharger 119
Lubrication System 119
Fuel System 119
Cooling System 119
Flywheel 119
Auxiliary Equipment 119
Special Torque Specifications 120
Flywheel and Housing 120
Turbocharger 120
Electrical Equipment 120
Auxiliary Equipment 120
Special Tools* 121
Troubleshooting 126
tables 1
Table 1 Cylinder Head 101
Table 2 Valve Guides 101
Table 3 Inlet Valves 101
Table 4 Exhaust Valves 102
Table 5 Valve Springs 104
Table 6 Tappets 104
Table 7 Rocker Arm Shaft 104
Table 8 Rocker Arms and Bushings 104
Table 9 Pistons (Engine AR) 104
Table 10 Pistons (Engines YG and YH) 104
Table 11 Piston Rings (Engine AR) 105
Table 12 Piston Rings (Engines YG and YH) 105
Table 13 Piston Pins 106
Table 14 Connecting Rods 106
Table 15 Small End Bushings 106
Table 16 Connecting Rod Bearings (Engines AR and YG) 106
Table 17 Connecting Rod Bearings (Engine YH) 106
Table 18 Piston Cooling Jets 107
Table 19 Crankshaft 107
Table 20 Main Bearings 107
Table 21 Crankshaft Thrust Washers 107
Table 22 Crankshaft Heat Treatment 108
Table 23 Crankshaft Overhaul Specifications 108
Table 24 Maximum Variation (Run-out) 110
Table 25 Camshaft 110
Table 26 Camshaft Thrust Washer 110
Table 27 Camshaft Gear 110
Table 28 Gear for Fuel Injection Pump 111
Table 29 Crankshaft Gear 111
Table 30 Idler Gear and Hub 111
Table 31 Cylinder Block (Engine AR) 111
Table 32 Cylinder Bore Specifications 112
Table 33 Cylinder Block (Engines YG and YH) 113
Table 34 Cylinder Liners (Engines YG and YH) 113
Table 35 Cylinder Liner Specifications (Partially Finished) 113
Table 36 Oil Pump (Engine AR) 114
Table 37 Oil Pump (Engines YG and YH) 114
Table 38 Idler Gear for Oil Pump 114
Table 39 Relief Valve 115
Table 40 Oil Filter 115
Table 41 Lucas Fuel Injection Pump 115
Table 42 Fuel Injector Codes 116
Table 43 Fuel Pump (Engine AR) 117
Table 44 Fuel Pump (Engines YG and YH) 117
Table 45 Fuel Filter 117
Table 46 Coolant Pump 117
Table 47 Thermostat 117
Table 48 Fan Drive Housing 117
Table 49 Limits for Flywheel Run Out and Alignment (Total Indic 117
Table 50 Alternator 118
Table 51 Starter Motor 118
Table 52 Cold Start Aid 118
Table 53 List of Possible Causes 126
524150775-0700YRM0626-(03-2003)-US-EN 131
toc 131
Cooling System 131
Safety Precautions Maintenance and Repair 132
General 135
Description 136
Radiator 136
Radiator Cap 136
Thermostat 136
Water Pump 137
Fan and Fan Shroud 137
Cooling System Checks 137
Radiator 137
Thermostat 137
Water Pump 138
Exhaust Leaks 138
Fan and Fan Shroud 138
Radiator Cleaning 138
Drain 138
Clean 138
Fill 139
Troubleshooting 140
524150783-1600YRM0326-(03-2007)-US-EN 143
toc 143
Steering Axle 143
Safety Precautions Maintenance and Repair 144
General 147
Description 147
Steering Axle Assembly Repair 152
Steering Axle GP/GLP/GDP070-110LG/MG (B813), GC/GLC070-120LG/MG 152
Remove 152
Install 152
Steering Axle GDP60-70CA (GP/GLP/GDP135-155CA) (A878, B878), GLP 153
Remove 153
Install 153
Wheels and Hubs Repair (All Units) 154
Remove and Disassemble 154
Clean 154
Inspect 154
Assemble and Install 154
Spindles and Bearings Repair (All Units) 156
Remove 156
Clean 156
Assemble and Install 157
Tie Rods Repair (All Units) 158
Remove 158
Clean 158
Install 158
Steering Cylinder Repair 161
Remove and Disassemble 161
Clean and Inspect 161
Assemble and Install 161
Troubleshooting 162
524150791-2200YRM0002-(01-2016)-US-EN 167
General 171
Description 172
Alternator Repair 174
Alternator Type A 174
Remove and Disassemble 174
Clean 176
Assemble 176
Install 177
Alternator Type B 180
Remove and Disassemble 180
Clean 180
Assemble 181
Install 182
General Check and Adjustment 182
Low Output Check (Type A or Type B) 183
High Output Check (Type A or Type B) 186
Brushes Circuit Check 187
Delco Alternators 187
Motorola Alternators 187
Diodes Check 188
Diode Bridge Check 188
Delco and Leece-Neville Alternators 188
Motorola Alternators 188
Rotor Field Winding Check 189
Stator Windings Check 190
Voltage Regulator Check 190
Troubleshooting 190
524150797-8000YRM0231-(02-2023)-US-EN 195
General 201
Threaded Fasteners 201
Nomenclature, Threads 201
Strength Identification 202
Cotter (Split) Pins 203
Fastener Torque Tables 208
Conversion Table 210
524150797-8000YRM0231-(03-2020)-US-EN 217
General 221
Threaded Fasteners 221
Nomenclature, Threads 221
Strength Identification 222
Cotter (Split) Pins 223
Fastener Torque Tables 228
Conversion Table 230
524153896-0100YRM0981-(02-2007)-US-EN 237
toc 237
Frame 237
Safety Precautions Maintenance and Repair 238
Description 241
Counterweight Repair 242
Remove 242
Install 247
Exhaust System Repair 249
Muffler 249
Remove 249
Install 249
Exhaust Pipe – LPG/Gas Engine 250
Remove 250
Install 250
Exhaust Pipe – Diesel Engine 253
Remove 253
Install 253
Hood Repair 254
Remove 254
Install 254
Overhead Guard Repair 255
Remove 255
Install 255
LED Backup and Brake Lights, Replace 255
Remove 255
Install 255
Operator Restraint System Repair 256
Automatic Locking Retractor (ALR) 256
Emergency Locking Retractor (ELR) 257
Radiator and Coolant System 258
Remove 258
Install 258
Alternator Replacement 260
Remove 260
Install 260
Engine Removal and Installation 260
Remove 260
Install 262
Fuel and Hydraulic Tanks Repair 266
Inspect 266
Repairs, Small Leaks 266
Repairs, Large Leaks 266
Clean 266
Steam Method of Cleaning 266
Chemical Solution Method of Cleaning 267
Other Methods of Preparation for Repair 267
Safety Labels 269
tables 237
Table 1 Weight of Counterweights 247
524153897-0600YRM0590-(04-2014)-US-EN 273
524153901-1300YRM0397-(02-2004)-US-EN 325
toc 325
Single-Speed Powershift Transmission 325
Safety Precautions Maintenance and Repair 326
General 329
Transmission Repair 329
Remove 329
Disassemble 330
Transmission, Disassemble 330
Input Shaft, Disassemble 331
Reverse Clutch, Disassemble 333
Output Shaft (Pinion) and Differential, Remove and Disassemble 336
Clean and Inspect 338
Assemble 338
Input Shaft, Assemble 339
Reverse Clutch, Assemble 347
Output Shaft (Pinion) and Differential, Assemble and Install 352
Transmission, Assemble 359
Control Valve, Install 362
Install 362
Control Valve Repair 363
Remove, Early Model GC/GLC070-120LG/MG Lift Trucks 363
Disassemble, Early Model GC/GLC070-120LG/MG Lift Trucks 363
Assemble, Early Model GC/GLC070-120LG/MG Lift Trucks 364
Install, Early Model GC/GLC070-120LG/MG Lift Trucks 364
Remove and Disassemble, Later Model GC/GLC070-120LG/MG Trucks an 364
Inspect, Later Model GC/GLC070-120LG/MG Trucks and GC070-120LJ/M 367
Assemble and Install, Later Model GC/GLC070-120LG/MG Trucks and 367
Foot Directional Control Pedal Repair 369
Remove and Disassemble, GC/GLC070-120LG/MG Model Lift Trucks 369
Assemble and Install, GC/GLC070-120LG/MG Model Lift Trucks 370
Remove and Disassemble, GC070-120LJ/MJ Model Lift Trucks 371
Assemble and Install, GC070-120LJ/MJ Model Lift Trucks 372
Direction Control Lever Repair 374
Remove and Disassemble 374
Assemble and Install 374
Stall Test 375
Linkages Adjustment 376
Linkage for Inching/Brake Pedal, GC/GLC070-120LG/MG (B818) Lift 376
Linkage for Direction Control Lever 378
Linkage for Inching/Brake Pedal, GC070-120LJ/MJ (C818, D818) Lif 378
Brake Shoe Adjustment 378
Inching/Brake Pedal Height Adjustment 378
Single Pedal Height Adjustment 378
Two Pedal Height Adjustment 378
Inching/Brake Linkage Adjustment 380
Oil Pressures Check 382
System Pressure Check Port 382
Torque Converter Check Port 382
Clutch Pressure Check Port 383
Inching Pressure 383
Solenoid Check Ports ( Foot Directional Control Only) 385
Lubrication Pressure Check Ports 385
System Pressure Check Port 385
Torque Converter Check Port 385
Reverse Clutch Pressure Check Port 385
Forward Clutch Pressure Check Port 385
Lubrication Pressure Check Port 385
Modulator Pressure Check Port 385
Troubleshooting 386
tables 325
Table 1 Ring and Pinion Tooth Contact Adjustment 357
Table 2 Stall Speed Specifications 375
Table 3 Transmission Oil Pressure Check, Early Model GC/GLC070- 383
Table 4 Transmission Oil Pressure Check, Later Model GC070-120L 384
524153902-1300YRM0399-(09-2003)-US-EN 393
toc 393
Single-Speed Powershift Transmission 393
Safety Precautions Maintenance and Repair 394
General 397
Mechanical Description 397
General 397
Torque Converter 397
Oil Pump 397
Shaft Assemblies 397
Input Shaft 397
Reverse Clutch Shaft 397
Countershaft 398
Ring Gear, Pinion, and Differential 398
Clutch Assemblies 399
Hydraulic Operation 400
Torque Converter 400
Shaft Assemblies 401
Control Valve 401
General 401
System Regulator 401
Clutch Pressure Regulator 401
Torque Converter Regulator 401
Inching Spool 401
Direction Spool, Manual Control 404
Direction Spool, Foot Directional Control Pedal 404
Modulation Spool 404
Accumulator 404
Drain Spool 404
Foot Directional Control Pedal 405
Control Valve 405
General 405
Regulator for Clutch Pressure 405
Inching Spool Assembly 405
Direction Spool 407
Direction Spool, Manual Control 407
Modulator Circuit 407
Regulator for Torque Convertor 407
Lubrication Circuit 407
Direction Control Lever 408
Foot Directional Control Pedal 409
Start Circuit, Foot Directional Control Pedal 410
Creep Speed Switch 410
Oil Flow Diagrams 411
Neutral 411
Forward 411
Forward-Inching 411
Reverse 411
524153903-1400YRM0984-(09-2003)-US-EN 427
toc 427
Drive Axle 427
Safety Precautions Maintenance and Repair 428
General 431
Description 431
Drive Axle Repairs 431
Remove and Disassemble 431
Clean and Inspect 433
Brakes 433
Drive Axle 434
Assembly and Installation 434
Torque Specifications 436
Troubleshooting 437
524153904-1600YRM0732-(10-2003)-US-EN 441
toc 441
Steering Control Unit 441
Safety Precautions Maintenance and Repair 442
General 445
Description 445
Operation 445
Steering Wheel and Column Assembly Repair 447
Remove and Disassemble 447
Assemble and Install 447
Steering Control Unit 450
Disassemble 450
Clean 452
Assemble 453
System Air Removal 456
Troubleshooting 456
524153906-1800YRM0985-(05-2005)-US-EN 461
toc 461
Brake System 461
Safety Precautions Maintenance and Repair 462
General 465
Description and Operation 465
Brake Booster and Master Cylinder 465
Service Brake Assembly 465
Parking Brake 465
Brake Shoe Assemblies Repair 466
Remove and Disassemble 466
Clean 466
Inspect 469
Assemble and Install 469
Brake Booster and Master Cylinder 472
Remove 472
Disassemble 472
Clean and Inspect 472
Assemble 472
Install 472
Brake Booster Filter, Replace 472
Parking Brake Repair 474
Remove and Disassemble 474
Assemble and Install 474
Brake System Air Removal 476
Brake Pedal Adjustment 476
Parking Brake Adjustment 476
Parking Brake Not Applied Switch Test 477
Parking Brake Switch Test ( Foot Directional Control Pedal Only) 477
Brake Shoes Adjustment 478
Troubleshooting 478
524153907-1900YRM0097-(05-2012)-US-EN 483
toc 483
Hydraulic Gear Pumps 483
Safety Precautions Maintenance and Repair 484
Description 487
Operation 488
Flow Control Valve 488
Relief Valve 488
Hydraulic Gear Pump Repair 489
Remove 489
Disassemble 490
Clean 490
Inspect 491
Assemble 494
Install 496
Pump Output Check 496
Method No 1 496
Method No 2 497
Hydraulic System Air Check 498
Troubleshooting 499
524153908-1900YRM0339-(10-2003)-US-EN 505
toc 505
Hydraulic Pump Drive Assembly 505
Safety Precautions Maintenance and Repair 506
General 509
Description 509
Hydraulic Pump Drive Assembly Repair 510
Remove and Disassemble 510
Clean 511
Inspect 511
Assemble and Install 511
Troubleshooting 512
524153909-1900YRM0743-(06-2005)-US-EN 515
toc 515
Hydraulic System 515
Safety Precautions Maintenance and Repair 516
General 519
Description 519
Operation 521
Hydraulic Pump GLP/GDP 3 5-5 5LJ/MJ (GP/GLP/GDP70-120LJ/MJ) 521
Hydraulic Pump GC070-120LJ/MJ 521
Main Control Valve 521
Steering Control Unit 522
Specifications 522
Hydraulic System Capacity (Powershift) 522
Hydraulic System Capacity (Hydrostatic) 522
Hydraulic Tank Capacity (Powershift and Hydrostatic) 523
Hydraulic Tank Capacity 523
Relief Pressures @ 2200 RPM, 50 to 80 C ( 120 to 180 F) 523
Hydraulic Pump Flow to Valve 523
Steering Priority Flow 523
Troubleshooting 523
Lift, Lower and Tilt Circuit 524
Steering Circuit 525
524153910-2000YRM0754-(12-2003)-US-EN 529
toc 529
Main Control Valve 529
Safety Precautions Maintenance and Repair 530
General 533
Description 533
Operation 533
Lift Section 533
Tilt and Auxiliary Sections 537
Reattaching the Clevis End of the Tilt Spool 538
Relief Valve 538
Main Control Valve Repair 538
Remove and Disassemble 538
Clean and Inspect 540
Assemble 542
Install 542
Pressure Relief Valve Check and Adjustment 543
Main Relief Valve (Lift) 543
Steering Relief Valve 543
Secondary Relief Valve (Tilt and Auxiliary) 546
Specifications 547
Troubleshooting 547
524153911-2100YRM0986-(11-2004)-US-EN 553
toc 553
Tilt Cylinders 553
Safety Precautions Maintenance and Repair 554
General 557
Description 557
Tilt Cylinder Repair 557
Remove 557
Disassemble 557
Clean 557
Inspect 557
Assemble 558
Install 559
Tilt Cylinder Leak Check 560
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment 560
Tilt Cylinder Specifications 560
tables 553
Table 1 Leak Check Specifications 560
524153913-2200YRM0755-(10-2003)-US-EN 563
toc 563
Starter 563
Safety Precautions Maintenance and Repair 564
General 567
Description 567
Yoke Assembly 568
Armature Assembly 568
Clutch Assembly 568
Magnetic Switch Assembly 568
Operation 568
Starter Repair 569
Remove 569
Disassemble 570
Clean 573
Assemble 574
Install 577
General Checks and Adjustments 577
Armature Tests 578
Armature Short Circuit Test 578
Armature Winding Ground Test 578
Commutator Run-Out Test 578
Yoke Test 579
Brush and Brush Holder Check 579
Brush Holder Insulation Test 579
Clutch Test 579
Magnetic Switch Test 580
Pull-In Test 580
Hold-In Test 580
Return Test 580
Performance Tests 581
No-Load Test 581
Troubleshooting 581
524153915-2200YRM0756-(02-2007)-US-EN 587
toc 587
Instrument Panel Indicators and Senders 587
Safety Precautions Maintenance and Repair 588
General 591
Description 591
Instruments and Senders 591
Password Function 597
Supervisor Password Function 597
Entering Operator Passwords 597
Deleting Operator Passwords 598
Retrieve the Most Recent Operator Password Used to Enable the Tr 598
Display All Operator Passwords Programmed Into the System 598
Enable and Disable Operator Passwords Function 598
Allow Supervisor Password to Enable the Truck to Start 598
Operator Passwords Function 598
Component Replacement – General Information 599
Sender Replacement 599
Fuel Level Sender 599
Pressure and Temperature Sender 600
Seat Sensor, Operator Presence System (OPS) 601
Remove 601
Install 601
Operator Presence System Module Replacement 601
Remove 601
Install 603
Display Panel Replacement 604
Specifications 606
Troubleshooting 607
Troubleshooting For Operator Presence System GP/GLP/GDP70-120LJ/ 608
Troubleshooting For Operator Presence System GC70-120LJ/MJ (C818 610
tables 587
Table 1 Instrument Panel Description 592
Table 2 Sender Description 596
Table 3 Meter and Sender Specifications 606
Table 4 Troubleshooting Procedure for the Operator Presence Mod 608
Table 5 Troubleshooting Procedure for the Operator Presence Mod 610
524153918-2200YRM0782-(03-2003)-US-EN 615
toc 615
Electronic Engine Control 615
Safety Precautions Maintenance and Repair 616
General 621
Troubleshooting Procedure 621
How This Section Is Arranged 621
Where Do I Start? 621
Visual/Physical Inspection 621
Knowledge/Tools Required 621
Damage From Static Discharge (Static Electricity) 621
Troubleshooting Information 622
Malfunction Indicator Lamp (MIL) 622
Reading Diagnostic Trouble Codes (DTC) 622
Clearing Diagnostic Trouble Codes (DTCs) 626
ECM Diagnostic Codes Available 627
Diagnostic Mode 627
Field Service Mode 627
ECM Learning Ability 627
SCAN Tool Information 628
On-Board Diagnostic (OBD) System Check 629
Test Description 629
Troubleshooting Charts 631
General 631
Tools and Test Equipment 631
Troubleshooting Chart Description Summary 632
A-1 – No Malfunction Indicator Lamp 632
Circuit Description 632
Test Description 633
Other Troubleshooting Checks 633
A-2 – No Scan Data, No DTC 12, Malfunction Indicator Lamp ON 635
Circuit Description 635
Test Description 635
A-3 – Starter Rotates Engine, Engine Will Not Run 637
Circuit Description 637
Test Description 637
Other Troubleshooting Checks 637
A-4 – Fuel Injector Circuit 639
Test Description 639
A-5 – Fuel Pump Relay Circuit 641
Circuit Description 641
Test Description 641
Other Troubleshooting Checks 641
A-6 – Fuel System Troubleshooting 643
Circuit Description 643
Test Description 643
Other Troubleshooting Checks 643
Test Description 645
Fuel Pressure Check 647
A-7 – Ignition System Troubleshooting 647
Test Description 648
DTC 14 Engine Coolant Temperature Sensor Circuit (Low Temperatur 651
Circuit Description 651
Test Description 651
Other Troubleshooting Checks 651
DTC 15 Engine Coolant Temperature Sensor Circuit (High Temperatu 653
Circuit Description 653
Test Description 653
Other Troubleshooting Checks 653
DTC 21 Throttle Position Sensor Circuit (Signal Voltage High) 655
Circuit Description 655
Test Description 655
Other Troubleshooting Checks 655
DTC 22 Throttle Position Sensor Circuit (Signal Voltage Low) 657
Circuit Description 657
Test Description 657
Other Troubleshooting Checks 657
DTC 31 Engine Governor Circuit 659
Circuit Description 659
Test Description 659
Other Troubleshooting Checks 659
DTC 33 Manifold Absolute Pressure (MAP) Sensor Circuit (Signal V 661
Circuit Description 661
Test Description 661
Other Troubleshooting Checks 661
DTC 34 Manifold Absolute Pressure (MAP) Sensor Circuit (Signal V 663
Circuit Description 663
Test Description 663
Other Troubleshooting Checks 663
DTC 41 Electronic Spark Timing (EST) – Open EST Circuit 665
Circuit Description 665
Test Description 665
Other Troubleshooting Checks 665
DTC 42 EST – Grounded EST Circuit, Open or Grounded Bypass Circu 667
Circuit Description 667
Test Description 668
Other Troubleshooting Checks 668
DTC 51 ECM Failure 670
Circuit Description 670
Other Troubleshooting Checks 670
Troubleshooting, Poor Operation 671
General 671
Make a Careful Visual Check 671
FAULT: Codes or Performance That Is Not Regular 671
FAULT: Loss of Diagnostic Trouble Code (DTC) Memory 671
FAULT: Engine Quits While Driving 671
Additional Checks 671
FAULT: Engine Is Difficult to Start 671
FAULT: Variation in Engine Power When Throttle Is Held Steady 672
FAULT: Decreased Engine Power 672
FAULT: Detonation 673
FAULT: Engine Momentarily Does Not Increase Power When Throttle 673
FAULT: One or More Cylinders Do Not Operate Correctly – Engine D 674
FAULT: Rough Idle or Engine Stalls During Idle 674
FAULT: Fuel Usage Too High 674
FAULT: Dieseling 675
FAULT: Backfire 675
System Test Charts 675
General 675
Engine Coolant Temperature (ECT) Sensor Test 675
Throttle Position (TP) Sensor Check 676
Minimum Idle Speed 676
Adjustment 677
B-1 – Idle Air Control (IAC) System Check 678
Circuit Description 678
Other Troubleshooting Checks 678
B-2 – Manifold Absolute Pressure (MAP) Sensor Output Test 680
Circuit Description 680
Test Description 680
B-3 – Check Governor System 682
Governor System Not Operating Correctly 682
Check Function of Governor System 682
Check PCV System 683
Fuel System Components Repair 683
General 683
Fuel Pressure Relief Procedure 683
Fuel Pump Replacement 683
Throttle Body Injection Unit (TBI) 684
Remove 684
Clean and Inspect 685
Install 685
Fuel Meter Body 685
Remove 685
Install 688
Fuel Injector 688
Remove 688
Install 689
Pressure Regulator 689
Remove 689
Inspect 689
Install 689
Throttle Position Sensor (TPS) 690
Remove 690
Install 690
Idle Air Control (IAC) Valve 690
Remove 690
Clean and Inspect 690
Install 691
Governor System 3 0L Engine Repair 691
Governor Module, Replace 691
Governor Motor, Replace 691
Throttle Cables, Install and Adjust 691
Foot Directional Control Pedal, Check 692
Governor System 4 3L Engine Repair 693
Governor Throttle Drive Assembly 693
Remove 693
Inspect 694
Install 694
Governor Drive Motor 694
Remove 694
Clean and Lubricate 694
Install 695
Inspect 696
Ignition System Components Repair 696
ECM Replacement 696
Function Check 696
Distributor 696
Remove 696
Disassemble 696
Inspect 697
Assemble 697
Install 697
Firing Order 698
Ignition Timing 698
Ignition Module Repair 698
Test For Fault 698
Replace 699
Sensing Coil 699
Test 699
Replace 700
Ignition Coil 700
Test 700
Remove 700
Install 701
Sensors Repair 701
Engine Coolant Temperature (ECT) Sensor, Replace 701
MAP Sensor, Replace 701
PCV System Repair 702
Replace 702
Wiring 702
Connectors and Terminals 702
Procedures for Spark Plugs, Spark Plug Wires, and Boots 705
Wiring Diagram 705
Spark Plugs Troubleshooting 710
Special Tools 711
tables 615
Table 1 ECM Diagnostic Codes Available 627
Table 2 SCAN Tool Information 628
Table 3 Troubleshooting Chart Description Summary 632
Table 4 ECT Sensor – Temperature vs Resistance 653
Table 5 ECT Sensor – Temperature vs Resistance 676
Table 6 ECM Connector J1 Identification 708
Table 7 ECM Connector J2 Identification 709
524153919-4000YRM0741-(03-2005)-US-EN 715
toc 715
Lift Cylinders 715
Safety Precautions Maintenance and Repair 716
Safety Procedures When Working Near Mast 719
General 721
Description 721
Lowering Control Valve (Velocity Fuse) 721
Lift Cylinder Repair 724
Remove 724
Disassemble 725
Assemble 725
Install 725
Lift System Leak Check 726
Troubleshooting 727
524153920-4000YRM0736-(07-2010)-US-EN 731
toc 731
Masts 731
Safety Precautions Maintenance and Repair 732
General 735
Description and Operation 735
Carriages 735
Two-Stage Mast With Limited Free-Lift 735
Two-Stage Mast With Full Free-Lift 736
Three-Stage Mast With Full Free-Lift 737
Safety Procedures When Working Near Mast 739
Fork Replacement 741
Remove 742
Install 742
Carriage Repair 743
Remove 743
Sideshift Carriage Repair 745
Remove 745
Disassemble 745
Assemble 745
Install 745
Two-Stage Mast With Limited Free-Lift Repair 747
Remove, GLP/GDP3 5-5 5LJ/MJ (GP/GLP/GDP070-120LJ/MJ) Model Lift 747
Remove, GC070-120LJ/MJ, ERC070-120HG (A839), and ERC35-55HG (ERC 749
Disassemble 752
Clean and Inspect 752
Assemble 753
Install, GLP/GDP3 5-5 5LJ/MJ (GP/GLP/GDP070-120LJ/MJ) Lift Truck 754
Install, GC070-120LJ/MJ, ERC070-120HG (A839), and ERC35-55HG (ER 756
Two-Stage Mast With Full Free-Lift Repair 758
Remove 758
Disassemble 758
Clean and Inspect 760
Assemble 760
Install 760
Three-Stage Mast With Full Free-Lift Repair 762
Remove 762
Disassemble 762
Clean and Inspect 766
Assemble 766
Install 767
Mast Operation Check 773
Lift and Tilt System Leak Check 774
Lift System 774
Tilt System 775
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment 776
Lift Chain Adjustments 778
Mast Adjustments 780
Carriage Adjustment 782
Troubleshooting 783
tables 731
Table 1 Tilt Cylinder Leak Check Specifications, GC070-120LJ/MJ 775
Table 2 Hook-Type Carriage Chain Adjustment 778
Table 3 Pin-Type Carriage Chain Adjustment 779
524153922-8000YRM0987-(06-2009)-US-EN 789
toc 789
Periodic Maintenance 789
Safety Precautions Maintenance and Repair 790
General 795
Serial Number Data 795
How to Move Disabled Lift Truck 795
How to Tow Lift Truck 795
How to Put Lift Truck on Blocks 796
How to Raise Drive Tires 796
How to Raise Steering Tires 796
Maintenance Schedule 797
Maintenance Procedures Every 8 Hours or Daily 804
How to Make Checks With Engine Stopped 804
Engine Oil 804
Hydraulic System Oil 804
Cooling System Reservoir Level 805
Fuel System 806
Battery 806
Tires and Wheels 807
Forks 807
Adjust 807
Hook Fork, Remove 807
Hook Fork, Install 809
Forks, Mast, and Lift Chains, Inspect 809
Operator Restraint System 810
Automatic Locking Retractor (ALR) 810
Emergency Locking Retractor (ELR) 810
Safety Labels 811
Cooling System, Clean Debris from Radiator Core 811
How to Make Checks With Engine Running 812
Gauges, Lights, Horn, and Fuses 812
Engine Oil Pressure 813
Cooling System Temperature 813
Powershift Transmission Oil level Check 813
Control Levers and Pedals 814
Lift System Operation 814
Service Brakes 814
Parking Brakes 815
Steering System 815
Maintenance Procedures Every 250 Hours or 6 Weeks 816
Engine Oil and Filter, GM V-6 Engines 816
Sideshift Carriage Lubrication 816
Tilt Cylinder Lubrication 817
Air Filter, GM V-6 EPA Compliant Engine 818
Maintenance Procedures Every 500 Hours or 3 Months 818
Lift Chain Lubrication 818
Engine Oil and Filter, Perkins Diesel Engine 818
Drive Belts 819
Fan Drive Belts 819
Perkins Diesel Engine 819
Alternator Drive Belt 819
GM 4 3L Engine 820
Serpentine Drive Belt 820
Tension Screw Adjustment 820
Hydraulic Tank Breather, Clean and Check 821
Brake Fluid 821
Lift Chains Wear Check 822
Forks, Wear and Damage Check 822
Mast Lubrication 822
Control Levers and Pedals Lubrication 823
Steering Axle Lubrication 823
Fuel System, Checks and Adjustments 823
LPG Carburetor 823
Fuel Injection (Perkins Engine) 823
GM V-6 Engine 823
Inching/Brake Pedal 823
Steering Tie Rods 823
Fork Pins and Guides 823
Wheel Nuts 824
Air Filter 824
Battery 824
Maintenance Procedures Every 1000 Hours or 6 Months 825
Fuel Filter, Replace (Diesel Engine) 825
Fuel System, Remove Air (Perkins 1004 42 Diesel Engine) 825
Water Separator, Diesel Engine 827
PCV Valve, GM V-6 827
Crankcase Breather, GM V-6 827
Valve Clearance, Check and Adjust 827
Differential and Drive Axle Oil 827
Spark Plugs, GM V-6 827
Ignition Timing 827
Cooling System, GM V-6 EPA Compliant Engine 828
LPG Fuel Filter GM V-6 EPA Compliant Engine, Replace 828
Inspect Engine Electrical System, Connectors, and FCVS Connectio 829
Maintenance Procedures Every 2000 Hours or Annually 829
Differential Thrust Screw 829
Hydraulic System 830
Hydraulic Oil and Filter, Replace 830
Powershift Transmission Oil and Filter, Replace 830
Spark Plugs, GM V-6 831
Cooling System 831
Wheel Bearings 831
Steering Wheels, Lubrication 831
Drive Wheels, Lubrication 831
PCV Valve, GM V-6 831
LPG Filter, Replace 831
Gasoline Fuel Filter, Replace 832
Brake Booster Filter, Replace 832
Differential Oil for Powershift Transmission, Replace 832
Air Filter Element, GM V-6 EPA Compliant Engine 832
Oxygen Sensor GM V-6 EPA Compliant Engine 832
Test LPG /GAS Regulator Pressure 832
Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks 833
Check Throttle Shaft for Sticking 834
Inspect Exhaust Manifold and Piping for Leaks 834
Safety Procedures When Working Near Mast 834
Lift Chain Adjustments 836
Fuel Injectors Repair 837
Lift and Tilt System Leak Check 838
Lift Cylinders, Leak Check 838
Tilt System 838
Welding Repairs 839
Overhead Guard Changes 840
Wheel and Tire Replacement 841
Solid Rubber Tire, Change 841
Wheels, Install 841
tables 789
Table 1 Maintenance Schedule 798
Table 2 Hook-Type Carriage Chain Adjustment 836
Table 3 Pin-Type Carriage Chain Adjustment 837
Table 4 Tilt Cylinder Leak Check Specifications 839
524153923-8000YRM0988-(06-2005)-US-EN 845
toc 845
Capacities and Specifications 845
Safety Precautions Maintenance and Repair 846
Tire Sizes 849
Hydraulic System 849
Electrical System 849
Engine Specifications 850
Capacities 850
Lift Truck Weights 851
Transmission Pressures (Single-Speed Powershift) 852
Mast Speeds 853
Torque Specifications 853
Frame 853
Engine – GM V-6 853
Engine – Perkins 854
Transmission 854
Drive Axle 854
Steering System 854
Brake System 854
Hydraulic System 854
Main Control Valve 854
Tilt Cylinders 855
Lift Cylinders 855
Mast 855
524153924-8000YRM0989-(03-2007)-US-EN 859
toc 859
Diagrams 859
Safety Precautions Maintenance and Repair 860
General 863
524208004-0900YRM1088-(05-2006)-US-EN 933
toc 933
Electronic Controlled LPG/Gasoline Fuel System 933
Safety Precautions Maintenance and Repair 934
General 939
Fuel System Warnings and Cautions 939
Glossary 940
Description and Operation of LPG Fuel System 944
Propane Fuel System 944
LPG Fuel Tank 946
Service Line 946
Fuel Filter 946
Low Pressure Lock-Off (LPL) 946
Low Pressure Regulator (LPR) 947
Air Fuel Mixer 947
Throttle Control Device 948
Drive By Cable 948
Three-Way Catalytic (TWC) Muffler 949
Electronic Control Module (ECM) 949
Heated Exhaust Gas Oxygen (HEGO) Sensor 950
Description and Operation of Gasoline Fuel System 952
Gasoline Fuel System Throttle Body Injection (TBI), 3 0L Engine 952
Gasoline Multi-Point Fuel Injection (MPFI) System, 4 3L Only 952
Gasoline Fuel Storage Tank 952
Gasoline Fuel Pump 952
Fuel Filter 952
Fuel Pressure Regulator, 3 0L Only 955
Fuel Rail and Pressure Regulator, 4 3L Only 956
Fuel Injector 956
Throttle Control Device 956
Drive By Cable 956
Three-Way Catalytic Muffler 957
Electronic Control Module (ECM) 957
Heated Exhaust Gas Oxygen (HEGO) Sensor 959
LPG Fuel System Repair 959
Propane Fuel System Pressure Relief 959
Propane Fuel System Leak Test 959
Propane Fuel Filter Replacement 960
Remove 960
Install 960
Low Pressure Lock-Off (LPL) Replacement 960
Remove 960
Install 960
Pressure Trim Valve (PTV) Replacement 962
Remove 962
Install 962
Low Pressure Regulator 962
Remove 962
Install 962
Fuel Trim Valve (FTV) Solenoid Replacement 963
Remove 963
Install 963
Temperature Manifold Absolute Pressure (TMAP) 963
Remove 963
Install 963
Throttle Body Replacement 965
Remove 965
Install 965
Mixer Replacement 967
Remove 967
Install 967
Coolant Hose Replacement 967
Remove 967
Install 968
Vapor Hose Replacement 968
Remove 968
Install 968
Balance Line Hose Replacement 968
Remove 968
Install 968
PTV Hose Replacement 968
Remove 968
Install 968
FTV Hose Replacement 969
Remove 969
Install 969
Throttle Position Sensor (TPS) Replacement 969
Foot Pedal Position (FPP) Sensor Replacement 971
Electronic Control Module (ECM) Replacement 974
Remove 974
Install 974
Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement 974
Remove 974
Install 975
Three-Way Catalytic Muffler (TWC) Replacement 975
Remove 975
Install 975
Restricted Exhaust System Diagnosis 975
Exhaust System Description 975
Tools Required 975
Diagnostic Tool 975
Check at Heated Exhaust Gas Oxygen Sensor (HEGO) 975
Gasoline Fuel System Repair 976
Gasoline MPFI and TBI Fuel System Pressure Relief 976
Gasoline Fuel System Leak Test 977
Throttle Body Injector (TBI) Assembly Replacement, 3 0L Only 977
Remove 977
Install 977
Throttle Body Assembly Replacement, 3 0L Only 979
Remove 979
Install 979
Throttle Body Assembly Replacement, 4 3L Only 980
Remove 980
Install 980
Fuel Rail Replacement, Gasoline 4 3L Only 981
Remove 981
Install 981
Injector Replacement, Gasoline 4 3L Only 981
Remove 981
Install 981
Injector Replacement, Gasoline 3 0L Only 983
Remove 983
Install 983
Temperature Manifold Absolute Pressure (TMAP) Replacement 983
Remove 983
Install 983
Throttle Position Sensor (TPS) Replacement 983
Foot Pedal Position (FPP) Sensor Replacement 986
Electronic Control Module (ECM) Replacement 989
Remove 989
Install 989
Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement 990
Remove 990
Install 990
Three-Way Catalytic Muffler (TWC) Replacement 990
Remove 990
Install 990
Restricted Exhaust System Diagnosis 990
Exhaust System Description 990
Tools Required 990
Diagnostic Tool 990
Check at Heated Exhaust Gas Oxygen Sensor (HEGO) 991
LPG System Diagnosis 991
Fuel System Description 991
Diagnostic Aids 992
Tools Required 992
Duty Cycle Monitoring Tool 992
Diagnostic Tool 992
Pressure Gauges 992
Test Description 992
Gasoline System Diagnosis 1000
Fuel System Description, 3 0L Only 1000
Fuel System Description, 4 3L Only 1000
Diagnostic Aids 1001
Tools Required 1001
Diagnostic Tool 1001
Test Description 1001
LPG Symptom Diagnosis 1008
Gasoline Symptom Diagnosis 1022
Wire Harness Repair 1033
On Vehicle Service Wiring Harness Repair 1033
Connectors and Terminals 1033
Twisted/Shielded Cable Repair 1034
Twisted Leads Repair 1035
Micro-Pack 1036
Metri-Pack 1036
Remove 1036
Weather-Pack 1038
Weather-Pack Terminal Repair 1039
tables 933
Table 1 TPS Replacement Procedure 969
Table 2 FPP Replacement Procedure 972
Table 3 TPS Replacement Procedure 984
Table 4 FPP Replacement Procedure 987
Table 5 LPG Fuel System Diagnosis 992
Table 6 Fuel Control Diagnosis 996
Table 7 Gasoline Fuel System Diagnosis, 3 0L Only 1002
Table 8 Gasoline Fuel System Diagnosis, 4 3L Only 1005
Table 9 Preliminary Checks 1008
Table 10 Intermittent 1009
Table 11 No Start 1010
Table 12 Hard Start 1012
Table 13 Cuts Out or Misses 1013
Table 14 Hesitation, Sag, or Stumble 1014
Table 15 Backfire 1015
Table 16 Lack of Power, Sluggishness, or Sponginess 1016
Table 17 Poor Fuel Economy 1017
Table 18 Rough, Unstable, Incorrect Idle, or Stalling 1019
Table 19 Surges or Chuggles 1021
Table 20 Preliminary Checks 1022
Table 21 Intermittent 1023
Table 22 No Start 1024
Table 23 Hard Start 1025
Table 24 Cuts Out or Misses 1026
Table 25 Hesitation, Sag, or Stumble 1027
Table 26 Backfire 1028
Table 27 Lack of Power, Sluggishness, or Sponginess 1029
Table 28 Poor Fuel Economy 1030
Table 29 Rough, Unstable, Incorrect Idle, or Stalling 1031
Table 30 Surges or Chuggles 1032
524208009-2200YRM1090-(04-2005)-US-EN 1043
toc 1043
Electronic Control Module (ECM) Diagnostic Troubleshooting 1043
Safety Precautions Maintenance and Repair 1044
General 1053
Description of ECM Based Diagnostics 1053
Definition of Terms 1053
Diagnostics Overview of the Spectrum Fuel System 1053
Malfunction Indicator Lamp (MIL) 1053
Spectrum Diagnostic Trouble Codes (DTC) 1054
Using a Laptop Computer to Diagnose the Spectrum System 1054
Installing the Spectrum Diagnostic Software 1054
Connecting a Laptop Computer to the Spectrum System 1054
Diagnostic Communication Error 1055
Diagnostic Trouble Codes 1055
Checking Diagnostic Trouble Codes 1056
Clearing Diagnostic Trouble Codes 1056
DATA Stream 1056
Reading Sensor and Actuator Values 1056
Graphing and Data Logging 1057
Ignition System Test 1058
Disabling Ignition Outputs 1058
Injector Test 1059
Disabling Injectors 1059
Throttle Test 1060
Using a Diagnostic Jumper to Diagnose the ECI System 1061
On-Board Diagnostics System Check/Malfunction Indicator Lamp 1062
Circuit Description 1062
Preliminary and Intermittent Checks 1065
GM 3 0L Wiring Schematics and Connectors 1067
GM 3 0L Diagnostic Trouble Codes 1081
DTC 111 – IAT High Voltage Motorola® TMAP 1081
Circuit Description 1081
Conditions for Setting the DTC 1081
DTC 112 – IAT Low Voltage Motorola® TMAP 1084
Circuit Description 1084
Conditions for Setting the DTC 1084
DTC 113 – IAT Higher Than Expected 1 Motorola® TMAP 1087
Circuit Description 1087
Conditions for Setting the DTC 1087
Diagnostic Aids 1087
DTC 114 – IAT Higher Than Expected 2 Motorola® TMAP 1088
Circuit Description 1088
Conditions for Setting the DTC 1088
Diagnostic Aids 1088
DTC 115 – Oil Pressure Low 1089
Circuit Description 1089
Conditions for Setting the DTC 1089
DTC 121 – ECT Voltage High 1092
Circuit Description 1092
Conditions for Setting the DTC 1093
DTC 122 – ECT Voltage Low 1096
Circuit Description 1096
Conditions for Setting the DTC 1096
DTC 123 – ECT Higher Than Expected 1 1098
Circuit Description 1098
Conditions for Setting the DTC 1098
DTC 124 – ECT Higher Than Expected 2 1100
Circuit Description 1100
Conditions for Setting the DTC 1100
DTC 131 – MAP High Pressure Motorola® TMAP 1102
Circuit Description 1102
Conditions for Setting the DTC 1102
Diagnostic Aids 1102
DTC 132 – MAP Low Voltage Motorola® TMAP 1104
Circuit Description 1104
Conditions for Setting the DTC 1104
DTC 134 – BP High Pressure Motorola® TMAP 1108
Circuit Description 1108
Conditions for Setting the DTC 1108
DTC 135 – BP Low Pressure Motorola® TMAP 1110
Circuit Description 1110
Conditions for Setting the DTC 1110
DTC 142 – Crank Sync Noise 1114
Circuit Description 1114
Conditions for setting the DTC 1114
DTC 143 – Never Crank Synced At Start 1117
Circuit Description 1117
Conditions for Setting the DTC 1117
DTC 144 – Camshaft Sensor Loss 1120
Circuit Description 1120
Conditions for Setting the DTC 1120
DTC 145 – Camshaft Sensor Noise 1123
Circuit Description 1123
Conditions for Setting the DTC 1123
DTC 211 – Closed Loop Multiplier High (LPG) 1126
Circuit Description 1126
Conditions for Setting the DTC 1126
Diagnostic Aids 1126
DTC 212 – HO 2 S Open/Inactive 1128
Circuit Description 1128
Conditions for Setting the DTC 1128
DTC 221 – Closed Loop Multiplier High (Gasoline) 1132
Circuit Description 1132
Conditions for Setting the DTC 1132
Diagnostic Aids 1133
DTC 222 – Closed Loop Multiplier Low (Gasoline) 1134
Circuit Description 1134
Conditions for Setting the DTC 1134
Diagnostic Aids 1134
DTC 224 – Closed Loop Multiplier Low (LPG) 1136
Circuit Description 1136
Conditions for Setting the DTC 1136
Diagnostic Aids 1137
DTC 241 – Adaptive Lean Fault (High Limit-Gasoline) 1138
Circuit Description 1138
Conditions for Setting the DTC 1138
Diagnostic Aids 1139
DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline) 1142
Circuit Description 1142
Conditions for Setting the DTC 1142
Diagnostic Aids 1142
DTC 243 – Adaptive Learn High (LPG) 1144
Circuit Description 1144
Conditions for Setting the DTC 1144
Diagnostic Aids 1144
DTC 244 – Adaptive Learn Low (LPG) 1148
Circuit Description 1148
Conditions for Setting the DTC 1148
Diagnostic Aids 1148
DTC 261 – System Voltage High 1150
Circuit Description 1150
Conditions for Setting the DTC 1150
DTC 262 – System Voltage Low 1152
Circuit Description 1152
Conditions for Setting the DTC 1152
DTC 411 – Injector Driver 1 Open 1155
Circuit Description 1155
Conditions for Setting the DTC 1155
DTC 412 – Injector Driver 1 Shorted 1158
Circuit Description 1158
Conditions for Setting the DTC 1158
DTC 511 – COP Failure 1161
Circuit Description 1161
Conditions for Setting the DTC 1161
DTC 512 – Invalid Interrupt 1163
Circuit Description 1163
Conditions for Setting the DTC 1163
DTC 513 – A/D Loss 1165
Circuit Description 1165
Conditions for Setting the DTC 1165
DTC 514 – RTI 1 Loss 1167
Circuit Description 1167
Conditions for Setting the DTC 1167
DTC 515 – Flash Checksum Invalid 1169
Circuit Description 1169
Conditions for Setting the DTC 1169
DTC 516 – Ram Failure 1171
Circuit Description 1171
Conditions for Setting the DTC 1171
DTC 531 – External 5V Ref Lower Than Expected 1173
Circuit Description 1173
Conditions for Setting the DTC 1173
DTC 532 – External 5V Ref Higher Than Expected 1176
Circuit Description 1176
Conditions for Setting the DTC 1176
DTC 555 – RTI 2 Loss 1178
Circuit Description 1178
Conditions for Setting the DTC 1178
DTC 556 – RTI 3 Loss 1180
Circuit Description 1180
Conditions for Setting the DTC 1180
DTC 611 – FPP High Voltage 1182
Circuit Description 1182
Conditions for Setting the DTC 1182
DTC 612 – FPP Low Voltage 1185
Circuit Description 1185
Conditions for Setting the DTC 1185
DTC 631 – TPS1 Signal Voltage High 1189
Circuit Description 1189
Conditions for Setting the DTC 1189
DTC 632 – TPS1 Signal Voltage Low 1192
Circuit Description 1192
Conditions for Setting the DTC 1192
DTC 638 – Throttle Unable To Close 1194
Circuit Description 1194
Conditions for Setting the DTC 1194
Diagnostic Aids 1194
DTC 651 – Maximum Govern Speed Override 1198
Circuit Description 1198
Conditions for Setting the DTC 1198
Diagnostic Aids 1198
DTC 652 – Fuel Rev Limit 1200
Circuit Description 1200
Conditions for Setting the DTC 1200
Diagnostic Aids 1200
DTC 653 – Spark Rev Limit 1203
Circuit Description 1203
Conditions for Setting the DTC 1203
Diagnostic Aids 1203
GM 4 3L Wiring Schematics and Connectors 1206
GM 4 3L Diagnostic Trouble Codes 1223
DTC 111 – IAT High Voltage Bosch® TMAP 1223
Circuit Description 1223
Conditions for Setting the DTC 1223
DTC 111 – IAT High Voltage Motorola® TMAP 1226
Circuit Description 1226
Conditions for Setting the DTC 1226
DTC 112 – IAT Low Voltage Bosch® TMap 1228
Circuit Description 1228
Conditions for Setting the DTC 1228
DTC 112 – IAT Low Voltage Motorola® TMAP 1231
Circuit Description 1231
Conditions for Setting the DTC 1231
DTC 113 – IAT Higher Than Expected 1 Bosch® TMAP 1234
Circuit Description 1234
Conditions for Setting the DTC 1234
Diagnostic Aids 1234
DTC 113 – IAT Higher Than Expected 1 Motorola® TMAP 1235
Circuit Description 1235
Conditions for Setting the DTC 1235
Diagnostic Aids 1235
DTC 114 – IAT Higher Than Expected 2 Bosch® TMAP€ 1236
Circuit Description 1236
Conditions for Setting the DTC 1236
Diagnostic Aids 1236
DTC 114 – IAT Higher Than Expected 2 Motorola® TMAP 1237
Circuit Description 1237
Conditions for Setting the DTC 1237
Diagnostic Aids 1237
DTC 115 – Oil Pressure Low 1238
Circuit Description 1238
Conditions for Setting the DTC 1238
DTC 121 – ECT Voltage High 1241
Circuit Description 1241
Conditions for Setting the DTC 1242
DTC 122 – ECT Voltage Low 1244
Circuit Description 1244
Conditions for Setting the DTC 1244
DTC 123 – ECT Higher Than Expected 1 1247
Circuit Description 1247
Conditions for Setting the DTC 1247
DTC 124 – ECT Higher Than Expected 2 1249
Circuit Description 1249
Conditions for Setting the DTC 1249
DTC 131 – MAP High Pressure Bosch® TMAP 1250
Circuit Description 1250
Conditions for Setting the DTC 1250
Diagnostic Aids 1250
DTC 131 – MAP High Pressure Motorola® TMAP 1254
Circuit Description 1254
Conditions for Setting the DTC 1254
Diagnostic Aids 1254
DTC 132 – MAP Low Voltage Bosch® TMAP 1257
Circuit Description 1257
Conditions for Setting the DTC 1257
DTC 132 – MAP Low Voltage Motorola® TMAP 1260
Circuit Description 1260
Conditions for Setting the DTC 1260
DTC 134 – BP High Pressure Bosch® TMAP 1264
Circuit Description 1264
Conditions for Setting the DTC 1264
DTC 134 – BP High Pressure Motorola® TMAP 1266
Circuit Description 1266
Conditions for Setting the DTC 1266
DTC 135 – BP Low Pressure Bosch® TMAP 1268
Circuit Description 1268
Conditions for Setting the DTC 1268
DTC 135 – BP Low Pressure Motorola® TMAP 1272
Circuit Description 1272
Conditions for Setting the DTC 1272
DTC 142 – Crank Sync Noise 1276
Circuit Description 1276
Conditions for setting the DTC 1276
DTC 143 – Never Crank Synced At Start 1279
Circuit Description 1279
Conditions for Setting the DTC 1279
DTC 144 – Camshaft Sensor Loss 1282
Circuit Description 1282
Conditions for Setting the DTC 1282
DTC 145 – Camshaft Sensor Noise 1285
Circuit Description 1285
Conditions for Setting the DTC 1285
DTC 211 – Closed Loop Multiplier High (LPG) 1288
Circuit Description 1288
Conditions for Setting the DTC 1288
Diagnostic Aids 1288
DTC 212 – HO 2 S Open/Inactive 1290
Circuit Description 1290
Conditions for Setting the DTC 1290
DTC 221 – Closed Loop Multiplier High (Gasoline) 1294
Circuit Description 1294
Conditions for Setting the DTC 1294
Diagnostic Aids 1294
DTC 222 – Closed Loop Multiplier Low (Gasoline) 1296
Circuit Description 1296
Conditions for Setting the DTC 1296
Diagnostic Aids 1297
DTC 224 – Closed Loop Multiplier Low (LPG) 1298
Circuit Description 1298
Conditions for Setting the DTC 1298
Diagnostic Aids 1299
DTC 241 – Adaptive Lean Fault (High Limit-Gasoline) 1300
Circuit Description 1300
Conditions for Setting the DTC 1300
Diagnostic Aids 1301
DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline) 1304
Circuit Description 1304
Conditions for Setting the DTC 1304
Diagnostic Aids 1305
DTC 243 – Adaptive Learn High (LPG) 1307
Circuit Description 1307
Conditions for Setting the DTC 1307
Diagnostic Aids 1308
DTC 244 – Adaptive Learn Low (LPG) 1310
Circuit Description 1310
Conditions for Setting the DTC 1310
Diagnostic Aids 1311
DTC 261 – System Voltage High 1312
Circuit Description 1312
Conditions for Setting the DTC 1312
DTC 262 – System Voltage Low 1314
Circuit Description 1314
Conditions for Setting the DTC 1314
DTC 511 – COP Failure 1317
Circuit Description 1317
Conditions for Setting the DTC 1317
DTC 512 – Invalid Interrupt 1319
Circuit Description 1319
Conditions for Setting the DTC 1319
DTC 513 – A/D Loss 1321
Circuit Description 1321
Conditions for Setting the DTC 1321
DTC 514 – RTI 1 Loss 1323
Circuit Description 1323
Conditions for Setting the DTC 1323
DTC 515 – Flash Checksum Invalid 1325
Circuit Description 1325
Conditions for Setting the DTC 1325
DTC 516 – Ram Failure 1327
Circuit Description 1327
Conditions for Setting the DTC 1327
DTC 531 – External 5V Ref Lower Than Expected 1329
Circuit Description 1329
Conditions for Setting the DTC 1329
DTC 532 – External 5V Ref Higher Than Expected 1332
Circuit Description 1332
Conditions for Setting the DTC 1332
DTC 555 – RTI 2 Loss 1334
Circuit Description 1334
Conditions for Setting the DTC 1334
DTC 556 – RTI 3 Loss 1336
Circuit Description 1336
Conditions for Setting the DTC 1336
DTC 611 – FPP High Voltage 1338
Circuit Description 1338
Conditions for Setting the DTC 1338
DTC 612 – FPP Low Voltage 1342
Circuit Description 1342
Conditions for Setting the DTC 1342
DTC 631 – TPS1 Signal Voltage High 1346
Circuit Description 1346
Conditions for Setting the DTC 1346
DTC 632 – TPS1 Signal Voltage Low 1349
Circuit Description 1349
Conditions for Setting the DTC 1349
DTC 638 – Throttle Unable To Close 1352
Circuit Description 1352
Conditions for Setting the DTC 1352
Diagnostic Aids 1353
DTC 651 – Maximum Govern Speed Override 1355
Circuit Description 1355
Conditions for Setting the DTC 1355
Diagnostic Aids 1355
DTC 652 – Fuel Rev Limit 1358
Circuit Description 1358
Conditions for Setting the DTC 1358
Diagnostic Aids 1358
DTC 653 – Spark Rev Limit 1360
Circuit Description 1360
Conditions for Setting the DTC 1360
Diagnostic Aids 1360
Wire Harness Repair 1363
On Vehicle Service Wiring Harness Repair 1363
Connectors and Terminals 1363
Twisted/Shielded Cable Repair 1364
Twisted Leads Repair 1365
Micro-Pack 1366
Metri-Pack 1366
Remove 1366
Weather-Pack 1368
Weather-Pack Terminal Repair 1368
tables 1043
Table 1 OBD System Check 1063
Table 2 Preliminary Checks 1065
Table 3 Intermittent Checks 1066
Table 4 Communication Port C002 1067
Table 5 Coil Connector C003 1067
Table 6 Fuel System Interface C004 1067
Table 7 Oil Pressure Connector C005 1068
Table 8 Distributor Connector C006 1068
Table 9 Magnetic Pickup Connector C007 1068
Table 10 Heated Oxygen Sensor C008 1068
Table 11 Throttle Position Sensor Connector C009 1069
Table 12 Foot Pedal Position Connector C010 1069
Table 13 Governor Motor Connector C011 1069
Table 14 TMAP Connector C012 1069
Table 15 Starter Solenoid C013 1070
Table 16 Engine Coolant Temperature C014 1070
Table 17 Battery Connector C015 1070
Table 18 Alternator Connection C016 1070
Table 19 Battery Connector C017 1070
Table 20 Alternator Connector C018 1071
Table 21 Instrument Panel Connector C019 1071
Table 22 Instrument Panel Connector C020 1071
Table 23 Instrument Panel Connector C021 1072
Table 24 Fuel Trim Valve Connector C022 1072
Table 25 Fuel Lockoff Connector C023 1072
Table 26 Pressure Trim Valve Connector C024 1073
Table 27 Throttle Body Injector Connector C025 1073
Table 28 Relay and Fuse Center 1073
Table 29 DTC 111 – IAT Voltage High (Motorola® TMAP) 1082
Table 30 DTC 112 – IAT Low Voltage (Motorola® TMAP) 1085
Table 31 DTC 115 – Oil Pressure Low 1090
Table 32 Temperature Resistance 1092
Table 33 DTC 121 – ECT VOLTAGE HIGH 1093
Table 34 DTC 122 – ECT Voltage Low 1097
Table 35 DTC 123 – ECT Higher Than Expected 1 1099
Table 36 DTC 124 – ECT Higher Than Expected 2 1101
Table 37 DTC 131 – MAP HIGH PRESSURE (Motorola® TMAP) 1103
Table 38 DTC 132 – MAP Low Voltage (Motorola® TMAP) 1105
Table 39 DTC 134 – BP High Pressure (Motorola® TMAP) 1109
Table 40 DTC 135 – BP Low Pressure (Motorola® TMAP) 1110
Table 41 DTC 142 – Crank Sync Noise 1114
Table 42 DTC 143 – Never Crank Synced At Start 1117
Table 43 DTC 144 – Camshaft Sensor Loss 1120
Table 44 DTC 145 – Camshaft Sensor Noise 1123
Table 45 DTC 211 – Closed Loop Multiplier High (LPG) 1127
Table 46 DTC 212 – HO 2 S Open/Inactive 1129
Table 47 DTC 221 – Closed Loop Multiplier High (Gasoline) 1133
Table 48 DTC 222 – Closed Loop Multiplier Low (Gasoline) 1136
Table 49 DTC 224 – Closed Loop Multiplier Low (LPG) 1138
Table 50 DTC 241 – Adaptive Lean Fault (High Limit-Gasoline) 1140
Table 51 DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline) 1143
Table 52 DTC 243 – Adaptive Learn High (LPG) 1146
Table 53 DTC 244 – Adaptive Learn Low (LPG) 1149
Table 54 DTC 261 – System Voltage High 1151
Table 55 DTC 262 – System Voltage Low 1153
Table 56 DTC 411 – Injector Driver 1 Open 1156
Table 57 DTC 412 – Injector Driver 1 Shorted 1159
Table 58 DTC 511 – COP Failure 1162
Table 59 DTC 512 – Invalid Interrupt 1164
Table 60 DTC 513 – A/D Loss 1166
Table 61 DTC 514 – RTI 1 Loss 1168
Table 62 DTC 515 – Flash Checksum Invalid 1170
Table 63 DTC 516 – Ram Failure 1172
Table 64 DTC 531 – External 5V Ref Lower Than Expected 1174
Table 65 DTC 532 – External 5 V Ref Higher Than Expected 1176
Table 66 DTC 555 – RTI 2 Loss 1179
Table 67 DTC 556 – RTI 3 Loss 1181
Table 68 DTC 611 – FPP High Voltage 1182
Table 69 DTC 612 – FPP Low Voltage 1186
Table 70 DTC 631 – TPS1 Signal Voltage High 1190
Table 71 DTC 632 – TPS1 Signal Voltage Low 1193
Table 72 DTC 638 – Throttle Unable To Close 1195
Table 73 DTC 651 – Maximum Govern Speed Override 1199
Table 74 DTC 652 – Fuel Rev Limit 1201
Table 75 DTC 653 – Spark Rev Limit 1204
Table 76 Communication Port C002 1206
Table 77 Injector Connector C003 1206
Table 78 Injector Connector C004 1206
Table 79 Oil Pressure Connector C005 1207
Table 80 Throttle Position Sensor 1 Connector C006 1207
Table 81 Foot Pedal Position Connector C006A 1207
Table 82 Coil Connector C007 1207
Table 83 Module Connector C008 1208
Table 84 Crank Sensor Connector C009 1208
Table 85 EGO Sensor Connector C010 1208
Table 86 Cam Connector C011 1208
Table 87 Throttle Connector C012 1209
Table 88 Bosch TMAP Connector C013 (Gasoline Fuel System Only) 1209
Table 89 Motorola TMAP Connector C013 (LPG Fuel System Only) 1209
Table 90 Starter Solenoid Connector C014 1209
Table 91 ECT Connector C015 1210
Table 92 Starter Relay C016 1210
Table 93 Power Relay C017 1210
Table 94 Fuel Pump Relay C018 1210
Table 95 Battery Connector C019 1210
Table 96 Alternator Connector C020 1210
Table 97 Alternator Connector C021 1211
Table 98 Instrument Panel Connector C022 1211
Table 99 Instrument Panel Connector C023 1211
Table 100 Instrument Panel Connector C024 1212
Table 101 Fuel Trim Valve Connector C025 1212
Table 102 Fuel Lockoff Connector C026 1212
Table 103 Pressure Trim Valve Connector C027 1213
Table 104 Injector 1 Connector C028 1213
Table 105 Injector 2 Connector C029 1213
Table 106 Injector 3 Connector C030 1213
Table 107 Injector 4 Connector C031 1214
Table 108 Injector 5 Connector C032 1214
Table 109 Injector 6 Connector C033 1214
Table 110 Relay and Fuse Center 1215
Table 111 DTC 111 – IAT Voltage High (Bosch® TMAP) 1224
Table 112 DTC 111 – IAT Voltage High (Motorola® TMAP) 1227
Table 113 DTC 112 – IAT Low Voltage (Bosch® TMAP) 1229
Table 114 DTC 112 – IAT Low Voltage (Motorola® TMAP) 1232
Table 115 DTC 115 – Oil Pressure Low 1239
Table 116 Temperature Resistance 1241
Table 117 DTC 121 – ECT VOLTAGE HIGH 1242
Table 118 DTC 122 – ECT Voltage Low 1245
Table 119 DTC 123 – ECT Higher Than Expected 1 1248
Table 120 DTC 124 – ECT Higher Than Expected 2 1250
Table 121 DTC 131 – MAP High Pressure (Bosch® TMAP) 1251
Table 122 DTC 131 – MAP HIGH PRESSURE (Motorola® TMAP) 1255
Table 123 DTC 132 – MAP Low Voltage (Bosch® TMAP) 1258
Table 124 DTC 132 – MAP Low Voltage (Motorola® TMAP) 1261
Table 125 DTC 134 – BP High Pressure (Bosch® TMAP) 1265
Table 126 DTC 134 – BP High Pressure (Motorola® TMAP) 1267
Table 127 DTC 135 – BP Low Pressure (Bosch® TMAP) 1268
Table 128 DTC 135 – BP Low Pressure (Motorola® TMAP) 1272
Table 129 DTC 142 – Crank Sync Noise 1276
Table 130 DTC 143 – Never Crank Synced At Start 1279
Table 131 DTC 144 – Camshaft Sensor Loss 1282
Table 132 DTC 145 – Camshaft Sensor Noise 1285
Table 133 DTC 211 – Closed Loop Multiplier High (LPG) 1289
Table 134 DTC 212 – HO 2 S Open/Inactive 1291
Table 135 DTC 221 – Closed Loop Multiplier High (Gasoline) 1295
Table 136 DTC 222 – Closed Loop Multiplier Low (Gasoline) 1298
Table 137 DTC 224 – Closed Loop Multiplier Low (LPG) 1300
Table 138 DTC 241 – Adaptive Lean Fault (High Limit-Gasoline) 1302
Table 139 DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline) 1305
Table 140 DTC 243 – Adaptive Learn High (LPG) 1308
Table 141 DTC 244 – Adaptive Learn Low (LPG) 1311
Table 142 DTC 261 – System Voltage High 1313
Table 143 DTC 262 – System Voltage Low 1315
Table 144 DTC 511 – COP Failure 1318
Table 145 DTC 512 – Invalid Interrupt 1320
Table 146 DTC 513 – A/D Loss 1322
Table 147 DTC 514 – RTI 1 Loss 1324
Table 148 DTC 515 – Flash Checksum Invalid 1326
Table 149 DTC 516 – Ram Failure 1328
Table 150 DTC 531 – External 5V Ref Lower Than Expected 1330
Table 151 DTC 532 – External 5 V Ref Higher Than Expected 1332
Table 152 DTC 555 – RTI 2 Loss 1335
Table 153 DTC 556 – RTI 3 Loss 1337
Table 154 DTC 611 – FPP High Voltage 1339
Table 155 DTC 612 – FPP Low Voltage 1343
Table 156 DTC 631 – TPS1 Signal Voltage High 1347
Table 157 DTC 632 – TPS1 Signal Voltage Low 1350
Table 158 DTC 638 – Throttle Unable To Close 1353
Table 159 DTC 651 – Maximum Govern Speed Override 1356
Table 160 DTC 652 – Fuel Rev Limit 1359
Table 161 DTC 653 – Spark Rev Limit 1361
524208014-2200YRM1097-(03-2020)-US-EN 1373
Series Code / Model Designation Reference Table 1377
Description 1378
Distributor Ignition (DI) System 1378
Crankshaft Position (CKP) Sensor 1378
Camshaft Position (CMP) Sensor 1378
Ignition Coil and Ignition Control Module (ICM) 1378
Secondary Ignition Components 1378
Spark Plugs and Wires 1379
Spark Plug Wire Inspection 1379
Spark Plug Wire Replacement 1379
Remove 1379
Install 1380
Spark Plug Inspection 1380
Usage 1380
Inspection 1380
Visual Inspection 1382
Spark Plug Replacement 1382
Remove 1382
Install 1382
Distributor Repair 1383
Inspect 1383
Overhaul 1383
Disassemble 1383
Assemble 1386
Replace 1387
Remove 1387
Install Procedure 1 1389
Install Procedure 2 1390
Ignition Coil Replacement 1391
Remove 1391
Install 1391
Ignition Control Module Replacement 1392
Remove 1392
Install 1392
Starter Replacement 1393
Remove 1393
Install 1396
Sensors and Switches 1397
Gas and LPG Trucks 1397
Crankshaft Position (CKP) Sensor 1397
Remove 1397
Install 1397
Camshaft Position (CMP) Sensor 1398
Remove 1398
Install 1400
Oil Pressure Sensor 1400
Remove 1400
Install 1401
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 1402
Remove 1402
Install 1402
Engine Coolant Temperature (ECT) Sensor 1403
Remove 1403
Install 1404
Air Flow Restriction Switch 1404
Remove 1404
Install 1405
Specifications and Special Tools 1406

S.V 06/24