Hyster H70XM-H120XM (L005 B813) Forklift Service Manual

Format: PDF (Printable Document)

File Language: English

File Pages (Total): 2864

File Size (Total): 75.73 MB (Speed Download Link)

Brand: Hyster

Model: H70XM-H120XM (L005 B813) Forklift

Type of Document: Service Manual

Categories: Hyster PDF, PDF

$ 45

Hyster H70XM-H120XM (L005 B813) Forklift Service Manual

Hyster H70XM-H120XM (L005 B813) Forklift Index:

toc
- Perkins Diesel Engines
- Safety Precautions Maintenance and Repair
- General
  - General Safety Rules
- Description
  - Engine Serial Number Codes
  - Engine Data
- Engine Removal and Installation
- Cylinder Head Assembly Repair
  - Engine Breather
  - Valve Cover
  - Rocker Arm Assembly
  - Valve Clearance Adjustments
  - Valve Springs
  - Cylinder Head Assembly
  - Valves and Valve Springs
  - Valve Guides
  - Valve Seats
- Piston and Connecting Rod Assemblies Repair
  - General
  - Rod Bearings
  - Piston and Connecting Rod Assembly
  - Piston Cooling Jets
- Crankshaft Assembly Repair
  - General
  - Crankshaft Pulley
  - Rear Oil Seal
  - Crankshaft Flange Wear Sleeve
  - Main Bearings
  - Thrust Washers
  - Crankshaft
  - Crankshaft Timing Ring
  - Flywheel
  - Flywheel Housing
- Timing Case and Timing Gears Repair
  - General
  - Timing Case Cover
  - Front Oil Seal
  - Crankshaft Pulley Wear Sleeve, Install
  - Fuel Pump Gear
  - Idler Gear and Hub
  - Camshaft Gear
  - Crankshaft Gear
  - Timing Case
  - Power Take-Off (PTO) Adaptor
  - Camshaft and Tappets
- Cylinder Block Assembly Repair
  - General
  - Cylinder Block
  - Cylinder Bore
- Engine Timing
  - General
  - How to Set Number One Piston to TDC on Compression Stroke
  - Fuel Injection Pump Timing, Check
  - Fuel Injection Pump Timing, Adjust
- Lubrication System Repair
  - General
  - Oil Filter, Replace
  - Oil Filter Head
  - Oil Sump
  - Oil Pump
  - Oil Strainer and Suction Pipe
  - Relief Valve
  - Dipstick Tube
- Fuel System Repair
  - General
  - Cold Start Advance Unit (KSB)
  - Typical Fuel System
  - Fuel Filter
  - Fuel Injectors
  - Fuel System Air Removal
  - Bosch EVPE Fuel Injection Pump
- Cooling System Repair
  - General
  - Thermostat
  - Coolant Pump
  - Fan
  - Fan Drive
  - Oil Cooler
  - Coolant Bypass Hose
- Electrical Equipment Repair
  - Drive Belt
  - Alternator
  - Starter Motor
  - Starting Aid
  - Pressure Sensor
  - Temperature Sensor
- Engine Specifications
  - Cylinder Head Assembly
  - Piston and Connecting Rods
  - Crankshaft Assembly
  - Timing Case and Drive Assembly
  - Engine Block Assembly
  - Lubrication System
  - Fuel System
  - Cooling System
  - Flywheel and Housing
  - Electrical Equipment
- Torque Specifications
- Special Torque Specifications
  - Cylinder Head Assembly
  - Piston and Connecting Rod Assemblies
  - Crankshaft Assembly
  - Timing Case and Drive Assembly
  - Cylinder block
  - Fuel System
  - Lubrication System
  - Cooling System
  - Flywheel and Housing
  - Electrical Equipment
- Special Tools
- Troubleshooting
tables
- Table 1. Cylinder Head
- Table 2. Valve Guides
- Table 3. Inlet Valves
- Table 4. Exhaust Valves
- Table 5. Valve Springs
- Table 6. Tappets
- Table 7. Rocker Arm Shaft
- Table 8. Rocker Arms and Bushings
- Table 9. Pistons
- Table 10. Piston Rings
- Table 11. Piston Pins
- Table 12. Connecting Rods
- Table 13. Small End Bushings
- Table 14. Connecting Rod Bearings
- Table 15. Piston Cooling Jets
- Table 16. Crankshaft Overhaul Specifications
- Table 17. Maximum Variation (Run-out)
- Table 18. Camshaft
- Table 19. Camshaft Thrust Washer
- Table 20. Camshaft Gear
- Table 21. Gear for Fuel Pump
- Table 22. Crankshaft Gear
- Table 23. Idler Gear and Hub
- Table 24. Timing Gear Backlash Values
- Table 25. Cylinder Block
- Table 26. Oil Pump
- Table 27. Idler Gear for Oil Pump
- Table 28. Relief Valve
- Table 29. Oil Filter
- Table 30. Bosch Fuel Injection Pump
- Table 31. Fuel Injector Settings
- Table 32. Fuel Pump
- Table 33. Fuel Filter
- Table 34. Coolant Pump
- Table 35. Thermostat
- Table 36. Fan Drive Housing
- Table 37. Limits for Flywheel Run Out and Alignment (Total Indic
- Table 38. Alternator
- Table 39. Starter Motor
- Table 40. Starting Aids
- Table 41. List of Possible Causes

toc
- Perkins Diesel Engines
- Safety Precautions Maintenance and Repair
- General
  - General Safety Rules
- Description
  - Engine Serial Number Codes
  - Engine Data
- Engine Removal and Installation
- Cylinder Head Assembly Repair
  - Engine Breather
  - Valve Cover
  - Rocker Arm Assembly
  - Valve Clearance Adjustments
  - Valve Springs
  - Cylinder Head Assembly
  - Valves and Valve Springs
  - Valve Guides
  - Valve Seats
- Piston and Connecting Rod Assemblies Repair
  - General
  - Rod Bearings
  - Piston and Connecting Rod Assembly
  - Piston Cooling Jets
- Crankshaft Assembly Repair
  - General
  - Crankshaft Pulley
  - Rear Oil Seal
  - Crankshaft Flange Wear Sleeve
  - Main Bearings
  - Thrust Washers
  - Crankshaft
  - Crankshaft Timing Ring
  - Flywheel
  - Flywheel Housing
- Timing Case and Timing Gears Repair
  - General
  - Timing Case Cover
  - Front Oil Seal
  - Crankshaft Pulley Wear Sleeve, Install
  - Fuel Pump Gear
  - Idler Gear and Hub
  - Camshaft Gear
  - Crankshaft Gear
  - Timing Case
  - Power Take-Off (PTO) Adaptor
  - Camshaft and Tappets
- Cylinder Block Assembly Repair
  - General
  - Cylinder Block
  - Cylinder Bore
- Engine Timing
  - General
  - How to Set Number One Piston to TDC on Compression Stroke
  - Fuel Injection Pump Timing, Check
  - Fuel Injection Pump Timing, Adjust
- Lubrication System Repair
  - General
  - Oil Filter, Replace
  - Oil Filter Head
  - Oil Sump
  - Oil Pump
  - Oil Strainer and Suction Pipe
  - Relief Valve
  - Dipstick Tube
- Fuel System Repair
  - General
  - Cold Start Advance Unit (KSB)
  - Typical Fuel System
  - Fuel Filter
  - Fuel Injectors
  - Fuel System Air Removal
  - Bosch EVPE Fuel Injection Pump
- Cooling System Repair
  - General
  - Thermostat
  - Coolant Pump
  - Fan
  - Fan Drive
  - Oil Cooler
  - Coolant Bypass Hose
- Electrical Equipment Repair
  - Drive Belt
  - Alternator
  - Starter Motor
  - Starting Aid
  - Pressure Sensor
  - Temperature Sensor
- Engine Specifications
  - Cylinder Head Assembly
  - Piston and Connecting Rods
  - Crankshaft Assembly
  - Timing Case and Drive Assembly
  - Engine Block Assembly
  - Lubrication System
  - Fuel System
  - Cooling System
  - Flywheel and Housing
  - Electrical Equipment
- Torque Specifications
- Special Torque Specifications
  - Cylinder Head Assembly
  - Piston and Connecting Rod Assemblies
  - Crankshaft Assembly
  - Timing Case and Drive Assembly
  - Cylinder block
  - Fuel System
  - Lubrication System
  - Cooling System
  - Flywheel and Housing
  - Electrical Equipment
- Special Tools
- Troubleshooting
tables
- Table 1. Cylinder Head
- Table 2. Valve Guides
- Table 3. Inlet Valves
- Table 4. Exhaust Valves
- Table 5. Valve Springs
- Table 6. Tappets
- Table 7. Rocker Arm Shaft
- Table 8. Rocker Arms and Bushings
- Table 9. Pistons
- Table 10. Piston Rings
- Table 11. Piston Pins
- Table 12. Connecting Rods
- Table 13. Small End Bushings
- Table 14. Connecting Rod Bearings
- Table 15. Piston Cooling Jets
- Table 16. Crankshaft Overhaul Specifications
- Table 17. Maximum Variation (Run-out)
- Table 18. Camshaft
- Table 19. Camshaft Thrust Washer
- Table 20. Camshaft Gear
- Table 21. Gear for Fuel Pump
- Table 22. Crankshaft Gear
- Table 23. Idler Gear and Hub
- Table 24. Timing Gear Backlash Values
- Table 25. Cylinder Block
- Table 26. Oil Pump
- Table 27. Idler Gear for Oil Pump
- Table 28. Relief Valve
- Table 29. Oil Filter
- Table 30. Bosch Fuel Injection Pump
- Table 31. Fuel Injector Settings
- Table 32. Fuel Pump
- Table 33. Fuel Filter
- Table 34. Coolant Pump
- Table 35. Thermostat
- Table 36. Fan Drive Housing
- Table 37. Limits for Flywheel Run Out and Alignment (Total Indic
- Table 38. Alternator
- Table 39. Starter Motor
- Table 40. Starting Aids
- Table 41. List of Possible Causes

toc
- Electronic Control Module (ECM) Diagnostic Troubleshooting
- Safety Precautions Maintenance and Repair
- General
- Description of ECM Based Diagnostics
  - Definition of Terms
  - Diagnostics Overview of the Spectrum Fuel System
  - Malfunction Indicator Lamp (MIL)
  - Spectrum Diagnostic Trouble Codes (DTC)
  - Using a Laptop Computer to Diagnose the Spectrum System
  - Diagnostic Trouble Codes
  - DATA Stream
  - Ignition System Test
  - Injector Test
  - Throttle Test
- On-Board Diagnostics System Check/Malfunction Indicator Lamp
  - Circuit Description
- Preliminary and Intermittent Checks
- GM 3.0L Wiring Schematics and Connectors
- GM 3.0L Diagnostic Trouble Codes
  - DTC 111 – IAT High Voltage Motorola® TMAP
  - DTC 112 – IAT Low Voltage Motorola® TMAP
  - DTC 113 – IAT Higher Than Expected 1 Motorola® TMAP
  - DTC 114 – IAT Higher Than Expected 2 Motorola® TMAP
  - DTC 115 – Oil Pressure Low
  - DTC 121 – ECT Voltage High
  - DTC 122 – ECT Voltage Low
  - DTC 123 – ECT Higher Than Expected 1
  - DTC 124 – ECT Higher Than Expected 2
  - DTC 131 – MAP High Pressure Motorola® TMAP
  - DTC 132 – MAP Low Voltage Motorola® TMAP
  - DTC 134 – BP High Pressure Motorola® TMAP
  - DTC 135 – BP Low Pressure Motorola® TMAP
  - DTC 142 – Crank Sync Noise
  - DTC 143 – Never Crank Synced At Start
  - DTC 144 – Camshaft Sensor Loss
  - DTC 145 – Camshaft Sensor Noise
  - DTC 211 – Closed Loop Multiplier High (LPG)
  - DTC 212 – HO 2 S Open/Inactive
  - DTC 221 – Closed Loop Multiplier High (Gasoline)
  - DTC 222 – Closed Loop Multiplier Low (Gasoline)
  - DTC 224 – Closed Loop Multiplier Low (LPG)
  - DTC 241 – Adaptive Lean Fault (High Limit-Gasoline)
  - DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline)
  - DTC 243 – Adaptive Learn High (LPG)
  - DTC 244 – Adaptive Learn Low (LPG)
  - DTC 261 – System Voltage High
  - DTC 262 – System Voltage Low
  - DTC 411 – Injector Driver 1 Open
  - DTC 412 – Injector Driver 1 Shorted
  - DTC 511 – COP Failure
  - DTC 512 – Invalid Interrupt
  - DTC 513 – A/D Loss
  - DTC 514 – RTI 1 Loss
  - DTC 515 – Flash Checksum Invalid
  - DTC 516 – Ram Failure
  - DTC 531 – External 5V Ref Lower Than Expected
  - DTC 532 – External 5V Ref Higher Than Expected
  - DTC 555 – RTI 2 Loss
  - DTC 556 – RTI 3 Loss
  - DTC 611 – FPP High Voltage
  - DTC 612 – FPP Low Voltage
  - DTC 631 – TPS1 Signal Voltage High
  - DTC 632 – TPS1 Signal Voltage Low
  - DTC 638 – Throttle Unable To Close
  - DTC 651 – Maximum Govern Speed Override
  - DTC 652 – Fuel Rev Limit
  - DTC 653 – Spark Rev Limit
- GM 4.3L Wiring Schematics and Connectors
- GM 4.3L Diagnostic Trouble Codes
  - DTC 111 – IAT High Voltage Bosch® TMAP
  - DTC 111 – IAT High Voltage Motorola® TMAP
  - DTC 112 – IAT Low Voltage Bosch® TMap
  - DTC 112 – IAT Low Voltage Motorola® TMAP
  - DTC 113 – IAT Higher Than Expected 1 Bosch® TMAP
  - DTC 113 – IAT Higher Than Expected 1 Motorola® TMAP
  - DTC 114 – IAT Higher Than Expected 2 Bosch® TMAP€
  - DTC 114 – IAT Higher Than Expected 2 Motorola® TMAP
  - DTC 115 – Oil Pressure Low
  - DTC 121 – ECT Voltage High
  - DTC 122 – ECT Voltage Low
  - DTC 123 – ECT Higher Than Expected 1
  - DTC 124 – ECT Higher Than Expected 2
  - DTC 131 – MAP High Pressure Bosch® TMAP
  - DTC 131 – MAP High Pressure Motorola® TMAP
  - DTC 132 – MAP Low Voltage Bosch® TMAP
  - DTC 132 – MAP Low Voltage Motorola® TMAP
  - DTC 134 – BP High Pressure Bosch® TMAP
  - DTC 134 – BP High Pressure Motorola® TMAP
  - DTC 135 – BP Low Pressure Bosch® TMAP
  - DTC 135 – BP Low Pressure Motorola® TMAP
  - DTC 142 – Crank Sync Noise
  - DTC 143 – Never Crank Synced At Start
  - DTC 144 – Camshaft Sensor Loss
  - DTC 145 – Camshaft Sensor Noise
  - DTC 211 – Closed Loop Multiplier High (LPG)
  - DTC 212 – HO 2 S Open/Inactive
  - DTC 221 – Closed Loop Multiplier High (Gasoline)
  - DTC 222 – Closed Loop Multiplier Low (Gasoline)
  - DTC 224 – Closed Loop Multiplier Low (LPG)
  - DTC 241 – Adaptive Lean Fault (High Limit-Gasoline)
  - DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline)
  - DTC 243 – Adaptive Learn High (LPG)
  - DTC 244 – Adaptive Learn Low (LPG)
  - DTC 261 – System Voltage High
  - DTC 262 – System Voltage Low
  - DTC 511 – COP Failure
  - DTC 512 – Invalid Interrupt
  - DTC 513 – A/D Loss
  - DTC 514 – RTI 1 Loss
  - DTC 515 – Flash Checksum Invalid
  - DTC 516 – Ram Failure
  - DTC 531 – External 5V Ref Lower Than Expected
  - DTC 532 – External 5V Ref Higher Than Expected
  - DTC 555 – RTI 2 Loss
  - DTC 556 – RTI 3 Loss
  - DTC 611 – FPP High Voltage
  - DTC 612 – FPP Low Voltage
  - DTC 631 – TPS1 Signal Voltage High
  - DTC 632 – TPS1 Signal Voltage Low
  - DTC 638 – Throttle Unable To Close
  - DTC 651 – Maximum Govern Speed Override
  - DTC 652 – Fuel Rev Limit
  - DTC 653 – Spark Rev Limit
- Wire Harness Repair
  - On Vehicle Service Wiring Harness Repair
  - Connectors and Terminals
tables
- Table 1. OBD System Check
- Table 2. Preliminary Checks
- Table 3. Intermittent Checks
- Table 4. Communication Port C002
- Table 5. Coil Connector C003
- Table 6. Fuel System Interface C004
- Table 7. Oil Pressure Connector C005
- Table 8. Distributor Connector C006
- Table 9. Magnetic Pickup Connector C007
- Table 10. Heated Oxygen Sensor C008
- Table 11. Throttle Position Sensor Connector C009
- Table 12. Foot Pedal Position Connector C010
- Table 13. Governor Motor Connector C011
- Table 14. TMAP Connector C012
- Table 15. Starter Solenoid C013
- Table 16. Engine Coolant Temperature C014
- Table 17. Battery Connector C015
- Table 18. Alternator Connection C016
- Table 19. Battery Connector C017
- Table 20. Alternator Connector C018
- Table 21. Instrument Panel Connector C019
- Table 22. Instrument Panel Connector C020
- Table 23. Instrument Panel Connector C021
- Table 24. Fuel Trim Valve Connector C022
- Table 25. Fuel Lockoff Connector C023
- Table 26. Pressure Trim Valve Connector C024
- Table 27. Throttle Body Injector Connector C025
- Table 28. Relay and Fuse Center
- Table 29. DTC 111 – IAT Voltage High (Motorola® TMAP)
- Table 30. DTC 112 – IAT Low Voltage (Motorola® TMAP)
- Table 31. DTC 115 – Oil Pressure Low
- Table 32. Temperature Resistance
- Table 33. DTC 121 – ECT VOLTAGE HIGH
- Table 34. DTC 122 – ECT Voltage Low
- Table 35. DTC 123 – ECT Higher Than Expected 1
- Table 36. DTC 124 – ECT Higher Than Expected 2
- Table 37. DTC 131 – MAP HIGH PRESSURE (Motorola® TMAP)
- Table 38. DTC 132 – MAP Low Voltage (Motorola® TMAP)
- Table 39. DTC 134 – BP High Pressure (Motorola® TMAP)
- Table 40. DTC 135 – BP Low Pressure (Motorola® TMAP)
- Table 41. DTC 142 – Crank Sync Noise
- Table 42. DTC 143 – Never Crank Synced At Start
- Table 43. DTC 144 – Camshaft Sensor Loss
- Table 44. DTC 145 – Camshaft Sensor Noise
- Table 45. DTC 211 – Closed Loop Multiplier High (LPG)
- Table 46. DTC 212 – HO 2 S Open/Inactive
- Table 47. DTC 221 – Closed Loop Multiplier High (Gasoline)
- Table 48. DTC 222 – Closed Loop Multiplier Low (Gasoline)
- Table 49. DTC 224 – Closed Loop Multiplier Low (LPG)
- Table 50. DTC 241 – Adaptive Lean Fault (High Limit-Gasoline)
- Table 51. DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline)
- Table 52. DTC 243 – Adaptive Learn High (LPG)
- Table 53. DTC 244 – Adaptive Learn Low (LPG)
- Table 54. DTC 261 – System Voltage High
- Table 55. DTC 262 – System Voltage Low
- Table 56. DTC 411 – Injector Driver 1 Open
- Table 57. DTC 412 – Injector Driver 1 Shorted
- Table 58. DTC 511 – COP Failure
- Table 59. DTC 512 – Invalid Interrupt
- Table 60. DTC 513 – A/D Loss
- Table 61. DTC 514 – RTI 1 Loss
- Table 62. DTC 515 – Flash Checksum Invalid
- Table 63. DTC 516 – Ram Failure
- Table 64. DTC 531 – External 5V Ref Lower Than Expected
- Table 65. DTC 532 – External 5 V Ref Higher Than Expected
- Table 66. DTC 555 – RTI 2 Loss
- Table 67. DTC 556 – RTI 3 Loss
- Table 68. DTC 611 – FPP High Voltage
- Table 69. DTC 612 – FPP Low Voltage
- Table 70. DTC 631 – TPS1 Signal Voltage High
- Table 71. DTC 632 – TPS1 Signal Voltage Low
- Table 72. DTC 638 – Throttle Unable To Close
- Table 73. DTC 651 – Maximum Govern Speed Override
- Table 74. DTC 652 – Fuel Rev Limit
- Table 75. DTC 653 – Spark Rev Limit
- Table 76. Communication Port C002
- Table 77. Injector Connector C003
- Table 78. Injector Connector C004
- Table 79. Oil Pressure Connector C005
- Table 80. Throttle Position Sensor 1 Connector C006
- Table 81. Foot Pedal Position Connector C006A
- Table 82. Coil Connector C007
- Table 83. Module Connector C008
- Table 84. Crank Sensor Connector C009
- Table 85. EGO Sensor Connector C010
- Table 86. Cam Connector C011
- Table 87. Throttle Connector C012
- Table 88. Bosch TMAP Connector C013 (Gasoline Fuel System Only)
- Table 89. Motorola TMAP Connector C013 (LPG Fuel System Only)
- Table 90. Starter Solenoid Connector C014
- Table 91. ECT Connector C015
- Table 92. Starter Relay C016
- Table 93. Power Relay C017
- Table 94. Fuel Pump Relay C018
- Table 95. Battery Connector C019
- Table 96. Alternator Connector C020
- Table 97. Alternator Connector C021
- Table 98. Instrument Panel Connector C022
- Table 99. Instrument Panel Connector C023
- Table 100. Instrument Panel Connector C024
- Table 101. Fuel Trim Valve Connector C025
- Table 102. Fuel Lockoff Connector C026
- Table 103. Pressure Trim Valve Connector C027
- Table 104. Injector 1 Connector C028
- Table 105. Injector 2 Connector C029
- Table 106. Injector 3 Connector C030
- Table 107. Injector 4 Connector C031
- Table 108. Injector 5 Connector C032
- Table 109. Injector 6 Connector C033
- Table 110. Relay and Fuse Center
- Table 111. DTC 111 – IAT Voltage High (Bosch® TMAP)
- Table 112. DTC 111 – IAT Voltage High (Motorola® TMAP)
- Table 113. DTC 112 – IAT Low Voltage (Bosch® TMAP)
- Table 114. DTC 112 – IAT Low Voltage (Motorola® TMAP)
- Table 115. DTC 115 – Oil Pressure Low
- Table 116. Temperature Resistance
- Table 117. DTC 121 – ECT VOLTAGE HIGH
- Table 118. DTC 122 – ECT Voltage Low
- Table 119. DTC 123 – ECT Higher Than Expected 1
- Table 120. DTC 124 – ECT Higher Than Expected 2
- Table 121. DTC 131 – MAP High Pressure (Bosch® TMAP)
- Table 122. DTC 131 – MAP HIGH PRESSURE (Motorola® TMAP)
- Table 123. DTC 132 – MAP Low Voltage (Bosch® TMAP)
- Table 124. DTC 132 – MAP Low Voltage (Motorola® TMAP)
- Table 125. DTC 134 – BP High Pressure (Bosch® TMAP)
- Table 126. DTC 134 – BP High Pressure (Motorola® TMAP)
- Table 127. DTC 135 – BP Low Pressure (Bosch® TMAP)
- Table 128. DTC 135 – BP Low Pressure (Motorola® TMAP)
- Table 129. DTC 142 – Crank Sync Noise
- Table 130. DTC 143 – Never Crank Synced At Start
- Table 131. DTC 144 – Camshaft Sensor Loss
- Table 132. DTC 145 – Camshaft Sensor Noise
- Table 133. DTC 211 – Closed Loop Multiplier High (LPG)
- Table 134. DTC 212 – HO 2 S Open/Inactive
- Table 135. DTC 221 – Closed Loop Multiplier High (Gasoline)
- Table 136. DTC 222 – Closed Loop Multiplier Low (Gasoline)
- Table 137. DTC 224 – Closed Loop Multiplier Low (LPG)
- Table 138. DTC 241 – Adaptive Lean Fault (High Limit-Gasoline)
- Table 139. DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline)
- Table 140. DTC 243 – Adaptive Learn High (LPG)
- Table 141. DTC 244 – Adaptive Learn Low (LPG)
- Table 142. DTC 261 – System Voltage High
- Table 143. DTC 262 – System Voltage Low
- Table 144. DTC 511 – COP Failure
- Table 145. DTC 512 – Invalid Interrupt
- Table 146. DTC 513 – A/D Loss
- Table 147. DTC 514 – RTI 1 Loss
- Table 148. DTC 515 – Flash Checksum Invalid
- Table 149. DTC 516 – Ram Failure
- Table 150. DTC 531 – External 5V Ref Lower Than Expected
- Table 151. DTC 532 – External 5 V Ref Higher Than Expected
- Table 152. DTC 555 – RTI 2 Loss
- Table 153. DTC 556 – RTI 3 Loss
- Table 154. DTC 611 – FPP High Voltage
- Table 155. DTC 612 – FPP Low Voltage
- Table 156. DTC 631 – TPS1 Signal Voltage High
- Table 157. DTC 632 – TPS1 Signal Voltage Low
- Table 158. DTC 638 – Throttle Unable To Close
- Table 159. DTC 651 – Maximum Govern Speed Override
- Table 160. DTC 652 – Fuel Rev Limit
- Table 161. DTC 653 – Spark Rev Limit

toc
- Electronic Control Module (ECM) Diagnostic Troubleshooting
- Safety Precautions Maintenance and Repair
- General
- Description of ECM Based Diagnostics
  - Definition of Terms
  - Diagnostics Overview of the Spectrum Fuel System
  - Malfunction Indicator Lamp (MIL)
  - Spectrum Diagnostic Trouble Codes (DTC)
  - Using a Laptop Computer to Diagnose the Spectrum System
  - Diagnostic Trouble Codes
  - DATA Stream
  - Ignition System Test
  - Injector Test
  - Throttle Test
- On-Board Diagnostics System Check/Malfunction Indicator Lamp
  - Circuit Description
- Preliminary and Intermittent Checks
- GM 3.0L Wiring Schematics and Connectors
- GM 3.0L Diagnostic Trouble Codes
  - DTC 111 – IAT High Voltage Motorola® TMAP
  - DTC 112 – IAT Low Voltage Motorola® TMAP
  - DTC 113 – IAT Higher Than Expected 1 Motorola® TMAP
  - DTC 114 – IAT Higher Than Expected 2 Motorola® TMAP
  - DTC 115 – Oil Pressure Low
  - DTC 121 – ECT Voltage High
  - DTC 122 – ECT Voltage Low
  - DTC 123 – ECT Higher Than Expected 1
  - DTC 124 – ECT Higher Than Expected 2
  - DTC 131 – MAP High Pressure Motorola® TMAP
  - DTC 132 – MAP Low Voltage Motorola® TMAP
  - DTC 134 – BP High Pressure Motorola® TMAP
  - DTC 135 – BP Low Pressure Motorola® TMAP
  - DTC 142 – Crank Sync Noise
  - DTC 143 – Never Crank Synced At Start
  - DTC 144 – Camshaft Sensor Loss
  - DTC 145 – Camshaft Sensor Noise
  - DTC 211 – Closed Loop Multiplier High (LPG)
  - DTC 212 – HO 2 S Open/Inactive
  - DTC 221 – Closed Loop Multiplier High (Gasoline)
  - DTC 222 – Closed Loop Multiplier Low (Gasoline)
  - DTC 224 – Closed Loop Multiplier Low (LPG)
  - DTC 241 – Adaptive Lean Fault (High Limit-Gasoline)
  - DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline)
  - DTC 243 – Adaptive Learn High (LPG)
  - DTC 244 – Adaptive Learn Low (LPG)
  - DTC 261 – System Voltage High
  - DTC 262 – System Voltage Low
  - DTC 411 – Injector Driver 1 Open
  - DTC 412 – Injector Driver 1 Shorted
  - DTC 511 – COP Failure
  - DTC 512 – Invalid Interrupt
  - DTC 513 – A/D Loss
  - DTC 514 – RTI 1 Loss
  - DTC 515 – Flash Checksum Invalid
  - DTC 516 – Ram Failure
  - DTC 531 – External 5V Ref Lower Than Expected
  - DTC 532 – External 5V Ref Higher Than Expected
  - DTC 555 – RTI 2 Loss
  - DTC 556 – RTI 3 Loss
  - DTC 611 – FPP High Voltage
  - DTC 612 – FPP Low Voltage
  - DTC 631 – TPS1 Signal Voltage High
  - DTC 632 – TPS1 Signal Voltage Low
  - DTC 638 – Throttle Unable To Close
  - DTC 651 – Maximum Govern Speed Override
  - DTC 652 – Fuel Rev Limit
  - DTC 653 – Spark Rev Limit
- GM 4.3L Wiring Schematics and Connectors
- GM 4.3L Diagnostic Trouble Codes
  - DTC 111 – IAT High Voltage Bosch® TMAP
  - DTC 111 – IAT High Voltage Motorola® TMAP
  - DTC 112 – IAT Low Voltage Bosch® TMap
  - DTC 112 – IAT Low Voltage Motorola® TMAP
  - DTC 113 – IAT Higher Than Expected 1 Bosch® TMAP
  - DTC 113 – IAT Higher Than Expected 1 Motorola® TMAP
  - DTC 114 – IAT Higher Than Expected 2 Bosch® TMAP€
  - DTC 114 – IAT Higher Than Expected 2 Motorola® TMAP
  - DTC 115 – Oil Pressure Low
  - DTC 121 – ECT Voltage High
  - DTC 122 – ECT Voltage Low
  - DTC 123 – ECT Higher Than Expected 1
  - DTC 124 – ECT Higher Than Expected 2
  - DTC 131 – MAP High Pressure Bosch® TMAP
  - DTC 131 – MAP High Pressure Motorola® TMAP
  - DTC 132 – MAP Low Voltage Bosch® TMAP
  - DTC 132 – MAP Low Voltage Motorola® TMAP
  - DTC 134 – BP High Pressure Bosch® TMAP
  - DTC 134 – BP High Pressure Motorola® TMAP
  - DTC 135 – BP Low Pressure Bosch® TMAP
  - DTC 135 – BP Low Pressure Motorola® TMAP
  - DTC 142 – Crank Sync Noise
  - DTC 143 – Never Crank Synced At Start
  - DTC 144 – Camshaft Sensor Loss
  - DTC 145 – Camshaft Sensor Noise
  - DTC 211 – Closed Loop Multiplier High (LPG)
  - DTC 212 – HO 2 S Open/Inactive
  - DTC 221 – Closed Loop Multiplier High (Gasoline)
  - DTC 222 – Closed Loop Multiplier Low (Gasoline)
  - DTC 224 – Closed Loop Multiplier Low (LPG)
  - DTC 241 – Adaptive Lean Fault (High Limit-Gasoline)
  - DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline)
  - DTC 243 – Adaptive Learn High (LPG)
  - DTC 244 – Adaptive Learn Low (LPG)
  - DTC 261 – System Voltage High
  - DTC 262 – System Voltage Low
  - DTC 511 – COP Failure
  - DTC 512 – Invalid Interrupt
  - DTC 513 – A/D Loss
  - DTC 514 – RTI 1 Loss
  - DTC 515 – Flash Checksum Invalid
  - DTC 516 – Ram Failure
  - DTC 531 – External 5V Ref Lower Than Expected
  - DTC 532 – External 5V Ref Higher Than Expected
  - DTC 555 – RTI 2 Loss
  - DTC 556 – RTI 3 Loss
  - DTC 611 – FPP High Voltage
  - DTC 612 – FPP Low Voltage
  - DTC 631 – TPS1 Signal Voltage High
  - DTC 632 – TPS1 Signal Voltage Low
  - DTC 638 – Throttle Unable To Close
  - DTC 651 – Maximum Govern Speed Override
  - DTC 652 – Fuel Rev Limit
  - DTC 653 – Spark Rev Limit
- Wire Harness Repair
  - On Vehicle Service Wiring Harness Repair
  - Connectors and Terminals
tables
- Table 1. OBD System Check
- Table 2. Preliminary Checks
- Table 3. Intermittent Checks
- Table 4. Communication Port C002
- Table 5. Coil Connector C003
- Table 6. Fuel System Interface C004
- Table 7. Oil Pressure Connector C005
- Table 8. Distributor Connector C006
- Table 9. Magnetic Pickup Connector C007
- Table 10. Heated Oxygen Sensor C008
- Table 11. Throttle Position Sensor Connector C009
- Table 12. Foot Pedal Position Connector C010
- Table 13. Governor Motor Connector C011
- Table 14. TMAP Connector C012
- Table 15. Starter Solenoid C013
- Table 16. Engine Coolant Temperature C014
- Table 17. Battery Connector C015
- Table 18. Alternator Connection C016
- Table 19. Battery Connector C017
- Table 20. Alternator Connector C018
- Table 21. Instrument Panel Connector C019
- Table 22. Instrument Panel Connector C020
- Table 23. Instrument Panel Connector C021
- Table 24. Fuel Trim Valve Connector C022
- Table 25. Fuel Lockoff Connector C023
- Table 26. Pressure Trim Valve Connector C024
- Table 27. Throttle Body Injector Connector C025
- Table 28. Relay and Fuse Center
- Table 29. DTC 111 – IAT Voltage High (Motorola® TMAP)
- Table 30. DTC 112 – IAT Low Voltage (Motorola® TMAP)
- Table 31. DTC 115 – Oil Pressure Low
- Table 32. Temperature Resistance
- Table 33. DTC 121 – ECT VOLTAGE HIGH
- Table 34. DTC 122 – ECT Voltage Low
- Table 35. DTC 123 – ECT Higher Than Expected 1
- Table 36. DTC 124 – ECT Higher Than Expected 2
- Table 37. DTC 131 – MAP HIGH PRESSURE (Motorola® TMAP)
- Table 38. DTC 132 – MAP Low Voltage (Motorola® TMAP)
- Table 39. DTC 134 – BP High Pressure (Motorola® TMAP)
- Table 40. DTC 135 – BP Low Pressure (Motorola® TMAP)
- Table 41. DTC 142 – Crank Sync Noise
- Table 42. DTC 143 – Never Crank Synced At Start
- Table 43. DTC 144 – Camshaft Sensor Loss
- Table 44. DTC 145 – Camshaft Sensor Noise
- Table 45. DTC 211 – Closed Loop Multiplier High (LPG)
- Table 46. DTC 212 – HO 2 S Open/Inactive
- Table 47. DTC 221 – Closed Loop Multiplier High (Gasoline)
- Table 48. DTC 222 – Closed Loop Multiplier Low (Gasoline)
- Table 49. DTC 224 – Closed Loop Multiplier Low (LPG)
- Table 50. DTC 241 – Adaptive Lean Fault (High Limit-Gasoline)
- Table 51. DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline)
- Table 52. DTC 243 – Adaptive Learn High (LPG)
- Table 53. DTC 244 – Adaptive Learn Low (LPG)
- Table 54. DTC 261 – System Voltage High
- Table 55. DTC 262 – System Voltage Low
- Table 56. DTC 411 – Injector Driver 1 Open
- Table 57. DTC 412 – Injector Driver 1 Shorted
- Table 58. DTC 511 – COP Failure
- Table 59. DTC 512 – Invalid Interrupt
- Table 60. DTC 513 – A/D Loss
- Table 61. DTC 514 – RTI 1 Loss
- Table 62. DTC 515 – Flash Checksum Invalid
- Table 63. DTC 516 – Ram Failure
- Table 64. DTC 531 – External 5V Ref Lower Than Expected
- Table 65. DTC 532 – External 5 V Ref Higher Than Expected
- Table 66. DTC 555 – RTI 2 Loss
- Table 67. DTC 556 – RTI 3 Loss
- Table 68. DTC 611 – FPP High Voltage
- Table 69. DTC 612 – FPP Low Voltage
- Table 70. DTC 631 – TPS1 Signal Voltage High
- Table 71. DTC 632 – TPS1 Signal Voltage Low
- Table 72. DTC 638 – Throttle Unable To Close
- Table 73. DTC 651 – Maximum Govern Speed Override
- Table 74. DTC 652 – Fuel Rev Limit
- Table 75. DTC 653 – Spark Rev Limit
- Table 76. Communication Port C002
- Table 77. Injector Connector C003
- Table 78. Injector Connector C004
- Table 79. Oil Pressure Connector C005
- Table 80. Throttle Position Sensor 1 Connector C006
- Table 81. Foot Pedal Position Connector C006A
- Table 82. Coil Connector C007
- Table 83. Module Connector C008
- Table 84. Crank Sensor Connector C009
- Table 85. EGO Sensor Connector C010
- Table 86. Cam Connector C011
- Table 87. Throttle Connector C012
- Table 88. Bosch TMAP Connector C013 (Gasoline Fuel System Only)
- Table 89. Motorola TMAP Connector C013 (LPG Fuel System Only)
- Table 90. Starter Solenoid Connector C014
- Table 91. ECT Connector C015
- Table 92. Starter Relay C016
- Table 93. Power Relay C017
- Table 94. Fuel Pump Relay C018
- Table 95. Battery Connector C019
- Table 96. Alternator Connector C020
- Table 97. Alternator Connector C021
- Table 98. Instrument Panel Connector C022
- Table 99. Instrument Panel Connector C023
- Table 100. Instrument Panel Connector C024
- Table 101. Fuel Trim Valve Connector C025
- Table 102. Fuel Lockoff Connector C026
- Table 103. Pressure Trim Valve Connector C027
- Table 104. Injector 1 Connector C028
- Table 105. Injector 2 Connector C029
- Table 106. Injector 3 Connector C030
- Table 107. Injector 4 Connector C031
- Table 108. Injector 5 Connector C032
- Table 109. Injector 6 Connector C033
- Table 110. Relay and Fuse Center
- Table 111. DTC 111 – IAT Voltage High (Bosch® TMAP)
- Table 112. DTC 111 – IAT Voltage High (Motorola® TMAP)
- Table 113. DTC 112 – IAT Low Voltage (Bosch® TMAP)
- Table 114. DTC 112 – IAT Low Voltage (Motorola® TMAP)
- Table 115. DTC 115 – Oil Pressure Low
- Table 116. Temperature Resistance
- Table 117. DTC 121 – ECT VOLTAGE HIGH
- Table 118. DTC 122 – ECT Voltage Low
- Table 119. DTC 123 – ECT Higher Than Expected 1
- Table 120. DTC 124 – ECT Higher Than Expected 2
- Table 121. DTC 131 – MAP High Pressure (Bosch® TMAP)
- Table 122. DTC 131 – MAP HIGH PRESSURE (Motorola® TMAP)
- Table 123. DTC 132 – MAP Low Voltage (Bosch® TMAP)
- Table 124. DTC 132 – MAP Low Voltage (Motorola® TMAP)
- Table 125. DTC 134 – BP High Pressure (Bosch® TMAP)
- Table 126. DTC 134 – BP High Pressure (Motorola® TMAP)
- Table 127. DTC 135 – BP Low Pressure (Bosch® TMAP)
- Table 128. DTC 135 – BP Low Pressure (Motorola® TMAP)
- Table 129. DTC 142 – Crank Sync Noise
- Table 130. DTC 143 – Never Crank Synced At Start
- Table 131. DTC 144 – Camshaft Sensor Loss
- Table 132. DTC 145 – Camshaft Sensor Noise
- Table 133. DTC 211 – Closed Loop Multiplier High (LPG)
- Table 134. DTC 212 – HO 2 S Open/Inactive
- Table 135. DTC 221 – Closed Loop Multiplier High (Gasoline)
- Table 136. DTC 222 – Closed Loop Multiplier Low (Gasoline)
- Table 137. DTC 224 – Closed Loop Multiplier Low (LPG)
- Table 138. DTC 241 – Adaptive Lean Fault (High Limit-Gasoline)
- Table 139. DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline)
- Table 140. DTC 243 – Adaptive Learn High (LPG)
- Table 141. DTC 244 – Adaptive Learn Low (LPG)
- Table 142. DTC 261 – System Voltage High
- Table 143. DTC 262 – System Voltage Low
- Table 144. DTC 511 – COP Failure
- Table 145. DTC 512 – Invalid Interrupt
- Table 146. DTC 513 – A/D Loss
- Table 147. DTC 514 – RTI 1 Loss
- Table 148. DTC 515 – Flash Checksum Invalid
- Table 149. DTC 516 – Ram Failure
- Table 150. DTC 531 – External 5V Ref Lower Than Expected
- Table 151. DTC 532 – External 5 V Ref Higher Than Expected
- Table 152. DTC 555 – RTI 2 Loss
- Table 153. DTC 556 – RTI 3 Loss
- Table 154. DTC 611 – FPP High Voltage
- Table 155. DTC 612 – FPP Low Voltage
- Table 156. DTC 631 – TPS1 Signal Voltage High
- Table 157. DTC 632 – TPS1 Signal Voltage Low
- Table 158. DTC 638 – Throttle Unable To Close
- Table 159. DTC 651 – Maximum Govern Speed Override
- Table 160. DTC 652 – Fuel Rev Limit
- Table 161. DTC 653 – Spark Rev Limit

toc
- Periodic Maintenance
- Safety Precautions Maintenance and Repair
- General
  - Serial Number Data
  - How to Move Disabled Lift Truck
  - How to Put Lift Truck on Blocks
- Maintenance Schedule
- Maintenance Procedures Every 8 Hours or Daily
  - How to Make Checks With Engine Stopped
  - How to Make Checks With Engine Running
- Maintenance Procedures Every 250 Hours or 6 Weeks
  - Engine Oil and Filter, GM V-6 EPA Compliant Engine (Americas Onl
  - Air Filter, GM V-6 EPA Compliant Engine
- Maintenance Procedures Every 500 Hours or 2 Months
  - Lift Chains Lubrication
  - Air Filter
  - Hydraulic Pump Drive Shaft
  - Engine Oil and Filter, Diesel and GM V-6 (European Only)
  - Drive Belts
  - Perkins Diesel Engine
  - GM 4.3L Engine
  - Hydraulic Tank Breather, Clean and Check
  - Hydrostatic Transmission Filter
  - Brake Fluid
  - Lift Chains Wear Check
  - Forks, Wear and Damage Check
  - Mast, Lubrication
  - Control Levers and Pedals, Lubrication
  - Steering Axle, Lubrication
  - Fuel System, Checks and Adjustments
  - Cooling System, Clean Debris from Radiator Core
- Maintenance Procedures Every 1000 Hours or 6 Months
  - PCV Valve, GM V-6
  - Crankcase Breather, GM-V6
  - Spark Plug Replacement
  - Valve Clearance, Check and Adjust
  - Water Separator, Diesel Engine
  - Fuel Filter, Replace (Diesel Engine)
  - Fuel System Air Removal, Perkins (1004.42 Diesel Engine)
  - Cooling System, GM V-6 EPA Compliant Engine
  - LPG Fuel Filter GM V-6 EPA Compliant Engine, Replace
  - Inspect Engine Electrical System, Connectors, and FCVS Connectio
- Maintenance Procedures Every 2000 Hours or Yearly
  - Differential Thrust Screw
  - Hydraulic System
  - Powershift Transmission Oil and Filter, Replace
  - Hydrostatic Transmission Oil and Filter, Replace
  - Cooling System
  - Wheel Bearings
  - PCV Valve, GM V-6
  - Service Brakes
  - Brake Booster Filter, Replace
  - LPG Filter, Replace (Pre-2004)
  - Gasoline Fuel Filter, Replace
  - Operator Restraint System
  - Oxygen Sensor (Pre 2004)
  - Oxygen Sensor GM V-6 EPA Compliant Engine
  - Air Filter Element, GM V-6 EPA Compliant Engine
  - Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks
  - Check Throttle Shaft for Sticking
  - Inspect Exhaust Manifold and Piping for Leaks
  - Test LPG/GAS Regulator Pressure
- Safety Procedures When Working Near Mast
- Lift Chain Adjustments
- Fuel Injectors Repair
- Lift and Tilt System Leak Check
  - Lift Cylinders, Leak Check
  - Tilt Cylinders, Leak Check
- Welding Repairs
- Overhead Guard Changes
- Wheel and Tire Replacement
  - Remove Wheels From Lift Truck
  - Remove Wheel From Tire
  - Install Wheel in Tire
  - Add Air to Tires
  - Wheels, Install
- Dual Drive Wheels Installation
- Solid Rubber Tire Repair
  - Wheel, Tire Remove
  - Wheel, Tire Install
  - SIT Tire, Change for H3.50-5.50XM (European Trucks Only)
- Adhesives and Sealants
- Hydraulic Oil, Lubricant, and Coolant Specifications
tables
- Table 1. Maintenance Schedule
- Table 2. Hook-Type Carriage Chain Adjustment
- Table 3. Pin-Type Carriage Chain Adjustment